FOLDED ARCHITECTURAL PANEL

Abstract

A folded architectural panel folded from a flat sheet, the panel having opposite longitudinal ends extending in a width direction, opposite lateral sides extending in a length direction and a depth perpendicular to the width and length directions. The panel includes a first downward fold adjacent one longitudinal end, extending in the width direction, and having opposite fold ends at the respective lateral sides of the panel; a second downward fold adjacent the other longitudinal end, extending in the width direction, and having opposite fold ends at the respective lateral sides of the panel; and a central upward fold at a central portion of the panel between the first and second downward folds; the first downward fold, the second downward fold and the central upward fold enable contraction of the opposite end folds towards each other to cause folding of the first and second end folds and an increase in the depth of the panel at the central portion. The panel further includes two pairs of respective side upward folds extending from the four opposite fold ends of the first and second end folds to the central upward fold such that, with contraction of the opposite end folds towards each other, a respective section of each respective lateral side between two respective fold ends contracts inwardly towards the opposite lateral side and a respective sidewall is formed on each respective lateral side of the panel extending from the respective pair of side upward folds in the depth direction.

Description

The present application relates to a folded architectural panel, in particular constructed from a sheet having respective portions of shape and size that may be folded to form the panel and that might be used, for example, as a suspended ceiling panel.

It is well known to provide three-dimensionally shaped blocks or panels for use in architectural structures. Such panels may be mounted vertically on walls or hung horizontally from ceilings and have particular application with respect to their acoustic absorption, reflection and diffusive properties.

Such blocks/panels have been useful and popular. It is now proposed to provide alternative panels with some improvements/advantages.

According to the present invention, there is provided an architectural panel which is folded from a flat sheet of material. This folded panel has opposite longitudinal ends extending in a width direction, opposite lateral sides extending in a length direction and has a height perpendicular to the width and the length directions. So as to facilitate folding of the architectural panel from the flat sheet, it includes a plurality of fold-lines. There is provided a first end fold-line adjacent one longitudinal end, extending in the width direction, and having opposite fold ends at the respective lateral sides of the panel, and a second end fold-line adjacent the other longitudinal end, extending in the width direction, and having opposite fold ends at the respective lateral sides of the panel. In addition, the panel has a central fold at a central portion of the panel between the first and the second end fold-lines. A first main wall extends between the first end fold-line and the central fold and a second main wall extends between the second end fold-line and the central fold. As will be clear from the following, this central fold may have an elongate extent along a fold-line or may be formed as a point where the other fold-lines meet. The first end fold-line, the second end fold-line and the central fold enable contraction of the opposite end fold-lines of the panel towards each other. As a result, the first and second end folds are formed along the first and second end fold-lines, the central portion of the panel is provided at a position out of a plane defined by the opposite end fold-lines and the panel has a height or depth (perpendicular to the width and length directions) at the central portion.

The panel may further include two pairs of respective side folds along respective side fold-lines extending from the four opposite fold ends of the first and second end fold-lines. The two pairs of respective side folds extend to the central fold. Thus, as a consequence of the contraction of the opposite end fold-lines towards each other, a respective section of each respective lateral side between two respective fold ends is positioned inwardly towards the opposite lateral side and a respective side wall is formed on each respective lateral side of the panel. Each respective side wall extends from a respective pair of side folds in the height direction.

In this way, a three-dimensional architectural panel may be supplied as a flat sheet, thereby simplifying shipping and reducing the occupied space during shipping. At the point of installation, the architectural panel may easily be folded merely by contracting the opposite end fold-lines towards each other. A three-dimensional shape can be achieved by folding and without any cut-away scrap or wasted material. The resulting architectural panel nevertheless includes, on all four sides, surfaces/sidewalls that extend in the height direction. In other words, a complete three-dimensional form is provided from folding of the flat sheet. In addition, in order to maintain/hold the folded architectural panel in its folded three-dimensional form/shape, it is enough merely to hold/secure only one of the longitudinal length and the lateral width of the folded architectural panel, for example the length in the length direction between the opposite end folds or the width in the width direction between the respective sections of the lateral sides. The architectural panel may be provided with a clip member specifically intended to secure the lateral width of the panel, for example by attaching to the lateral sides. Alternatively or in addition, the architectural panel may be secured/held in its folded form merely by virtue of its attachment to a mounting structure. For example, when used as ceiling panels, the architectural panels may be suspended from a carrier structure including spaced elongate carriers. By attaching the respective longitudinal ends of an architectural panel with respect to the carriers, the architectural panel will, as a consequence be held in its folded/formed state.

In some embodiments, the central fold has an elongate extent such that one pair of side upward folds meet at one end of that elongate extent and the other pair of side upward folds meet at the other end of that elongate extent. With this arrangement, the central fold extends along a central fold-line at least in a width-wise direction parallel with the first and second end folds and, hence, extends only in the width direction of the panel.

In other embodiments, the two pairs of respective side folds may all meet together at the central fold so that the central fold occurs at only one point. As a result, the panel will have an overall form that generally resembles a pyramid with four sides meeting at a single point.

