Ceiling panel

Abstract

A ceiling panel that conceals the grid in a suspended ceiling, having opposed active first and second edges with profiles different from one another, and opposed passive edges. An access kerf, and a registration kerf, at different levels in the active edges, along with a registration step in one active edge, permit the panel to be inserted, or removed, by successive hinge actions. When installed, the panel is locked to the ceiling with no visual indications on how the panel can be removed. During installation the panel is self-centering and self-aligning.

I claim: 
     
       1. For use in a suspended ceiling that has a panel supporting grid formed of inverted T-section beams, a panel, when extending horizontally, having:
 a) opposing first and second edges (A and B,) that are active in installing and removing the panel into and from the grid, each of which has a profile different from the other; 
 b) opposing third and fourth edges (C and D), each of which has a profile; 
 c) an access kerf ( 33 ) in the profile of the first edge (A) that extends along the first edge (A) at a first level; 
 d) a registration kerf ( 35 ) in the profile of the second edge (B) that extends along the second edge (B); 
 e) a tread ( 30 ) in the registration kerf ( 35 ) of the second edge (B) that extends along the second edge (B) above the first level of the access kerf ( 33 ) in the profile of the first edge (A); 
 f) a registration step having a riser ( 34 ) and a tread ( 39 ) in the profile of the first edge (A) that extends along the first edge (A) above the first level of the access kerf ( 33 ) in the first edge (A), the tread ( 39 ) being approximately at the same level as the tread ( 30 ) in the second edge (B); and 
 g) an upper lip ( 42 ) on the first edge (A) having an underside formed by the tread ( 39 ) of the registration step, and an upper lip ( 43 ) on the second edge (B) having an underside formed by the tread ( 30 ) of the second edge B, each of said undersides of said upper lips ( 42 ,  43 ) being at approximately the same level when the panel extends in the plane of the grid, that support the panel in the ceiling; 
 h) wherein none of the first, second, third or fourth edges can be identified as the first edge, the second edge, the third edge, or the fourth edge by visual inspection of the ceiling from below; and 
 i) wherein the first and second edges can be determined when the panel is installed in the ceiling by an upward force on the center of the panel, whereby the panel will pivot upward about the registration kerf in the second edge. 
 
     
     
       2. The panel of  claim 1  having a rectangular shape. 
     
     
       3. The panel of  claim 1 , wherein said panel can be inserted into and removed from a the grid ceiling without tools. 
     
     
       4. The panel of  claim 1  wherein said panel further having a lower lip on an edge of the panel each of the third and fourth edges that is passive in installing and removing the panel from the grid. 
     
     
       5. The panel of  claim 1  in combination with the grid recited in the preamble of  claim 1 , further having lower lips on at least the first edge (A) and the second edge (B) of the panel intended to conceal the grid when the panel is installed in a ceiling the grid. 
     
     
       6. The panel of  claim 1  in combination with the grid recited in the preamble of  claim 1 , wherein the access kerf ( 33 ) in the first edge (A) and the registration kerf ( 35 ) in the second edge (B) successively form hinge means about a grid flange during installation and removal of the panel into and from a ceiling the grid. 
     
     
       7. The panel of  claim 1  in combination with the grid recited in the preamble of  claim 1 , wherein the upper lips, the access and registration kerfs, the treads, and the riser of the registration step form means to lock the panel in the ceiling grid. 
     
     
       8. The panel of  claim 7  in combination with the grid recited in the preamble of  claim 1 , wherein said panel further having a lower lips lip on each of the first edge (A) and second edge (B) edges intended to conceal the grid when installed in a ceiling the grid. 
     
     
       9. The panel of  claim 7  wherein the registration kerf ( 35 ) in the second edge (B) and the access kerf ( 33 ) in the first edge (A) successively form hinge means to remove the panel from the ceiling. 
     
     
       10. The panel of  claim 7 , wherein the tread ( 39 ) and the riser ( 34 ) in the registration step ( 36 ) and surfaces adjacent the access and registration kerfs ( 33  and  35 ) in the first and second edges (A and B) provide means for a feedback in positioning the panel during installation. 
     
     
       11. The panel of  claim 1  or  2  wherein none of the edges can be identified as first edge (A), second edge (B), or third or fourth edges (C or D) by visual inspection of the ceiling from below. 
     
