Ceiling System and Method of Installation

This application is a continuation of U.S. patent application Ser. No. 18/615,036, filed on Mar. 25, 2024, which is a continuation of U.S. patent application Ser. No. 17/495,437, filed Oct. 6, 2021, now U.S. Pat. No. 12,018,486, granted Jun. 25, 2024, which claims the benefit of U.S. Provisional Patent Application Ser. No. 63/089,837, filed Oct. 9, 2020, and also a continuation-in-part of U.S. patent application Ser. No. 17/409,369, filed Aug. 23, 2021, now U.S. Pat. No. 11,946,250, granted Apr. 2, 2024, which claims the benefit of U.S. Provisional Patent Application Ser. No. 63/069,368, filed Aug. 24, 2020. The disclosures of the above applications are incorporated herein by reference.

Many types of ceiling systems exist. Ceiling systems comprising a hanging grid of acoustic panels or individual hanging panels have become increasingly popular in recent years. These systems can be used to provide noise absorption without completely covering the structure of the room or building. “Islands” of hanging panels can provide a desirable aesthetic appearance while simultaneously providing or exceeding the benefits of more traditional drop ceiling systems. These systems require that the panels be hung from a support structure. Installation can be time consuming and expensive. Therefore, a need exists for improved ceiling systems which make installation easier and reduce the complexity of the hanging systems.

Embodiments of the invention provide a solution to the above problem by allowing more flexibility in grid design and more flexibility in ceiling tile construction and arrangement.

In one aspect, the invention can be a ceiling system having an open cell grid structure and hanging hardware. The open cell grid structure has a plurality of first panels, each of the first panels having a first top edge, a first bottom edge, and a plurality of first upper slots in the first top edge. The first panels are arranged in a non-intersecting arrangement so that the first bottom edges face downward. The open cell grid structure further has a plurality of second panels, each of the second panels having a second top edge, a second bottom edge, a plurality of second upper slots in the second top edge, and a plurality of second lower slots in the second bottom edge that are offset from the second upper slots. The second panels are mounted to the first panels in a first intersecting arrangement so that the second lower slots mate with the first upper slots to form primary intersection nodes, the second bottom edges facing downward. The open cell grid structure also has a plurality of third panels, each of the third panels having a third top edge, a third bottom edge, and a plurality of third lower slots in the third bottom edge. The third panels are mounted to the second panels in a second intersecting arrangement so that the third lower slots mate with the second upper slots at secondary intersection nodes, the third bottom edges facing downward. The hanging hardware is connected to each of the first panels and to a support structure to hang the open cell grid structure from the support structure in an occupied space of a building.

In another aspect, the invention can be a method of installing a ceiling system in a building. The method starts with hanging a plurality of first panels in a non-intersecting arrangement from an overhead support with hanging hardware. Each of the first panels has a first top edge, a first bottom edge, and a plurality of first upper slots in the first top edge, the first bottom edges facing downward. Second, a plurality of second panels are mounted to the first panels in a first intersecting arrangement by mating second lower slots of the second panels with the first upper slots of the first panels to form primary intersection nodes. The second lower slots are formed in second bottom edges of the second panels that face downward. Third, a plurality of third panels are mounted to the second panels in a second intersecting arrangement by mating third lower slots of the third panels with second upper slots of the second panels to form secondary intersection nodes. The third lower slots are formed in third bottom edges of the third panels that face downward. The second upper slots are formed in second top edges of the second panels, thereby forming an open cell grid structure that hangs in an occupied space of the building.

