Patent Description:
Linear ceiling panels have a longitudinal length which is substantially greater than their width, the longitudinal length of the panel generally being at least three times the width of the panel, and usually at least five times the width of the panel.

Carriers for mounting ceiling panels are known in the art. The carriers are attached to or are suspended from the structural ceiling or upper part of a wall adjacent to the structural ceiling. The ceiling panel is attached to the carrier, and is thereby mounted on the ceiling.

<CIT> discloses a linear ceiling panel mounting system according to the preamble of independent claim <NUM>.

The present invention seeks to provide an improved carrier which is suitable for mounting linear panels on the ceiling without requiring adhesive or mechanical fastening means such as screws for attaching the ceiling panel to the carrier.

According to the present invention in one embodiment thereof, there is provided a linear ceiling panel mounting system comprising at least one carrier for mounting linear panels on a ceiling, the carrier extending in a longitudinal direction and having at least one recess formed therein, the recess being for receiving a linear ceiling panel, the recess extending through the cross-section of the carrier, the recess being defined by a surface comprising at least a first wall portion and a second wall portion, the recess separating the first wall portion from the second wall portion, and the second wall portion defining a flange which extends at least partially into the recess, thereby providing the recess with a neck portion and a main portion, and wherein the neck portion has, at its narrowest point, a distance d1 separating the first wall portion from the second wall portion,.

the linear ceiling panel mounting system further comprising a linear ceiling panel having a flexible, resilient flange which extends along the whole or part of an edge of the panel, the flange being configured to slot into the recess of the carrier and be retained therein to thereby attach the linear ceiling panel to the carrier,
wherein.

The neck portion may have, at its narrowest point, a distance d1 of less than <NUM> separating the first wall portion from the second wall portion. Advantageously, the distance d1 is less than <NUM> and preferably less than <NUM>. Preferably, the distance d1 is at least <NUM>.

The distance d1 is preferably approximately three-quarters to two times the combined thickness of the flange and that part of the panel adjacent the flange. Preferably the distance d1 is approximately <NUM> to <NUM> times the combined thickness of the flange and that part of the panel adjacent the flange.

The carrier may comprise a plurality of recesses formed therein, each recess being configured to receive the flange of a linear ceiling panel.

The carrier may comprise a plurality of identical recesses formed therein, each recess being configured to receive the flange of a linear ceiling panel.

Alternatively, the carrier may comprise a pair of recesses formed therein, the recesses being mirror images of each other and both recesses being configured to each receive a flange of a linear ceiling panel. Advantageously, the carrier may comprise several pairs of such recesses. Alternatively, the recesses of a pair may be different from each other.

The linear ceiling panel mounting system may comprise a plurality of carriers each comprising several pairs of recesses formed therein, the recesses of each pair being mirror images of each other, and the system further comprising a plurality of linear ceiling panels each having a flexible, resilient flange extending along the whole or part of two opposing edges of the panel, both recesses of each pair being configured to each receive a flange of the linear ceiling panel, the flanges of the linear ceiling panel being configured to slot into the recesses of the carrier and be retained therein to thereby attach the linear ceiling panel to the carrier.

Each linear ceiling panel preferably has a longitudinal length which is at least three times, and more preferably at least five times, the width of the panel.

The linear ceiling panel mounting system of any of the embodiments described above may comprise at least one linear ceiling panel having substantially a "U"-shaped cross-section, and comprising a central region and two side walls extending from the central region, the panel further comprising a flexible, resilient flange extending from each of the side walls, the resilience of the flange acting to retain the angle between each flange and its corresponding side wall at preferably approximately <NUM>° or less.

The flexible, resilient flange is preferably configured to be bent towards the corresponding side wall of the panel to permit insertion of the flange and adjacent side wall of the panel in the neck portion of the recess of the carrier, the angle β of the flange with respect to the adjacent side wall being thereby reduced to <NUM>° or less, more preferably <NUM>° or less and most preferably less than <NUM>°.

The flexible, resilient flange is formed from
a thermoformable, non-woven fibrous material.

The combined thickness of the flange and that part of the panel adjacent the flange is preferably in the range of <NUM> - <NUM> and more preferably in the range of <NUM> - <NUM>.

Further features of the carrier and the linear ceiling panel mounting system are to be found in the appended claims.