     
       12. A panel of  claim 11  wherein the first and second edges (A and B) can be determined in a panel installed in a ceiling by an upward force on the center of the panel, whereby the panel will pivot upward about the registration kerf ( 35 ) in the edge (B). 
     
     
       13. The panel of  claim 1  wherein the third edge (C) is an edge that is passive during the installation and removal of the panel into and from the ceiling. 
     
     
       14. The panel of  claim 13  wherein the fourth edge (D) is an edge that is passive during the installation and removal of the panel into and from the ceiling. 
     
     
       15. In a horizontal suspended ceiling having:
 a grid of inverted T-sections having flanges; and 
 panels supported by the grid flanges; means for locking a panel to the grid flanges comprising opposed parallel first and second edges (A and B) that are active in installing and removing the panel from the grid, having
 a) in the first edge (A), an access kerf ( 33 ) extending horizontally along the first edge (A); 
 b) in the first edge (A), a registration step ( 36 ) extending horizontally along the first edge (A) above the access kerf ( 33 ); 
 c) in the second edge (B), a registration kerf ( 35 ) extending horizontally along the second edge (B), at a level above the access kerf ( 33 ) in the first edge (A); 
 d) an upper lip above and a lower lip below the access kerf ( 33 ) and the registration step ( 36 ) in the first edge (A), and an upper lip above and a lower lip below the registration kerf ( 35 ) in the second edge (B); and 
 e) means for positioning the upper lips above the grid flange, and the lower lips below the grid flange on the first and second edges (A and B) having
 e.1) first hinge means formed of the access kerf ( 33 ) in the first edge (A) and its adjacent flange side for first rotating the panel into a first position; 
 e.2) means that permit translation of the panel to disengage the first hinge means and engage second hinge means formed of the registration kerf ( 35 ) in the second edge (B) and its adjacent flange whereby the panel can be rotated in a direction counter to the first rotation; and 
 e.3) means formed by the registration step ( 36 ) in the first edge (A) and the registration kerf ( 35 ) in the second edge (B) to position the first and second edges (A and B) with respect to the flange side adjacent each of the first and second edges (A and B). 
 
 
 
     
     
       16. For use in a suspended ceiling that has a panel supporting grid formed of inverted T-section beams, a panel, when extending horizontally, having:
 a) opposing first and second edges (A and B), each of which has a profile different from the other; 
 b) at least two opposing third and fourth edges (C and D) that are passive in installing and removing the panel from the grid; 
 c) a substantially horizontal access kerf ( 33 ) in the profile of the first edge (A) that extends along the first edge (A) at a first level; 
 d) a substantially horizontal registration kerf ( 35 ) having an upper side in the profile of the second edge (B) that extends at a second level along the second edge above the first level of the access kerf ( 33 ) in the profile of the first edge (A); 
 e) a registration step ( 36 ) having a riser and a tread in the profile of the first edge (A) that extends along the first edge (A) above the first level of the access kerf in the first edge (A), the tread being at approximately the same level as the upper side of the registration kerf in the second edge (B); 
 f) a lower lips lip on at least each of the first and second edges (A and B) of the panel for concealing a portion of a the grid when installed; 
 g) a substantially vertical wall on the passive third and fourth edges (C and D) of the panel; and 
 h) an upper lip on the first edge (A) having an under side underside formed by the tread of the registration step, and an upper lip on the second edge having an underside (B) formed by the upper side of the registration kerf in the second edge (B), such each of said upper lips formed by the underside having a lower surface at approximately the same level when the panel extends in a horizontal plane, that support the panel in the ceiling; and 
 i) wherein the registration kerf has a substantially horizontal lower surface and the access kerf has a substantially horizontal upper surface. 
 
     
     
       17. In a group of component parts first capable of being assembled in the field into a horizontal suspended ceiling, and then capable of being disassembled; the group having a ceiling grid of intersecting beams of inverted T cross section forming grid openings, and panels, each of which is adapted to fit into, and extend horizontally within, a grid opening; the improvement comprising a panel having
 a) first and second opposing edges (A and B) in combination, each edge having a profile different from the other edge;   b) an upper and lower lip on each of the first and second edges (A and B);   c) a registration step in the first edge (A) having a horizontal tread formed by the upper lip;   d) an access kerf ( 33 ) in the first edge (A) at a first level below the registration step ( 36 );   e) a registration kerf ( 35 ) in the second edge (B) formed by the upper and lower lip of the second edge (B) at a second level above the first level of the access kerf;   
       wherein
 a) in assembling a panel into the ceiling,
 a.1) the access kerf ( 33 ) in the first edge (A) permits the registration kerf ( 35 ) in the second edge (B) to engage, and form a hinge with, the grid; and then 
 a.2) the registration kerf in the second edge (B) permits the panel to be shifted and rotated to engage the registration step in the first edge (A) with the grid; 
 