In yet another aspect, the invention can be a ceiling system having an open cell grid structure. The open cell grid structure has a plurality of bottom panel rows arranged in a non-intersecting arrangement with respect to one another, each of the plurality of bottom panel rows comprising first and second bottom panels of different axial lengths arranged in axial alignment with one another so that a bottom gap exists between adjacent side edges of the first and second bottom panels, each of the first and second bottom panels having a downwardly facing bottom edge and an upwardly facing top edge, and wherein the bottom gaps of transversely adjacent ones of the plurality of bottom panel rows are offset from one another in an axial direction of the bottom panel rows. The open cell grid structure also has a plurality of middle panel rows mounted to the bottom panel rows in a first intersecting arrangement with the plurality of bottom panel rows, each of the middle panel rows comprising at least one middle panel having a downwardly facing bottom edge and an upwardly facing top edge. The open cell grid structure also has a plurality of top panel rows mounted to the middle panel rows in a second intersecting arrangement with the middle panel rows and a non-intersecting arrangement with the bottom panel rows, each of the top panel rows comprising at least one top panel having a downwardly facing bottom edge and an upwardly facing top edge. Finally, the system has hanging hardware connected to each one of the first panel rows and to a support structure to hang the open cell grid structure from the support structure in an occupied space of a building.

In another aspect, the invention may be a method of installing a ceiling system. First, a first ceiling system kit is provided, the kit having (i) a plurality of first kit panels configured to mate with one another to form a first open cell grid structure when assembled; and (ii) first hanging hardware for hanging the first open cell grid structure. Second, a second ceiling system kit is provided, the kit having (i) a plurality of second kit panels configured to mate with one another to form a second open cell grid structure when assembled; and (ii) second hanging hardware for hanging the second open cell grid structure. Third, instructions are provided on how to mate the first and second kit panels to form a combined open cell grid structure in which no complete cell of the combined open cell grid structure has edge-to-edge interfaces or edge-to-edge gaps that oppose one another. Fourth, the combined open cell grid structure is built using the first and second ceiling system kits in accordance with the instructions in an occupied space of a building in which the combined open cell grid structure is hung from a support structure by the first and second hanging hardware.

Another aspect of the invention may be a method of installing a ceiling system. First, a plurality of bottom panel rows are hung from a support structure in a non-intersecting arrangement with one another using hanging hardware, each of the bottom panel rows comprising a first bottom panel and a second bottom panel of different axial lengths arranged in axial alignment with one another, wherein the first and second bottom panels of adjacent rows of the bottom panel rows are staggered with one another. Second, a plurality of middle panel rows are mounted to the bottom panel rows in a first intersecting arrangement with the bottom panel rows. Third, a plurality of top panel rows are mounted to the middle panel rows in a second intersecting arrangement with the middle panel rows and a non-intersecting arrangement with the bottom panel rows, each of the top panel rows comprising a first top panel and a second top panel of different axial lengths arranged in axial alignment with one another. The first and second top panels of adjacent rows of the top panel rows are staggered with one another, thereby forming an open cell grid structure.

In another embodiment, the invention is a method of installing a ceiling system. First, a first ceiling system kit is provided, the kit having (i) a plurality of first kit panels configured to mate with one another to form a first open cell grid structure having an A×B completed cell grid when assembled; and (ii) first hanging hardware for hanging the first open cell grid structure. Second, a second ceiling system kit is provided, the kit having (i) a plurality of second kit panels configured to mate with one another to form a second open cell grid structure having an X×B completed cell grid when assembled; and (ii) second hanging hardware for hanging the second open cell grid structure. Third, instructions are provided on how to mate the first and second kit panels to form a combined open cell grid structure having an A+X+1×B completed cell grid portion when assembled in which: (i) at least one of the first kit panels has a left side edge that forms a portion of a first side of a perimeter of the combined open cell grid structure; and (ii) at least one of the first kit panels has a right side edge that forms a portion of a second side of the perimeter of the combined open cell grid structure opposite the first side. Fourth, the combined open cell grid structure is built using the first and second ceiling system kits in accordance with the instructions in an occupied space of a building in which the combined open cell grid structure is hung from a support structure by the first and second hanging hardware

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

All drawings are schematic and not necessarily to scale. Parts given a reference numerical designation in one figure may be considered to be the same parts where they appear in other figures without a numerical designation for brevity unless specifically labeled with a different part number and described herein.

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

In the description of embodiments disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “attached,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term “fixed” refers to two structures that cannot be separated without damaging one of the structures. The term “filled” refers to a state that includes completely filled or partially filled.

