CEILING SYSTEM

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 63/720,951, filed Nov. 15, 2024, the entirety of which is incorporated herein by reference.

BACKGROUND

Various types of ceiling systems have been used in commercial and residential building construction to provide the desired aesthetic and acoustical performance. Installing and removing panels within these systems often can be difficult necessitating a better ceiling system design.

BRIEF SUMMARY

According to some embodiments, the present invention is directed to a ceiling system comprising: a plurality of ceiling modules, each of the plurality of ceiling modules comprising: a panel comprising a perimetric edge; and at least one magnet comprising a magnetic axis extending from a north pole to a south pole, the at least one magnet coupled to the panel adjacent the perimetric edge to allow the least one magnet to adjust orientation relative to the panel while remaining coupled to the panel; a hanger assembly configured to hang the ceiling module from a support structure in a manner that allows tilting, swaying, and/or rotational movement of the ceiling module; and the magnets located at predetermined locations on the panels so that when the plurality of ceiling modules are hung from the support structure by the hanger assemblies and positioned sufficiently close to one another, the magnetic fields of adjacent ones of the magnets of adjacent ones of the plurality of ceiling modules cause one or more of the adjacent ones of the magnets to adjust orientation so that the magnetic axes of the adjacent ones of the magnets become aligned, thereby causing adjacent portions of the perimetric edges of the adjacent ones of the plurality of ceiling modules to magnetically lock together in a predetermined position and orientation.

Other embodiments of the present invention include a ceiling system comprising: a first ceiling module comprising: a first panel comprising a first perimetric edge; and a first magnet comprising a first magnetic axis extending from a first north pole to a first south pole, the first magnet coupled to the first panel adjacent the first perimetric edge to allow the first magnet to adjust orientation relative to the first panel while remaining coupled to the first panel; a second ceiling module comprising: a second panel comprising a second perimetric edge; and a second magnet comprising a second magnetic axis extending from a second north pole to a second south pole, the second magnet coupled to the second perimetric edge to allow the second magnet to adjust orientation relative to the second panel while remaining coupled to the second panel; a hanger assembly configured to hang the first and second ceiling module from a support structure in a manner that allows tilting, swaying, and/or rotational movement of the first and second ceiling module; and the first ceiling module and the second ceiling module are positioned sufficiently close to one another, the magnetic fields of the first magnet and the second magnet cause one or more of the first and second magnet to adjust orientation so that the first magnetic axis and the second magnetic axis become aligned, thereby causing the first perimetric edge of the first ceiling module and the second perimetric edge of the second ceiling module to magnetically lock together in a predetermined position and orientation.

Other embodiments of the present invention include a ceiling module comprising: a panel comprising a perimetric edge; and at least one magnet having a magnetic field and comprising a magnetic axis extending from a north pole to a south pole, the at least one magnet coupled to the panel adjacent the perimetric edge to allow the least one magnet to adjust orientation relative to the panel while remaining coupled to the panel; wherein the magnets are located at predetermined locations on the panel so that the magnetic field interacts with a separate magnetic field located adjacent to the perimetric edge, the magnet adjusts orientation so that the magnetic axis of the magnet aligns with the separate magnetic field while remaining coupled to the panel.

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 the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is an upward facing perspective view of a ceiling system according to the present disclosure;

FIG. 2 is a downward facing perspective view of the ceiling system of FIG. 1;

FIG. 3A is an exploded close-up upward facing perspective view of a ceiling module of the ceiling system of FIG. 1;

FIG. 3B is an exploded close-up downward facing perspective view of a ceiling module of the ceiling system of FIG. 1;

FIG. 4 is a downward facing close-up view of two adjacent ceiling modules of FIG. 1 in an unassembled state;

FIG. 5 is a downward facing close-up view of the two adjacent ceiling modules of FIG. 4 in an assembled state;

FIG. 6A is a first cross-sectional view of a panel of the ceiling module of FIG. 4 along line V-V;

FIG. 6B is a second cross-sectional view of the panel of FIG. 6A;

FIG. 7 is a cross-sectional view of the ceiling module of FIG. 4 along line V-V;

FIG. 8 is a cross-sectional view of the ceiling module of FIG. 5 along line X-X;

FIG. 9 is a downward facing perspective view of a ceiling system according to another embodiment of the present invention;

FIG. 10 is a bottom view of a backer panel of the panel of the ceiling module of the present invention;

FIG. 11 is a close-up view of region I in FIG. 10;

FIG. 12 is a close-up view of magnet-containing backer panel in the same close-up region I in FIG. 10;

FIG. 13 is a close-up view of two adjacent magnet-containing backer panels of the ceiling module of the present invention in an unassembled state;

FIG. 14 is a close-up view of two magnet-containing backer panels of the ceiling module of the present invention in an assembled state; and

FIG. 15 is a perspective view of the magnet.

DETAILED DESCRIPTION

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.

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 referenced 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.

The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention 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 derivatives 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 unless explicitly indicated as such.

Terms such as “attached,” “affixed,” “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. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.

According to the present application, the term “about” means +/−5% of the reference value. According to the present application, the term “substantially free” less than about 0.1 wt. % based on the total of the referenced value.