 b) in the panel in an assembled ceiling, the registration kerf in the second edge (B) combines with the registration step in the first edge (A) to position the panel within the grid opening; 
 c) in disassembling the panel from the ceiling,
 c.1) the registration step in the first edge (A) permits the panel to be rotated about the hinge formed by the registration kerf in the second edge (B) and the grid, and then 
 c.2) the access kerf in the first edge (A) permits the panel to be shifted to disengage the kerf in the second edge (B) from the grid. 
 
 
     
     
       18. In a process, a group of component parts first capable of being assembled in the field into a horizontal suspended ceiling, and then capable of being disassembled; the group having a ceiling grid of intersecting beams of inverted T cross section forming grid openings, and panels, each of which is adapted to fit into, and extend horizontally within, a grid opening; 
       the improvement comprising a panel having
 a) first and second opposing edges (A and B) in combination, each edge having a profile different from the other edge; 
 b) an upper and lower lip on each of the first and second edges (A and B); 
 c) a registration step in the first edge (A) having a horizontal tread formed by the upper lip; 
 d) an access kerf ( 33 ) in the first edge (A) at a first level below the registration step ( 36 ); 
 e) a registration kerf ( 35 ) in the second edge (B) formed by the upper and lower lip of the second edge (B) at a second level above the first level of the access kerf; 
 
       wherein
 a) in assembling a panel into the ceiling,
 a.1) the access kerf ( 33 ) in the first edge (A) permits the registration kerf ( 35 ) in the second edge (B) to engage, and form a hinge with, the grid; and then 
 a.2) the registration kerf ( 35 ) in the second edge (B) permits the panel to be shifted and rotated to engage the registration step in the first edge (A) with the grid; 
 
 b) in the panel in an assembled ceiling, the registration kerf ( 35 ) in the second edge (B) combines with the registration step ( 35 ) in the first edge (A) to position the panel within the grid opening; 
 c) in disassembling the panel from the ceiling,
 c.1) the registration step ( 36 ) in the first edge (A) permits the panel to be rotated about the hinge formed by the registration kerf ( 35 ) in the second edge (B) and the grid, and then 
 c.2) the access kerf ( 33 ) in the first edge (A) permits the panel to be shifted to disengage the registration kerf ( 35 ) in the second edge (B) from the grid. 
 
 
     
     
       19. In a ceiling panel capable of being assembled into place in an opening in a ceiling grid to form, with the grid, a horizontal suspended ceiling and, the panel having first (A) and second (B) opposing active edges, each of such said first and second active edges having an upper and a lower lip, wherein, when the panel is in place horizontally in an the opening, the grid is at least partially concealed when viewed from below;
 the improvement comprising an access kerf ( 33 ) in the first edge (A) at a lower level from a level of a registration kerf ( 35 ) in the second edge (B), and a registration step ( 36 ) in the first edge (A) at a level above the level of the access kerf ( 33 ); 
 whereby, when the panel is being assembled into place in the opening, the access kerf ( 33 ) provides the registration kerf ( 35 ) with access to the grid, to, in combination with the registration step ( 36 ) in the first edge (A), fit the panel correctly in the opening; and 
 wherein the registration kerf has a substantially horizontal lower surface and the access kerf has a substantially horizontal upper surface, the substantially horizontal lower surface being at a level above a level or the substantially horizontal upper surface. 
 
     
     
       20. A panel for use in a suspended ceiling having a panel supporting grid formed of inverted T-section beams, the panel, when extending horizontally, having:
 a) opposing first and second edges that are active in installing and removing the panel into and from the grid, each of which has a profile different from the other;   b) opposing third and fourth edges, each of which has a profile;   c) an access kerf in the profile of the first edge that extends along the first edge at a first level;   d) a registration kerf in the profile of the second edge that extends along the second edge;   e) a tread in the registration kerf of the second edge that extends along the second edge above the first level of the access kerf in the profile of the first edge;   f) a registration step having a riser and a tread in the profile of the first edge that extends along the first edge above the first level of the access kerf in the first edge, the tread being approximately at the same level as the tread in the second edge;   g) an upper lip on the first edge having an underside formed by the tread of the registration step, and an upper lip on the second edge having an underside formed by the tread of the second edge, each of said undersides of said upper lips being at approximately the same level when the panel extends in the plane of the grid, that support the panel in the ceiling; and   h) the registration kerf having a substantially horizontal lower surface.    
     