As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by reference in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.

shows an occupied spacein a building. A ceiling systemis attached to a support structuresuch as the building's roof, trusses, or other structure forming an interior of the building. The ceiling systemis attached to the support structurevia hanging hardware. The ceiling systemforms a floating island structure that is not directly connected to any walls within the building. Instead, the ceiling systemis exclusively connected to the support structure, the ceiling support structurebeing a roof, roof trusses, ceiling, or ceiling structural members of the interior of the building. The hanging hardwaremay comprise wire, rods, or any other tensile member capable of supporting the components of the ceiling system. In one embodiment the hanging hardwareis a plurality of individual tensile members, each tensile membercomprising a first hook attached to the support structure, a wire connected to the first hook, and a second hook connected to the wire and to a panel of the ceiling system. The number of tensile membersutilized to support the ceiling systemdepends on a variety of factors including the area covered by the ceiling system, the strength of the ceiling systemand the strength of the support structure, the availability of suitable connection points on the support structure, and a variety of other factors.

shows the ceiling systemin greater detail. The ceiling systemhas a plurality of first panels, a plurality of second panels, and a plurality of third panels. The plurality of first panelsare arranged such that they are substantially parallel to a first axis A-A and do not intersect with other ones of the first panels. Each of the first panelsis attached to the support structurevia one or more tensile membersof the hanging hardwareand hang downward due to the force applied by gravity. The plurality of second panelsextend substantially parallel to the second axis B-B such that each one of the second panelsdoes not intersect other ones of the second panels. Each of the plurality of second panelsare free of tensile members.

Each of the plurality of second panelsdo intersect the plurality of first panels. The first axis A-A is substantially perpendicular to the second axis B-B. As a result, the plurality of first panelsis substantially perpendicular to the plurality of second panels. The plurality of third panelsare substantially parallel to other ones of the plurality of third panelsand substantially parallel to the plurality of first panels. The plurality of third panelsare also substantially parallel to the first axis A-A. The plurality of third panelsdo not intersect other ones of the plurality of third panelsor any of the plurality of first panels. Each of the plurality of third panelsare free of tensile members. In other embodiments, the second axis B-B may not be perpendicular to the first axis A-A.

As can be seen, the pluralities of first, second, and third panels,,form a rectilinear grid. Thus, the ceiling systemforms an open cell grid structure. A plurality of open cellsare formed between the pluralities of first, second, and third panels,,. Ideally, the open cellsare of substantially equal cross-sectional area. In other embodiments, the open cellsmay be of different cross-sectional area. The open cellsare ideally rectangular or square in shape, but may also take other shapes.

In the preferred embodiment, the plurality of first panelscomprise a first end first panel, a second end first panel, and a pair of central first panelsadjacent one another and located between the first and second end first panels. At least one third panelis located between the first end first paneland the pair of central first panels. At least one third panelis also located between the second end first paneland the pair of central first panels. Preferably, two third panelsare located between the first end first paneland the pair of central first panels. In addition, two third panelsare preferably located between the second end first paneland the pair of central first panels.

show the ceiling systemin various states of assembly.shows the plurality of first panelsinstalled in a first step. The plurality of first panelsare installed to the hanging hardware, with a plurality of tensile membersattached to each of the first panels. As discussed above, the plurality of first panelsare arranged in a non-intersecting and substantially parallel arrangement. Each of the first panelshave a first top edge, a first bottom edge, and a plurality of first upper slotsin the first top edge. Each of the first bottom edgesof the plurality of first panelsextend downward. Gravity ensures that the plurality of first panelshang downward and are retained in position as shown in.

shows a second step of assembling the ceiling system. The plurality of first panelsare shown in their assembled position along with the plurality of second panelsoriented prior to installation. The plurality of second panelseach have a second top edge, a second bottom edge, a plurality of second lower slots, and a plurality of second upper slots. The plurality of second lower slotsare located on the second bottom edge. The plurality of second upper slotsare located on the second top edge. Each of the plurality of second panelsis mounted to the plurality of first panelsby mating the second lower slotsof the second panelsto the first upper slotsof the first panels. This results in an interlocking arrangement that forms a plurality of primary intersection nodes. The weight of the plurality of second panelsis then supported by the plurality of first panelsat the plurality of primary intersection nodes. The plurality of primary intersection nodes will be discussed in greater detail below. Gravity ensures that the plurality of second panelsremain interlocked with the plurality of first panels. No other fastening is required, although additional fasteners may be added if so desired.

