Ceiling panel

A ceiling panel is provided for use in a grid-type suspended ceiling, wherein the grid includes a plurality of spaced grid runners. The ceiling panel comprises a tile base with perimeter segments and perimeter profiles along at least a portion of at least two of the perimeter segments. Each profile is supportable by the grid runners during suspension. A facing material is secured across the perimeter segments, and extends beyond the perimeter profiles in order to at least partially conceal two of the grid runners when the tile is suspended from the two grid runners and viewed from below.

TECHNICAL FIELD

This invention relates generally to suspended ceiling systems and, more particularly, to panels used in a suspended ceiling system.

BACKGROUND

Suspended ceiling systems are widely used in a variety of applications, such as in commercial and residential buildings. Grid-type suspension ceilings cover the plenum area, while still allowing access to the plenum area, which typically contains components of the building's wiring, heating, venting, air conditioning, plumbing, among other mechanical components. A grid of spaced runners and cross-runners are frequently used to position and support the panels. The runners and cross-runners are generally suspended from the ceiling using wires, rods, or other suspension runners, and are arranged and sized according to the shape and size of the panels being supported therein.

The ceiling tile or panel is commonly supported in the grid by laying the perimeter of the panel on the panel-support flanges of the runners. This results in an exposed suspension grid system, which must be, among other requirements, finished and otherwise made aesthetically pleasing. Thus, by decreasing the exposed portion of the grid, manufacturing costs may be reduced by avoiding the finishing requirements. In addition, if grid exposure is decreased by positioning a portion of the panel to cover the grid, as opposed to using additional structures such as framing or molding, the desired monolithic appearance of a ceiling grid may be achieved.

While it is often preferable that at least a portion of the grid runners be concealed to provide a more aesthetically pleasing ceiling, installation and removal of the ceiling panels within the grid can be complicated by the features used to conceal the grid. For example, additional trim pieces can be added to the grid to provide an aesthetically pleasing transition from panel to panel. This, however, adds additional costs by way of adding more components and installation time. In addition, the trim pieces may interfere with easy installation of the panel.

Another known installation and removal method is a lift-and-shift installation, wherein one edge of the ceiling panel is lifted and mounted onto a grid runner and then the edge is shifted toward the first grid runner to allow the opposite edge of the panel, including any concealment features, to give clearance so that the opposite edge can be mounted onto a second grid runner and then shifted and centered. This design enables the panel to include structure that extends beyond the grid to conceal the grid. The lift-and-shift installation reduces the amount of space needed above the grid and makes installation faster since the installer can more easily raise and manipulate the ceiling panel into position without raising the panel through and above the grid.

As with most construction, quicker and easier installation saves both time and money. Thus, the ceiling panels and the method of installation should be efficient, economical, and effective. Further, since access is required to the plenum area above the suspension ceiling, the panels should be readily removable.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Generally, in one form, a ceiling panel is provided for use in a grid-type suspended ceiling, wherein the grid includes a plurality of spaced grid runners. The ceiling panel comprises a tile base with perimeter segments and perimeter profiles along at least a portion of at least two of the perimeter segments. Each profile is supportable by the grid runners during suspension. A facing material is secured across the perimeter segments, and extends beyond the perimeter profiles in order to at least partially conceal two of the grid runners when the tile is suspended from the two grid runners and viewed from below.

More specifically, and with reference toFIG. 1, a suspended ceiling is depicted generally at10, and includes a plurality of main tee grid runners12,14,16and a plurality of cross tee grid runners18,20connected to the main tee grid runners12,14,16to form a grid structure22. The main tee grid runners12,14,16, are typically hung from a ceiling structure (not shown), such as, for example, joists or a slab ceiling. The main tee grid runners12,14,16are hung from the ceiling structure by suspension members (not shown), such as wires or rods.