Referring now to FIGS. 1 and 2, the present invention is directed to a ceiling system 1 comprising a hanger assembly 500 and at least one ceiling module 100 supported from the hanger assembly 500. In some embodiments, the ceiling system 1 comprises a plurality of the ceiling modules 100 supported from the hanger assembly 500.

A plenary space 2 may exist above the plurality of ceiling modules 100. The plenary space 2 is the space that exists above the plurality of ceiling modules 100 and below a roof or a subfloor of an above adjacent floor in a building. The plenary space 2 provides room for mechanical lines to be run throughout a building—e.g. HVAC, plumbing, data lines, etc. A room environment 3 may exist below the plurality of ceiling modules 100. The room environment 3 is the space occupied by inhabitants of a room—e.g. room environments 3 in an office building would be the space occupied by desks, office workers, computers, etc. The combination of the plurality of ceiling modules 100 may be configured in an array to act as an acoustic, thermal, and aesthetic barrier between the room environment 3 and the plenary space 2, as well as a sound deadening layer for noise that exists within the room environment 3, as discussed herein.

As discussed in greater detail, each of the ceiling modules 100 may be supported by the hanger assembly 500. The hanger assembly 500 may be supported from a support structure positioned in or immediately adjacent to the plenary space 2—such as, but not limited to, a plurality of struts that form a support grid, one or more joists, or a subfloor of an adjacent floor in the building.

The hanger assembly may be configured to hang each ceiling module 100 from the support structure in a manner that allows for tilting, swaying, and/or rotational movement of the ceiling module 100.

Referring now to FIGS. 1-5 and 15, each ceiling module 100 may comprise a panel 200 and at least one magnet 300.

The magnet 300 may comprise a magnetic axis N-S. The magnetic axis N-S may extend from a north pole 301 to a south pole 302. The magnet 300 may further comprise a central axis A-A. The magnet 300 may comprise a circular outer transverse cross-sectional profile. The magnetic axis N-S of each magnet 300 may be oriented substantially transverse to the central axis A-A.

Each of the magnets 300 may comprise a magnet body 310 comprising an upper surface 311 opposite a lower surface 312. Each of the magnets 300 may further comprise an outer wall 313 extending between the upper surface 311 and the lower surface 312 of the magnet 300. The outer wall 311 of the magnet 300 may form a curved surface that is concentric to the central axis A-A. The outer wall 311 of the magnet body 310 may form the circular outer transverse cross-sectional profile.

In some embodiments, the north pole 301 may be located on a first portion 314 of the magnet body 310 and the south pole 302 may be located on a second portion 315 of the magnet body 310. The first portion 314 of the magnet body 310 forming at least a portion of the outer wall 311 of the magnet 300 and the second portion 315 of the magnet body 310 forming at least a portion of the outer wall 311 of the magnet 300. The first portion 314 of the magnet body 310 may be semi-circular in cross-sectional shape and the second portion 315 of the magnet body 310 may be semi-circular in cross-section shape—with the first and second portions 314, 315 forming circular outer transverse cross-sectional profile.

In some embodiments, the magnet 300 may comprise a central opening 320 that extends continuously from the upper surface 311 to the lower surface 312 of the magnet 300. The central opening 320 may extend along a direction that is substantially parallel to the central axis A-A. The central opening 320 may be circumscribed by an opening wall 321 that extends from the upper surface 311 to the lower surface 312 of the magnet 300.

The magnet 300 may have an outer diameter D_M1 as measured by the distance along opposite sides of the outer wall 313 of the magnet 300. The magnet 300 may have an inner diameter D_M2 as measured by the distance along opposite sides of the opening wall 321 of the magnet 300. The magnet 300 may have a magnet height H_M as measured by the distance from the upper surface 311 to the lower surface 312 along the central axis A-A.

In a non-limiting embodiment, the outer diameter D_M1 of the magnet 300 may range from about 0.25 inch to about 1.0 inches—including all diameters and sub-ranges there-between. In a non-limiting embodiment, the outer diameter D_M1 of the magnet 300 may range from about 0.25 inch to about 0.75 inches—including all diameters and sub-ranges there-between. In a non-limiting embodiment, the outer diameter D_M1 of the magnet 300 may range from about 0.25 inch to about 0.5 inches—including all diameters and sub-ranges there-between.

In a non-limiting embodiment, the outer diameter D_M1 of the magnet 300 may be about 0.375 inches. In a non-limiting embodiment, the inner diameter D_M2 of the magnet 300 may range from about 0.05 inch to about 0.15 inches—including all diameters and sub-ranges therebetween. In a non-limiting embodiment, the inner diameter D_M2 of the magnet 300 may range from about 0.094 inches. In a non-limiting embodiment, the magnet height H_M may be about 0.25 inches to about 0.5 inches—including all heights and sub-ranges there-between. In a non-limiting embodiment, the magnet height H_M may be about 0.375 inches.

The magnet 300 may be a permanent magnet. The magnet 300 may be a rare earth magnet. In a non-limiting embodiment, the magnet 300 may be a neodymium magnet. In a non-limiting embodiment, the magnet 300 may be a NdFeB magnet. The magnet body 310 may be a permanent magnet. The magnet body 310 may be a rare earth magnet. In a non-limiting embodiment, the magnet body 310 may be a neodymium magnet. In a non-limiting embodiment, the magnet body 310 may be a NdFeB magnet. In some embodiments, the magnet 300 may further comprise a plating layer. The plating layer may be formed of NiCuNi.

