Abstract:
The invention provides lattice-configured panel fixtures that include a plurality of rods joined together in a predetermined pattern, articles for supporting the panel fixtures from a support structure, and automated systems and methods for manufacturing the panel fixtures.

Description:
FIELD OF THE INVENTION 
     The invention relates to the field of ceiling and wall fixtures. 
     BACKGROUND OF THE INVENTION 
     Various types of ceiling and wall treatments such as stucco, paneling, tin ceiling tiles and drop ceilings are known in the art. 
     What is needed and provided by the present invention are new types of ceiling and wall fixtures. 
     SUMMARY OF THE INVENTION 
     One embodiment provides a lattice-configured fixture panel having an expansive horizontal dimension with a top side and a bottom side and a vertical height, said panel including: 
     a plurality of rods each having a first and second end and a length, 
     wherein at least some of the rods have different lengths, 
     wherein each rod is directly joined to at least two other rods, 
     wherein the intersection of rods in the horizontal dimensions occurs at a plurality of acute and obtuse angles. At least half of the rods, such as at least 80% or all of the rods, of the panel may be tilted such that their first ends and second ends are disposed at different vertical heights. The expansive horizontal dimension of the panel may have an at least substantially rectangular configuration with four sides and the vertical height of the panel may be at least 5-10 times, such as 6-8 times, smaller than the longest of the four sides of the substantially rectangular configuration. The fixture may further include a plurality of wire-hanging support brackets attached to the top side of the panel. 
     Another embodiment of the invention provides an automated manufacturing system for producing lattice-configured panel fixtures that includes: 
     a rod support jig comprising an expansive base and a plurality of rod support tabs extending upwardly from the base to predetermined heights at predetermined positions; 
     a computerized manufacturing control unit comprising at least one processor, processor-accessible tangible memory and processor-executable computer instructions stored in the processor-accessible memory; 
     a first articulated robot arm under control of the at least one processor, said arm comprising a grabbing tool; and 
     a second articulated robot arm under control of the at least one processor, said arm comprising a joining tool; 
     wherein the computer instructions are configured to direct the at least one processor to control the first and second robot arms to perform an ordered plurality of steps including placing rods of predetermined lengths in the jig and joining the rods together according to a predetermined pattern to form a lattice-configured panel fixture. 
     A related embodiment of the invention provides an automated method for manufacturing lattice-configured panel fixtures that includes the steps of: 
     providing a manufacturing system that includes: 
     a rod support jig comprising an expansive base and a plurality of rod support tabs extending upwardly from the base to predetermined heights at predetermined positions, 
     a computerized manufacturing control unit comprising at least one processor, processor-accessible tangible memory and processor-executable computer instructions stored in the processor-accessible memory, 
     a first articulated robot arm under control of the at least one processor, said arm comprising a grabbing tool, and 
     a second articulated robot arm under control of the at least one processor, said arm comprising a joining tool, 
     wherein the computer instructions are configured to direct the at least one processor to control the first and second robot arms to perform an ordered plurality of steps including placing rods of predetermined lengths in the jig and joining the rods together according to a predetermined pattern to form a lattice-configured panel fixture; and 
     the first and second robot arms placing rods of predetermined lengths in the jig and joining the rods together under control of the at least one processor according to a predetermined pattern and order to form the lattice-configured panel fixture. Each rod may be joined to at least two other rods to form the fixture. 
     The method may further include the steps of: 
     providing a plurality of support brackets for joining to some of the rods; and 
     joining the plurality of support brackets to different predetermined rods of the fixture panel at predetermined positions on the different predetermined rods. The joining of the brackets to the rods may be performed by the first and second robot arms. 
     Other objects and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  shows a top plan view of a lattice-configured modular panel embodiment of the invention.  FIG. 1B  shows a side elevational view of the embodiment shown in  FIG. 1A . 
         FIG. 2A  is a density diagram in the horizontal plane (expansive dimension) for the embodiment shown in  FIGS. 1A and 1B .  FIG. 2B  is a density diagram in the vertical plane for the embodiment shown in  FIGS. 1A and 1B . 
         FIG. 3A  shows the rectangular envelope and peripheral overlap zones for the modular panel embodiment shown in  FIG. 1A .  FIG. 3B  shows a side elevational view of the embodiment. 
         FIG. 4A  shows a perspective view of a hanger bracket attached to a rod and connected to a support wire.  FIG. 4B  shows a side view of the hanging hardware in more detail.  FIG. 4C  shows how a lattice-configured panel embodiment of the invention may be hung from four points. 
         FIG. 5  shows an embodiment of the invention that includes an array of six lattice-configured panel fixtures. 
         FIG. 6  shows an embodiment of an automated rod picking system including a rod storage rack and a robotic picking arm, which may be employed in the manufacture of lattice-configured panel fixtures according to the invention. 
         FIG. 7  shows a manufacturing system embodiment of the invention that includes a rod placement jig, a robotic picking/placing arm, a robotic welding arm and a partially constructed lattice-configured panel fixture. 