The main tee grid runners12,14,16are generally available in standard lengths, such as 12 feet (3.66 meters), and multiple main tee grid runners may be spliced together to run the length of a room. The main tee grid runners12,14,16and cross tee grid runners18,20are configured and positioned according to the size and shape of the panel to be positioned within the grid. As shown inFIG. 1, the panels24are generally rectangular in shape and, therefore, the main tee grid runners12,14,16are generally oriented parallel and spaced apart from each other. The cross tee grid runners18,20are also generally oriented parallel and spaced apart from each other, while extending generally perpendicular to the main tee grid runners12,14,16to form the grid22. Once the grid22is formed, the ceiling panels24, such as those described below, are placed into spaces formed by the grid22and suspended by the grid structure22. The ceiling panels24are generally suspended in a horizontal plane, although other configurations are possible. It should be noted that the grid22ofFIG. 1, including the configuration and orientation of the main tee grid runners12,14,16and cross tee grid runners18,20, is merely illustrative and other configurations are contemplated to accommodate ceiling panels of different shapes and sizes.

With reference toFIG. 2, there is illustrated a perspective view of a first embodiment of a ceiling panel100to be used in the grid structure22ofFIG. 1. In this embodiment, the ceiling panel100comprises a core tile or tile base102and a lightweight facing material104secured across a lower face126(shown inFIG. 4) of the tile base102. Both the tile base102and the facing material104are shown as being generally rectangular in shape, although other shapes are contemplated. The facing material104generally functions to provide an aesthetically pleasing and monolithic ceiling appearance. The tile base102provides the suspension structure for the ceiling panel100such that the ceiling panel100engages with and is supported by the grid22. The tile base102can have a variety of materials known in the art, such as, for example, fiberglass, mineral fiber, plastic, wood, or metal. The tile base102is preferably lightweight in order to minimize the overall weight of the ceiling panel100.

As illustrated inFIG. 4, each main tee12,14,16has a generally identical configuration, with such configuration being generally known in the art. The cross-section of each main tee12,14,16includes an upper bulb30, a web32extending from the bulb30, and a support flange34, having laterally extending sides36and38. The ceiling panels100are generally supported or engaged with the sides36,38of the support flange34to maintain the ceiling panels100in a suspended position within the grid22.FIGS. 3 and 4show the installed condition of the ceiling panel100.

As seen inFIGS. 2-5, the tile base102has perimeter segments106,108,110, and112and a stepped perimeter profile128along at least two opposing perimeter segments or edge regions106,108. In this embodiment, the stepped profile128is comprised of a horizontal support kerf114formed approximately half way down edge regions106,108of the tile base102and is defined by an upper horizontal surface130and an end vertical surface132. A positioning kerf116is formed below the support kerf114along the edge regions106,108, with the positioning kerf116defined by an upper horizontal surface134and an end vertical surface136and the positioning kerf116extending horizontally deeper than the support kerf114to complete the stepped profile128. The support kerf114generally functions to provide a suspension surface for the ceiling panel100, with the support kerf114being supported by the flange34of the main tee grid runner12during suspension of the ceiling panel100, as shown inFIGS. 3 and 4. The support kerf114also assists in accurately positioning the ceiling panel100on the grid flange34. As shown, the support kerf114has a height slightly greater than the height of the flange34of the main tee grid runner12and extends deep enough to allow the support kerf114to be supported with stability by the flange34. The positioning kerf116allows for the lift and shift installation and/or removal of the ceiling panel100from the grid22. The height of the positioning kerf116is preferably greater than the thickness of the facing material104to provide for sufficient clearance for the installation and removal of the ceiling panel100. In other words, the facing material104has a thickness less than a distance between perimeter profile128and the facing material104so that the facing material104from an adjacent ceiling panel can fit within this space as described below. The tile base102should be generally thick enough to accommodate the stepped profile128. Another pair of opposing perimeter segments or side regions110,112of the ceiling panel100are shown onFIG. 2as vertically extending linear walls, although other profile options may be used.