The magnet 300 may have a magnetic strength. The magnetic strength may be measured by the pull force, measured by weight in which a magnet can hold to a steel plate. In some embodiments, the pull force of the magnet may range from about 3 lbs. to about 20 lbs.—including all weights and sub-ranges there-between. In some embodiments, the pull force of the magnet may be about 5.35 lbs. In some embodiments, the pull force of the magnet 300 may be such that the magnet 300 is capable of holding together adjacent ones of the ceiling module 100—as discussed further herein.

The ceiling module 100 may comprise a first exposed major surface 101 opposite a second major exposed surface 102 and a side exposed surface 103 extending between the first major exposed surface 101 and the second major exposed surface 102. As discussed, the ceiling module 100 may comprise a panel 200. The panel 200 may comprise a first major surface 201 opposite a second major surface 202 and a perimetric edge 203 extending between the first major surface 201 and the second major surface 202. In some embodiments, the first major surface 201 may be parallel to the second major surface 202. In some embodiments, the perimetric edge 203 may be substantially orthogonal to the first major surface 201 and. /or the second major surface 202 of the panel 200.

In an alternative embodiment (not shown), the first major surface 201 of the panel 200 may be parallel to the second major surface 202 and the perimetric edge 203 may be oblique to the first major surface 201 and./or the second major surface 202 of the panel 200.

The first exposed major surface 101 of the ceiling module 100 may comprise the first major surface 201 of the panel 200. The second exposed major surface 102 of the ceiling module 100 may comprise the second major surface 202 of the panel 200. The side exposed major surface 103 of the ceiling module 100 may comprise the perimetric edge 203 of the panel 200. In some embodiments, the panel 200 may comprise a chamfer 205 formed into the first major surface 201 of the panel 200 located at the side surface 203 of the panel 200.

The perimetric edge 203 of each panel 200 may comprise at least one liner edge portion 210. In some embodiments, the perimetric edge 203 of each panel 200 may comprise a plurality of liner edge portions 210. The perimetric edge 203 may consist of the plurality of linear edge portions 210. Stated otherwise, the perimetric edge 203 may be formed entirely of the linear edge portions 210. In such embodiments, the plurality of linear edge portions 210 may collectively form a polygonal shape. In an alternative embodiment, the perimeter edge 203 may comprise at least one linear edge portion 210 as well as a non-linear edge portion (not pictured).

In a non-limiting embodiment the polygonal shape may include a 3-sided polygon, 4-sided polygon, 5-sided polygon, 6-sided polygon, 7-sided polygon, 8-sided polygon, 9-sided polygon, 10-sided polygon, 11-sided polygon, 12-sided polygon, 13-sided polygon, 14-sided polygon, 15-sided polygon. In some embodiments, the ceiling system may comprise a plurality of ceiling modules 100 having at least two panels 200 having perimetric edges of different polygonal geometry.

The perimetric edge 203 may further comprise a non-polygonal edge geometry. The perimetric edge 203 may comprise a curved edge geometry—so long as the curvature of the perimetric edge 203 of adjacent ones of the ceiling modules may mate together.

Although not shown, the parametric edge 203 may also comprise cutout geometry to allow for the presence of a light module positioned between at least two adjacent ceiling modules 100.

The panel 200 may comprise a body. The body may be formed of a fibrous material. The fibrous material may be present in the body an amount ranging from about 90.0 wt. % to about 99.9 wt. % based on the total weight of the body —including all weight percentages and sub-ranges there-between. In a preferred embodiment, the fibrous material may be present in the body an amount ranging from about 95.0 wt. % to about 99.9 wt. % based on the total weight of the body—including all weight percentages and sub-ranges there-between.

The fibrous material may comprise a plurality of fibers having a substantially straight geometry, whereby the fibers extend substantially straight. In some embodiments, the fibrous material may comprise a plurality of fibers having a crimped geometry, whereby the fibers have a planar zig-zag and/or spiral shape. In some embodiment, the fibers may comprise a zig-zag shape. In some embodiments, the fibers may have a spiral shape.

The fibrous material may comprise an organic fiber. The organic fiber may be a synthetic organic fiber. The organic fiber may be present in an amount ranging from about 95 wt. % to about 100 wt. % based on the total weight of the fibrous material—including all weight percentages and sub-ranges there-between. In some embodiments, the organic fiber may be present in an amount of at least 99 wt. % based on the total weight of the fibrous material—including all weight percentages and sub-ranges there-between. In some embodiments, the organic fiber may be about 100 wt. % of the fibrous material.

In some embodiments, the fibrous material consists essentially of organic fiber. In some embodiments, the fibrous material consists of organic fiber. In some embodiments, the fibrous material is substantially free of inorganic fiber. In some embodiments, the body is substantially free of inorganic fiber.

In some embodiments, the fibrous material consists essentially of synthetic organic fiber. In some embodiments, the fibrous material consists of synthetic organic fiber. In some embodiments, the fibrous material is substantially free of inorganic fiber. In some embodiments, the body is substantially free of inorganic fiber. In some embodiments, the fibrous material is substantially free of natural organic fiber. In some embodiments, the body 100 is substantially free of natural organic fiber.