shows a third step of assembling the ceiling system. The plurality of first panelsare shown assembled with the plurality of second panels. The plurality of third panelsare shown oriented prior to installation. Each of the plurality of third panelsare oriented substantially parallel to the plurality of first panels. Each of the plurality of third panelshas a third top edge, a third bottom edge, and a plurality of third lower slots. The plurality of third lower slotsis located on the third bottom edgeof the third panels. Each of the plurality of third panelsis mounted to the plurality of second panelsby mating the third lower slotsof the third panelsto the second upper slotsof the second panels. This results in an interlocking arrangement that forms a plurality of secondary intersection nodes.

The weight of the plurality of third panelsis then supported by the plurality of second panelsat the plurality of secondary intersection nodes. The weight of the plurality of third panelsis carried to the plurality of first panelsvia the primary intersection nodes formed by plurality of second panelswith the plurality of first panels. The plurality of secondary intersection nodes will be discussed in greater detail below. Gravity ensures that the plurality of third panelsremain interlocked with the plurality of second panels. No other fastening is required, although additional fasteners may be added if so desired. None of the plurality of third panelsis directly supported by any one of the plurality of first panels. Instead, the third panelsare spaced and isolated from the first panels. Preferably, each of the first, second, and third top edges,,are substantially flush at the primary and secondary intersection nodes. In one embodiment, each of the first, second, and third top edges,,lie in the same plane.

shows a cross section taken along the line VI-VI inshowing the primary intersection nodesand secondary intersection nodes. The primary intersection nodesare formed by the intersection of the plurality of first panelswith the plurality of second panels, with the first panelsengaging the second lower slotsat the primary intersection nodes. The second intersection nodesare formed by the intersection of the plurality of second panelswith the plurality of third panels, with the third panelsengaging the second upper slotsof the second panels. Thus, the plurality of first upper slotsand the plurality of second lower slotsmate to form the first intersection nodes. The plurality of second upper slotsand the plurality of third lower slotsmate to form the second intersection nodes.

shows a cross section taken along line VII-VII inshowing the primary intersection nodesfrom a different perspective. One of the plurality of first panelscan be seen with a the plurality of primary intersection nodesformed by the plurality of second panelsbeing inserted into the first upper slotsof the first panel.

show a perspective view and a side view of one of the first panels. As discussed previously, the first panelhas a plurality of first upper slots, a first top edge, and a first bottom edge. The first panelis free of slots on the first bottom edge. The first panelalso has a panel thickness T. As can be seen, each of the first upper slotsare of equal height and of equal width. However, in other embodiments, the first upper slotsmay have different heights. Each of the first upper slotshave a width W. In some embodiments, the first upper slotsmay have different widths to accommodate different thicknesses of panels. In the present embodiment, the first top edgeis linear or straight and the first bottom edgehas a curvilinear shape. Thus, the first bottom edgehas both convex and concave shapes. In some embodiments, the first top edgemay have a curvilinear shape. In yet other embodiments, the first bottom edgemay be linear or have a shape formed by a plurality of linear segments which are non-parallel. It is important to note that not all of the plurality of first panelsare necessarily identical. Indeed, in most installations the first panelsmay have different shapes to provide a varying height along the first axis A-A and along the second axis B-B. In some embodiments, all of the first panelsmay have the same shape on the first bottom edgesto provide a more uniform appearance.

show a perspective view and a side view of one of the second panels. The second panelhas a plurality of second upper slotsthat are equal in height and equal in width. The second panelalso has a plurality of second lower slots, the plurality of second lower slotshaving a varying height and equal width. The second panelhas a panel thickness T. Each of the second upper slotshave a width W. Each of the second lower slotshave a width W. In other embodiments, the second upper slotsmay have differing height or width and the second lower slotsmay have equal height and differing width.

