Decorative Acoustical Ceiling Panel

Abstract

A decorative acoustical ceiling panel which, when assembled with other like panels in edge-to-edge relation in a suitable ceiling installation, provides the appearance of a blanket of carpeting covering the ceiling. The panel comprises a rigid rectangular frame member having a rectangular layer of carpeting material fastened to its lower surface so as to form a facing thereover. Mounting means in the form of hook members are fastened to the upper surface of the frame member for mounting the panel on support members suspended from a ceiling.

Description

This invention relates to a decorative and acoustical panel and, more particularly, to such a panel designed for installation in a ceiling structure.

It is an object of this invention to provide a strong, light-weight panel structure having excellent acoustical properties and great versatility in decorative designs.

Another object of the invention is to provide a decorative and acoustical panel structure which, when installed in a suitable ceiling installation with other like panels in edge-to-edge relation, presents the appearance of a blanket of carpeting covering the ceiling.

A further object of the invention is to provide a decorative acoustical panel of the type described above, which is designed to be easily mounted in a ceiling installation.

Still another object of the invention is to provide a decorative and acoustical panel of the type described above, which has fire-resistant properties.

A still further object of the invention is to provide a decorative and acoustical panel of the type described above, which is simple in construction, easy to manufacture, aesthetically appealing, and efficient in use.

The decorative and acoustical panel of the present invention comprises a rigid rectangular frame member having a rectangular layer of carpeting material fastened to the lower surface thereof so as to form a facing over the frame member. The peripheral side edges of the carpeting material are in alignment with the peripheral side edges of the frame member. Mounting means in the form of hook members are fastened to opposite sides of the upper surface of the frame member for mounting the panel on support members suspended from a ceiling. The carpeting material is provided with a fire resistant coating on its backing. The panels are designed for installation in a ceiling structure in edge-to-edge relation so that when so installed, they present the appearance of a blanket of carpeting covering the ceiling.

The above and other objects, features, and advantages of the present invention will become more readily apparent from the following detailed description when considered in connection with the accompanying drawings, wherein like reference characters indicate like parts throughout the several figures and in which:

FIG. 1 is a fragmentary perspective view of an installation of ceiling panels constructed according to the present invention;

FIG. 2 is an exploded perspective view showing the construction of the ceiling panels of the present invention;

FIG. 3 is a perspective view of the ceiling panels of the present invention in assembled form;

FIG. 4 is an enlarged sectional view taken along line 4--4 of FIG. 3, and showing the panel mounted on support members;

FIG. 5 is an enlarged fragmentary perspective view showing the construction of the frame member of the ceiling panel of the present invention; and

FIG. 6 is a perspective view of a modified form of ceiling panel in accordance with the present invention.

Referring to the drawings, the reference numeral 10 generally indicates the decorative acoustical panel of the present invention, which comprises a rigid rectangular frame member 12, preferably formed of a light gauge, light-weight metal such as aluminum or the like. The frame member 12 is formed of four generally U-shaped side members 14 which, in the embodiment shown in FIGS. 2 and 3, are all substantially the same in length so as to provide the frame member with a square configuration. Each side member 14 includes a top edge 16, a bottom edge 18, and a peripheral side edge 20. The bottom edges 18 are provided with a plurality of holes 22 along their length. As best seen in FIG. 5, the side members 14 have their ends overlapping, with the top edge 16 and bottom edge 18 of one side member resting on the top and bottom edge, respectively, of the adjacent side member, and with a hole 22 on each adjacent side member being in alignment so that the adjacent side members can be fastened together by suitable screws. The adjacent side members 14 are also preferably spot-welded together at their ends for added strength and rigidity.

A rectangular layer of carpeting material 24 is fastened to the lower surface of the bottom edge 18 of frame member 12 by means of suitable screws 26 which pass through the carpeting material 24 and are received in engagement in the holes 22 in the frame member 12.

The carpeting material 24 is of the same dimensions as the frame member 12, with the peripheral side edges 28 of the carpeting material 24 being in alignment with the peripheral side edges 20 of the frame member 12. The pile 30 of the carpeting material 24 faces away from the frame member 12 and forms a decorative and acoustical facing thereover.

The backing 32 of the carpeting material 24 is provided with a fire-resistant coating 34 so as to impart fire-resistant properties to the panel. A particularly suitable fire-resistant coating material is "Harnisch's Asbestos Furnace Cement", which is manufactured by L. E. Harnisch and Company of Chicago, Ill., and may be readily sprayed onto the backing 32 of the carpeting material 24. This material is particularly suitable, since besides its fire-resistant properties, it also renders the carpeting material mildew-proof, waterproof and acid-proof and further imparts added strength and stiffness to the carpeting material so as to eliminate sagging thereof.

Mounting means for mounting the panel in a suitable ceiling installation are provided in the form of generally U-shaped hook members 36 which are welded onto the upper surface of the top edge 16 of opposite side members 14 of the frame member 12. As shown in the drawings, two such hook members 36 are provided on each of two opposite side members 14. The hook members 36 have their openings 38 facing laterally outwardly of the frame member 12, with a lower leg 40 fastened to the upper surface of the top edge 16 of the frame member 12, a free upper leg 42 spaced from and parallel to the top edge 16, and an intermediate leg 44 joining the lower leg 40 and the free upper leg 42 laterally inwardly of the peripheral side edge 20.