The term “natural organic fiber” may refer to naturally occurring fiber—such as, but not limited to, cellulosic fiber (also referred to as “cellulose” fiber).

The synthetic organic fiber may be a polymeric fiber. The polymeric fiber may be formed of a thermoplastic polymer. The polymeric fiber may be a polyester fiber. The polyester fiber may be formed from thermoplastic polyester. In other embodiments, the polymeric fiber may be formed by one or more thermoplastic polymers such as, but not limited to olefinic polymers, e.g., polyethylene and polypropylene; polyamide, e.g., nylon 6 and nylon 6,6; thermoplastic elastomers, e.g., SBS and ABS, and the like. In some embodiments, a portion of the polymeric fiber may be formed from thermoset polymer.

In some embodiments, the polyolefin may be from ethylene polymers, such as high-density polyethylene (“HDPE”); medium-density polyethylene (“MDPE”); low-density polyethylene (“LDPE”); and linear low-density polyethylene (“LLDPE”).

The polyester fiber may be present in an amount ranging from about 95.0 wt. % to about 100 wt. % based on the total weight of the fibrous material—including all weight percentages and sub-ranges there-between. The polyester fiber may be present in an amount of at least about 70 wt. % based on the total weight of the fibrous material. In some embodiments, the polyester fiber may be present in an amount of at least about 99 wt. % based on the total weight of the fibrous material. In some embodiments, the polyester fiber may be about 100 wt. % of the fibrous material.

Non-limiting examples of polyester fiber include fibers formed of polymeric material selected from one or more of terephthalate polymers, such as polyethylene terephthalate (“PET”), polybutylene terephthalate (“PBT”), polyethylene terephthalate glycol (“PETG”), glycol-modified PBT, and the like.

The polyester polymer that forms the polyester fiber may have a glass transition temperature ranging from about 70° C. to about 85° C.—including all temperatures and sub-ranges there-between. The polyester polymer that forms the polyester fiber may have a melt temperature ranging from about 110° C. to about 295° C.—including all temperatures and sub-ranges therebetween.

In some embodiments, the polyester fiber may be a single component fiber formed entirely of a single polyester polymer. In other embodiments, the polyester fiber may be a bicomponent fiber formed of two different polyester polymers (i.e., a first polyester polymer and a second polyester polymer). The first polyester may have a first melt temperature ranging from about 245° C. to about 255° C.—including all temperatures and sub-ranges there-between. The second polyester may have a second melt temperature ranging from about 255° C. to about 265° C.—including all temperatures and sub-ranges there-between. Independent of the melt temperature ranges recited above, the first melt temperature may be equal to about 90 % to about 97 % the second melt temperature—including all percentages and sub-ranges there-between.

The bicomponent fiber may have a side-by-side configuration or a core sheath configuration. In the core-sheath configuration, the first polyester polymer forms the core and the second polyester forms the sheath that at least partially surrounds the core. In the core-sheath configuration, the bicomponent fiber may comprise one or more fibers that is a concentric sheath-core (symmetrical core sheath) or an eccentric sheath-core (asymmetrical core-sheath).

In the bicomponent fibers, the first polyester may be present in an amount ranging from about 25 wt. % to about 75 wt. % of the bicomponent fiber and the second polyester being present in an amount ranging from about 75 wt. % to about 25 wt. %—wherein both amounts are based on the total weight of the bicomponent fiber and include all amounts and sub-ranges therebetween.

The body may further comprise at least one additional component selected from fire retardants, finishing oils, and/or colorants. The additional component may be present in an amount ranging from about 0.1 wt. % to about 10.0 wt. % based on the total weight of the body—including all amounts and sub-ranges there-between. In some embodiments, the additional component may be present in an amount ranging from about 0.1 wt. % to about 5.0 wt. % based on the total weight of the body—including all amounts and sub-ranges there-between.

The sum of the weight of the fibrous material and the additional component may be equal to 100 wt. % of the body. The body may consist essentially of the fibrous material and the additional component. The body may consist of the fibrous material and the additional component. The body may be substantially free of ferreous materials. In some embodiments, the body may be free of ferreous materials.

The fire retardant may be present in an amount ranging from about 0.1 wt. % to about 5.0 wt. % based on the total weight of the body—including all amounts and sub-ranges therebetween. In some embodiments, the fire retardant may be present in an amount ranging from about 0.5 wt. % to about 4.0 wt. % based on the total weight of the body—including all amounts and sub-ranges there-between. Non-limiting examples of fire retardant may include non-halogenated phorphorous containing compounds, phosphine oxides, phosphinates, phosphonates, phosphates, and mixtures thereof.

The finishing oil may be present in an amount ranging from about 0.1 wt. % to about 5.0 wt. % based on the total weight of the body—including all amounts and sub-ranges therebetween. Non-limiting examples of finishing oil may include one or more fiber lubricant compounds.