The present invention also provides a method of mounting a linear ceiling panel in a carrier comprising the steps of: providing a linear ceiling panel mounting system as described above; bending, prior to or during mounting of the panel, a flange of the panel towards an adjacent part of the panel; inserting the flange and adjacent part of the panel into a recess of the carrier, such that the flange passes past the neck portion of the recess into the main portion of the recess, the resilient nature of the flange then urging the flange to return to its original configuration once it is no longer constrained by the neck portion of the recess.

The present invention will now be described by way of example only and with reference to the following drawings, of which:.

<FIG> shows a carrier <NUM> for mounting linear panels on a ceiling in accordance with the present invention. The carrier <NUM> extends in a longitudinal direction L and comprises a central portion <NUM> and two arms <NUM>, <NUM> which extend from the central portion and which are provided along the longitudinal length of the carrier. The carrier has a cross-sectional shape in the form of an inverted truncated "V". Holes <NUM> are provided along the central portion of the carrier and/or the arms <NUM>, <NUM> to permit the carrier to be attached to or suspended from the ceiling.

The carrier <NUM> is provided with a plurality of recesses <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, arranged in pairs a, b, c, d along the length L of the carrier. Each pair of recesses includes two recesses being the mirror image of each other. Generally, each pair of recesses of the carrier will be identical for ease of manufacture, however, in this example each pair of recesses a, b, c, d is of a different shape to show examples of suitable recess configurations. Other recess configurations may also be suitable. Alternatively, the pair of recesses could include two recesses which are not the mirror image of each other. In this case, the recesses of the pair may be identical or may be different.

Each recess extends through the cross-section of the carrier and is defined by a surface <NUM>. The surface <NUM> comprises a first wall portion <NUM> and a second wall portion <NUM> with the recess between the first and second wall portions. The second wall portion <NUM> of the surface <NUM> defines a flange <NUM> which extends into the recess, thereby providing the recess with a neck portion <NUM> and a main portion <NUM>. The neck portion <NUM> is narrower than the main portion <NUM>.

The neck portion <NUM>, at its narrowest point, has a distance d1 of less than <NUM> separating the first wall portion <NUM> from the second wall portion <NUM>. Flange <NUM> may have substantially square edges as exemplified by recess pairs a, c, d or may alternatively have rounded edges as recess pair b shows.

Although the carrier of <FIG> has an inverted, truncated "V"-shaped cross-section, other cross-sectional shapes such as, for example, inverted or non-inverted "U", "V", "L"-shapes or "omega"-shapes, are also possible. The carrier may exhibit a space between arms <NUM>, <NUM> as shown in <FIG> or may alternatively be formed from a solid bar, having a cross-section as defined above. However, for cost and ease of manufacturing reasons, a carrier having arms with a space between is preferred over a solid bar.

<FIG> shows a carrier <NUM> for mounting linear panels on a ceiling in a further embodiment of the present invention. In this example, the carrier <NUM> extends in a longitudinal direction L and comprises a central portion <NUM> and an arm <NUM> which extends from the central portion and which is provided along the longitudinal length L of the carrier <NUM>. The carrier has a cross-sectional shape in the form of an inverted "L". Holes <NUM> are provided along the central portion <NUM> of the carrier and/or the arm <NUM> to permit the carrier to be attached to or suspended from the structural ceiling.

The carrier <NUM> is provided with a plurality of recesses <NUM>, <NUM>, <NUM>, <NUM> arranged along the length of the carrier. Generally, each recess will be identical for ease of manufacture, however, in this example, each of the recesses <NUM>, <NUM>, <NUM>, <NUM> are of a different shape to show examples of suitable recess configurations. Other recess configurations may also be suitable.

As described with respect to <FIG>, each recess extends through the cross-section of the carrier and is defined by a surface <NUM>. The surface <NUM> comprises a first wall portion <NUM> and a second wall portion <NUM> with the recess between the first and second wall portions. The second wall portion <NUM> of the surface <NUM> defines a flange <NUM> which extends into the recess, thereby providing the recess with a neck portion <NUM> and a main portion <NUM>. The neck portion <NUM> is narrower than the main portion <NUM> and, at its narrowest point, the neck portion has a distance d1 of less than <NUM> separating the first wall portion <NUM> from the second wall portion <NUM>.

