FIELD OF THE INVENTION

[0001] The present invention is directed to mounting hardware and mounting system for use with vertical panels, and more particularly to mounting hardware for vertically extending acoustical ceiling baffles.

BACKGROUND OF THE INVENTION

[0002J In many commercial buildings, it is desirable to alter room acoustics by providing vertically extending ceiling components intended to absorb sound waves to diminish room noise, In addition, vertically extending panels may be used to aesthetically separate areas of a large space with overhead panels or decorative valances projecting downward from a ceiling. These overhead panels are also referred to as soffits, valances, and bulkheads in different settings. Additionally, overhead panels may be connected to a ceiling to provide a vertical mounting surface for advertising information, menu information, or other displays in various retaii establishments.

[0( 83] Generally, vertically extending panels are mounted using wires which are directly mounted to the ceiling. However, as the panels are mounted with wires or the like, the repair and replacement of the panels is made difficult, as there is no easy method of removing the panels from the wires. In addition, as the panels are mounted directly to the ceiling, in order to move or rearrange the panels requires that the wires be removed from the ceiling and reaffixed to the ceiling in a different location. This is both time consuming and costly, in addition, depending on the duct work, lighting, etc. found in the ceiling, the mounting of the panels in the proper position may be difficult to accomplish. [0004] It would, therefore, be beneficial to provide mounting hardware and a mounting system which allowed to the vertical panels to be easiiy removed and replaced, thereby allowing the repair or replacement of damaged panels. It would also be beneficial to provide mounting hardware and a mounting system which allows for the repositioning of the panels as needed.

SUMMARY OF THE INVENTION

[0005] One embodiment of the invention is directed to a mounting hardware for mounting a vertical panel from a support member suspended from a ceiling, The mounting hardware has a panel mounting section, a support member receiving portion, and a movable mounting section. The support member receiving portion extends from the panei mounting section. The movable mounting section can be rotate relative to the support member receiving portion to secure the mounting hardware to the support member.

[0086] One embodiment of the invention is directed to a mounting system for mounting at least one vertical panel to a ceiling. The mounting system has a support member suspended from the ceiling and mounting hardware for mounting the at least one vertical panei to the support member. The mounting hardware has a panei mounting section, a support member receiving portion, and a movable mounting section. The support member receiving portion extends from the panel mounting section. The movable mounting section can be rotate relative to the support member receiving portion to secure the mounting hardware to the support member.

10007] One embodiment of the invention is directed to a method of mounting a vertical panel to a ceiling. The method comprising: positioning a support member receiving portion of a mounting hardware on a support member which is extended from the ceiling; rotating a movable mounting section relative to the support member receiving portion to secure the mounting hardware to the support member; and securing a the vertical panel to a panel mounting section of the mounting hardware. [ΘΘ08] Other features and advantages of the present invention wsiS be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWI NGS

[0(509] FIG. 1 is a perspective view of an exemplary mounting hardware according the invention.

[0010J FIG. 2 is an alternate perspective view of the exemplary mounting hardware shown in FIG. 1.

[0011] FIG, 3 is an end view of the exemplary mounting hardware shown in FIG. 1.

[0012] FIG. 4 is a side view of the exemplary mounting hardware shown in FIG. 1.

[0013] FIG. 5 is a top view of the exemplary mounting hardware shown in F!G. 1 , with the teeth shown in phantom.

[0014] FiG. 8 is a perspective view of two panels positioned proximate a support member, with one of the mounting hardware shown in an open position and the other mounting hardware shown in a closed position.

[0015] FIG. 7 is an end view of the two panels, support member and mounting hardware shown in FiG, 6, 0016] FiG. 8 is a perspective view of an alternate exemplary mounting hardware according the invention,

[0017] FIG. 9 is an end view of the exemplary mounting hardware shown in F!G. 8. [0018] FIG. 10 is a side view of the exemplary mounting hardware shown in FIG. 8.

[ 01 3 F'G. 11 is a bottom view of the exemplar/ mounting hardware shown in FIG. 8.

[0020] FiG. 12 Is a perspective view of a panel positioned proximate to and mounted on two support members.