The colorant may be present in an amount ranging from about 0.1 wt. % to about 2.0 wt. % based on the total weight of the body—including all amounts and sub-ranges there-between. Non-limiting examples of colorant may include dyes, pigments, and combinations thereof. Non-limiting examples of pigments may include titanium dioxide, carbon black, and mixtures thereof. Other non-limiting examples of colorants include 2,2-(Vinylenedi-p-phenylene) bisbenzoxazole; Copper Phthalocyanine; Diiron trioxide; 1,1′-((6-Phenyl-1,3,5-triazine-2,4-diyl)diimino)bis-9,10-antharcenedione; and combinations thereof.

The colorant may be white, black, grey, and any color within the color spectrum. According to the present invention the term “color” may include colors of the visible light spectrum (e.g., red, orange, yellow, green, cyan, blue, violet, brown, etc.) as well as white, black, and grey. In a non-limiting example, the body may be white and the colorant may be titanium dioxide. In a non-limiting example, the body may be black and the colorant may be carbon black. In a non-limiting example, the body may be white and the colorant may be grey and a blend of titanium dioxide and carbon black.

The body may be porous—also referred to as a “porous body”. The porous body may allow for air and water vapor to flow between the first major surface 201 and the second major surface 202 of the panel 200. The body may be porous enough that it allows for enough airflow through the panel 200 under atmospheric conditions for the panel 200 to function as an acoustic panel 200—making the ceiling module an acoustic ceiling module 100, which requires properties related to noise reduction and sound attenuation properties—as discussed further herein.

Specifically, the body of the present invention may have a porosity ranging from about 90.0 % to about 97.0 %-including all values and sub-ranges there between. In a preferred embodiment, the body 100 has a porosity ranging from about 91 % to 94 %—including all values and sub-ranges there between. According to the present invention, porosity refers to the following:

% ⁢ Porosity = [ V Total - ( V F + V A ⁢ C ) ] / V Total

Where V_Total refers to the total volume of the body defined by outermost surfaces—in some cases the first major surface 201, the second major surface 202, and the perimetric edges 203 of the panel 200—when the body is the panel 200. V_F refers to the total volume occupied by the fibrous material in the body. V_AC refers to the total volume occupied by the additional components in the body. Thus, the % porosity represents the amount of free volume within the body. The porous nature of the body may result in a network of open pathways that exist as voids between the V_F and V_AC. The network of open pathways may be fluidly coupled and allow for the airflow through the body between at least the first major surface 201 and the second major surface 202 of the panel 200.

The panel 200 may exhibit sufficient airflow for the ceiling module 100 to have the ability to reduce the amount of reflected sound in a room. The reduction in amount of reflected sound in a room is expressed by a Noise Reduction Coefficient (NRC) rating as described in American Society for Testing and Materials (ASTM) test method C423. This rating is the average of sound absorption coefficients at four ⅓ octave bands (250, 500, 1000, and 2000 Hz), where, for example, a system having an NRC of 0.90 has about 90% of the absorbing ability of an ideal absorber. A higher NRC value indicates that the material provides better sound absorption and reduced sound reflection.

The ceiling module 100 of the present invention exhibits an NRC of at least about 0.5. In some embodiments, the ceiling module 100 of the present invention may have an NRC ranging from about 0.60 to about 1.0—including all value and sub-ranges there-between. In a preferred embodiment, the ceiling module 100 of the present invention may have an NRC ranging from about 0.70 to about 1.0—including all value and sub-ranges there-between.

The ceiling module 100 of the present invention may comprise at least one of the magnets 300 coupled to the panel 200 in a location that is adjacent to the perimetric edge 203 of the panel 200. In such configuration, the magnet 300 may be allowed to change orientation relative to the panel 200 while remaining coupled to the panel 200. The magnet 300 may be capable of rotating freely about the central axis A-A while remaining coupled to the panel 200 in the location adjacent to the perimetric edge 203. In such embodiment, the magnet 300 may be capable of changing the relative position of the magnetic axis N-S relative to the perimetric edge 203.

In a non-limiting example, the magnet 300 may be first positioned such that the north pole 301 is located proximate to the perimetric edge 203 of the panel 200 and capable of changing orientation (e.g., by rotation about the central axis A-A) such that the south pole 302 is located adjacent to the perimetric edge 203—such change in orientation may occur while the magnet 300 remains coupled to the panel 200. In a non-limiting example, the magnet 300 may be first positioned such that the south pole 302 is located proximate to the perimetric edge 203 of the panel 200 and capable of changing orientation (e.g., by rotation about the central axis A-A) such that the north pole 301 is located adjacent to the perimetric edge 203—such change in orientation may occur while the magnet 300 remains coupled to the panel 200. In a non-limiting example, the magnet 300 may be first positioned such that the north pole 301 and south pole 302 are substantially equally located proximate to the perimetric edge 203 of the panel 200 and capable of changing orientation (e.g., by rotation about the central axis A-A) such that either one of the north pole 301 or the south pole 302 is located adjacent to the perimetric edge 203—such change in orientation may occur while the magnet 300 remains coupled to the panel 200.

In some embodiments, during the orientation change of the magnet, the magnetic axis N-S may remain substantially parallel to at least one of the first major surface 201 and/or second major surface 202 of the panel 200 during orientation change. In other embodiments, during the orientation change, the magnetic axis N-S may cycle between each of being parallel, oblique, and orthogonal to the parametric edge 203 of the panel 200.

The magnet 300 may be cylindrical in shape. In other embodiment, the magnet 300 may be polygonal in shape—such as, rectangular.