In the present embodiment, the second top edgeis straight and the second bottom edgehas a curvilinear shape comprising both convex and concave shapes. As with the first panels, the second top edgeand the second bottom edgemay be linear or curvilinear or have a shape formed by a plurality of linear segments which are non-parallel. As with the first panels, the second panelsneed not be identical, and may vary to provide the appearance of texture as a result of the varying height of the panelsalong both the first axis A-A and the second axis B-B. The second lower slotsof the present embodiment are varying in height but equal in width. This is done to compensate for the curved second bottom edge. By altering the height of the second lower slots, the second top edgelies in the same plane as the first top edgewhen the first panelsand the second panelsare assembled. In alternate configurations, the second lower slotsmay be altered in height and the first upper slotsmay be altered in height so that the first and second top edges,lie in the same plane. In yet other embodiments, the first and second top edges,may not lie in the same plane. In addition, the first bottom edgeand the second bottom edgeof each of the first and second panels,are substantially flush at the primary intersection nodes. However, alternate configurations may have the first bottom edgeand the second bottom edgeat different heights.

show a perspective view and a side view of one of the third panels. The third panelhas a plurality of third lower slotson the third bottom edgehaving a width Wand a plurality of unequal heights. The third top edgeis free of slots. As discussed above with respect to the second lower slots, the third lower slotsmay be of equal height or equal width. The third panelhas a panel thickness T, a third top edgeand a third bottom edge. The third top edgeis linear and the third bottom edgeis curvilinear. When the third panelsare mated with the second panels, the third top edgesand the second top edgesare substantially flush at the secondary intersection nodesand lie in the same plane as the first and second top edges,. The second bottom edgesand the third bottom edgesare flush at the secondary intersection nodes. However, in alternate embodiments the second and third top edges,may not be flush. In alternate embodiments the second and third bottom edges,may also not be flush. The height of the second upper slotsand the third bottom slotsmay vary. The third bottom edgesmay be curvilinear, linear or have a shape formed by a plurality of linear segments which are non-parallel. Each of the third panelsneed not be identical.

As discussed above, different shapes of the first, second, and third panels,,may be used to create a textured appearance that varies along the first axis A-A, along the second axis B-B, or along both the first and second axes A-A, B-B. As best shown in, the textured appearance provided by the bottom edges,,can be seen in greater detail. This shape can be constructed by gradually altering the shapes of the first, second, and third bottom edges,,such that the resulting ceiling systemhas the appearance of a wave, a saw tooth, or any other shape.

Preferably, the first, second, and third panels,,are acoustical panels. The panels,,are preferably constructed of a sound absorbing material. The sound absorbing material may be formed into a non-woven fabric, a foam material, or other structure that provides adequate rigidity to support the weight of the assembled first, second, and third panels,,. In one embodiment, the panels,,have sufficient rigidity that when mounted in a cantilevered fashion, a tip of a cantilevered portion of the panels,,of 1 meter in length does not bend at greater than a 45 degree angle from the horizontal plane as a result of gravity. Thus, the panels,,are sufficiently rigid that they do not collapse when cantilevered for a distance of 1 meter. The panels,,should provide a noise reduction coefficient (“NRC”) rating of at least 0.6. The panels,,may be constructed of a polyester felt. Alternately, mineral wool, fiberglass, or various plastic materials may be used. Ideally, the panels,,are constructed of 6.35 mm thick polyester felt material.

In the preferred embodiment, each of the panels,,have the same panel thickness. Thus, the thickness Tof the plurality of first panelsis equal to the thickness Tof the plurality of second panels, which is in turn equal to the thickness Tof the plurality of third panels. Preferably, the widths W, W, W, Ware greater than the thicknesses T, T, Tof the panels,,. This ensures easy assembly of the panels,,without the need to force the panels together. However, an interference fit may be used to further improve retention of the panels,,. Preferably, the widths W, W, W, Ware equal. However, different widths may be utilized in concert with different panel heights to provide a unique visual impression.