[0021] FIG. 13 is a perspective view of an alternate exemplary mounting hardware according the invention.

[ 22] FIG. 14 is a side view of the exemplary mounting hardware shown in FiG. 13.

[0023] FIG. 15 is an end view of the exemplary mounting hardware shown in FIG, 13.

[0024] FIG. 16 is a bottom view of the exemplary mounting hardware shown in FIG. 3,

[0025] FIG. 17 is a perspective view of a panel mounted on the support member using the mounting hardware of FiG 13.

[0026] FIG. 18 is a perspective view of numerous panels mounted on the support member.

DETAILED DESCRIPTION OF THE INVENTION

|0Θ27] The present invention will be described more fully hereinafter with reference to the accompanying drawings, in which illustrative embodiments of the invention are shown. In the drawings, the relative sizes of regions or features may be exaggerated for clarity. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[Q028] it will be understood that spatially relative terms, such as "vertical", "horizontal", "upper", "lower" and the like, may be used herein for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "upper" other elements or features would then be oriented "lower" the other elements or features. Thus, the exemplary term "upper" can encompass both an orientation of upper and lower. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

|0029f FIGS. 1 through 7 illustrate an exemplary embodiment of mounting hardware 10 and a mounting system 12 for mounting a vertical panel 14 to a structural support member 16 which is mounted to a ceiling or the like. The panels may be used to for different purposes, including, but not limited to improving the acoustics of the space, aesthetically separating areas of a large space, or providing a vertical mounting surface for advertising information, menu information, or other displays in various retail establishments.

£0030] In accordance with one exempiary embodiment of the invention, the mounting system 12 provides a platform for mounting at least one overhead, vertical panel 14 that is supported on the support member 16, as will be discussed in further detail below. The overhead panel 14 drops down in a generally vertical orientation from the plane of the ceiling and can be combined with additional panels 14 or used individually. FIGS. 6 and 7 illustrate a perspective view of the overhead mounting system 12 in accordance with one exemplary embodiment. The mounting system 12 includes one or more support members 16, the mounting hardware 10, and one or more panels 14.

[0031] The panels 14 are any known panels which perform the desired function. As is best shown in F!GS. 6, 7 an 12, in general, the panels are made from lightweight material having a first surface 20 and an oppositely facing second surface 22. A mounting surface or edge 24 extends between the first surface 20 and the second surface 22. In the exemplary embodiment shown, the panels 14 are rectangular, however, the panel can take any suitable shape, length, or width. While other embodiments may be used, in one example the panel 14 contains a cellular core having first and second side walls that are covered by a veneer or laminated outer skin. The veneer or outer skin may be any color according to the aesthetic desired. The cellular core may be made of a foam material, such as, but not limited to polystyrene that allows the vertical panel to be lightweight, for example, around 1-2 pounds per linear foot of elongate length. The outer skin may be formed of a suitable lightweight material, such as, but not limited to, material having the acoustic properties required, high impact polystyrene or expanded PVC. The type of material will depend upon the application for which the panel is to be used.

|(S032| As is best shown in FIGS. 6, 7 an 12, in the exemplary embodiment shown, the support members 16 have a modified l-shaped cross-section, which is most clearly shown in FIG. 6. The support member 16 has a top mounting section 30 having a slot 32 for receiving and end 34 of a mounting wire 36 which is mounted to the ceiling or the like. However, other configurations of the top mounting section 30 and other methods of mounting the support member 16 to the ceiling can be used without departing from the scope of the invention. A vertical flange 38 extends between the mounting section 30 and horizontal cross members or flanges 40, 42, As shown in the alternate embodiment of F!G. 12, locating slots 43 may also be provided periodically along the vertical flange 38. 0Θ33 According to the exemplary embodiment, the mounting hardware or mounting clip 10 includes an upper generally horizontal piate section 50 with a support member receiving portion or flange receiving portion or hook arm 52 which extends from one end thereof. The hook arm 52 has a iead-in surface 54 and a slot 56. Extending from the other end of the horizontai piate section 50 is a movable mounting section 58. The movable mounting section 58 has connection legs 80 which extend between the plate section 50 and the mounting section 58, the !egs being 80 being configured to allow the mounting section 58 to rotate about the plate section 50. The mounting section 58 has a mounting flange 62 with a screw receiving opening 84 which extends therethrough. As shown in the alternate exemplary embodiment of FIG. 8 through 12, a locating tab 67 may also be provided on the mounting section 58.