Each of the plurality of magnets 300 may be located at predetermined locations on the panel 200. The predetermined locations may be selected such that when the plurality of ceiling modules 100 are hung from the support structure by the hanger assemblies 500 and positioned sufficiently close to one another, the magnetic fields of adjacent ones of the magnets 300 of adjacent ones of the plurality of ceiling modules 100 cause one or more of the adjacent ones of the magnets 300 to adjust orientation (as discussed above) so that the magnetic axes N-S of the adjacent ones of the magnets 300 become aligned, thereby causing adjacent portions of the perimetric edges 203 of the adjacent ones of the plurality of ceiling modules 100 to magnetically lock together at the predetermined locations along the perimetric edge 203 of the panel 200 of the ceiling modules 100.

The magnetic lock created by plurality of magnets 300 located at predetermined locations in the panel 200 along the perimetric edge 203 may have a strength as measured by a separation force. The separation force may be the force required to separate two adjacent ceiling modules 100 that have been magnetically locked together along the respective perimetric edge 203 of the respective panel 200 of each ceiling module 100.

In some embodiments, the separation force may range from about 4.0 lbf to about 5.0 lbf.—including all forces and sub-ranges there-between. In some embodiments, the separation force may range from about 4.0 lbf to about 4.9 lbf.—including all forces and sub-ranges therebetween. In some embodiments, the separation force may be about 4.6 lbf.

The term “sufficiently close” in this application refers to the magnetic field of a first magnet 300 capable of interacting with the magnetic field of a second magnet 300 in adjacent ones of the plurality of ceiling modules 100. Evidence of magnetic field interaction may be the position change of at least one of two magnets 300 about the respective central axis A-A once the two magnets 300 are brought within sufficiently proximate distance for the respective magnetic fields.

The plurality of ceiling modules 100 may be magnetically interlocked at the perimetric edges 203 of the panels 200 such that the ceiling modules 100 form a substantially planar topography along the first exposed major surfaces 101 of the ceiling modules 100. In such embodiments, the perimetric edge 203 of each the panel 200 may be substantially orthogonal to at least the first major surface 201 of the panel 200 of each respective ceiling module 100. In such embodiments, the perimetric edge 203 of the panel 200 may be orthogonal to at least the first major surface 201 of the panel 200.

In an alternative embodiment (not shown), the plurality of ceiling modules 100 may be magnetically interlocked at the perimetric edges 203 of the panels 200 such that the ceiling modules 100 form a non-planar topography along the first exposed major surfaces 101 of the ceiling modules 100. In such embodiments, the perimetric edges 203 of each panel 200 of each ceiling module 100 may be oblique to at least the first major surface 201 of the panel 200 of the respective ceiling module 100.

Referring now to FIGS. 3A, 6A, 6B, 7, 8, and 10-14, for each of the plurality of ceiling modules 100, the panel 200 may comprise at least one cavity 230 in which the magnet 300 is positioned. In some embodiments, for each of the plurality of ceiling modules 100, the panel 200 may comprise a plurality of cavities 230 in which the magnet 300 is positioned. For each of the plurality of ceiling modules 100, the cavity 230 may be enclosed such that the at least one magnet 300 is trapped within the cavity 300 and cannot be removed from the cavity 300 irrespective of orientation.

For each of the plurality of ceiling modules 100, the cavity 230 may extend along a cavity axis B-B. For each of the plurality of ceiling modules 100, the cavity 230 may comprise a circular transverse cross-sectional profile. For each of the plurality of ceiling modules 100, the cavity 230 may be circumscribed by a cavity wall 231 that is concentric to the cavity axis B-B. The cavity wall 231 may extend from an upper cavity surface 232 to a lower cavity surface 233. The cavity 230 may have a cavity diameter D_C as measured from opposite sides of the cavity wall 231. The cavity 230 may have a cavity height H_C as measured from the upper cavity surface 232 to the lower cavity surface 233.

The cavity diameter D_C may be greater than the outer diameter D_M1 of the magnet 300. A ratio of the cavity diameter D_C to the outer diameter D_M1 of the magnet 300 may range from about 1.05:1 to about 1.5:1—including all ratios and sub-ranges there-between. The cavity height H_C may be greater than the magnet height H_M of the magnet 300. A ratio of the cavity height H_C to the magnet height H_M may range from about 1.05:1 to about 1.5:1—including all ratios and sub-ranges there-between.

For each of the plurality of ceiling modules 100, the at least one magnet 300 may be nested within the cavity 300 and rotate about the central axis A-A relative to the panel 200 when subjected to the magnetic field of a magnet 300 of another ceiling module 100 that is sufficiently close.

For each of the plurality of ceiling modules 100, the cavity 230 may be sized (in both the cavity diameter D_C and the cavity height H_C) such that the magnet 300 may freely rotate about the central axis A-A such that the magnetic axis N-S may change relative position to the panel 200 while the central axis A-A of the magnet 300 remains substantially parallel to the cavity axis B-B of the respective cavity 230 of that ceiling module 100. Stated otherwise, for each of the plurality of ceiling modules 100, the cavity 230 may be sized (in both the cavity diameter D_C and the cavity height H_C) such that the magnet 300 may freely rotate about the central axis A-A such that the magnetic axis N-S may change relative position to the panel 200 while the central axis A-A of the magnet 300 remains unchanged in position relative to the panel 200.