     
       21. The panel of claim 20 wherein the access kerf has a substantially horizontal upper surface, the substantially horizontal lower surface of the registration kerf being at a level above the substantially horizontal upper surface of the access kerf.  
     
     
       22. The panel of claim 20 wherein the substantially horizontal lower surface of the registration kerf extends substantially parallel to the tread of the registration step.  
     
     
       23. The panel of claim 20 wherein the substantially horizontal lower surface of the registration kerf extends substantially parallel to the tread of the second edge.  
     
     
       24. The panel of claim 20 further comprising a lower lip on each of the first and second edges, the lower lip of the first edge located at a level below the first level of the access kerf and the lower lip of the second edge located at a level below a level of the registration kerf, the lower lips of the first and second edges at least partially concealing the grid when the panel is installed in the grid.  
     
     
       25. The panel of claim 24 wherein the upper lip of the second edge has an end surface that is inwardly offset from an end surface of the lower lip of the second edge.  
     
     
       26. The panel of claim 25 wherein the lower lip of the second edge comprises a cutout.  
     
     
       27. The panel of claim 26 wherein the cutout of the lower lip of the second edge comprises a substantially vertical surface and a substantially horizontal surface.  
     
     
       28. The panel of claim 27 wherein the substantially vertical surface of the cutout of the lower lip of the second edge is inwardly offset from the end surface of the lower lip of the second edge; and wherein the end surface of the upper lip of the second edge is inwardly offset from the substantially vertical surface of the cutout.  
     
     
       29. The panel of claim 20 further comprising a lower lip on each of the third and fourth edges, the lower lips of the third and fourth edges at least partially concealing the grid when the panel is installed in the grid.  
     
     
       30. The panel of claim 20 further comprising:
 i) the access kerf having a substantially horizontal upper surface, the substantially horizontal lower surface of the registration kerf being at a level above the substantially horizontal upper surface of the access kerf;   j) the substantially horizontal lower surface of the registration kerf extending substantially parallel to the tread of the registration step;   k) the substantially horizontal lower surface of the registration kerf extending substantially parallel to the tread of the second edge;   l) a lower lip on each of the first and second edges, the lower lip of the first edge located at a level below the first level of the access kerf and the lower lip of the second edge located at a level below a level of the registration kerf;   m) the upper lip of the second edge having an end surface that is inwardly offset from an end surface of the lower lip of the second edge;   n) the lower lip of the second edge comprising a cutout having a substantially vertical surface and a substantially horizontal surface;   o) the substantially vertical surface of the cutout of the lower lip of the second edge being inwardly offset from the end surface of the lower lip of the second edge; and   p) the end surface of the upper lip of the second edge being inwardly offset from the substantially vertical surface of the cutout.    
     
     
       31. A panel for use in a panel supporting grid formed of inverted T-section beams, the panel, when extending horizontally, having:
 a) opposing first and second edges that are active in installing and removing the panel into and from the grid, each of which has a profile different from the other;   b) opposing third and fourth edges, each of which has a profile;   c) an access kerf in the profile of the first edge that extends along the first edge at a first level;   d) a registration kerf in the profile of the second edge that extends along the second edge;   e) a tread in the registration kerf of the second edge that extends along the second edge above the first level of the access kerf in the profile of the first edge;   f) a registration step having a riser and a tread in the profile of the first edge that extends along the first edge above the first level of the access kerf in the first edge, the tread being approximately at the same level as the tread in the second edge;   g) an upper lip on the first edge having an underside formed by the tread of the registration step, and an upper lip on the second edge having an underside formed by the tread of the second edge, each of said undersides of said upper lips being at approximately the same level when the panel extends in the plane of the grid, that support the panel in the ceiling;   h) a lower lip on each of the first and second edges, the lower lip of the first edge located at a level below the first level of the access kerf and the lower lip of the second edge located at a level below a level of the registration kerf, the lower lips of the second and third edges at least partially concealing the grid when the panel is installed in the grid; and   i) the upper lip of the second edge having an end surface that is inwardly offset from an end surface of the lower lip of the second edge.    
     