It is possible, in some embodiments, for the central fold (whether with an elongate extent or as a point) to be closer to one of the first and second end fold-lines than the other. In this way, the folded architectural panel is asymmetric in the length direction. In other embodiments, the central fold may be mid-way in the length direction between the first and second downward fold-lines.

Similarly, in some embodiments, it is possible for the central fold (whether with an elongate extent or as a point fold) to be closer to one of the opposite lateral sides than the other. In this way, the folded architectural panel will asymmetric in the width direction. Alternatively, the central fold may be mid-way in the width direction between the opposite lateral sides.

Embodiments may combine the length and width asymmetry and/or mid-way length and width positioning as desired.

Where a respective lateral side of the panel includes, as folds, only the respective pair of side folds, then, by using a panel material of appropriate flexibility, the resulting respective side wall can have a curved form. In particular, in the folded architectural panel, the section of the lateral side between two respective fold ends will take the form of an arc extending inwardly of the panel.

In other embodiments, it is also possible for the folded architectural panel to include respective intermediate folds extending from a respective intermediate point of each said respective section to the central fold. In other words, each respective intermediate point lies somewhere on/along the respective lateral edge of the panel. In this way, each respective side wall is divided into a pair of substantially flat sidewalls.

It should be appreciated that, in other embodiments, a plurality of such respective intermediate folds may extend from a plurality of respective intermediate points of each said respective section to the central fold. In other words, multiple intermediate points lie somewhere on/along each respective lateral edge of the panel and corresponding multiple intermediate folds on that respective side of the panel. In this way, each respective sidewall is divided into a plurality of substantially flat sidewalls. Between the respective pair of side folds, there are a plurality of intermediate folds all extending between the central fold and the respective section of the respective lateral side so as to form the plurality of substantially flat sidewalls between adjacent side folds and intermediate folds, in other words dividing a respective side wall not into just a pair of substantially flat sidewalls, but into three or more substantially flat sidewalls.

With regard to a single intermediate point between the opposite folds of a respective pair of side folds, this point may be offset towards one of the first and second folds so as to provide an asymmetric form. Alternatively, each respective intermediate point may be mid-way between the opposite fold ends of the respective pair of side folds.

According to the present invention, there is also provided a flat sheet formed with respective portions of shape and size to form parts of the folded architectural panel noted above. In particular, the sheet may be folded so that those respective portions together form the folded architectural panel.

It is possible to provide an elongate sheet having a plurality of the architectural panels adjacent to one another in the longitudinal direction. In particular, the one longitudinal end of one architectural panel is integral with the other longitudinal end of an adjacent architectural panel. In other words, the first end fold-line of one architectural panel is adjacent and parallel with the second end fold-line of the adjacent architectural panel. A fold-line may be provided where the one longitudinal end of one architectural panel is integrally connected with the other longitudinal end of the other architectural panel. A first portion at one longitudinal end of one panel may thus be folded onto the second portion at the other longitudinal end of the adjacent panel so as to form a folded portion to be supported by a carrier member for suspending the folded architectural panels.

The architectural panel at the end of a sheet may include an additional portion adjacent one of the first portion and the second portion, the additional portion being joined by a fold-line to said one of the first portion and the second portion and foldable against said one of the first portion and the second portion so as to form a folded portion to be supported by a carrier member for suspending the folded architectural panel.

The additional portion may be smaller than the first and second portions and the corresponding one of the first and second portions at the opposite end may have a length corresponding to that shortened amount. In this way, it is possible to use a single design, or in other words style, of sheet having ends which may be mounted either against an adjacent sheet or at the edge of the mounted arrangement (and not adjacent another sheet). In particular, at the otherwise free respective one longitudinal end of the respective architectural panel at one end of the sheet, there may be provided a first additional portion adjacent to the respective first portion of the respective architectural panel having, by a predetermined amount, an extent less in the length direction than the extent of the respective first portion from the respective first end fold line to the respective one longitudinal end. The first additional portion may be joined by a fold line to the respective first portion and may be foldable against the respect first portion so as to form a folded portion to be supported by a carrier member for suspending the respective folded architectural panel. The respective second portion of the respective architectural panel at the other end of the sheet may have an extent from the respective second end fold line to the respective other longitudinal end of substantially the predetermined amount. The first additional portion folded onto the respective first portion may thus define a space to receive the second portion of an architectural panel of another said sheet.

Thus, there may be provided a folded architectural panel for use with another folded architectural panel as explained above. The folded architectural panel may include a first additional portion adjacent the first portion having, by a predetermined amount, an extent less in the length direction than the extent of the first portion from the first end fold line to the one longitudinal end so as, when folded against the first portion, to define a space against the first portion to receive the second portion of the another folded architectural panel having an extent of said predetermined amount from the respective second end fold line to the other longitudinal end.

Similarly, there may be provided a folded architectural panel for use with another folded architectural panel as explained above wherein the second portion has an extent of a predetermined amount in the length direction from the second end fold line to the other longitudinal end and less than the extent of the first portion from the first end fold line to the one longitudinal end so as to define a space to receive a first additional portion of the another folded architectural panel adjacent to and folded against the respective first portion of the another architectural panel and having an extent in the length direction less than the extent of the first portion by substantially the predetermined amount.