For each of the plurality of ceiling modules 100, the panel 200 may further comprise a main panel 250 and a backer panel 240.

The main panel 250 may comprise a front surface 251 opposite a rear surface 252. The main panel 250 may comprise a side surface 253 extending between the front surface 251 and the rear surface 252 of the main panel 250. The backer panel 240 may comprise a front surface 241 opposite a rear surface 242. The backer panel 240 may comprise a side surface 243 extending between the front surface 241 and the rear surface 242 of the backer panel 240. The side surface 253 of the main panel 250 and the side surface 243 of the backer panel 240 may be parallel. The side surface 253 of the main panel 250 and the side surface 243 of the backer panel 240 may be co-planar to form a continuous surface along the perimetric edge 203 of the panel 200.

The backer panel 240 may have a first thickness t₁ as measured by the distance between the front surface 241 and the rear surface 242 of the backer panel 240. The first thickness t₁ of the backer panel 240 may range from about 5 mm to about 24 mm—including all thickness and sub-ranges there-between. In some embodiments, the first thickness t₁ of the backer panel 240 may be about 12 mm.

The main panel 250 may have a second thickness t₂ as measured by the distance between the front surface 251 and the rear surface 252 of the main panel 250. The second thickness t₂ of the main panel 250 may range from about 5 mm to about 24 mm—including all thickness and sub-ranges there-between. In some embodiments, the second thickness t₂ of the main panel 250 may be about 12 mm.

In some embodiments, the first thickness t₁ may be greater than the second thickness t₂. In some embodiments, the second thickness t₂ may be greater than the first thickness t₁. In some embodiments, the second thickness t₂ may be equal to the first thickness t₁.

In some embodiments, the cavity 230 may be formed into the main panel 250 (not shown). In such embodiments, the cavity height H_C may be less than the second thickness t₂ of the main panel 250. In other embodiments, the cavity 230 may be formed into the backer panel 240. In such embodiments, the cavity height H_C may be less than the first thickness t₁ of the backer panel 240. In some embodiments, the cavity 230 may be formed into each of the main panel 250 and the backer panel 240 (not shown). In such embodiments, the cavity height H_C may be less than the summation of the first thickness t₁ of the backer panel 240 and the second thickness t₂ of the main panel 250.

In some embodiments, the cavity 230 may be a blind hole that is formed in the front surface 241 of the backer panel 240.

The backer panel 240 may be in contact with the main panel 250. The backer panel 240 may be in direct contact with the main panel 250. The backer panel 240 may be coupled to the main panel 250. The backer panel 240 may be directly coupled to the main panel 250. The backer panel 240 and the main panel 250 may be coupled by fastener 120, adhesive, or a combination thereof. In a non-limiting embodiment, a fastener 120 may extend through the rear surface 242 of the backer panel 240 into the rear surface 252 of the main panel 250. In a non-limiting embodiment, adhesive may be present in an interface that exists between the front surface 241 of the backer panel and the rear surface 252 of the main panel 250.

The panel 200 may comprise both the main panel 250 and the backer panel 240 such that backer panel 240 may be coupled to the rear surface 252 of the main panel 250. In some embodiments, the panel 200 may comprise both the main panel 250 and the backer panel 240 such that front surface 241 of the backer panel 240 may be coupled to the rear surface 252 of the main panel 250.

In an alternative embodiment (not shown), the ceiling module 100 may not include a backer panel 240. Rather, in such embodiments, the ceiling module 100 may comprise a main panel 20 and a bracket hardware that may be fastened to the rear surface 252 of the main panel 200. A magnet 300 may be coupled to the bracket hardware such that the magnet 300 is capable of the aforementioned rotation about the central axis A-A while being in an otherwise fixed position. The ceiling module 100 may comprise a plurality of the bracket hardware and magnet positioned at predetermined locations along the perimetric edge 203 of the panel 200. In such embodiments, the magnet 300 may be exposed on the second major exposed surface 102 of the ceiling module. In such embodiments, the magnet 300 may be located above the second major exposed surface 102 of the ceiling module.

In some embodiments, the magnet 300 may be secured to the panel 200 by a fastener that extends through the central opening 320 of the magnet 300. In such embodiments, the fastener may extend through the central opening 320 such that the fastener is secured to the panel 200 however not tightened enough to prevent the rotation of the magnet 300 about the central axis A-A.

Referring now to FIGS. 1, 2, 4, 5, 8, 13, and 14, the ceiling system 1 of the present invention may comprise a plurality of ceiling modules 100. The plurality of ceiling modules 100 may include at least a first ceiling module 100a and a second ceiling module 100b. Additional ceiling modules 100c, 100d, etc., may further be part of the ceiling system 1. For the purpose of the following discussion, only the first ceiling module 100a and the second ceiling module 100b will be discussed—however—the discussion applies to each of the plurality of ceiling modules 100 of the present ceiling system 1 and overall invention.

Generally, the foregoing discussion applies to the following ceiling modules. The following discussion will be made in reference to a first ceiling module 100a that comprises a first panel 200a and a first magnet 300a, and a second ceiling module 200b that comprises a second panel 200b and a second magnet 300b—but the following discussion is not limited to just a first ceiling module 100a and a second ceiling module 100b.