The facing material104is preferably a thin, lightweight scrim. The lightweight nature of the facing material104allows for alternate suspension and installation methods. The facing material104may be any of a variety of materials known in the art, such as, for example, woven or non-woven material, wood, fiber, plastic, polymer, metal, foam, foil, film, ceramic, glass, or any combination thereof. In addition, the facing material104properties may be varied by treating the material, such as, for example, by coating, forming, thermosetting, or layering the material to enhance or modify structural or performance capabilities or appearance. The material and/or treatment of the material may be selected based on any of a variety of targeted properties for the facing material104, such as, for example, the weight, rigidity, structural integrity, noise-reduction coefficient characteristics, sound transmission coefficient characteristics, fire resistance, acoustical performance, aesthetics, humidity and moisture resistance, and microbial resistance, just to name a few. The facing material104may be rigid, semi-rigid, or flexible, depending on the properties and thickness of the material that is used. For the present embodiment, the facing material is preferably thick enough to provide some structure and rigidity to the facing material. By one optional approach, the material of the tile base102and the facing material104may be selected and coordinated to acquire desired aesthetics and acoustical properties.

The facing material104may be secured to the tile base102by any method known in the art, such as, for example, by adhering or laminating the layers together or by a mechanical connection between the layers. The facing material104is sized to extend beyond an edge region of the tile base102. As shown inFIGS. 2-5, the facing material104is secured across the perimeter segments106-112, and preferably extends beyond the tile base102around the entire perimeter of the core tile104. As a result, the facing material104conceals the stepped profile128of the opposing edge regions106,108of the tile base102during suspension when viewed from below, thereby at least partially concealing two of the grid runners and the ceiling panel's point of engagement and support with the grid22.

In this embodiment, the facing material104extends beyond the edge region of the core tile to at least partially conceal the grid during suspension when viewed from below. Referring toFIG. 3, when the support kerf114on opposing sides of the tile base102are supported by adjacent parallel main tee grid runners12,14such that the ceiling panel100is suspended, the facing material104extends to conceal the stepped profile128and then extends beyond the edge region of the tile base102and below the flange34such that at least a portion of the grid22is concealed. It also should be appreciated that the facing material104extends beyond opposing side regions110,112of the tile base102to at least partially conceal the cross tee grid runners extending between the main tee grid runners.

Referring now toFIG. 4, adjacent ceiling panels are shown being supported by a common main tee grid runner12, with the support kerf114of edge region106of panel100A being supported by side36of the flange34and the support kerf114of edge region108of panel100B being supported by the other side38of the flange34. In this embodiment, when adjacent panels100A and100B are suspended from each side36,38of the grid flange34, the facing material104of each ceiling panel100A,100B extends beyond the edge regions106,108of the respective tile bases102to at least partially conceal the respective sides36,38of the grid flange34. In addition, the facing material104of each ceiling panel extends beyond the side regions110,112of the respective tile bases102to at least partially conceal the cross tee grid runners. Preferably, a portion of the facing material104of one ceiling panel100A contacts a portion of the facing material104of the adjacent ceiling panel100B to conceal a portion of one of the grid runners12. More specifically, the outer edge regions120of the adjacent facing materials104of ceiling panels100A and100B extend to touch and seat flush against each other such that the main tee grid runners and cross tee grid runners are fully concealed to provide a monolithic suspended ceiling appearance. As can be seen, the length of the facing material104beyond the tile base102edge regions106,108and side regions110,112is generally a function of the depth of the support kerf114, the width of the flange34of the main tee grid runner12, and the size of the portion of the flange34that is to be concealed.

FIG. 5illustrates a ceiling panel100being installed and/or removed from a suspended position within the grid22using a lift-and-shift motion. The removal of the ceiling panel100will be described, with the installation of the ceiling panel100being accomplished by the same series of steps being performed in reverse order and in the reverse direction.FIG. 5shows adjacent parallel main tee grid runners12,14with a series of three adjacent ceiling panels100A,100B, and100C. Ceiling panels100A and100B share common main tee grid runner14, and ceiling panels100B and100C share common main tee grid runner12. In this illustration, ceiling panel100B is being removed. As the ceiling panels are symmetrical in that there is the stepped profile128along opposing edge regions106,108, it is understood that the installation and/or removal may be performed using the features along either edge region106,108of the ceiling panel100.