         FIG. 8  illustrates the stacking order of rods for the manufacture of a panel fixture embodiment of the invention. 
         FIG. 9  is table showing the lengths of rods in one panel embodiment of the invention. 
         FIG. 10A  is a key diagram enumerating the four sides of the panel embodiment shown in  FIG. 1A . Each of  FIGS. 10B-10E  shows an elevational view of one of the four sides.  FIG. 10B  shows side  1 ,  FIG. 10C  shows side  2 ,  FIG. 10D  shows side  3 , and  FIG. 10E  shows side  4 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention provides lattice-configured panel fixtures for ceilings and walls that are made of a plurality of rod elements joined to each other. The invention also provides automated systems and methods for manufacturing the fixtures. 
     The rod elements may, for example, be solid, hollow or tubular and may be metallic, such as but not limited to aluminum, or non-metallic, such as a synthetic polymer or wood. The cross-sectional profile of the rods may, for example, be oval, circular, rectangular, square, triangular or any shape. For a single panel fixture or group of panel fixtures, all of the rods may have the same cross-sectional shapes or a plurality of different shaped rods may be used. At least some of the rods in a single panel fixture may have different cross-sectional dimensions (different diameters) or they may all have the same cross-sectional dimensions (same diameters). Each panel fixture may be made from a plurality of rods wherein at least some of the rods, such as all of the rods, have different lengths. For example, each panel fixture may be made of rods having 2, 3, 4, 5, 6, 7, or 8 different lengths. For all of the different length rods used to make a panel fixture, at least two of the rods of each length may be included in the panel fixture. 
     The rods are arranged and joined in a three-dimensional lattice configuration having an expansive dimension and a thickness or height to provide the form of a panel. For each panel fixture, each component rod may touch (be joined to) at least one other rod via weldment or other fastening method (glue, fastener, etc.), creating the structural integrity of the module. In another variation, each of the rods may touch (be joined to) at least two, such as two or three, other rods of the module. 
     At least some of the rods may be straight such as all of the rods may be straight (as shown in the figures). In a variation, none of the rods in a single panel fixture are collinear. In a variation, none of the rods may be at a right angle to a rod it touches (is joined to). In a variation, none of the rods in a panel may be at a right angle to each other. At least some of the rods may be curved, such as all of the rods may be curved. With respect to the height (thickness) of the panel, at least some of the rods of the panel may be axially tilted in the z-plane (rather than level). The total number of rods in a panel may, for example, be in the range of 5-50, such as 5-35, such as 10-30, such as 10-20, such as 10-15. In one embodiment, for a panel having a 48″×48″ border, the rods may vary in length from 12 inches to 60 inches. In one variation, none of the rods in the panel are the same length.  FIG. 9  is a table showing the rods lengths for a panel embodiment of the invention. 
     The entire grouping of rods in a panel may be contained within a rectilinear profile, such as a rectangular or square profile (of the expansive dimension) with varying heights possible in the z-plane envelope. The ratio of the longest dimension in the expansive plane to the height (thickness) of the panel may, for example, be in the range of 40:1 to 4:1. In one embodiment, the panel fixture has an approximate 48″L×48″W area in the expansive plane with varying heights of z plane envelope achieving a maximum of approximately 12″. 
     When viewed from above or below, the projection of the expansive dimension of a panel embodiment of the invention may, for example, have in the range of 60%-90% open area (area not blocked by the projection of area taken up by the rods). In the expansive dimension, the panel may, for example, consist of 50-120 open areas bounded by the projection of the rods making up the panel. The density of the rods in the area of the expansive dimension of a panel may be significantly less than the density of the rods viewed from the side of the panel. 
     There may, for example, be 2 to 4 attachments points on the same side of a panel fixture for hanging or otherwise attaching the panel to a ceiling or wall. A tab, i.e., a hanging plate, configured to reversibly attach to a support wire may be connected to a rod of the panel at each of the attachment points. A slot and/or hole may be formed in the tab which is configured to receive a ball end of a wire or other wire connection to a hole or hook in the tab. The other end of the wire may be fastened to the base building support structure above in a manner appropriate for the specific condition of that substrate. Multiple panel fixtures may be installed adjacent to each other as modules. 
     The manufacture of the panel fixtures according to the invention may be automated and performed, at least in part, by industrial robots. The rods are cut into a variety of required lengths from longer rods, or otherwise provided in the needed lengths, and then stocked in a picking rack with like sizes. A plurality of hanging plates may also be provided in the vicinity for use in the manufacturing process. The rods are then picked by a robotic claw and placed into a custom fixture (jig) to a specific location in a specific sequence. This assembly logic avoids lock outs or collisions among the rods. A robot arm then passes over the fixture touching and joining sticks at their points of intersection via welding, fastener or glue, etc. The hanging plates are then picked by the robotic claw, and held in place while the secondary robot fastens them with one of the methods mentioned above. Suitable programmable industrial robot systems including articulated robot arms with grasping and welding capabilities are commercially available and well known in the manufacturing art. 
