Abstract:
A curved suspension ceiling panel that creates the appearances of a curved or wavy ceiling surface when used in combination with a planar grid system. The curved suspension ceiling panel comprises a curved exterior surface. The curved panel includes a pair of opposed sidewalls that are attached to the curved exterior surface and includes a curved surface along a first edge and a substantially linear surface along a second edge. The linear edges include a flange that permits the panel to be attached to grid members of a planar grid system. The curved panels are designed so that they can be inverted within the grid so that the curved exterior surface is above the grid members. During installation, the curved panels can be arranged to form an undulating or wavy pattern to create a desired effect when viewed from below.

Description:
BACKGROUND  
       [0001]     This disclosure relates to suspended ceiling systems and more particularly to a novel and improved system using curved ceiling panels having a curved exterior surface in combination with a planar perimeter that is adapted to be used with a horizontal grid structure.  
         [0002]     By way of background but not limitation, suspended ceiling systems typically include grid members that provide for oppositely extending ceiling panel support flanges. In these systems, the edges of the ceiling panels are installed by laying them in the panel opening created by the grid members. There are also suspended-ceiling systems that have grid members, which include channels designed to grip the vertically extending edges of metal ceiling panels. These ceiling panels are typically installed by snapping the flanges up into the grid member channel, and are generally referred to as “snap-up ceiling panels.” Typical lay-in grid panels are manufactured to fit within a horizontal grid and are planar in nature. In order to obtain a curved ceiling surface in typical ceiling systems, curved panels are used in combination with curved ceiling grid members. The use of curved grid members to form the ceiling structure increases cost and difficulty of installation.  
         [0003]     In view of the above, it should be appreciated that there is a need for a ceiling system that provides for a curved ceiling surface while permitting the use of a standard horizontal grid arrangement. The present disclosure satisfies these and other needs and provides further related advantages.  
       SUMMARY  
       [0004]     The disclosure may be described as a novel and improved curved suspension ceiling system that creates the appearance of a curved or wavy ceiling surface when used in combination with a planar grid system. In the preferred embodiment, the curved panel system comprises a metallic or polymer curved panel having a curved exterior surface formed by a curved wall. The curved panel includes a pair of opposed sidewalls that are attached to the curved wall and include a curved surface along a first edge and a substantially linear surface along a second edge. The linear edges each include flanges that permit the curved panel to be attached to grid members of the planar grid system. The curved panels are designed so that they can be flipped over so that the face of the curved wall can be oriented to face above or below the ceiling grid. During installation, the curved panels can be alternately flipped to form an undulating or wavy pattern to create a desired effect when viewed from below.  
         [0005]     Other features and advantages of the disclosure will be set forth in part in the description which follows and the accompanying drawings, wherein the embodiments of the disclosure are described and shown, and in part will become apparent upon examination of the following detailed description taken in conjunction with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0006]     The above mentioned and other features of this disclosure and the manner of obtaining them will become more apparent and the disclosure will be best understood by reference to the following description of embodiments of the disclosure taken in conjunction with the accompanying drawings in which:  
         [0007]      FIG. 1  is a perspective view of a ceiling system illustrating curved ceiling panels;  
         [0008]      FIG. 2  is a sectional view of the ceiling system, taken along lines  2 - 2 , illustrating the curved ceiling panels connected to a grid system;  
         [0009]      FIG. 3  is a perspective view of the curved ceiling panel;  
         [0010]      FIG. 4  is a top view of the curved ceiling panel;  
         [0011]      FIG. 5  is a side elevational view of the curved ceiling panel; and  
         [0012]      FIG. 6  is an end view of the curved ceiling panel. 
     
    
     DETAILED DESCRIPTION  
       [0013]     While the present disclosure will be described fully hereinafter with reference to the accompanying drawings, in which a particular embodiment is shown, it is to be understood at the outset that persons skilled in the art may modify the disclosure herein described while still achieving the desired result. Accordingly, the description that follows is to be understood as a broad informative disclosure directed to persons skilled in the appropriate art and not as limitations on the present disclosure.  
         [0014]     As illustrated in the drawings,  FIG. 1  illustrates a portion of an assembled suspension ceiling incorporating curved ceiling panels  10  in accordance with the present disclosure. In such a ceiling panel system, grid members  12  are interconnected to form a grid structure  13 . The grid members  12  are arranged to form openings sized to receive the curved ceiling panels  10 . The grid members  12  are suspended from the building structure by wire hangers  16  or other supporting structures.  