To begin removal, the ceiling panel100B of this embodiment is lifted vertically until the facing material104along sides106,108is generally adjacent the flanges34of main tee grid runners12,14and positioned above the facing material104of adjacent ceiling panels100A and100C. The ceiling panel100B is then shifted to the right toward ceiling panel100C (although the removal may also be completed by shifting the ceiling panel100B to the left toward ceiling panel100A). When the ceiling panel100B is shifted to the right, the facing material104on side106of the ceiling panel100B is inserted in the space between flange34of main tee grid runner12and the facing material of ceiling panel100C. In addition, side36of the main tee grid runner12is positioned within the positioning kerf116of side106of the ceiling panel100B. As the ceiling panel100B is further shifted to the right, the tile base102shifts clear of the flange34of main tee grid runner14and is able to drop down. As the side108of the ceiling panel100B continues to drop, the facing material104of side106is removed from the space between the flange34of main tee grid runner12and the facing material104of ceiling panel100C and also is free to drop down such that panel100B can be removed.

Referring now toFIGS. 6-9, there is illustrated a second embodiment of a ceiling panel200to be used in the grid structure22ofFIG. 1. As with ceiling panel100, the ceiling panel200of this embodiment comprises a core tile or tile base202and a facing material204secured across a lower face226of the tile base202as indicated onFIG. 8. The tile base202has generally the same configuration as the tile base102of ceiling panel100, including a stepped perimeter profile along a pair of opposing edge regions206,208and vertically extending linear walls along a pair of opposing side regions210,212. The stepped perimeter profile228is comprised of a horizontal support kerf214and a horizontal positioning kerf216positioned below the support kerf214, with each kerf214,216configured similarly to the kerfs114,116of ceiling panel100.

The facing material204of the ceiling panel200has a first pair of opposing outer edge regions220adjacent the stepped profile228edge regions206,208of the tile base202and a second pair of opposing outer edge regions222adjacent the side regions210,212of the core tile. As with the facing material104of the ceiling panel100, the facing material204is sized to extend beyond an edge region of the lower face226of the tile base202. The facing material204preferably extends beyond the tile base202around the entire perimeter of the tile base202. The facing material204conceals the stepped profile228of the opposing edge regions206,208of the core panel202during suspension when viewed from below, in addition to at least partially concealing the grid22during suspension.

In this embodiment, the facing material204of the ceiling panel200is generally thinner than the facing material104of ceiling panel100. To give the edge regions of the facing material204thickness and rigidity, each pair of opposing perimeter edge regions220,222of the facing material204are rolled, as shown inFIG. 6. As can be seen in the cross-sectional view ofFIG. 8, the rolled edge regions220are formed by rolling the edge regions of the facing material204back over on top of the upper face224of the facing material. The other pair of perimeter edge regions222of the facing material204also are rolled in the same manner. To fully conceal the grid structure22, the perimeter rolled edge regions220of the adjacent facing material204of ceiling panels200A and200B extend to touch and seat flush against each other such that the flange34is fully concealed, as shown inFIG. 8. It also is appreciated that the other pair of perimeter rolled edge regions222extend to conceal the cross tee grid runners and also may mate with the edge region222of an adjacent ceiling panel to fully conceal the cross tee grid runners. As a result, the facing material204fully conceals the main tee grid runners and the cross tee grid runners to provide a monolithic suspended ceiling appearance.