The plurality of architectural panels provided in a single sheet may also take the form of an array extending in the width direction with an architectural panel adjacent another architectural panel in the width direction. With this arrangement, between two adjacent architectural panels in the width direction, a slot should extend through the depth of the sheet along the co-located lateral sides of the adjacent architectural panels and between the first end folds and the second end folds. In this way, when the adjacent architectural panels are both/all folded with contraction of the end folds towards each other, the respective lateral sides of each architectural panel are able to contract inwardly towards each other.

Thus, the flat sheet may be provided with respective portions of shape and size to form the respective parts of a plurality of the folded architectural panels.

It will be appreciated that the sheet will have a thickness. Elongate recesses may be formed within that thickness. The recesses in the thickness may define the respective fold lines of the architectural panel or architectural panels.

In some embodiments, the sheet may be a sheet of felt, such as polyester felt, woven or non-woven fabrics, PET etc.

The invention will be more clearly understood from the description, given by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 illustrates a perspective view of a plurality of panels embodying the present invention and arranged as an array for suspension from a ceiling;

FIGS. 2 to 13 illustrate alternative arrangements for an architectural panel;

FIG. 14 illustrates a sheet including a longitudinal array of architectural panels;

FIG. 15 illustrates schematically the sheet of FIG. 14 partially folded;

FIG. 16 illustrates a sheet with an array of architectural panels in both longitudinal and lateral direction;

FIGS. 17(a), (b) and (c) illustrate schematically steps of installing the architectural panels;

FIG. 18 illustrates a cross section through a carrier member supporting the ends of two panels;

FIG. 19 illustrates a cross section through a carrier member supporting the end of a panel;

FIG. 20 illustrates an alternative sheet including a longitudinal array of architectural panels; and

FIGS. 21(a)-(c) illustrate mounting of the ends of the sheet of FIG. 20.

A plurality of architectural panels may be provided together, for example in a two-dimensional array, to cover an architectural structure such as a wall or a ceiling. FIG. 1 illustrates a plurality of architectural panels 10 embodying the present invention and suspended from a ceiling. In particular, the panels 10 may be coupled to and suspended from a carrier. Each architectural panel 10 is folded from a flat sheet. It has a first end fold along a first end fold-line 12 adjacent/close to one longitudinal end and a second end fold along a second end fold-line 14 adjacent/close to the opposite longitudinal end. A first main wall 16 is folded downward from the first end fold-line 12 and meets with a second main wall 18 which is folded down from the second end fold-line 14. As illustrated in FIG. 1, on both opposite lateral sides (one lateral side labelled 20a) of an individual architectural panel 10, a respective sidewall (one sidewall labelled 22) is formed. FIGS. 2 to 13 illustrate schematically alternative embodiments of a folded architectural panel both in its folded and its flat states.

As illustrated in FIGS. 2(a) and (b), a first longitudinal end 24 of the architectural panel extends in a width direction X of the panel and an opposite second longitudinal end 26 also extends in the width direction X of the panel. The architectural panel extends between the longitudinal ends 24, 26 with opposite lateral sides 20a, 20b extending in the length direction Y of the panel. A central fold-line 28 is provided as a central portion of the panel between the first and second end fold-lines 12, 14. The central fold-line 28 extends in a width-wise direction, parallel with the first and second end fold-lines 12, 14. In the illustrated arrangement, the distance in the width direction X between a first end 28a of the central fold-line 28 is closer to its respective lateral side 20a than a second end 28b of the central fold-line 28 is to its lateral side 20b. In the illustrated arrangement, a first main wall 16 extends between the first end fold-line 12 and the central fold-line 28. Similarly, a second main wall 18 extends between the second end fold-line 14 and the central fold-line 28.

It will be appreciated that when the first and second end fold-lines 12, 14 are moved towards each other in the length direction Y, the first and second main walls 16, 18 pivot/fold out of the plane formed by the first and second end fold-lines 12, 14 and give the architectural panel 10 a height or depth Z perpendicular to the width and length directions X, Y. In particular, there is a height or depth between the central fold at the central fold-line 28 and the plane formed by the first and second end fold-lines 12, 14. When used as an architectural ceiling panel suspended from a ceiling, the central fold may form a downward depth away from a ceiling.

From each lateral side 20a, 20b of the panel 10, a pair of respective side fold-lines 30a, 32a, and 30b, 32b extend to the central fold-line 28. In particular, on one lateral side 20a, one side fold-line 30a extends from a fold end 12a of the first end fold-line 12 and the other side fold-line 32a extends from one fold end 14a of the second end fold-line 14. Similarly, on the opposite lateral side 20b of the architectural panel 10, one side fold-line 30b extends from the other fold end 12b of the first end fold-line 12 and the other side fold-line 32b extends from the other fold end 14b of the second end fold-line 14.

In the illustrated arrangement where the central fold has an elongate extent along a central fold-line 28 with a first end 28a and a second end 28b, the pair of respective side fold-lines 30a, 32a on one lateral side 20a extend to and meet at the first end 28a of the central fold-line 28. Similarly, the other pair of respective side fold-lines 30b, 32b at the other lateral side 20b extend to and meet at the other end 28b of the central fold-line 28.

