Ceiling system

A ceiling system in one embodiment includes a grid support member including a flange defining a bottom surface and a ceiling panel supported by the grid support member. A first facing sheet includes a peripheral edge portion attached to the grid support member. An integral cutting guide groove is formed in the bottom surface of the grid support member. The peripheral edge portion of first facing sheet includes an edge which is axially aligned with the groove. A second ceiling panel includes a second facing sheet including a peripheral edge portion having an edge axially aligned with the groove and disposed adjacent the edge of the first facing sheet to form a seam. The first and second facing sheets conceal the grid support member. A related method of installation is disclosed.

FIELD

The present invention relates to suspended ceiling systems with concealed support grids.

BACKGROUND

Numerous types of suspended ceiling systems and methods for mounting ceiling panels have been used. One type of system includes a suspended support grid including an array of intersecting grid support members configured to hang a plurality of individual ceiling panels therefrom. It is desirable in some cases to conceal the support grid for providing the appearance of a monolithic ceiling.

SUMMARY

A ceiling system is provided which conceals the ceiling support grid with adjoining facings or scrims between adjacent ceiling panels. The ceiling system includes grid support members having an integral cutting guide groove to permit tight and straight seams to be made between the facings.

In one embodiment, a ceiling system includes a longitudinally extending grid support member including a longitudinal axis and a bottom flange defining a bottom surface, and a ceiling panel supported by the grid support member. A first facing sheet having a peripheral edge portion is attached to the grid support member. An integral cutting guide groove is formed in the bottom surface of the grid support member, the groove extending linearly along the longitudinal axis. The peripheral edge portion of first facing sheet includes an edge which is axially aligned with the groove. In some embodiments, a second facing sheet of a second ceiling panel is supported by the grid support member. The second facing sheet has an edge which is axially aligned with the groove and disposed adjacent the edge of the first facing sheet. The first and second facing sheets conceal the grid support member.

In another embodiment, a ceiling system includes a first grid support member and second grid support member spaced apart from the first grid support member. Each of the first and second grid support members includes a longitudinal axis, a bottom flange defining a bottom surface, a vertical web extending upwards from the bottom flange, and an integral cutting guide groove formed in the bottom surface and extending linearly along the longitudinal axis. A ceiling panel extends between the first and second grid support members. The ceiling panel is supported by the first and second grid support members. A first facing sheet is disposed below the ceiling panel and attached to the first and second grid support members. The first facing sheet includes a first edge which is axially aligned with the groove of the first grid support member and an opposing second edge which is axially aligned with the groove of the second grid support member.

A method for concealing a grid support member of a ceiling system is provided. The method includes the following steps: providing a grid support member including a longitudinal axis and cutting guide groove formed in a bottom surface; positioning a first ceiling panel on the grid support member, the first ceiling panel including a bottom facing sheet having a peripheral edge portion; laterally positioning the peripheral edge portion of the first ceiling panel beneath the grid support member by a distance sufficient to extend across the cutting guide groove; positioning a second ceiling panel on the grid support member, the second ceiling panel including a bottom facing sheet having a peripheral edge portion; laterally positioning the peripheral edge portion of the second ceiling panel beneath the grid support member by a distance sufficient to extend across the cutting guide groove, the peripheral edge portion of the second ceiling panel overlapping the peripheral edge portion of the first ceiling panel; running a blade of a cutting tool along the grid support member in the cutting guide groove and through the overlapping peripheral edge portions of the first and second ceiling panels; and trimming the overlapping peripheral edge portions of the first and second ceiling panel to form an abutment seam. The grid support member is concealed by the overlapping peripheral edge portions of the bottom facing sheets of the first and second ceiling panels.

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

DETAILED DESCRIPTION

The features and benefits of the invention are illustrated and described herein by reference to exemplary embodiments. This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. Accordingly, the disclosure 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.

FIG. 1depicts an exemplary embodiment of a ceiling system100according to the present disclosure. The ceiling system100includes an overhead support grid200including a plurality of overhead longitudinal grid support members202and ceiling panels300supported by the grid support members. The grid support members202are mountable in a suspended manner from an overhead building support structure.

Referring toFIGS. 1, 4, and 5, grid support members202are elongated in shape having a length greater than their width (e.g. at least twice), and in various embodiments lengths substantially greater than their widths (e.g. 3 times or more). The grid support members202may form “runners” or “rails” and are laterally spaced apart and oriented parallel to each other as shown inFIG. 1to position a ceiling panel300therebetween. In some embodiments, the longitudinal grid support members202may be maintained in a substantially parallel spaced apart relationship to each other by lateral grid support members (not shown) attached between adjacent (but spaced apart) grid support members202at appropriate intervals using any suitable permanent or detachable manner of coupling.