The decorative acoustical panels of the present invention are adapted to be mounted in a ceiling installation on spaced parallel inverted T-shaped support members 46 suspended from a ceiling by means of suspension members 48, as shown in FIGS. 1 and 4. Each support member 46 has an upper vertical leg 50 fastened at its top to a suspension member 48, and a pair of horizontal arms 52 extending substantially equi-distantly in opposite directions from the bottom of the vertical leg 50.

As shown in FIG. 4, the free legs 42 of the hook members 36 on opposite sides of the frame member 12 engage the horizontal arms 52 of adjacent support members 46, with the horizontal arms 52 extending into the openings 38 of the hook members 35, so as to mount the panel between adjacent support members 46. The spacing between adjacent support members 46 is such that when the panels are so mounted, the peripheral side edges 20 of the hook-carrying side members 14 of the frame member 12 are in vertical alignment with the vertical legs 50 of each of the adjacent support members 46. In this manner, adjacent panels on opposite sides of each support member 46 are in substantially edge-to-edge relation. With adjacent panels between adjacent support members 46 also being is substantially edge-to-edge relation, as shown in FIG. 1, the resulting ceiling installation presents the appearance of a blanket of carpeting covering the entire ceiling.

The decorative acoustical panels of the present invention may be made in any of the standard paneling sizes, such as 1' .times. 1', 1' .times. 2', 2' .times. 2', 2' .times. 4', and the like. In general, standard sized panels either have a square configuration or have one dimension twice as long as the other. In FIG. 6 is shown a modified form of the invention wherein the panel is of the latter type. The panel 60 is identical in construction with the panel 10, with the exception that its rectangular frame member 62 is formed of a shorter pair of parallel generally U-shaped side members 64 and a longer pair of parallel generally U-shaped side members 66, the side members 66 being about twice the length of the side members 64. The frame member 62 also includes a generally U-shaped reinforcing member 68 parallel to the shorter side members 64 and joining together the longer side members 66 intermediate their ends so as to divide the frame member 62 into two square sections. The reinforcing member 68 provides the frame member 62 with the necessary strength and rigidity and also serves as another point of attachment of the carpeting material 70 to the frame member 62 so as to prevent sagging of the carpeting material.

The carpeting material employed in the panels of the present invention may be any of a wide variety of types, grades, colors, and decorative designs, depending upon the type and size of the room in which the panel is to be installed, the acoustical properties desired, and the interior decorating effect desired. For example, in addition to the usual type of room in which acoustical ceiling panels are ordinarily employed, such as libraries, auditoriums, home recreation rooms, offices, computer rooms, and the like, the panels of the present invention, when constructed with the indoor-outdoor type of carpeting material having exceptional moisture-resistant properties, have particular utility in indoor swimming pools, shower rooms, and other high humidity areas where soundproofing is desirable.

Although the invention has been described in its preferred embodiment wherein the panels are mounted in a ceiling installation in edge-to-edge relation so as to present the appearance of a blanket of carpeting covering the ceiling, the panels could also be mounted in a more conventional "drop-in" type of ceiling installation wherein the bottom of the panel rests on the horizontal arms 52 of adjacent support members 46. In this latter type of installation, the horizontal arms 52 would be exposed as seams between adjacent panels.

While in the foregoing there has been shown and described certain specific embodiments of this invention, it is to be understood that many modifications thereof are possible. The invention, therefore, is not to be restricted except insofar as is necessitated by the prior art and by the spirit of the appended claims.

Claims

What is claimed is:

1. A decorative acoustical ceiling panel comprising,

a rigid rectangular frame member including a top edge, bottom edge and peripheral side edges connecting said top and bottom edges,

a rectangular layer of carpeting material fastened to the lower surface of said bottom edge and forming a facing over said frame member,

the peripheral side edges of said carpeting material being in alignment with said peripheral side edges of said frame member, and

hook members fastened to opposite sides of the upper surface of said top edge of said frame member for mounting said panel on support members suspended from a ceiling,

said hook members are generally U-shaped with their openings facing laterally outwardly of said frame member, one leg fastened to the upper surface of said top edge of said frame member, and a free leg spaced from and parallel to said top edge.

2. The ceiling panel of claim 1 wherein a plurality of said hook members are fastened to each of two opposite sides of the upper surface of said top edge of said frame member.

3. The ceiling panel of claim 1 wherein said support members are spaced parallel inverted T-shaped members having laterally extending arms, and the free legs of said hook members on opposite sides of said frame member are adapted to engage the arms of adjacent support members so as to mount said panel therebetween.

4. A decorative acoustical ceiling panel comprising a rigid rectangular frame member including four generally U-shaped side members each having a top edge, bottom edge and peripheral side edges connecting said top and bottom edges, the ends of said side members overlapping and being fastened together, one pair of said side members being about twice the length of the other pair of side members and joined together intermediate their ends by a reinforcing member parallel to said other pair of side members,

a rectangular layer of carpeting material fastened to the lower surface of said bottom edge and forming a facing over said frame member,

the peripheral side edges of said carpeting material being in alignment with said peripheral side edges of said frame member, and mounting means on said frame member for mounting said panel on a ceiling.

5. The ceiling panel of claim 4 wherein said carpeting material is provided with a fire-resistant coating.

6. The ceiling panel of claim 5 wherein said fire-resistant coating is on the backing surface of said carpeting material.