Turning to, this figure shows a first ceiling system kitcomprising a plurality of panels. The kitcomprises a plurality of first panels, a plurality of second panels, and a plurality of third panels. The kitfurther comprises a package, hanging hardware, and instructions. The packagemay be a box, a crate, or any other known means for containing the components of the ceiling system kit. The instructionsmay be a book, paper instruction sheets, a representation on the product packaging. Alternately, the instructionsmay be provided in electronic format such as a PDF or a website, with the packaging comprising a link or other reference to the website. For the purposes of clarifying the assembly sequence, the plurality of first panelsare sometimes referred to as bottom panels. Similarly, the second panelsare sometimes referred to as middle panelsand the third panelsare sometimes referred to as top panels. Furthermore all details discussed above with respect to the construction, arrangement, and assembly of the panels is identical unless otherwise noted.

It should be noted that not all of the panels,,need to have the same length. Indeed, in the kit, the bottom and top panels,are of a first axial length Land the middle panels are of a shorter second axial length L. Different lengths may be selected depending on the desired size of the assembled ceiling system. As shown in, the kitresults in a ceiling system having a 4 foot width and an 8 foot length. The assembly of the kitwill be discussed in greater detail with respect to. Hanging hardwareattaches exclusively to the bottom panelsas discussed above. The middle and top panels,are free of hanging hardware. The hanging hardwarealso attaches to the support structureof the buildingas discussed above.

shows an assembled kithaving bottom, middle, and top panels,,as shown. The plurality of bottom panelsare arranged in a non-intersecting arrangement with respect to one another, each bottom panelforming its own bottom panel row. In the kit, each bottom panel rowcomprises only a single bottom panel, but in other embodiments, more than one bottom panelmay form each bottom panel row. Furthermore, each bottom panelin each of the bottom panel rowsneed not be identical. Each bottom panelin each of the bottom panel rowsmay differ in length or other characteristics.

Each of the middle panelsare assembled with the plurality of bottom panelsin an intersecting arrangement as discussed above. Each of the middle panelslies in a middle panel row. Each of the middle panel rowsintersects with each of the bottom panel rows. In the kit, only one middle panelforms each middle panel row. In other embodiments, more than one middle panelmay form each middle panel row. Furthermore, each middle panelin each of the middle panel rowsneed not be identical. Each middle panelin each of the middle panel rowsmay differ in length or other characteristics.

Each of the top panelsare assembled with the plurality of middle panelsin an intersecting arrangement as discussed above. Each of the top panelslies in a top panel row, each of the top panel rowsintersecting with each of the middle panel rows. Each of the top panel rowsis substantially parallel and non-intersecting with each of the bottom panel rows. In the kit, only one top panelforms each top panel row. In other embodiments, more than one top panelmay form each top panel row. Furthermore, each top panelin each of the top panel rowsneed not be identical. Each top panelin each of the top panel rowsmay differ in length or other characteristics.

The kithas a perimeter P comprising a plurality of planes. A plurality of left side edges,of certain ones of the bottom panelsand top panelslie in a first plane P. A plurality of right side edges,of certain ones of the bottom panelsand top panelslie in an opposite second plane P. Where the bottom panel rowsand top panel rowseach comprise a plurality of bottom panelsand top panels, not all left and right side edges,,,may lie in the first and second planes P, P. Instead, the left side edges,of a first portion of the bottom panelsand top panelsmay lie in the first plane Pwhile the right side edges,of a second portion of the bottom panelsand top panelsmay lie in the second plane P.

Furthermore, a plurality of front side edgesof the middle panelslie in the front plane Pwhile a plurality of rear side edgesof the middle panelslie in the opposite rear plane P. As before, not all of the front side edgesof the middle panelsneed lie in the front plane Pand not all of the rear side edgeof the middle panelsneed lie in the rear plane P. Instead, only a portion of the front and rear side edges,of the middle panelsneed lie in each of the front and rear planes P, Pin the event that there is more than one middle panelin some or all of the middle panel rows.