In one embodiment, grid support members202may be horizontally oriented when installed. It will be appreciated, however, that other suitable mounted orientations of grid support members202such as angled or sloped (i.e. between 0 and 90 degrees to horizontal) may be used. Accordingly, although support members202may be described in one exemplary orientation herein as horizontal, the invention is not limited to this orientation alone and other orientations may be used.

With continuing reference toFIGS. 1, 4, and 5, grid support members202may be T-shaped (e.g. T-rails) in transverse cross section. The grid support members have an inverted T-shaped configuration when in an installed position suspended from an overhead building ceiling support structure. The grid support members202may be suspended from the building ceiling support structure via an appropriate hanger mechanism, such as for example without limitation fasteners, hangers, wires, cables, rods, struts, etc.

Grid support members202may each include a longitudinally-extending horizontal bottom flange210, an enlarged top stiffening channel220, and a vertical web212extending upwards from the flange to the stiffening channel. In some embodiments, the top stiffening channel220may be omitted. The grid support members202each define a respective longitudinal axis LA and axial directions. Bottom flange210has opposing portions which extend laterally outwards from web212and terminate in opposed longitudinally extending edges214. Web212may be centered between the edges214and vertically aligned with the centerline CL1of the grid support member in one non-limiting embodiment. In other embodiments, the web212may be laterally offset from centerline CL1. Bottom flange210further defines a bottom surface206facing downwards away from the flange and towards a room or space below the support grid200. Bottom surface206defines a horizontal ceiling reference plane for the overhead support grid200. Flange210further defines a top surface216for positioning and supporting the ceiling panel300thereon.

Grid support members202may be made of any suitable metallic or non-metallic materials structured to support the dead weight or load of ceiling panels300without undue deflection. In some non-limiting embodiments, the grid support members may be made of metal including aluminum, titanium, steel, or other. In one embodiment, the grid support members202may be a standard heavy duty 15/16 inch aluminum T-rail.

Referring nowFIGS. 1-3, ceiling panel300may have a generally flattened body with a substantially greater horizontal width and length than vertical thickness as shown. Ceiling panel300includes a top surface302, bottom surface304, and lateral sides306extending therebetween along four sides of the panel. Sides306define peripheral surfaces which may be oriented substantially parallel to the vertical centerline CL2of the ceiling panel300. In some embodiments, the peripheral surfaces may be angled or sloped, or have a stepped edge profile or configuration. Top and bottom surfaces302,304may be generally planar and arranged substantially parallel to each other in one non-limiting embodiment.

Ceiling panels300may be constructed of any suitable material including without limitation mineral fiber board, fiberglass, jute fiber, metals, polymers, wood, composites, resin impregnated kraft paper, or other. In addition, the ceiling panels300may have any suitable dimensions and shapes (in top plan view) including without limitation square or rectangular.

In one embodiment, ceiling panels300may have an inner core301comprising a honeycomb structure formed from a plurality of interconnected cell walls308that define a plurality of open cells310(best shown inFIG. 3). The cell walls308are oriented perpendicular to the top and bottom surfaces302,304of the ceiling panels300and extend vertically between the top and bottom surfaces. Any suitable shape of cells310(in top plan view) may be used, including hexagon, triangular, square, circular, etc. as some non-limiting examples.

In one embodiment, the core301may be formed by paper cell walls308. Paper used to construct cell walls308may be at least 20 pound kraft paper, and in some embodiments 20 to 80 pound kraft paper (thicknesses of about 0.004 to 0.015 inches) which generally provides the requisite stiffness to the core to resist sagging of the ceiling panel without unduly adding weight to the ceiling panel structure. As opposed to other materials, paper is generally more economical and cost-effective as a core wall material. The paper may be resin-impregnated in some embodiments. In other possible embodiments, lightweight non-paper material such as fiberglass and thin aluminum metal sheet also may perform satisfactorily for cell walls and be used. Non-woven materials, such as for example without limitation non-woven glass fibers in a resin matrix, may also be used.

With continuing reference toFIGS. 1-3, ceiling panel300further includes a top facing sheet320and bottom facing sheet330. The facing sheets320,330may be directly or indirectly coupled to the core310thereby forming part of the ceiling panel structure. The facing sheets320,330may be permanently bonded to core301using a suitable industrial adhesive35which is applied to the exposed upper and lower edges of the core cell walls308, thereby closing the upper and lower ends of the cells310. Industrial adhesives which may be used include Swift®tak from H.B. Fuller Company and others. The combination of core301and the top and bottom facing sheets320,330collectively form a relatively rigid composite structure which resists sagging when installed in the support grid200.