[0034J The plate section 50 has a first edge 86 and an oppositely facing second edge 88. A first vertical sidewali section 70 extends downwardly from the plate section 50 at the first edge 66. A second vertical sidewali section 72 extends downwardly from the plate section 50 at the second edge 68. The first and second vertical sidewali sections 70, 72 extend from the plate section 50 such that the first and second vertical sidewali sections 70, 72 are allowed to rotate or pivot about the plate section 50 allowing the first and second vertical sidewali sections 70, 72 to be moved between an open and an dosed position. The piate section 50 and the first and second vertical sidewali sections 70, 72 form a panel mounting section. The first and second vertical sidewali sections 70, 72 include a plurality of teeth 74, which, in the exemplary embodiment shown, are also formed along the length of the sidewali sections 70, 72 proximate the edge of the first and second vertical sidewali sections 70, 72 which are furthest from the plate section 50, The teeth 74 are substantially in alignment on both the first and second vertical sidewali sections 70, 72 so that the teeth 74 are in general vertical alignment with each other in elevation when the first and second vertical sidewali sections 70, 72 are moved to the closed position, as will be more fully described. However, other configurations of the teeth 74 are possible without departing from the scope of the invention.

[0Θ35] An optional opening 76 may be provided in the first and second vertical sidewaii sections 70, 72. This opening is shown in the embodiment illustrated in F!GS. 8 through 12, however, the opening may be provided in other embodiments, including, but not limited to the embodiment shown in FIGS. 1 through 7. The openings 76 permit mounting hardware 78 _» such as, but not limited to, a nut and boit, to extend through the openings,

[0036] Referring to FIGS. 6, 7 and 12, the mounting hardware or mounting clips 10 cooperate with the support members 16 to mount the panels 14 to the support members 16 and indirectly to the ceiling. The hook arm 52 of each respective mounting clip 10 is configured to wrap around a respective flange 40, 42 of the support member 16. The respective flange 40, 42 is guided into the slot 58 by lead-in surface 54, Once the respective flange 40, 42 is positioned in the slot 58, the movable mounting section 58 is rotated or pivoted about the connection legs 60, thereby allowing the mounting flange 62 to be moved proximate the vertical flange 38. As this occurs, the locating tab 87 may be inserted into a respective locating slot 37 to help properly position the mounting ciip 10 relative to the support member 18, With the mounting flange 62 positioned proximate the vertical flange 38, a screw may be inserted into either the screw receiving opening 64 or the screw receiving opening 65, thereby causing the mounting clips 10 to be securely fastened and positioned relative to the support members 16. The cooperation of the hooked arm 52 and the mounting flange 62 prevents the movement of the mounting dip 10 is a direction which is perpendicular to the longitudinal axis of the support member 16. The use of the screw prevents the movement of the mounting clip 10 is a direction which is essentially parallel to the longitudinal axis of the support member 18.

[0037] With the mounting ciip 10 properly mounted and maintained in position on the support member 16, the panel 14 is moved into engagement with the mounting clip 10. In order to facilitate the movement of the pane! 14 into the mounting clip 10, the first and second vertical sidewall sections 70, 72 are spread apart in the open position. In this position, the first and second vertical sidewall sections 70, 72 are spread apart a distance greater than the width of the panel 14, thereby allowing the panel 14 to be inserted until is positioned proximate to or engages the plate section 50.