Turning to, a second ceiling system kitis shown comprising a plurality of bottom, middle, and top panels,,. The kitalso comprises hanging hardware, instructions, and a packageanalogous to the packagediscussed above. Each of the panels,,has a first axial length L. As can be seen in, the kitis assembled into a square open cell grid structure of equal width and length. In this embodiment, the kitforms an 8 foot by 8 foot structure. As illustrated, the bottom panelsare non-intersecting and substantially parallel. The middle panelsintersect the bottom panelsand are substantially perpendicular to the bottom panels. The top panelsare non-intersecting with other ones of the top panelsand with the bottom panels, but are substantially perpendicular to the middle panels. The panels,,are assembled as discussed above, with the bottom panelsbeing attached to the hanging hardwareand the middle panelsresting on the bottom panels. Furthermore, the top panelsrest on the middle panels. Each of the middle and top panels,are free of hanging hardware. As with the kit, each of the panels,,lies in a respective bottom, middle, and top row. Each of these rows comprise only a single panel in this embodiment. Furthermore, the perimeter is defined by a plurality of planes in the same manner as the kit. The ends of the panels,,lie in the plurality of planes as discussed above with respect to.

Turning to, a third ceiling system kitis shown. The kitcomprises a plurality of bottom, middle, and top panels,,. The kitalso comprises hanging hardware, instructions, and a packageanalogous to the packagediscussed above. Each of the bottom and top panels,has a second axial length Land each of the middle panels has a first axial length L. The second axial length Lis less than the first axial length L. The panels,,are assembled as discussed above, with the bottom panelsbeing attached to the hanging hardwareand the middle panelsresting on the bottom panels. Furthermore, the top panelsrest on the middle panels. Each of the middle and top panels,are free of hanging hardware. As can be seen, the bottom and top panels,can be shorter than the middle panels. In the kit, an 8 foot wide by 4 foot long system is assembled. Alternately, the middle panelscan be shorter than the bottom and top panels,as shown in the kit. Thus, a variety of axial lengths can be used to assemble a variety of different sized open cell grid systems, depending on the requirements of the space.

Turning to, a first embodiment is shown employing a plurality of kits of different types to provide an installation which is non-rectangular. Furthermore, the component kits of this embodiment are interconnected such that the system is one cohesive installation rather than a plurality of separate systems which are free to move independently from each other. As best shown in, the resulting system is 12 feet wide by 12 feet long and arranged in an “L” shape. This embodiment is constructed using one of each of the kits,,discussed above.

In a first installation step shown in, the plurality of bottom panelsare assembled into bottom panel rows, with each of the plurality of bottom panelssecured to the support structureof the building 2 via hanging hardware(not shown). Each of the bottom panel rowsare substantially parallel and non-intersecting. As can be seen, a first portion of the bottom panel rowshave a plurality of bottom panelswhile a second portion of the bottom panel rowshave only a single bottom paneltherein. The bottom panelscomprise a first plurality of bottom panelshaving an axial length Land a second plurality of bottom panelshaving an axial length Lthat is less than the first axial length L. As can be seen, some of the bottom panelsare axially aligned. A plurality of bottom gapsare formed where the side edgesof two bottom panelsmeet in an individual bottom panel row. It should be noted that no two adjacent bottom panel rowshas a pair of transversely adjacent bottom gapswith respect to the bottom panel rows. Instead, the bottom panelsof different lengths are arranged such that the bottom gapsare always separated from each other in the direction of the bottom panel rows. Thus, no two bottom gapsare adjacent in a direction perpendicular to the bottom panel rows. This serves to ensure that the bottom panelsare interleaved such that they form a single system rather than individual separate systems. This ensures that the visual appearance of the resulting open cell grid structure is integral, without the appearance of separate structures simply mounted adjacent to one another. This improves the resulting aesthetic appearance as well as improving the strength and rigidity of the resulting installation.