With the arrangement as described with reference to FIGS. 2(a) and (b), it will be appreciated that when the first and second end fold-lines 12, 14 are moved/contracted towards each other so as to cause the central fold-line 28 to have the height or depth as described, respective sidewalls 34a, 34b are formed on each respective lateral side 20a, 20b of the panel 10. In particular, a respective sidewall 34a is defined extending between a lateral side 20a and the pair of respective side fold-lines 30a, 32a and a respective sidewall 34b is defined extending between a lateral side 20b and the pair of respective side fold-lines 30b, 32b . With this arrangement, as illustrated in FIG. 2(b), in the folded form of the architectural panel, with an appropriately flexible material for the panel, the edge of the lateral side 20a will naturally take a curved/arcuate form.

In the folded state, a panel depth is defined between the plane containing the first and second end fold-lines 12, 14 and the central fold-line 28. In order to provide a clear description of the various folds, FIG. 2 (as well as FIGS. 3 to 13) illustrates a portion 36 between the first longitudinal end 24 and the first end fold-line 12 and a portion 38 between the second longitudinal end 26 and the second end fold-line 14 in a coplanar state with the main walls 16, 18 and the central fold-line 28 extending out of that plane. However, as will be explained below, particularly when a plurality of such panels 10 are provided end-to-end in the longitudinal direction, it may be advantageous for the portions 36, 38 to be folded in a direction opposite to the panel depth. For example, the portions 36, 38 may extend in planes defined by the width X direction and a Z direction opposite to the panel depth. This enables adjacent architectural panels 10 to be located immediately adjacent one another, in some arrangements being attached together by means of the portions 36, 38 or, in other arrangements, being formed integrally with a fold 44 connecting one portion 36 of one panel 10 to another portion 38 of an adjacent panel 10 as a folded portion 46. (see FIGS. 13 to 17 and the description below) Advantageously, folded portions 46 (formed from folding together the adjacent portions 36,38) can be used to couple the folded panels to a carrier structure. In particular, the carrier structure (perhaps by means of carrier fasteners/clips) can attach to the folded portions 46 so that the panels between the folded portions 46 are suspended from the carrier structure.

In the arrangement of FIG. 3, the central fold-line 28 is located nearer one of the first and second end fold-lines 12, 14 than the other. Actually, by way of example only, as illustrated, the central fold-line 28 is located closer to the first end fold-line 12.

In the arrangement of FIGS. 4(a) and (b), the central fold-line 28 is positioned mid-way in the length direction Y between the first and second end fold-lines 12, 14. This provides the folded architectural panel 10 with a symmetric appearance.

In the arrangements of FIGS. 2, 3 and 4, the respective sidewalls 34a, 34b have a continuous form and result in a curved/arcuate edge at the respective lateral sides 20a, 20b. As an alternative, it is possible to provide at least one intermediate fold in each respective sidewall. FIGS. 8, 9 and 10 are equivalent to FIGS. 2, 3 and 4 respectively and illustrate similar architectural panels which are modified to include a single intermediate fold in each respective sidewall. In a section of a lateral side 20a, 20b between two respective fold ends 12a, 14a, 12b, 14b, a respective intermediate fold 40a, 40b extends from an intermediate point 42a, 42b (on that respective section) to the central fold-line 28. Thus, as illustrated, on one lateral side 20a having fold ends 12a, 14a, the pair of respective side folds 30a, 32a and the respective intermediate fold 40a all extend to meet at the first end 28a of the central fold-line 28. Similarly, on the other lateral side 20b having the fold ends 12b, 14b, the pair of respective side folds 30b, 32b and the intermediate fold 40b all extend and meet at the second end 28b of the central fold-line 28.

In this way, as illustrated in each of FIGS. 8(a), 9(a) and 10(a), the respective sidewalls 34a, 34b are divided by the respective intermediate folds 40a, 40b into a pair of substantially flat sidewalls 34a1, 34a2, 34b1, 34b2.

In all of the arrangements discussed so far, the central fold-line 28 has an elongate extent between a first end 28a and a second end 28b. However, this elongate extent can be reduced to such an extent that the central fold forms a single central point fold 28.

The arrangement of FIG. 5 may be considered as equivalent to that of FIG. 2, but with the elongate extent of the central fold-line 28 reduced in length to a point at the first end 28a of the arrangement of FIG. 2. Thus, in this arrangement, the central point fold 28 is positioned closer to the first end fold-line 12 than to the second end fold-line 14 and is positioned closer to one lateral side 20a than to the other lateral side 20b.

As illustrated in FIG. 6, the central point fold 28 may be positioned mid-way in the width direction X between the two opposite lateral sides 20a, 20b.

Of course, the arrangement of FIG. 5 could be modified so that the central point fold 28 is positioned closer to one lateral side 20a than to the other lateral side 20b, but is positioned mid-way in the length direction Y between the first and second end fold-lines 12, 14. However, in the arrangement illustrated in FIG. 7, the central fold 28 is positioned both mid-way in the length direction Y between the first and second end fold-lines 12, 14 and mid-way in the width direction X between the two opposite lateral sides 20a, 20b.