         [0015]     To create the grid structure  13 , a row of parallel evenly spaced grid members  12  are suspended by the wire hangers  16 . Each row of the grid members  12  are spaced apart to accommodate the size of the curved ceiling panels  10 . To accommodate a two foot by two foot ceiling panel, the grid members  12  would be spaced apart two feet on-center. The grid structure  13  also includes a second set of grid members  18  that are perpendicularly oriented in relation to the first set of grid members  12  to create the opening required for hanging the curved ceiling panels  10 .  
         [0016]     The curved ceiling panels  10  are normally rectangular or square in shape, and are preferably made out of metal or polymer. The curved ceiling panels  10  are durable in that they are impact resistant, self-supporting do not sag when spanned between grid members  12 . Metal and plastic polymeric material, such as polycarbonate, are preferred since panels can be molded or stamped to include a desired shape or to form various edge configurations for connection to the grid structure  13 . Alternately, among other rigid, and semi-rigid materials, glass reinforces gypsum, wood or thermoformed fabrics may be used.  
         [0017]     The curved ceiling panel  10  used within the grid structure  13  as shown in  FIGS. 1 and 2  are comprised of a curved wall  20  that includes a first face  22  and second face  24 , opposing the first face  22 . Depending upon the orientation of the curved panels  10  within the grid structure  13 , either the first face  22  or the second face  24  may be exposed to the area below the grid structure  13 . The curved wall  20  of the curved ceiling panel  10  is curved about its length and extends from a first edge  26  to a second edge  28  of the curved ceiling panel  10 . The curved ceiling panels  10  also includes a first sidewall  30  and a spaced apart second sidewall  32 . The first sidewall  30  is substantially parallel to the second sidewall  30 .  
         [0018]     The first sidewall  30  of the curved ceiling panel  10  includes a relatively linear edge  34  and a curved edge  36 . The curved edge  36  of the first sidewall  30  is spaced apart from the linear edge  34  in the central region of the panel  10  but converges with the linear edge  34  at the endpoints  38  of the curved edge  36 . The curved edge  36  is formed by the intersection of the curved wall  20  with the first sidewall  30 .  
         [0019]     The second sidewall  32  of the panel  10  is parallel to and spaced apart from the first sidewall  30 . The second sidewall  32  of the panel  10  includes a relatively linear edge  40  and a curved edge  42  as shown in  FIG. 5 . The curved edge  42  of the second sidewall  32  is spaced apart from the linear edge  40  in the central region of the panel  10  but converges with the linear edge  40  at the endpoints  44  of the curved edge  42 . The curved edge  42  is formed by the intersection of the curved wall  20  with the second sidewall  32 .  
         [0020]     The first and second edges  26 ,  28  of the panel  10  form a portion of the perimeter of the panel  10 . The first edge  26  includes a first flange  46  that extends outwardly from the panel  10 . The first flange  46  is adapted to be connected to the grid members  12  of the grid structure  13  to aid in supporting the panel  10 . In a lay-in panel arrangement, the first flange  46  is horizontally oriented and rests upon a base portion  58  of the grid members  12  as shown in  FIG. 2 . When using a snap-in panel arrangement, the first flange  46  is adapted to be connected to a channel portion of the grid members  12 . The second edge  28  includes a second flange  48  that extends outwardly from the panel  10 . The second flange  48  is adapted to be connected to the grid members  12  of the grid structure  13  to aid in supporting the panel  10  as shown in  FIG. 4 .  
         [0021]     The linear edge  34  of the first sidewall  30  of the curved panel  10  includes a third flange  50  that extends outwardly from the curved panel  10  as shown in  FIG. 3 . The third flange  50  is adapted to be connected to the grid members  12  of the grid structure  13  to aid in supporting the panel  10 . The linear edge  40  of the second sidewall  32  includes a fourth flange  52  that extends outwardly from the curved panel  10 . The first, second, third and fourth flanges  46 ,  48 ,  50  and  52  form the perimeter of the curved ceiling panel  10 . The flanges  46 ,  48 ,  50  and  52  may also include tabs that aid in retaining the curved ceiling panels  10  to the grid structure  13 .  
         [0022]     The curved ceiling system, as shown in  FIGS. 1 and 2 , illustrates the curved panels  10  connected to the grid structure  13  by use of flanges  46 ,  48 . While the curved ceiling panels  10  preferably are connected to the grid structure  13  with flanges, a hinge may be used to permit the curved ceiling panel  10  to be pivoted to an open position for service above the ceiling structure  13 . While flanged edges and a hinged edge are disclosed, other edge configurations may be used to secure the curved ceiling panels  10  to the grid system  13 . It is beneficial to use the hinge to support the curved ceiling panel  10  when all metal ceiling panels become as large as 4 feet by 4 feet, because the panels become awkward to install and remove due to their relatively large size and weight. Further illustrations of the use of a hinge can be found in U.S. Pat. No. 6,467,228, incorporated herein by reference. When working with a piece of sheet metal with such a large surface, any improper handling may result in damage to the overall finish of the ceiling panel  10 . Also, by using the hinge that spans the width of the curved ceiling panel  10 , the weight of the panel is evenly distributed across the entire edge of the curved panel  10 , preventing rippling that would be apparent in the curved wall  20  of the curved panel  10 . Furthermore, once the curved ceiling panel  10  is connected to the grid members  12 , the curved ceiling panel  10  will automatically be in alignment to allow for easy closure by pivoting the ceiling panel  10  upward and snapping in the flanges into the grid.  