The flange <NUM> may have substantially square edges, as exemplified by recesses <NUM>, <NUM>, and <NUM>, or may alternatively have rounded edges as demonstrated by recess <NUM>.

Although the carrier of <FIG> has an inverted "L"-shaped cross-section, other cross-sectional shapes such as, for example, those described above with respect to <FIG> are also possible.

<FIG> shows a side view of a linear ceiling panel mounting system <NUM> comprising a carrier <NUM> similar to that depicted in <FIG>. For simplicity, all of the pairs of recesses are shown as being identical and have the form of pair b of <FIG>. It will be appreciated that the pairs of recesses may instead have the form shown as recess pair a, c or d or any other suitable shape of recess. Each of the recess pairs is preferably identical for ease of manufacture.

The linear ceiling panel mounting system <NUM> further comprises a linear ceiling panel <NUM>. The panel <NUM> is shaped to facilitate mounting of the panel <NUM> to the carrier <NUM>. In particular, the panel comprises a central region <NUM>, two side walls <NUM>, <NUM> and a flange <NUM>, <NUM> extending from each of the side walls <NUM>, <NUM>. The central region, side walls and flanges may be formed separately but are preferably formed integrally with respect to each other. The flanges <NUM>, <NUM> of the ceiling panel <NUM> are formed from a flexible resilient material which permits the flanges to be bent towards the side wall and, when released, to spring back to their original position.

<FIG> show a linear ceiling panel such as that described with respect to <FIG> being mounted in a carrier. <FIG> shows the panel with its flanges in their original position, just prior to being mounted in the carrier. <FIG> shows the panel during mounting, and it can be seen that the flanges are bent towards the side walls of the panel to enable the flange to pass through the narrow neck portion. <FIG> shows the panel once it is mounted to the carrier and the flanges have passed through the neck portion of the recess and, due to their resilient nature, have sprung back into their original position insofar as surface <NUM> defining the main portion <NUM> of the recess permits.

The flanges <NUM>, <NUM> are configured to fit within the corresponding recesses <NUM>, <NUM> of the carrier. The angle β between the side wall and the flange is, in this example, approximately <NUM>°, although other angles β, preferably in the range of <NUM>°-<NUM>°, may be used instead. The flanges retain some flexibility due to the nature of the material from which they are made, and are able to be bent towards the side wall, as shown in <FIG>, thereby decreasing the angle β. As the flanges are able to be bent sufficiently to allow the flange and the adjacent part of its associated side wall to pass through the neck portion of the recess, the flanges and their adjacent side walls are able to be inserted into their respective recesses <NUM>, <NUM> of the carrier. Once inserted, the resilient flanges will have a tendency to spring back to their original shape as shown in <FIG>, thereby wedging themselves securely in the recess. The flexible and resilient nature of the flanges ideally allows the flanges to be bent such that β is very small, preferably less than <NUM>°, and may approach or reach zero. The flange will then be substantially parallel to, and almost or actually touching the side wall. In this configuration, the flange and adjacent side wall are able to be inserted together through the thin neck portion <NUM> of the recess. The neck portion <NUM> needs to have a gap d1 large enough to permit insertion of the flange and adjacent side wall, and should therefore be at least the thickness of the flange plus the thickness of the adjacent side wall for substantially incompressible materials which are flexible enough to permit the flange to be bent such that β is substantially zero. Once the flange is no longer constrained by the neck portion, it springs back to its original shape, in so far as the surface <NUM> defining the main portion <NUM> of the recess permits. Over time, and especially if the ceiling panels are subjected to humidity or excess heat, the flanges may start to "open out", i.e. bend away from the side walls, the angle β tending to increase. However, due to the configuration of the recess, the flange is constrained and is not able to "open out" due to the surface <NUM> defining the recess. Thus, the flange of the panel is securely retained in the recess, without the need for additional retaining means such as adhesives or mechanical fasteners (e.g. screws or bendable locking lips provided on the carrier).

Although the panel central region <NUM> is shown in this example as being substantially parallel to the carrier, the panel central region <NUM> may be angled with respect to the carrier. Similarly, the panel side walls may be provided at an angle other than <NUM>° with respect to the panel central region <NUM>.

