초록 ▼

A panel for use in a drop ceiling system, or with appropriate modification, a wall, wherein the ceiling system includes stringers and cross-members defining areas therebetween for support of the panels wherein the panels include at least one planar sheet of material secured to a reinforcement member

A panel for use in a drop ceiling system, or with appropriate modification, a wall, wherein the ceiling system includes stringers and cross-members defining areas therebetween for support of the panels wherein the panels include at least one planar sheet of material secured to a reinforcement member having channels formed therein to extend in at least one direction relative to the sheet material. When more than one sheet of material is used, the sheets of material are disposed on opposite sides of the reinforcement member. The panels are flexible for easy insertion into the openings between the stringers and cross-members of the support system and are readily compressed into a thinner profile for shipping purposes.

대표청구항 ▼

What is claimed is: 1. A flexible and resilient ceiling panel that can be folded and flexed as an entire panel and return to its original configuration while being inserted into an opening in a supporting grid work of a ceiling of a building structure, comprising: at least one first sheet; and at l

What is claimed is: 1. A flexible and resilient ceiling panel that can be folded and flexed as an entire panel and return to its original configuration while being inserted into an opening in a supporting grid work of a ceiling of a building structure, comprising: at least one first sheet; and at least one second sheet formed into a first reinforcement layer that is a three-dimensional body, said at least one second sheet having a plurality of elongated channels; and wherein said elongated channels are positioned to confront said first sheet; and wherein said first sheet and said first reinforcement layer are each of a somewhat rigid material that can be flexed and that comprises heat-resistant fibers bound together by a resin. 2. The panel of claim 1 wherein said reinforcement layer is a furrowed sheet defining oppositely directed elongated channels at least some of which are confronting with said first sheet so as to define elongated cells between said reinforcement layer and said first sheet. 3. The panel of claim 2 wherein at least some of said channels are of trapezoidal transverse cross-section. 4. The panel of claim 2 wherein at least some of said channels are of triangular transverse cross-section. 5. The panel of claim 2, 3 or 4 wherein said reinforcement layer is secured to said first sheet. 6. The panel of claim 2, 3 or 4 wherein said reinforcement layer is adhesively bonded to said first sheet. 7. The panel of claim 2, 3 or 4 wherein said reinforcement layer is heat welded to said first sheet. 8. The panel of claim 2, 3 or 4 wherein said reinforcement layer is ultrasonically bonded to said first sheet. 9. The panel of claim 2 further including a secondary reinforcement layer that is a furrowed sheet defining oppositely directed elongated channels, the channels of said secondary reinforcement layer being less deep than the channels in the first mentioned reinforcement layer and wherein said secondary reinforcement layer is overlaid across said first mentioned reinforcement layer such that at least some of said channels in said secondary reinforcement layer are positioned within channels of said first mentioned reinforcement layer. 10. The panel of claim 9 wherein said secondary reinforcement layer is secured to said first mentioned reinforcement layer. 11. The panel of claim 9 wherein there are a pair of furrowed secondary reinforcement layers with one overlaid and one underlaid across said first mentioned reinforcement layer. 12. The panel of claim 11 wherein each of said secondary reinforcement layers is secured to said first mentioned reinforcement layer. 13. The panel of claim 2 further including a secondary reinforcement portion having planar surfaces extending perpendicularly to said channels in said reinforcement layer. 14. The panel of claim 13 wherein said secondary reinforcement portion is of elongated furrowed construction and adapted to be received in one of said channels in said first mentioned reinforcement layer. 15. The panel of claim 14 wherein there are a plurality of said secondary reinforcement portions with each secondary reinforcement portion received in a separate channel of said first mentioned reinforcement layer. 16. The panel of claim 2, 9, 11, 13 or 15 further including a decorative layer of material secured to said first sheet of material with said reinforcement layer secured to one face of said first sheet of material and said decorative layer secured to an opposite face of said first sheet of material. 17. The panel of claim 16 wherein said decorative layer is an elastomeric polymer. 18. The panel of claim 17 wherein said elastomeric polymer is a thermoplastic or thermosetting polymeric film. 19. The panel of claim 2 wherein the material from which said reinforcement layer is made is creasable and the material from which said first sheet is made is creasable. 