In all of the arrangements of FIGS. 5, 6 and 7, like the arrangements of FIGS. 2, 3 and 4, a single sidewall 34a, 34b is formed on each lateral side and, when the architectural panel is in its folded state, forms a curved/arcuate edge.

The arrangements discussed in relation to FIGS. 5, 6 and 7 of course could be modified similarly to the arrangements of FIGS. 8, 9 and 10 with one or more intermediate folds on each respective side. Like FIGS. 8, 9 and 10, FIGS. 11, 12 and 13 illustrate modifications of the arrangements of FIGS. 5, 6 and 7 in which a single intermediate fold-lines 40a, 40b is provided in each side wall 34a, 34b. As with the arrangements of FIGS. 8, 9 and 10, the intermediate fold-lines 40a, 40b extend from respective intermediate points 42a, 42b. However, as illustrated in FIGS. 11, 12 and 13, in these arrangements, all folds of both the two pairs of respective side folds 30a, 32a, 30b, 32b and both intermediate folds 40a, 40b meet at the central point fold 28.

It will be appreciated that the arrangement of the architectural panel of FIG. 13 is what is used for the plurality of panels 10 as illustrated in FIG. 1.

Considering each of FIGS. 2 to 13 and comparing the folded and flat states of the architectural panel, it will be appreciated that the flat sheets define respective portions of shape and size to form the parts of the folded architectural panel.

The panels can be arranged to span smaller or larger gaps. In order to span larger gaps, panels may be constructed from thicker material. In general, the minimum thickness may be about 3 mm and the maximum thickness may be about 20 mm. In preferred embodiments, thickness may be between about 4 mm and 8 mm. Examples of particular embodiments are thicknesses of about 6.5 mm and thicknesses of about 5 mm.

The flat sheets may be pre-formed with appropriate creases configured to allow, and preferably facilitate, folding of the flat sheet to its three-dimensional shape merely by moving the parallel first and second fold-lines 12, 14 towards each other. Where the sheet has a thickness, such creases may be configured in the thickness of the sheet as grooves, cut outs, in particular V-shaped grooves. In one preferred embodiment, the side fold-lines are grooves of substantially 22.5°, the intermediate fold-lines are grooves of substantially 22.5°, and the first and second end fold-lines are grooves of substantially 45°. The depth of the grooves may depend on the thickness of the material and the characteristics of the material. In principle, the thickness of the material at the bottom of the grooves may be minimal.

In some arrangements, the sheet may be made of felt, such as polyester felt, woven or non-woven fabrics, PET etc.

It should be appreciated that a single sheet could be provided with respective portions of shape and size to form an array (in width and length directions) of a plurality of the folded architectural panels, in particular as a single integral part.

FIG. 14 illustrates a plurality of panels 10 formed integrally in a single sheet as a longitudinal array. In other words, the plurality of panels 10 are arranged end-to-end in the longitudinal direction Y. The first longitudinal end 24 of one panel 10 adjoins the second longitudinal end 26 of the adjacent panel 10. In one arrangement, the adjoining ends 24, 26 of adjacent panels 10 may connect by means of an adjoining fold 44. In this way, as was discussed above in relation to FIG. 2, the portions between a first longitudinal end 24 and a first end fold 12 and between a second longitudinal end 26 and a second end fold 14 may be folded in an opposite direction to the panel depth. By means of the adjoining fold 44, the adjacent portions of adjacent panels 10 may be folded onto one another. This is illustrated schematically in FIG. 15 showing the arrangement of FIG. 14 before the downward folds are moved/contracted towards one another so as to form the downward panel depth. The resulting upward folded portions 46 (formed from portions 36 and 38 of adjacent panels) may be useful in attaching/mounting the plurality of panels 10 to a carrier, for example suspending the panels from a carrier.

FIG. 18 illustrates a cross-section through a folded sheet with two integral panels 10 attached to one another via fold 44, and with a folded portion 46 formed from portions 36 and 38 of the adjacent panels. As illustrated, the folded portion 46 is held and supported by a carrier member 52. As illustrated, the carrier member 52 includes opposing parallel walls 52a, 52b defining an elongate channel 56 therebetween. The folded portion 46 is supported between the walls 52a, 52b in the channel 56. As illustrated, the distal ends 58a, 58b of the respective walls 52a, 52b may be turned in towards each other so as to form a narrowed entrance to the channel The distal ends 58a, 58b may fit respectively into the folds 12, 14 of the adjacent panels 10 so as to more securely hold/support the folded portion 46.

For the end of a sheet of panels 10, of course, only end of only one panel will be supported by a carrier member 52. A different type of carrier member 52 could be provided, for example with a narrower channel 56. Alternatively, an additional part could be provided to extend along the portion 36 or 38 of the suspended panel 10. FIG. 19 illustrates an alternative arrangement for the end of a panel 10 in which an additional portion 36A is attached to the portion 36 by means of a fold-line 46. The additional portion 36A is substantially the same in form as the end portion 38 of another panel 10. In this way, when folded over against the portion 36, the portion 36 and additional portion 36A form a folded portion 46 to be held/supported by the carrier member 52 in the same way as the other folded portions. Of course, at the other end of a sheet of panels 10, the end panel 10 may similarly have an additional portion to be folded to form a folded portion 46.