In some embodiments, the bottom facing layer330may be in the form of a scrim comprised of laminated non-woven glass fibers in a resin matrix. This type construction is suitable for high end acoustical panels to impart a smooth visual appearance, durability, and dimensional stability. Other suitable scrim materials may be used for both the top and bottom facing sheets320,330and are available from suppliers such as Owens Corning, Lydall, Ahlstrom and Johns Manville. Such materials may include films, sheets, woven materials and open cell foamed materials are all suitable

Ceiling panel300may further include a spacer panel325in some embodiments as shown inFIGS. 1 and 2. Bottom facing sheet330is permanently attached to the spacer panel325, which in turn is permanently attached to the bottom of ceiling panel300. In some embodiments, the attachment may be made via a suitable industrial adhesive (e.g. Swift®tak adhesive from H.B. Fuller Company and others). Spacer panel325may be in the form of a substantially flat sheet of material having a thickness (measured vertically) sufficient to make up and fill the vertical gap between the bottom of ceiling panel core301and bottom surface206of grid support member202, as best shown inFIG. 1(which substantially equates to the thickness of the flange210). This locates the bottom facing sheet330in a vertical position that is substantially flush with the bottom surface206on the grid support member bottom flange210. Spacer panel325has a horizontal width dimensioned to fit and extend between opposed edges214of a pair of grid support members300(see, e.g.FIG. 1). When a ceiling panel300having a honeycomb core301is used, the spacer panel325may provide a convenient and cost-effective means to fill the gap between the grid support member flanges210rather than cutting of the open-celled honeycomb core to form a stepped side edge profile at the sides of the ceiling panel. In addition to a cut or pressed edge, non-wovens, polymer frames or panels, foamed materials or other fibrous or non-fibrous materials may be used.

In alternative embodiments as shown inFIG. 10, the ceiling panel300however may have a sufficient vertical thickness between the sides306and an integral stepped side edge profile or configuration (in transverse cross section) so that the bottom facing sheet330is in a vertical position that is substantially flush with the bottom surface206on the grid support member bottom flange210without the need for a spacer panel325. This construction may be convenient particularly with non-honeycomb core ceiling panels.

Either construction ofFIG. 1 or 10essentially forms a tegular ceiling panel300having a stepped side edge profile (see alsoFIG. 2) so that the ceiling panel may be seated on and supported by the top surface216of the grid support member's bottom flange210. This stepped edge profile also helps to properly horizontally position and secure the ceiling panels300between the grid support members202.

Referring toFIGS. 1 and 2, the bottom facing sheet330in one embodiment has an extension that projects or extends laterally in a horizontal direction beyond the sides306of the ceiling panel300by a distance D1. Accordingly, bottom facing sheet330has a horizontal width that is larger than the horizontal width of the ceiling panel core301measured between opposite lateral sides306. This creates free or cantilevered peripheral edge portions332that allow the bottom facing sheet330to extend underneath and at least partially across the face or bottom surface206of the grid support member202for concealing the support grid, as further described herein. A peripheral slot322is formed between the ceiling panel core301and bottom facing sheet310that extends horizontally along at least two sides306of the ceiling panel as shown inFIG. 1. The slot322allows insertion of the grid support member bottom flange210therein when mounting the ceiling panel300to the grid support members202.

In one embodiment with reference toFIGS. 4 and 5, a linear cutting guide groove250is provided to facilitate neatly trimming adjacent bottom facing sheets330of two ceiling panels300to conceal the grid support member202from building occupants for creating a monolithic ceiling appearance. Groove250is formed in bottom surface206of the grid support member202. The groove250extends linearly in an axial direction along and parallel to the longitudinal axis of the grid support member202. In one embodiment, the groove250may be vertically aligned with the web212and centerline CL1of the grid support member202, thereby centering the groove between the longitudinally extending edges214of flange210. The cutting guide groove250has a depth which is less than the vertical thickness of the grid support member flange210. The depth need only be sufficient to engage a cutting tool which may be slid along the length of the groove250for trimming the facings330, as further described herein.

A method for concealing a grid support member202of a ceiling system100will now be described.FIGS. 6-9illustrate sequential steps in the process.

Referring toFIG. 6, a grid support member202is provided which may be hung from an overhead ceiling support structure. The grid support member202includes cutting guide groove250formed in the downward facing bottom surface206as described herein. For securing the bottom facing sheet330to the grid support member202, a pair of longitudinally-extending adhesive strips240may be provided on the bottom surface206of the grid support member. The strips240extend axially along and parallel to the longitudinal axis of the grid support member202. The adhesive strips240may have a length that extends for substantially the entire portion of the grid support member to which the bottom facing sheets330will come into contact when the ceiling panel300is mounted. In one embodiment, a continuous length of adhesive strip240may be used for this purpose. In alternative embodiments, however, intermittent gaps may be formed between multiple pieces of adhesive strips240.