In a second installation step shown in, the plurality of bottom panelsare assembled with a plurality of middle panelsin a plurality of middle panel rowsas shown. The plurality of middle panelsare of first and second lengths L, L. The middle panelsare arranged such that those middle panel rowshaving a plurality of middle panelswhich are axially aligned. A middle gapis formed where adjacent side edgesof the plurality of middle panelsmeet within a middle panel row. Each of the middle gapsare arranged such that there are no transversely adjacent middle gapsalong the direction of the middle panel rows. Thus, no two middle gapsare adjacent in a direction perpendicular to the middle panel rows. This helps to tie the resulting open cell grid structure together as discussed above.

In a third installation step shown in, the plurality of bottom panelsand middle panelsare assembled with a plurality of top panelsin a plurality of top panel rowsas shown. Some of the top panelshave a first axial length Lwhile other ones of the top panelshas a second axial length Lwhich is shorter than the first axial length L. Some of the top panel rowshave a plurality of top panelstherein, these plurality of top panelsbeing axially aligned. In contrast, other ones of the top panel rowshave only a single top paneltherein. In those top panel rowshaving a plurality of top panelstherein, there is a top gapwhere adjacent side edgesmeet. The top panelsare assembled such that no adjacent top panel rowsor bottom panel rowshave a top gapor bottom gaptransversely adjacent any other top gapor bottom gapin the direction of the top panel rows. Thus, no two top or bottom gaps,are adjacent in a direction perpendicular to the top panel rows. Although some of the top and bottom gaps,may be adjacent middle gaps, this has no negative effect on the strength or rigidity of the resulting assembly because these gaps are perpendicular to one another. In this manner, a variety of different kits can be combined to create an open cell grid structure of virtually any shape or size.

As can be seen, a first plane Pis defined by the left edges of a portion of the top and bottom panels,. A second plane Pis defined by the right edges of a portion of the top and bottom panels,. A third plane Pis defined by the front edges of a portion of the middle panels. A fourth plane Pis defined by the rear edges of a portion of the middle panels. The first and second planes P, Pare perpendicular to the bottom panel rowsand the top panel rows. The third and fourth planes P, Pare perpendicular to the middle panel rows.

Where the user intends to install a system which is a combination of a plurality of kits, instructions for the individual kits are supplemented with instructions for how to mate panels from a first kit and a second kit in order to create the combined open cell grid structure. In these instructions, the arrangement of the bottom, middle, and top panels,,is disclosed so as to prevent any edge to edge interfaces or edge to edge gaps opposing each other or otherwise being adjacent in a transverse direction to the respective panel row. An edge to edge interface is defined as when two panels are in contact and an edge to edge gap is defined as when two panels are spaced from each other. The instructions may further comprise information regarding using the hanging hardwareof the first kit and the second kit together. The instructions may be provided as instruction sheets, an instruction manual, a representation on the product packaging, or in electronic format such as a PDF or a website, with the packaging comprising a link or other reference to the website.

Turning to, two of the 8 foot by 8 foot kitsare assembled to form an 8 foot wide by 16 foot long open cell grid structure. In the first step shown in, the bottom panelsare assembled as shown. Instead of utilizing two different kits, it is possible to utilize two of the same kit and cut two of the bottom panelsin half, rearranging the halves to ensure that the bottom gapsare alternating as shown. This reduces the number of different kits which must be stocked and allows the installer to field-modify the panels to complete an installation with fewer components. Thus, the bottom panel rowseach have a plurality of bottom panels, some of which are cut from longer bottom panelsas shown.

In the second step shown in, the middle panelsare assembled to the bottom panelsas shown. Each of the middle panelshas the same length and none of the middle panelsneeds to be cut to facilitate installation. Due to the use of a single middle panelin each middle panel row, there are no middle gaps.

In the third step shown in, the top panelsare assembled to the middle panelsas shown. A portion of the top panelsmust be cut to provide top panelsof two different lengths as shown. The top gapsare transversely separated from each and every other top gapand bottom gapas discussed above. Although it is possible to utilize top panelsof identical length without cutting them, this would result in transversely adjacent top gaps. This would reduce the strength and rigidity of the system, so it is an undesirable configuration. It is also possible to supply top panelsand bottom panelsin differing lengths to permit assembly without the need to cut the top and bottom panels,.