[0038] With the panel 14 properly inserted between the first and second vertical sidewall sections 70, 72, the first and second vertical sidewall sections 70, 72 are rotated inward, toward each other, thereby moving the first and second vertical sidewall sections 70, 72 from the open position to the dosed position. As this occurs the teeth 74 engage and pierce the panel 14. As the teeth 74 dig into the panel and are maintained in this position when the first and second vertical sidewall sections 70, 72 are in the closed position, the panel is maintained in position relative to the mounting clips 10 and the support member 18. The configuration of the first and second vertical sidewall sections 70, 72 allows the first and second vertical sidewall sections 70, 72 to be rotate using a hand tool such as a pliers or the like. This allows the first and second vertical sidewall sections 70, 72 to exhibit a sufficient force on the panel 14 when the first and second vertical sidewall sections 70, 72 are in the closed position to maintain the panel 14 in position. Additionally, if the optional hardware 78 is used, the hardware provides additional support to the panel 14 and prevents the first and second vertical sidewall sections 70, 72 from moving back toward the open position. This provides additional safety in areas which have increased seismic activity,

[0039] Depending upon the configuration and size of the panels 14, each mounting clip 10 is long enough to provide sufficient teeth 74 to support the weight of the pane! 0 in the verticai position or a combination mounting clips 10 are sufficient to support the weight of the panel 10 in the vertical position.

[0040] in the exemplary embodiments, if the screw is loosened, the mounting clips 10 may slide freeiy aiong the support member 18. This allows the mounting ciips, and ultimately the panels 14, to be positioned and repositioned in the appropriate location to achieve the desired acoustic properties or the desired aesthetics.

|0 4lj While the exemplary embodiment described thai the mounting dips 10 are mounted on the support member 16 first and the panels 14 are then mounted to the mounting dips 10, this is just one exemplary method of assembly. As one exemplary alternative, the panels 14 may be mounted to the mounting clops 10 prior to the mounting clips being mounted to the support member 16.

[0042] Another alternate exemplary embodiment, not shown, has first and second vertical sidewali sections with no teeth. The mounting hardware the extends through the openings provides the support for the panel, in this embodiment the first and second vertical sidewall sections are fixed and do not move between and open and a closed position.

|0043] Another alternate exemplary embodiment is illustrated in FIGS. 13 through 18. The mounting system 112 provides a platform for mounting at least one overhead, vertical panel 114 that is supported on the support member 1 8, as will be discussed in further detail below. The overhead panel

114 drops down in a generally vertical orientation from the plane of the ceiling 118 and can be combined with additional panels 1 14 {as shown in FIG. 17) or used individually. FIG. 18 illustrates a perspective view of the overhead mounting system 112 in accordance with this exemplary embodiment. The mounting system 112 includes one or more support members 116, the mounting hardware 1 10, and one or more panels 14.

[0044] The panels 114 are made by joining two panels 15. The panels

115 any known panels which perform the desired function. In general, each panel 1 15 is made from Iightweight material having a first surface 20 and an oppositely facing second surface 122. A mounting surface or edge 124 extends between the first surface 120 and the second surface 122. In the exemplary embodiment shown, the panels 1 14 are rectangular however, the panel can take any suitable shape, length, or width. While other embodiments may be used, in one example the panel 1 14 contains a cellular core having first and second side walis that are covered by a veneer or laminated outer skin. The veneer or outer skin may be any color according to the aesthetic desired. The cellular core may be made of a foam material, such as, but not limited to polystyrene that allows the vertical panef to be lightweight, for example, around 1-2 pounds per linear foot of elongate length. The outer skin may be formed of a suitable lightweight material, such as, but not limited to, material having the acoustic properties required, high impact polystyrene or expanded PVC. The type of material will depend upon the application for which the panel is to be used.

[0045] In the exemplary embodiment shown, the support members 116 have a modified l-shaped cross-section, which is most dearly shown in FIGS. 17 and 13. The support member 115 has a top mounting section 130 having a slot 132 for receiving and end 34 of a mounting wire 136 which is mounted to the ceifing 1 18 or the like. However, other configurations of the top mounting section 130 and other methods of mounting the support member 118 to the ceiling 118 can be used without departing from the scope of the invention. A vertical flange 138 extends between the mounting section 130 and horizontal cross members or flanges 140, 142. Locating slots 143 may also be provided periodically along the vertical flange 138.