The linear ceiling panels <NUM> are mounted in the carrier <NUM> such that they extend longitudinally in a direction substantially perpendicular to the longitudinal direction L of the carrier <NUM>. <FIG> shows a linear ceiling panel mounting system comprising a plurality of carriers <NUM> and panels <NUM>, the carriers being suspended from a ceiling. The spacing between each recess of a pair of recesses determines the width of the linear ceiling panel and the spacing between recess pairs determines the spacing between adjacent linear panels. These spacing parameters will be determined according to the architectural requirements for the building, including its desired acoustic properties and cooling mechanisms, for example.

<FIG> shows a side view of a linear ceiling panel mounting system <NUM> comprising a carrier <NUM> similar to that depicted in <FIG>. For simplicity, all of the recesses 51a, b, c are shown as being identical and have the form of the recess <NUM> of <FIG>. It will be appreciated that the recesses may instead have the form shown as recess <NUM>, <NUM> or <NUM> or any other suitable shape of recess. The recess may alternatively be in the form of a mirror image of those recesses depicted, or may comprise recess pairs such as those shown in <FIG> and <FIG>, for example.

The linear ceiling panel mounting system <NUM> further comprises a linear ceiling panel <NUM> in the form of a baffle. The panel <NUM> is shaped to facilitate mounting of the panel to the carrier <NUM>. In particular, the panel comprises a baffle portion <NUM> and a flange <NUM> which extends from the baffle portion <NUM>. The flange <NUM> is formed from a flexible, resilient material as described with respect to <FIG>. The baffle portion <NUM> and flange <NUM> may be formed separately but are preferably formed integrally with respect to each other.

The linear ceiling panels <NUM> are mounted in the carrier <NUM> such that they extend longitudinally in a direction substantially perpendicular to the longitudinal direction L of the carrier <NUM> (i.e. through the plane of the paper in <FIG>) in a manner similar to the panels depicted in <FIG>. The longitudinal length of the panels <NUM> is preferably at least <NUM> x (l<NUM> + l<NUM>) where l<NUM> is the length of the baffle portion <NUM> and l<NUM> is the length of the flange <NUM>, and more preferably at least <NUM> x (l<NUM> + l<NUM>).

As for the linear ceiling panel mounting system <NUM> of <FIG>, the flanges <NUM> of the linear ceiling panel mounting system <NUM> are configured to be received and retained within the corresponding recesses 51a, b, c of the carrier <NUM>. In this manner the panels <NUM> may be mounted on the carrier <NUM> without the need for adhesives or mechanical fasteners (e.g. screws).

<FIG> shows a side view of an alternative linear ceiling panel mounting system <NUM>. The linear ceiling panel mounting system <NUM> comprises a carrier <NUM> which is similar to that depicted in <FIG> and <FIG> except that the recesses <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> which make up recess pairs e, f, g, respectively are mirror images of the recesses <NUM> and <NUM> as shown in <FIG>. Again, it will be appreciated that the pairs of recesses e, f, g may instead be mirror images of the recesses <NUM> and <NUM> (recess pair a) or mirror images of the recesses <NUM> and <NUM> (recess pair c) or minor images of the recesses <NUM> and <NUM> (recess pair d) which appear in <FIG>. Any other suitable shape of recess may alternatively be used. Again, each of the recess pairs e, f, g are preferably identical for ease of manufacture.

The linear ceiling panel mounting system <NUM> further comprises a linear ceiling panel <NUM>. The panel <NUM> is shaped to facilitate mounting a panel to the carrier <NUM>. In particular, the panel <NUM> comprises a central region <NUM>, two side walls <NUM>, <NUM> and a flange <NUM>, <NUM> extending from each of the side walls <NUM>, <NUM>. The flanges <NUM>, <NUM> are formed from a flexible, resilient material as described with respect to <FIG>. The central region side walls and flanges may be formed separately, but are preferably formed integrally with respect to each other. However, instead of extending inwardly of the side walls as in the previous examples, the flanges <NUM>, <NUM> extend outwardly of the side walls <NUM>, <NUM> as can be seen in <FIG>. Again, the flanges <NUM>, <NUM> are sufficiently flexible to be bent towards the side walls as the flanges and their adjacent side walls are inserted into their respective recesses <NUM>, <NUM> via the neck portion of the recesses. Once inserted, the resilient flanges spring back to their original shape in so far as the surface <NUM> defining the main portion <NUM> of the recesses permits. Again, the flanges <NUM>, <NUM> are configured to fit and be retained within the corresponding recesses <NUM>, <NUM> of the carrier <NUM>, the surface <NUM> securely retaining the flanges in the recess. As for the previous examples, the linear ceiling panels <NUM> are mounted in the carrier <NUM> such that they extend longitudinally in a direction perpendicular to the longitudinal direction L of the carrier <NUM> (i.e. through the plane of the paper in <FIG>). Although the central regions <NUM> of the panels <NUM> are shown in this example as being substantially parallel to the carrier, the panel central regions <NUM> may be angled with respect to the carrier. Similarly, the panel side walls <NUM>, <NUM> may be provided at an angle other than <NUM>° with respect to the panel central region <NUM>.