Of course, two separate panels may be mounted adjacent one another and supported together by a common carrier member 52. The arrangement is similar to that illustrated in FIG. 18, but without the fold 44 joining portions 36 and 38 of the adjacent panels. In this case, considering a plurality of panels 10 formed integrally in a single sheet as a longitudinal array, one end of the sheet (for example at the top of FIG. 14 as illustrated) may be provided with the additional portion 36A to be folded over against the portion 36 so that that end of the sheet of panels may be supported by a carrier member 52. The other end of the sheet (the bottom as illustrated in FIG. 14) may terminate with the end portion 38 so that that end of the sheet can be mounted together with an adjacent another sheet of panels 10 by means of a common carrier member 52. Of course, sheets of panels 10 which are to be mounted adjacent other sheets of panels 10 at both ends need include only the portions 36 and 38 without any additional portion 36A.

An alternative arrangement for a sheet of panels 10 is illustrated in FIG. 20. With this arrangement, the same design of sheet may be used irrespective of whether the sheet of panels is to be mounted at an end or adjacent other sheets of panels.

As illustrated, a shortened second portion 38S at one end (the bottom as illustrated) of the sheet of panels 10 has a smaller or shorter extent than the other second portions 38 of the sheet of panels 10. In particular, the extent of the shortened second portion 38S in the length direction (namely the direction from the second end fold line 14 to the other/second longitudinal end 26 (at the furthest extent of the sheet of panels 10)) is a predetermined extent. That predetermined extent is a predetermined amount and that predetermined amount is less than the extent of the first portion 36 and the (not shortened) second portion 38.

As illustrated, similar to the embodiment described with reference to FIG. 19, an additional portion is attached to the portion 36 by means of a fold-line 46. However, unlike the embodiment of FIG. 19, where the additional portion 36A has substantially the same extent as a second portion 38, the additional portion of the arrangement of FIG. 20 is a shortened additional portion 36AS and has an extent less than that of a first portion 36 and a second portion 38 by the predetermined amount. In other words, the shortened additional portion 36AS of one sheet of panels 10 is arranged to abut with the shortened second portion 38S of another sheet of panels 10 so that the shortened additional portion 36AS of one sheet of panels 10 and the abutting shortened second portion 38S of the other sheet of panels 10 take the form of one of the intermediate second portions 38. This is illustrated in FIG. 21(a). The shortened additional portion 36AS adjacent the first portion 36 has, by a predetermined amount, an extent less in the length direction than the extent of the first portion 36 from the first end fold line 12 to the one longitudinal end 24, and indeed the fold line 46. To compliment this, the shortened second portion 38S of the adjacent sheet of panels 10 has an extent of the predetermined amount in the length direction from the second end fold line 14 to the other longitudinal end 26. With the shortened additional portion 36AS folded against the first portion 36, there is defined a space against the first portion 36 for receiving the adjacent shortened second portion 38S having the predetermined amount extent. In this configuration, as illustrated, the one longitudinal end of one sheet of panels 10 may be supported together with the other longitudinal end of an adjacent sheet of panels 10 with the same carrier member 52.

As illustrated in FIG. 21(b), where the one longitudinal end of the sheet of panels 10 is to be supported on its own, for example at the edge of the installed sealing arrangement, an additional part 37 (for example as mentioned above as an alternative to the FIG. 19 arrangement) may be provided to take the place of the shortened second portion 38S of an adjacent sheet of panels 10. As illustrated, the additional part 37 fills the space formed by the shortened additional portion 36AS folded against the first portion 36. The resulting assembly may be supported by a carrier member 52 as illustrated.

Similarly, as illustrated in FIG. 21(c), it is possible to support the other longitudinal end without an adjacent other sheet of carrier panels 10. In this respect, an alternative additional part 39 is provided to take the place of the first portion 36 and shortened additional portion 36AS of an adjacent sheet of panels 10. The additional part 39 includes a part 39a taking the place of a first portion 36 and a second part 39b joined by the fold 39c taking the place of a shortened additional portion 36AS of an adjacent sheet of panels 10. The second part 39b folded against the first part 39a defines a space matching the size and shape of the shortened second portion 38S having the predetermined amount extent. The resulting assembly, as illustrated in FIG. 21(c) may be supported by a carrier member 52.

Of course, a plurality of architectural panels 10 may similarly be formed from a flat sheet in an arrangement with the panels extending laterally side-by-side in the width direction X.

FIG. 16 illustrates an example of a flat sheet in which a plurality of architectural panels 10 are formed in an array extending both in the width direction X and the length direction Y.