20. The panel of claim 2, 9, 11, 13 or 14 wherein there are two of said first sheets defining substantially flat substrate materials and said reinforcement layer is positioned therebetween. 21. The panel of claim 20 wherein said two of said first sheets are secured to said reinforcement layer. 22. The panel of claim 21 wherein said reinforcement layer is compressible allowing the panel to be compressed by moving one of said first sheets perpendicularly toward the other of said first sheets. 23. The panel of claim 20 wherein said reinforcement layer is compressible allowing the panel to be compressed by moving one of said first sheets perpendicularly toward the other of said first sheets. 24. The panel of claim 20 wherein said reinforcement layer is collapsible allowing the panel to be compressed by moving said first sheets toward each other while shifting one of said first sheets relative to the other of said first sheets in a lateral direction. 25. The panel of claim 2 or 4 further including at least one support member operatively connected to said reinforcement layer on an opposite side thereof from said first sheet of material, said support member being elongated and extending perpendicularly to said elongated channels. 26. The panel of claim 25 wherein said at least one support member is mechanically connected to said reinforcement layer. 27. The panel of claim 26 wherein said at least one support member includes tabs adapted to be received in channels of said reinforcement layer to mechanically connect said at least one support member to said reinforcement layer. 28. The panel of claim 27 wherein said support member further includes an inverted U-shaped body projecting away from said reinforcement layer. 29. The panel of claim 28 wherein said at least one support member further includes flanges adapted to abut said reinforcement layer. 30. The panel of claim 26 wherein said at least one support member and said reinforcement layer are made of the same material. 31. The panel of claim 25 wherein said at least one support member and said reinforcement layer are made of the same material. 32. The panel of claim 25 wherein there are a plurality of said support members. 33. A flexible ceiling panel for incorporation into a building structure comprising at least one sheet of a substantially flat substrate material and a reinforcement layer secured to said substrate material, said reinforcement layer including at least one sheet of material having a plurality of channels formed therein, said panel being formed into a three-dimensional, self-supporting, resilient body having a plurality of elongated cells, said body being flexible and foldable as an entire body while retaining its resiliency to return to a substantially flat state after having been flexed as an entire body and wherein at least one sheet of substrate material is made of a fibrous material. 34. The panel of claim 33 wherein said elongated cells are formed between said at least one sheet of substrate material and said reinforcement layer being made from at least one separate piece of material than said at least one sheet of substrate material. 35. The panel of claim 34 wherein said reinforcement layer is a furrowed sheet defining oppositely directed elongated channels at least some of which are confronting with said at least one sheet of substrate material so as to define said elongated cells between said reinforcement member and said at least one sheet of substrate material. 36. The panel of claim 35 wherein at least some of said channels are of trapezoidal transverse cross-section. 37. The panel of claim 35 wherein at least some of said channels are of triangular transverse cross-section. 38. The panel of claim 35 further including a secondary reinforcement layer that is a furrowed sheet defining oppositely directed elongated channels, the channels of said secondary reinforcement layer being less deep than the channels in the first mentioned reinforcement layer and wherein said secondary reinforcement layer is overlaid across said first mentioned reinforcement layer such that at least some of said channels in said secondary reinforcement layer are positioned within channels of said first mentioned reinforcement layer. 39. The panel of claim 38 wherein said secondary reinforcement layer is secured to said first mentioned reinforcement layer. 40. The panel of claim 38 wherein there are a pair of corrugated secondary reinforcement layers with one overlaid and one underlaid across said first mentioned reinforcement layer. 41. The panel of claim 40 wherein each of said secondary reinforcement layers is secured to said first mentioned reinforcement layer. 42. The panel of claim 35 further including a secondary reinforcement portion having planar surfaces extending perpendicularly to said channels in said reinforcement layer. 43. The panel of claim 42 wherein said secondary reinforcement portion is of elongated furrowed construction and adapted to be received in one of said channels in said first mentioned reinforcement layer. 44. The panel of claim 43 wherein there are a plurality of said secondary reinforcement portions with each secondary reinforcement portion received in a separate channel of said first mentioned reinforcement layer. 