<FIG> show side views of further alternative linear ceiling panel mounting systems <NUM>, <NUM>. <FIG> shows a linear ceiling panel mounting system <NUM> comprising a carrier <NUM> similar to that shown in <FIG>, but with different shaped recesses <NUM>, <NUM>, and further comprising a linear ceiling panel <NUM>. The panel <NUM> is identical to those panels described with respect to <FIG> except that the flanges <NUM>, <NUM> are formed so as to extend at substantially right angles from the side walls <NUM>, <NUM> (i.e. in this example β is approximately <NUM>°). <FIG> shows a linear ceiling panel mounting system <NUM> comprising a carrier <NUM> similar to that shown in <FIG>, but with different shaped recesses <NUM>, <NUM>, and further comprising a linear ceiling panel <NUM>. The panel <NUM> is identical to those panels described with respect to <FIG> except that the flanges <NUM>, <NUM> extend at substantially right angles from the side walls <NUM>, <NUM> (i.e. in this example β is approximately <NUM>°). Again, the flexible, resilient flanges <NUM>, <NUM> of the panels <NUM>, <NUM> of <FIG> are retained in the recesses of carriers <NUM>, <NUM> by the surface <NUM> of the recesses, without the need for adhesives or mechanical fasteners (e.g. screws). As for the previous example, the linear ceiling panels <NUM>, <NUM> are mounted in the carriers <NUM>, <NUM> such that they extend longitudinally in a direction perpendicular to the longitudinal direction L of the carriers <NUM>, <NUM> (i.e. through the plane of the paper in <FIG>).

Although specific angles β are described above, the panels may be formed such that the angle β between the flange and the adjacent side wall of the panel may be any angle which permits the flange, when in its original position, to be retained in the recess of the carrier. A suitable range would be, for example, <NUM>°≤β≤<NUM>°.

Claim 1:
A linear ceiling panel mounting system (<NUM>,<NUM>,<NUM>,<NUM>,<NUM>) comprising at least one carrier (<NUM>,<NUM>,<NUM>,<NUM>,<NUM>) for mounting linear panels on a ceiling, the carrier extending in a longitudinal direction (L) and having at least one recess (<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>) formed therein, the recess being for receiving a linear ceiling panel (<NUM>,<NUM>,<NUM>,<NUM>,<NUM>), the recess extending through the cross-section of the carrier, the recess being defined by a surface (<NUM>) comprising at least a first wall portion (<NUM>) and a second wall portion (<NUM>), the recess separating the first wall portion from the second wall portion, and the second wall portion defining a flange (<NUM>) which extends at least partially into the recess, thereby providing the recess with a neck portion (<NUM>) and a main portion (<NUM>),
and wherein the neck portion has, at its narrowest point, a distance d1 separating the first wall portion from the second wall portion,
the linear ceiling panel mounting system further comprising a linear ceiling panel (<NUM>,<NUM>,<NUM>,<NUM>,<NUM>) having a flexible, resilient flange (<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>,<NUM>) which extends along the whole or part of an edge of the panel, the flange being configured to slot into the recess of the carrier and be retained therein to thereby attach the linear ceiling panel to the carrier,
wherein
the flexible, resilient flange is configured to be bent towards an adjacent part of the panel to permit insertion of the flange and adjacent part of the panel into the recess of the carrier, and
the flexible, resilient flange is configured to return to its original configuration once it is has been inserted past the neck portion of the recess into the main portion of the recess and is no longer constrained by the neck portion of the recess, and characterized in that
the flexible resilient flange of the linear ceiling panel is formed from a thermoformable, non-woven fibrous material.