The adhesive strips240are placed laterally adjacent and proximate to the cutting guide groove250on both sides to form a neat seam between peripheral edges334of adjacent bottom facing sheets330beneath the grid support member202. The adhesive strips may be suitably strong double-side tape having two tacky sides—one for attachment to the grid support member and the other for attachment to the bottom facing sheet330. In some embodiments, a releasable type adhesive may be used to allow the ceiling panels300and facing sheets to be cleanly removed and replaced if temporary access is needed to utilities above the ceiling system100. In alternative embodiments, a spray adhesive may be used instead which is applied to the bottom surface206of the grid support member202to form two longitudinally extending strips of adhesive. The spray adhesive may be a releasable type in some embodiments. In yet other possible embodiments, a hook and loop releasable fastening element such as Velcro® strips may be used in which one piece is attached to the grid support member202and the other piece is attached to the upper surface of the peripheral edge portion332of the ceiling panel bottom facing sheet330. Activated adhesives such as hot melt film could also be used for attachment to grid support member—pre-attached to grid and activated in field with hot element (i.e. iron) for example. Mechanical methods or magnets could also be used.

Referring toFIG. 7, a first ceiling panel300(e.g. the right panel shown in dashed lines for clarity) is installed on one side of the grid support member202. The peripheral edge portion332of the bottom facing sheet330is laterally inserted and positioned beneath the bottom surface206of the bottom flange210by a sufficient distance that extends across and over the cutting guide groove250. This locates the peripheral edge334defined by the peripheral edge portion332of the bottom facing sheet330on the opposite (e.g. left) side of the cutting guide groove250. The free or cantilevered peripheral edge portion332provides sufficient flexibility to allow the bottom facing sheet330to deflect slightly to accomplish this placement. During the placement, the peripheral edge portion332may be pressed upwards against the exposed tacky side of the near side adhesive strip240for attachment after the edge portion is properly positioned.

In a similar manner, a second ceiling panel300(e.g. the left panel shown in dashed lines for clarity) is next installed on the opposite side of the grid support member202. The peripheral edge portion332of the bottom facing sheet330is laterally inserted and positioned beneath the bottom surface206of the bottom flange210by a sufficient distance that extends across and over the cutting guide groove250. This locates the peripheral edge334of the bottom facing sheet330of the second ceiling panel300on the opposite side (e.g. right) of the cutting guide groove250. The peripheral edge portion334of the second ceiling panel preferably overlaps the peripheral edge portion334of the first ceiling panel300by a distance D2(seeFIG. 7).

The next step in the ceiling panel installation process to conceal the grid support member202is cutting and trimming the overlapped peripheral edges portions of the first and second ceiling panels300using the cutting guide groove250to form a tight and neat seam therebetween. Referring toFIG. 8, a cutting tool such as a razor knife may be used for trimming the overlapping bottom facing sheets330. The tip of the blade252may be first placed at least partially into the groove250near one end of the overlapped peripheral edge portions332at a first axial position. The blade252may then be run or slid along the length of the cutting guide groove250and longitudinal axis LA to a second spaced apart axial position towards the opposite end of the overlapped bottom facings peripheral edge portions332. Using the cutting guide groove, a straight linear cut through the edge portions332can be made, thereby trimming or cutting the overlapped peripheral edge portions332off to form a straight seam therebetween as shown inFIG. 9. The peripheral edge portion332of the second ceiling panel300may then be pressed firmly upwards against the remaining adhesive strip240to complete the installation. The peripheral edge portions332of the first and second ceiling panels300are now each adhesively bonded to the bottom surface206of the grid support member202. Advantageously, the combination of straight-cut adjoining bottom facing edges334between adjacent ceiling panels300and adhesive bonding of their respective bottom facing sheets to the grid support member202contribute to creating a neat, tight abutment seam.

It will be appreciated that numerous variations in the foregoing ceiling panel installation process and sequence are possible.

While the foregoing description and drawings represent exemplary embodiments of the present disclosure, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. In addition, numerous variations in the methods/processes described herein may be made within the scope of the present disclosure. One skilled in the art will further appreciate that the embodiments may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the disclosure, which are particularly adapted to specific environments and operative requirements without departing from the principles described herein. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive. The appended claims should be construed broadly, to include other variants and embodiments of the disclosure, which may be made by those skilled in the art without departing from the scope and range of equivalents.