45. The panel of claim 35 or 37 further including at least one support member operatively connected to said reinforcement layer on an opposite side thereof from said at least one sheet of substrate material, said support member being elongated and extending perpendicularly to said elongated channels. 46. The panel of claim 45 wherein said at least one support member is mechanically connected to said reinforcement layer. 47. The panel of claim 46 wherein said at least one support member includes tabs adapted to be received in channels of said reinforcement layer to mechanically connect said at least one support member to said reinforcement layer. 48. The panel of claim 47 wherein said support member further includes an inverted U-shaped body projecting away from said reinforcement layer. 49. The panel of claim 48 wherein said at least one support member further includes flanges adapted to abut said reinforcement layer. 50. The panel of claim 46 wherein said at least one support member and said reinforcement layer are made of the same material. 51. The panel of claim 45 wherein said at least one support member and said reinforcement layer are made of the same material. 52. The panel of claim 45 wherein there are a plurality of said support members. 53. The panel of claim 34, 35, 36 or 37 wherein said reinforcement layer is secured to said at least one sheet of substrate material. 54. The panel of claim 34, 35, 36 or 37 wherein said reinforcement layer is adhesively bonded to said at least one sheet of substrate material. 55. The panel of claim 34, 35, 36 or 37 wherein said reinforcement layer is heat welded to said at least one sheet of substrate material. 56. The panel of claim 34, 35, 36 or 37 wherein said reinforcement layer is ultrasonically bonded to said at least one sheet of substrate material. 57. The panel of claims 34, 35, 39, 40, 42 or 43 wherein there are two sheets of a substantially flat substrate material and said reinforcement layer is positioned therebetween. 58. The panel of claim 57 wherein said two sheets of substrate material are secured to said reinforcement layer. 59. The panel of claim 58 wherein said reinforcement layer is compressible allowing the panel to be compressed by moving one of said sheets perpendicularly toward the other of said sheets. 60. The panel of claim 57 wherein said reinforcement layer is compressible allowing the panel to be compressed by moving one of said first sheets perpendicularly toward the other of said first sheets. 61. The panel of claim 57 wherein said reinforcement layer is collapsible allowing the panel to be compressed by moving said first sheets toward each other while shifting one of said first sheets relative to the other of said first sheets in a lateral direction. 62. The panel of claim 33 wherein said fibrous material includes fibers of glass embedded in a resin. 63. The panel of claim 33, 34, 35, 38, 40, 42 or 44 further including a decorative layer of material secured to said at least one sheet of substrate material with said reinforcement layer secured to one face of said at least one sheet of substrate material and said decorative layer secured to an opposite face of said at least one sheet of substrate material. 64. The panel of claim 63 wherein said decorative layer is an elastomeric polymer. 65. The panel of claim 64 wherein said elastomeric polymer is a thermoplastic or thermosetting polymeric film. 66. The panel of claim 33, 34 or 35 wherein the material from which said reinforcement layer is made is creasable and the material from which said at least one sheet of substrate material is made is creasable. 67. The panel of claim 33 wherein there are two sheets of a substantially flat substrate material and said elongated reinforcement layer is secured to each of said sheets of substrate material so as to define a plurality of elongated cells between said sheets of substrate material and said reinforcement layer. 68. A flexible and resilient ceiling panel that can be folded and flexed as an entire panel and return to its original configuration while being inserted into an opening in a supporting grid work for a ceiling or a building structure, comprising: at least one first sheet; and at least one second sheet formed into a first reinforcement layer that is a three-dimensional body, said at least one second sheet having an elongated channel; and wherein said elongated channel is positioned to confront said first sheet; and wherein said first sheet and said second sheet are each of a somewhat rigid material that can be flexed and that comprises heat-resistant fibers bound together by a resin, said second sheet having been creased and folded without damaging the fibers therein. 69. A resilient ceiling panel for incorporation into a building structure comprising at least one sheet of a substantially flat substrate material and a reinforcement layer made from at least one sheet of material having a plurality of channels formed thereon, said panel being formed into a three-dimensional, self-supporting, fully-compressible body having a plurality of elongated cells when in a normal at-rest position, said cells being fully compressed when the panel is fully compressed, said elongated cells being formed between said at least one sheet of substrate material and said reinforcement layer, said reinforcement layer being made from at least one separate piece of material than said at least one sheet of substrate material and wherein said at least one sheet of substrate material is made from a fibrous material. 