The first panel 200a may comprise a first perimetric edge 203a. The first magnet 300a comprises a first magnetic axis extending from a first north pole to a first south pole. The first magnet 300a may be coupled to the first panel 200a adjacent the first perimetric edge 203a to allow the first magnet 300a to adjust orientation relative to the first panel 200a while remaining coupled to the first panel 200a.

The second ceiling module 100b may comprise a second panel 200b and a second magnet 300b. The second panel 200b may comprise a second perimetric edge 203b. The second magnet may comprises a second magnetic axis extending from a second north pole to a second south pole, the second magnet 300b coupled to the second perimetric edge 203b to allow the second magnet 300b to adjust orientation relative to the second panel 200b while remaining coupled to the second panel.

For each of the plurality of ceiling modules 100, the backer panel 240 is an open frame positioned along a main panel edge 253 of the main panel 250. Each of the plurality of ceiling modules 100 comprises a plurality of the magnets 300 positioned about the perimetric edge 203 of the panel 200 in a space apart manner. At least some of the plurality of magnets 300 are arranged along each of the plurality of linear edge portions of the perimetric edge 203. Each of the plurality of ceiling modules 100, at least some of the plurality of magnets 300 are arranged along each of the plurality of linear edge portions of the perimetric edges 203.

Referring now to FIGS. 13 and 14, when the first ceiling module 100a and the second ceiling module 100b are positioned not sufficiently close, the first and second magnets 300a, 300b may be in magnetic misalignment (e.g., the north poles of each of the first and second magnets may face each other; the south poles of each of the first and second magnets may face each other, etc.)—such as demonstrated in FIG. 13.

However, when the first ceiling module 100a and the second ceiling module 100b are positioned sufficiently close to one another, the magnetic fields of the first magnet 300a and the second magnet 300b cause one or more of the first and second magnet to adjust orientation so that the first magnetic axis and the second magnetic axis become aligned, thereby causing the first perimetric edge 203a of the first ceiling module 100a and the second perimetric edge 203b of the second ceiling module 100b to magnetically lock together in a predetermined position and orientation.

Referring to FIG. 9, the ceiling system 1 of the present invention may further comprise a anchor element 8. The anchor element 8 may comprise one or more magnets and/or a non-magnetic ferrous material capable of mating with the perimetric edge 203 of the ceiling module 100. The anchor element 8 may be a wall. The anchor element 8 may be a structure locating in the plenary space 2. The anchor element 8 may be fixed within the building to help stabilize the ceiling system 1 into place and prevent swaying over the overall plurality of ceiling modules 100.

In an alternative embodiment, one or more ceiling module 100 may comprise a perimetric edge 203 that does not comprise a plurality of magnets but rather a non-magnetic ferrous material that is capable of interacting with the magnetic field of the magnets 300 of an adjacent ceiling module 100.

The present invention provides for an effective and efficient manner in which a plurality of ceiling modules 100 may be installed to form the ceiling system 1 of the present invention. By attaching each ceiling module 100 to the hanger assembly 500, which allows for the hanging ceiling modules 100 to tilting, swaying, and/or rotate—each ceiling module 100 may then be quickly coupled to an adjacent ceiling module 100.

The predetermined location of the magnets 300 along the perimetric edge 203 ensures accurate positioning of each of the plurality of ceiling modules 100 within the ceiling system 1. Additionally, through having a magnetic connection, the plenary 2 may be readily accessible by simply by breaking the magnetic connection between adjacent ceiling modules to access the plenary 2 from the room environment 3 without the need of additional tools. By attaching each ceiling module 100 to the hanger assembly 500, even in an detached state (i.e., breaking the magnetic connection with adjacent ceiling modules) a single ceiling module may still be vertically supported within a space by the hanger assembly 500, thereby preventing such panel 200 from accidentally falling or being damaged during maintenance.

According to the present invention, the separation force created by the magnetic lock between adjacent ceiling modules 100 may be overcome by pushing a ceiling module 100 upwards in a direction spanning from the room environment 3 to the plenary space 2. In a non-limiting embodiment, an individual may press the first major exposed surface 101 of the ceiling module 100 upwards toward the plenary space 2—thereby overcoming the separation force and separating that particular ceiling module 100 from the adjacent ceiling modules 100 without the adjacent ceiling modules 100 also becoming separated from the overall array of ceiling modules 100.

In some embodiments (not shown), the ceiling system 1 may comprise a nested-panel that comprises one of the ceiling modules 100. In such embodiments, the ceiling system 1 may comprise a fixed support element, such as a support grid, whereby the nested panel is fixed to the support grid. The nested-panel may comprise at least one surround panel comprising an opening. The opening of the surround panel may be at least partially circumscribed by an edge that comprises either a non-magnetic ferrous material or a plurality of magnets located in predetermined positions. The nest-panel may further comprise at least one ceiling module that includes the panel 200 and magnets 300—whereby the magnets 300 of the ceiling module magnetically lock with the edge of the surround panel. In such configuration, a ceiling system may be substantially fixed to a support grid while still providing magnetic access to the plenary space 2 by the magnetic coupling mechanism of the present invention.