     Various aspects of the invention are further described below with reference to the accompanying drawing. 
       FIG. 1A  shows a top plan view of a lattice-configured modular panel embodiment of the invention. The rods are disposed within a square 48″×48″ imaginary border except that the ends of some rods extend slightly past the border on each side of the panel. Various angles between the rods are shown. Overall, there are 63% acute angles and 37% obtuse angles between the rods, in the perspective shown. Four support attachment points are shown by black dots.  FIG. 1B  shows a side elevational view of the embodiment shown in  FIG. 1A . Various angles between the rods are shown for this perspective. Overall, there are 64% acute angles and 36% obtuse angles in this perspective. Two of the support wires attached to the panel are shown (the other two are obscured by those shown). 
       FIG. 2A  is a density diagram in the horizontal plane (expansive dimension) for the embodiment shown in  FIGS. 1A and 1B . The density of the rods in two dimensions varies across the panel.  FIG. 2B  is a density diagram for the vertical plane for the embodiment shown in  FIGS. 1A and 1B . The density of the rods in the vertical plane as viewed from the side of the panel is much greater than that in the horizontal plane. 
       FIG. 3  shows the rectangular 48″×48″ envelope and peripheral overlap zones for the modular panel embodiment shown in  FIG. 1A . 
       FIG. 4A  shows a perspective view of a hanger element (tab, bracket, plate) embodiment of the invention attached to a rod and connected to a support wire. The attachment may, for example, include a weld, mechanical attachment such as with a fastener, and/or adhesive attachment. The hanger element may be formed from a bent metal plate. A hole and connected slot are formed in the hanger element so that a terminal ball member of a support wire can pass through the hole, which has a diameter wider than the width of the slot, and be captively retained by the slot while the panel hangs from the support wire. The terminal ball member and hole and slot of the hanger are mutually sized and configured so that the ball can pass through the hole from one side of the hanger plate to the other and vertically ride up the slot (as the wire connected to the ball member moves along the slot) whilst the width of the slot is smaller than the ball member thereby preventing it from passing through the slot itself to the other side of the hanger plate. In the embodiment shown, the ends of the hanger elements are curved to match the curvature of the rod to which they are attached (in this case, having a circular cross-section).  FIG. 4B  shows a side view of the hanging hardware in more detail.  FIG. 4C  shows how a lattice-configured panel embodiment of the invention may be hung from four points. The invention also provides hanger plates having a bend defining a vertex and a slot extending downward on each side of the bend, to a hole having a width/diameter larger than the width of the slot on each side. The slot on each side may be part of one continuous slot, or the slot on each side may be a separate, unconnected slot. 
       FIG. 5  shows an embodiment of the invention that includes an array of six lattice-configured panel fixtures (one labeled  501 ) disposed next to each other. The rod ends that extend into the overlap zone (beyond the 48″×48″ envelope in  FIG. 3 ) for each panel overlap each other for the adjacent sides of neighboring panels. In this manner, the array of panels takes on a unitary appearance to the observer. The four support attachment points for each of the modules are shown by black dots in the figure. 
       FIG. 6  shows an embodiment of an automated rod picking system including a rod storage rack  601  and a robotic picker  602 , which may be employed in the manufacture of lattice-configured panel fixtures according to the invention. 
       FIG. 7  shows a manufacturing system embodiment of the invention that includes a robotic picking/placing arm  602 , robotic welding arm  703 , a rod placement jig  704 , and a partially constructed lattice-configured panel fixture  705 . Jig  704  includes a base from which upwardly extending support tabs are disposed. Each of the support tabs includes a notch at its top end which is sized and configured so that the rod stock can rest within the notch. 
       FIG. 8  illustrates the stacking order of rods for the manufacture of a panel fixture embodiment of the invention. A rod placement jig  804  is shown with the complete set of rods joined as a panel. The placement order of particular rods is correspondingly represented by the numbering of the projected rods represented above jig  804  (the first placed rod being number  1 , the second placed being number  2 , and so on). For any particular panel fixture embodiment of the invention, the placement order of the rods (and corresponding joining process(es)) may be programmed into the robotic systems. 
       FIG. 10A  is a key diagram enumerating the four sides of the panel embodiment shown in  FIG. 1A . Side  1  is the rear side; side  2  is the right side, side  3  is the front side; and side  4  is the left side. Each of  FIGS. 10B-10E  shows the corresponding elevational views of the four sides. In one aspect, the invention also provides the design and shape of a fixture panel as shown in any one of or combination of the figures, with or without the hangers and/or support wires. 
     Although the foregoing description is directed to the preferred embodiments of the invention, other variations and modifications may be made without departing from the spirit or scope of the invention. Moreover, features described in connection with one embodiment of the invention may be used in conjunction with other embodiments, even if not explicitly stated above.