70. The panel of claim 69 wherein said fibrous material includes fibers of glass embedded in a resin. 71. The panel of claim 70 wherein said reinforcement layer includes fibers of glass embedded in a resin. 72. A resilient ceiling panel for incorporation into a building structure comprising at least one sheet of a substantially flat substrate material and a reinforcement layer made from at least one sheet of material having a plurality of channels formed thereon, said panel being formed into a three-dimensional, self-supporting, fully-compressible body having a plurality of elongated cells when in a normal at-rest position, said cells being fully compressed when the panel is fully compressed, said elongated cells being formed between said at least one sheet of substrate material and said reinforcement layer, said reinforcement layer being made from at least one separate piece of material than said at least one sheet of substrate material, said reinforcement layer being a furrowed sheet defining oppositely directed elongated channels at least some of which are confronting with said at least one sheet of substrate material so as to define said elongated cells between said reinforcement layer and said at least one sheet of substrate material, said furrowed sheet being folded into a substantially flat configuration when said panel is fully compressed. 73. The panel of claim 72 wherein at least some of said channels are of trapezoidal transverse cross-section. 74. The panel of claim 69, 72, or 73 wherein said reinforcement layer is secured to said at least one sheet of substrate material. 75. The panel of claim 69, 72, or 73 wherein said reinforcement layer is adhesively bonded to said at least one sheet of substrate material. 76. The panel of claim 69, 72, or 73 wherein said reinforcement layer is heat welded to said at least one sheet of substrate material. 77. The panel of claim 69, 72, or 73 wherein said reinforcement layer is ultrasonically bonded to said at least one sheet of substrate material. 78. The panel of claim 72 further including at least one support member operatively connected to said reinforcement layer on an opposite side thereof from said at least one sheet of substrate material, said support member being elongated and extending perpendicularly to said elongated channels. 79. The panel of claim 78 wherein at least one support member is mechanically connected to said reinforcement layer. 80. The panel of claim 79 wherein said at least one support member and said reinforcement layer are made of the same material. 81. The panel of claim 78 wherein said at least one support member and said reinforcement layer are made of the same material. 82. The panel of claim 78 wherein there are a plurality of said support members. 83. The panel of claim 69 or 72 further including a decorative layer of material secured to said at least one sheet of substrate material with said reinforcement layer secured to one face of said at least one sheet of substrate material and said decorative layer secured to an opposite face of said at least one sheet of substrate material. 84. The panel of claim 83 wherein said decorative layer is an elastomeric polymer. 85. The panel of claim 84 wherein said elastomeric polymer is a thermoplastic or thermosetting polymeric film. 86. The panel of claim 69 or 72 wherein the material from which said reinforcement layer is made is creasable and the material from which said at least one sheet of substrate material is made is creasable. 87. The panel of claim 69 or 72 wherein there are two sheets of a substantially flat substrate material and said reinforcement layer is positioned therebetween. 88. The panel of claim 87 wherein said two sheets of substrate material are secured to said reinforcement layer. 89. A resilient ceiling panel for incorporation into a building structure comprising at least one sheet of a substantially flat substrate material and a reinforcement layer made from at least one sheet of material having a plurality of channels formed therein, said panel being formed into a three-dimensional, self-supporting, fully-collapsible body having a plurality of elongated cells when in a normal at-rest position, said cells being fully collapsed when the panel is fully collapsed, said elongated cells being formed between said at least one sheet of substrate material and said reinforcement layer, said reinforcement layer being made from at least one separate piece of material and said at least one sheet of substrate material, and wherein said at least one sheet of substrate material is made of a fibrous material. 90. The panel of claim 89 wherein said fibrous material includes fibers of glass embedded in a resin. 91. The panel of claim 90 wherein said reinforcement layer includes fibers of glass embedded in a resin.