         [0023]     The grid member  12 , as shown in  FIG. 2 , in this example  12  is fabricated out of die-formed sheet metal. The grid member  12  after fabrication includes a bulb portion  56 , a base portion  58  and a bridge portion  60  that connects the bulb portion  56  and the base portion  58 . The overall shape of the grid member  12  is to give the member  12  strength to prevent flexing. Typically, apertures (not shown) are placed along the length of the bridge portion  60  so that wire hangers  16  can be threaded through and wrapped around the bulb portion  56 . Once the wire hanger  16 , as shown in  FIG. 1 , which can be in the form of a wire, is threaded through an aperture (not shown) and around the bulb portion  56 , the wire hanger  16  is wrapped around itself several times to prevent it from unraveling.  
         [0024]     The bridge portion  60  typically includes slots (not shown) that allow one grid member  12  to be connected to the second grid member  18  to form the grid structure  13 . The base portion  58 , as shown in  FIG. 2  is formed by bending the double layers of the bridge portion  60 , ninety degrees outward and one hundred eighty degrees inward to form a planar surface. If a hinge is used, a modified grid member  12  is used that includes a boxed channel located on the bottom portion of the grid member  12 . The hinge is formed in the curved ceiling panel  10  by die-forming the hinge ninety degrees upward to create an upwardly extending leg and then die-forming the edge ninety degrees inward to create an inward lip. The inward lip of the hinge rests within the channel of the grid member  12 . The flanges  46 ,  48 ,  50 ,  52 , shown in  FIG. 2 , are formed by die-forming or molding the edges  34 ,  36 ,  40 ,  42  of the curved ceiling panel  10  outward to form a horizontal surface. The ceiling panel  10  is retained to the grid structure  13  by positioning the flanges  46 ,  48 ,  50 ,  52  on the base portion  58  of the grid members.  
         [0025]     The environmental area of the building structure is defined as the space within a building used by occupants to work or conduct other activities. It is the inhabitable space within a structure. From the environmental area, the curved wall  20  of the curved ceiling panel  10  is substantially exposed and viewable by the occupants below. Depending upon the orientation of the curved ceiling panel  10  within the grid structure  13 , either the first face  22  or the second face  24  will be viewable from the environmental area below. When the curved ceiling panel  10  is positioned with the curved wall  20  in an arched position, the first face  22  is viewable from below. When the curved ceiling panel  10  is positioned within the grid structure  13  with the curved wall  20  in an inverted arch position, the second face  24  of the curved wall  20  is viewable from the environmental area below.  
         [0026]     The curved ceiling panels  10  are designed with four edges that are adapted to be connected to the grid structure  13 . The curved ceiling panels  10  can be connected to the grid structure  13  using various edge configurations. The edges can be outfitted with flanges that permit either snap in or lay in configurations.  
         [0027]     In use the curved ceiling panels  10  are an economical solution to achieving a unique ceiling appearance. The present arrangement permits the creation of a wavy or rolling ceiling appearance while utilizing easy to install planar grid structure  13 . Using the curved ceiling panels various patterns can be formed in the ceiling including having all panels oriented in an arched position or all panels oriented in an inverted arch position. Alternating the orientation of the panels in adjacent grid openings permits the creation of wavy or rolling patterns. Since standard linear grid members can be used additional hardware to secure the proper orientation of the panels with respect to the grid structure  13  is not required. In systems where curved grid members are used, it is necessary to use additional fasteners to ensure the panels conform to the shape of the grid members.  
         [0028]     While the concepts of the present disclosure have been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only the illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired and protected.  
         [0029]     There are a plurality of advantages that may be inferred from the present disclosure arising from the various features of the apparatus, systems and methods described herein. It will be noted that alternative embodiments of each of the apparatus, systems, and methods of the present disclosure may not include all of the features described yet still benefit from at least some of the inferred advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of an apparatus, system, and method that incorporate one or more of the features of the present disclosure and fall within the spirit and scope of the invention as defined by the appended claims.