It will be appreciated from the discussions above that, in order for first and second end fold-lines 12, 14 to be moved towards one another and the central fold-line 28 to be moved in the depth direction, it is necessary for the lateral sides 20 to be able to move towards one another in the width direction. Hence, as illustrated in FIG. 16, where panels 10 are arranged together in a width direction, a slot 48, which extends in the length direction Y, is formed between adjacent panels 10. In particular, the slot 48 extends between the first and second end fold-lines 12, 14 of both adjacent panels 10 such that the adjacent lateral edges of the respective adjacent panels 10 are able to move away from each other when the sheet is folded to form the architectural panel.

FIGS. 17(a), (b) and (c) illustrate schematically steps of installing architectural panels 10 as a suspended ceiling and the advantageous swing-down feature.

In the illustrated arrangement, four architectural panels 10 are provided together as a flat sheet with an array of 2×2 panels 10. In the illustrated arrangement, the panels are to be suspended from a carrier 50 having a plurality of parallel spaced apart carrier members 52. The carrier 50 as a whole may be suspended from a ceiling for example by means of brackets 54.

First, as illustrated in FIG. 17(a), one of the folded portions 46 (or at least a portion 36) at an end of the flat sheet is coupled/mounted to a carrier member 52. As illustrated, the flat sheet of panels 10 may hang flat from that carrier member 52.

At least the side-by-side upper two panels 10 are then folded such that the end fold-lines 12 and 14 are contracted towards one another and, similarly, the opposite lateral sides 20 of both panels 10 contract towards one another respectively.

For the preferred dimensions of the panel, especially in combination with the mounting structure and its dimensions, it is possible for the panel to hold its own shape on its own. However, for different relative dimensions or added strength/stability, a clip member 60 may be provided. The clip member 60 may be attached to the opposite respective lateral sides of a respective folded architectural panel 10. This restricts the relative spacing between the opposite respective lateral sides to a maximum predetermined distance whereby the folded architectural panel is maintained in the folded state. For the illustrated arrangement, this distance corresponds to a folded state in which the distance between the first and second end folds 12, 14 corresponds to the spacing between the carrier members 52. Thus, as illustrated in FIG. 17(b) the portion 46 of the two panels 10 adjacent the second end fold-line 14 is mounted/coupled to a carrier member 52.

FIG. 17(b) also illustrates the next pair of panels 10 hanging or swinging down from the folded portion 46 mounted/coupled to the carrier member 52, but with clip members 60 attached across the opposite respective lateral sides 20a, 20b of the panels 10 so as to hold them respectively in their folded states. It will also be observed that the slot 48 between laterally adjacent panels 10 widens as a result of the opposite lateral sides 20a, 20b of respective panels 10 contracting towards one another when the respective panel 10 is folded.

In FIG. 17(c), the folded portion 46 adjacent the second end fold-line 14 of the hanging panel in FIG. 17(b) has been mounted/coupled to the next carrier member 52. Also, another flat sheet of panels 10 is suspended from that same carrier member 52 ready to be installed in the same manner as described above for FIGS. 17(a) and (b).

The feature of consecutive sections swinging down from the end portion or a previous section is highly advantageous. It facilitates installation. With an end portion or previous section securely installed, the installer has easy access to the section swinging down. The swinging down section may be conveniently formed into shape and then swung up for installation. Furthermore, with a fully installed ceiling, it is convenient to open the ceiling. Merely a single section may be opened by swinging it down whilst the adjacent section is still mounted/installed. It is not necessary to completely remove a panel.

According to the present invention, there may, thus, also be provided a method of installing, to a carrier, a folded architectural panel of the present invention using a flat sheet of the present invention. The method includes securing the one longitudinal end to the carrier with the remainder of the flat sheet swinging down from the first end fold line, folding at least the central fold and the two pairs of respective side folds to form the folded architectural panel, swinging the folded architectural panel about the first end fold line and securing the other fold end to the carrier. There is also provided a method of opening a part of a ceiling formed from a plurality of the folded architectural panels of the present invention by detaching the other longitudinal end of one of the folded architectural panels and allowing the folded architectural panel to swing down about the first end fold line.

As illustrated in the figures, the various respective folds at the respective fold lines can be folded inwardly or outwardly to form valley folds with an angle of less than 180° and mountain folds with an angle of more than 180°. Viewed from the intended visible side of the panels 10, for example as viewed in FIGS. 2 to 13, with the central portion extending towards the viewer, the following folds are preferred. The side folds are mountain folds, the central fold is a mountain fold and the intermediate folds are valley folds. With the portions 36, 38 extending in the plane of the first and second end fold-lines 12, 14, the first and second end folds will be valley folds. However, with the portions 36, 38 folded away from the panel depth as illustrated in FIG. 15, they will be mountain folds. Of course, for an alternative arrangement in which the underside of the panel is presented to the viewer and the central portion extends away from the viewer, then the valley and mountain folds will be reversed.