[0046] According to the exemplary embodiment, the mounting hardware or mounting clip 110 includes a generally vertical p!ate section or pane! mounting section 150 with a support member receiving portion or hook arm 152 which extends thereof. Extending from the a portion of the hook arm 152 is a movable mounting section 158. The movable mounting section 158 has connection legs 180 which extend between the hook arm 152 and the mounting section 158, the legs 160 being configured to allow the mounting section 158 to rotate about the hook arm 152. The mounting section 158 has a mounting flange 162 with at least one screw receiving opening 164 which extends therethrough. More than one screw receiving opening 164 may be provided to allow the mounting section 158 to be bent to accommodate different support members 116 and still be secured thereto. A locating tab 187 may also be provided on the mounting section 158.

[0047] The configuration of the hook arm 152 is designed to allow the hook arm 152 to be inserted on standard grid, U-profiies, i-beam carrying members, peaked roof bulb design and other such configurations. j¾§48] The plate section 150 has openings 188 which extend therethrough. The openings 188 allow adhesive to flow therethrough, as will be more fully described. Alignment notches 168 and a mounting opening 170 are also provided on the plate section 150. Projections or teeth 174 (as best shown in FIGS. 13 through 15), extend from both sides of the plate section 150. In the exemplary embodiment shown, the teeth 174 are formed along the edge of the plate section 150 which is furthest from the hook arm 152. The teeth 174 are in general vertical alignment with each other. However, other configurations of the teeth 174 are possible without departing from the scope of the invention.

|$049j in this embodiment, the mounting clips 110 are embedded in the panels 1 5 as the panels 115 are formed. Panels 1 14 have adhesive applied to facing surfaces, The panels 114 are moved together. As this occurs, the mounting clips 1 10 are positioned between the panels 114 such that the movement of the panels 1 14 together causes the mounting clips 110 to be captured between the panels 1 14. As this occurs, the teeth 174 engage and pierce the panels 114. Continued movement of the panels 1 14 toward each other causes the plate section 150 to be trapped between the panels 1 14. Sn this position, the adhesive applied to the panels 1 14 flows through the openings 186 to provide a strong bond between the panels 114 and the piate section 150. The alignment notches 188 are positioned proximate the top of the panels 14 to provide visual alignment as the panels and mounting clips 110 are joined together. Θ050] The mounting hardware or mounting clips 1 10 cooperate w th the support members 1 16 to mount the panels 114 to the support members 16 and indirectly to the ceiling. As shown in FIG, 16, the hook arm 152 of each respective mounting clip 10 is configured to wrap around a respective the support member 116. Once the hook arm 152 is positioned on the support member 116, the movable mounting section 158 is rotated or pivoted about the connection legs 160, thereby allowing the mounting flange 162 to be moved proximate a vertical flange 138 of the support member 116. As this occurs, the locating tab 167 may be Inserted into a respective locating slot 137 to help properly position the mounting clip 110 relative to the support member 1 18. With the mounting flange 162 positioned proximate the vertical fiange 138, a screw may be inserted into either the appropriate screw receiving opening 164, thereby causing the mounting dips 1 10 to be securely fastened and positioned relative to the support members 116.

[0051] if the screw is loosened, the mounting clips 1 10 may slide freely along the support member 1 16. This allows the mounting clips, and ultimately the panels 114, to be positioned and repositioned in the appropriate location to achieve the desired acoustic properties or the desired aesthetics.

[0Θ52] As will be appreciated from all of the embodiments, different number of panels can be mounted in differing configurations to accommodate the acoustic and/or aesthetic characteristics desired,

[0053] The mounting clips and mounting system allows for the panels to be removed and repaired/replaced if there is damage. There is no need to remove the mounting hardware or the mounting system in order to accomplish the repair/replacement.

[0 54) The mounting clips and mounting system also allow for the repositioning of the paneis. This alfows for the panels to be repositioned as the needs or space changes. 0055] The mounting clips and mounting system are also versatile. A wide range of materials and sizes of panels can be installed with the same hardware and same system, thereby reducing the need to change hardware.

[0056] The exemplary dips can be used to hang panels from standard grid, U-profiles, I-beam carrying members, peaked roof bulb design and other such configurations.

|0Ci§7J While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention, in addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but thai the invention wiii include all embodiments falling within the scope of the appended claims.