     
       32. The panel of claim 31 further comprising a lower lip on each of the third and fourth edges, the lower lips of the third and fourth edges at least partially concealing the grid when the panel is installed in the grid.  
     
     
       33. The panel of claim 31 wherein the registration kerf has a substantially horizontal lower surface.  
     
     
       34. The panel of claim 33 wherein the access kerf has a substantially horizontal upper surface, the substantially horizontal lower surface of the registration kerf being at a level above the substantially horizontal upper surface of the access kerf; and wherein the substantially horizontal lower surface of the registration kerf extends substantially parallel to the tread of the registration step.  
     
     
       35. The panel of claim 31 wherein the lower lip of the second edge comprises a cutout; wherein the cutout of the lower lip of the second edge comprises a substantially vertical surface and a substantially horizontal surface; and wherein the substantially vertical surface of the cutout of the lower lip of the second edge is inwardly offset from the end surface of the lower lip of the second edge; and wherein the end surface of the upper lip of the second edge is inwardly offset from the substantially vertical surface of the cutout.  
     
     
       36. A suspended ceiling comprising:
 a panel supporting grid formed of inverted T-section beams having flanges;   a plurality of panels supported by the flanges, each of the panels comprising, when extending horizontally in the grid:
 a) opposing first and second edges that are active in installing and removing the panel into and from the grid, each of which has a profile different from the other; 
 b) opposing third and fourth edges, each of which has a profile; 
 c) an access kerf in the profile of the first edge that extends along the first edge at a first level; 
 d) a registration kerf in the profile of the second edge that extends along the second edge; 
 e) a tread in the registration kerf of the second edge that extends along the second edge above the first level of the access kerf in the profile of the first edge; 
 f) a registration step having a riser and a tread in the profile of the first edge that extends along the first edge above the first level of the access kerf in the first edge, the tread being approximately at the same level as the tread in the second edge; 
 g) an upper lip on the first edge having an underside formed by the tread of the registration step, and an upper lip on the second edge having an underside formed by the tread of the second edge, each of said undersides of said upper lips being at approximately the same level when the panel extends in the plane of the grid, that support the panel in the ceiling; and 
 h) a lower lip on each of the first and second edges, the lower lip of the first edge located at a level below the first level of the access kerf and the lower lip of the second edge located at a level below a level of the registration kerf; 
   wherein the lower lips of the second edges of the plurality of the panels abut the lower lips of the first edges of adjacent ones of the plurality of the panels.    
     
     
       37. The suspended ceiling of claim 36 wherein each of the plurality of panels further comprises a lower lip on each of the third and fourth edges; and wherein the lower lips of the third edges of the plurality of the panels abut the lower lips of the fourth edges of adjacent ones of the plurality of the panels. 
     
     
       38. The suspended ceiling of claim 37 wherein the first, second, third, and fourth edges totally conceal the grid.  
     
     
       39. The suspended ceiling of claim 36 wherein for each of the plurality of panels, the registration kerf comprises a substantially horizontal lower surface.  
     
     
       40. The suspended ceiling of claim 39 wherein for each of the plurality of panels, the access kerf has a substantially horizontal upper surface, the substantially horizontal lower surface of the registration kerf being at a level above the substantially horizontal upper surface of the access kerf.  
     
     
       41. The suspended ceiling of claim 39 wherein for each of the plurality of panels, the substantially horizontal lower surface of the registration kerf extends substantially parallel to the tread of the registration step.  
     
     
       42. The suspended ceiling of claim 39 wherein for each of the plurality of panels, the substantially horizontal lower surface of the registration kerf extends substantially parallel to the tread of the second edge.  
     
     
       43. The suspended ceiling of claim 36 wherein for each of the plurality of panels, the upper lip of the second edge has an end surface that is inwardly offset from an end surface of the lower lip of the second edge.  
     
     
       44. The suspended ceiling of claim 43 wherein for each of the plurality of panels, the lower lip of the second edge comprises a cutout.  
     
     
       45. The suspended ceiling of claim 44 wherein for each of the plurality of panels, the cutout of the lower lip of the second edge comprises a substantially vertical surface and a substantially horizontal surface, and the substantially vertical surface of the cutout of the lower lip of the second edge is inwardly offset from the end surface of the lower lip of the second edge, and the end surface of the upper lip of the second edge is inwardly offset from the substantially vertical surface of the cutout.