Claims

1. A folded architectural panel folded from a flat sheet, the panel having opposite longitudinal ends extending in a width direction, opposite lateral sides extending in a length direction and a height perpendicular to the width and length directions, the panel including:

a first end fold along a first end fold-line adjacent one longitudinal end, extending in the width direction, and having opposite fold ends at the respective lateral sides of the panel;

a second end fold along a second end fold-line adjacent the other longitudinal end, extending in the width direction, and having opposite fold ends at the respective lateral sides of the panel;

a central fold at a central portion of the panel between the first and second end fold-lines; and

a first main wall extending between the first end fold-line and the central fold and a second main wall extending between the second end fold-line and the central fold;

wherein the first end fold-line, the second end fold-line and the central fold are configured to enable, with contraction of the first and second end fold-lines towards each other, the first main wall to pivot about the first end fold-line and the second main wall to pivot about the second end fold-line to cause an increase in the height of the panel at the central portion; and

wherein the panel further includes two pairs of respective side folds along respective side fold-lines extending from the four opposite fold ends of the first and second end fold-lines to the central fold such that, as a consequence of the contraction of the first and second end fold-lines towards each other, a respective section of each respective lateral side between two respective fold ends is contracted inwardly towards the opposite lateral side and a respective sidewall is formed on each respective lateral side of the panel extending from the respective pair of side folds in the depth direction.

2. The folded architectural panel of claim 1, wherein the central fold extends along a central fold-line in a width-wise direction parallel with the first and second end fold-lines.

3. The folded architectural panel of claim 1, wherein the central fold is a point where the two pairs of respective side fold-lines meet.

4. The folded architectural panel of claim 1, wherein the central fold is mid-way in the length direction between the first and second end fold-lines.

5. The folded architectural panel of claim 1, wherein the central fold is mid-way in the width direction between the opposite lateral sides.

6. The folded architectural panel of claim 1, further including respective folds along respective intermediate fold-lines extending from a respective intermediate point of each said respective section to the central fold.

7. The folded architectural panel of claim 6, wherein each respective intermediate point is mid-way between the opposite fold ends of the respective pair of side fold-lines.

8. The folded architectural panel of claim 1, wherein a first portion between the one longitudinal end and the first end fold-line and a second portion between the other longitudinal end and the second end fold-line are both respectively folded to extend in a direction opposite to the height of the central portion and are both respectively configured to be coupled to a carrier so as to suspend the folded architectural panel.

9. The folded architectural panel of claim 8, further including an additional portion adjacent at least one of the first portion and the second portion, the additional portion being joined by a fold-line to said at least one of the first portion and the second portion and foldable against said at least one of the first portion and the second portion so as to form a folded portion to be supported by a carrier member for suspending the folded architectural panel.

10. The folded architectural panel of claim 8 for use with another folded architectural panel of claim 1, the folded architectural panel including a first shortened additional portion adjacent the first portion having, by a predetermined amount, an extent less in the length direction than the extent of the first portion from the first end fold line to the one longitudinal end so as, when folded against the first portion, to define a space against the first portion to receive the second portion of another folded architectural panel shortened to have an extent of substantially said predetermined amount from the respective second end fold line to the other longitudinal end.

11. The folded architectural panel of claim 8 for use with another folded architectural panel of claim 1, wherein the second portion has a shortened extent of a predetermined amount in the length direction from the second end fold line to the other longitudinal end and less than the extent of the first portion from the first end fold line to the one longitudinal end so as to define a space to receive a first shortened additional portion of the another folded architectural panel adjacent to and folded against the respective first portion of the another architectural panel and having an extent in the length direction less than the extent of the first portion by substantially the predetermined amount.

12. The flat sheet formed with respective portions of shape and size to form parts of the folded architectural panel of claim 1.

13. The flat sheet of claim 1 with respective portions of shape and size to form the respective parts of a plurality of folded architectural panels of claim 1.

14. The flat sheet of claim 13, wherein:

at the otherwise free respective one longitudinal end of the respective architectural panel at one end of the sheet, there is provided a first shortened additional portion adjacent the respective first portion of the respective architectural panel having, by a predetermined amount, an extent less in the length direction than the extent of the respective first portion from the respective first end fold line to the respective one longitudinal end, the first shortened additional portion being joined by a fold line to the respective first portion and foldable against the respective first portion so as to form a folded portion to be supported by a carrier member for suspending the respective folded architectural panel;

the respective second portion of the respective architectural panel at the other end of the sheet has a shortened extent from the respective second end fold line to the respective other longitudinal end of substantially the predetermined amount; and

the first additional portion folded onto the respective first portion defines a space to receive a shortened second portion of an architectural panel of another said sheet.

15. The flat sheet of claim 13, wherein one longitudinal end of one architectural panel is integral with the other longitudinal end of an adjacent architectural panel and a fold line is provided where the one longitudinal end of the one architectural panel is integrally connected with the other end of the adjacent architectural panel.

16. The flat sheet of claim 15, wherein the first portion of the one architectural panel is folded onto the second portion of the adjacent architectural panel so as to form a folded portion which may be supported by a carrier member.

17. The flat sheet of claim 13, further including recesses in the thickness of the sheet defining the respective fold-lines.

18. An architectural panel system including a folded architectural panel of claim 1 and a clip member configured to attach to the opposite respective lateral sides of the folded architectural panel and restrict the relative spacing between the opposite respective lateral sides to a maximum predetermined distance whereby the folded architectural panel is maintained in the folded state.