FIG. 9illustrates a ceiling panel200being installed and/or removed from a suspended position within the grid22using a lift-and-shift motion. Again, the installation of the ceiling panel200of this embodiment is accomplished by reversing the removal steps.FIG. 9shows adjacent parallel main tee grid runners12,14with a series of three adjacent ceiling panels200A,200B, and200C. To remove ceiling panel200B, the same general series of steps are followed as outlined above for ceiling panel100B. That is, the ceiling panel200B is lifted vertically until the facing material204along sides206,208is generally adjacent the flanges34of main tee grid runners12,14and positioned above the facing material204of adjacent ceiling panels200A and200C. The ceiling panel200B is then shifted to the right toward ceiling panel200C. When the ceiling panel200B is shifted to the right, the facing material204on side206of the ceiling panel200B is inserted in the space between flange34of main tee grid runner12and the facing material204of ceiling panel200C. In addition, side36of the main tee grid runner12is positioned within the positioning kerf216of side206of the ceiling panel200B. As the ceiling panel200B is further shifted to the right, the tile base202of the opposing side208of the ceiling panel200B shifts clear of the flange34of main tee grid runner14and is able to drop down. As the side208of the ceiling panel200B continues to drop, the facing material204of side206is removed from the space between the flange34of main tee grid runner12and the facing material204of ceiling panel200C and also is free to drop down such that panel200B can be removed.

Referring now toFIGS. 10-14, there is illustrated a third embodiment of a ceiling panel300to be used in the grid structure22ofFIG. 1. As with ceiling panels100and200, the ceiling panel300of this embodiment comprises a tile base302and a facing material304secured across a lower face336of the tile base302. The core tile or tile base302has generally the same configuration as the tile base102of ceiling panel100, including a stepped perimeter profile328along a pair of opposing edge regions306,308and vertically extending linear walls along a pair of opposing side regions310,312. The stepped perimeter profile328is comprised of a horizontal support kerf314and a horizontal positioning kerf316positioned below the support kerf314, with each kerf314,316configured similarly to the kerfs114,116of ceiling panel100.

The facing material304of the ceiling panel300has a first pair of opposing edge regions320adjacent the stepped profile328of edge regions306,308of the tile base302and a second pair of opposing edge regions322adjacent the side regions310,312of the tile base302. As with the facing material104of ceiling panel100, the facing material304of this embodiment is sized to extend beyond an edge of the lower face336of the tile base302. The facing material304preferably extends beyond the tile base302around the entire perimeter of the tile base302. The facing material304conceals the stepped profile328of the opposing edge regions306,308of the core panel302during suspension when viewed from below, in addition to at least partially concealing the grid22during suspension.

In this embodiment, an edge segment326of the facing material304is upturned toward the tile base302. The facing material304preferably has upturned edge segments326along the entire perimeter of edge regions320,322. As shown inFIG. 12, when the ceiling panel300is suspended from a main tee grid runner12, the upturned edge segments326of adjacent ceiling panels300A and300B are angled toward the flange34of the grid runner12. As a result, the upturned edge segments326conceal the stepped profile328of the opposing edge regions306,308of the tile base302and also partially conceal the flange34of the grid runner12. It also is appreciated that upturned edge segments326adjacent opposing side regions310,312partially conceal the cross tee grid runners. The facing material304, including the upturned edge segments326, is preferably made of a resilient flexible material. The resilient nature of the material will assist in the installation and removal of the ceiling panel300. While the ceiling panel300is shown to partially conceal the grid runners, in alternative embodiments the edge regions320may have edge segments upturned at such an angle and/or have a certain length to entirely conceal the grid runners.

FIGS. 13 and 14illustrate a ceiling panel300being installed and/or removed from a suspended position within the grid22using a lift-and-shift motion. Again, the basic steps are generally the same as those described for ceiling panels of100and200. The installation of the ceiling panel300of this embodiment is accomplished by reversing the removal steps.FIG. 13shows adjacent parallel main tee grid runners12,14with a series of three adjacent ceiling panels300A,300B, and300C. To remove ceiling panel300B, the same general series of steps are followed as outlined above for ceiling panel100B. The ceiling panel300B first is lifted vertically until the flanges34of main tee grid runner12,14are generally aligned with the positioning kerf314of sides306,308of the ceiling panel300B, with the upturned edge segment326of the resilient facing material304flattening as the upturned edge segment326is forced into contact with the flange34. The ceiling panel300B is then shifted to the right toward ceiling panel300C. When the ceiling panel300B is shifted to the right, the outer edge region320of the now flattened upturned edge segment326of ceiling panel300B pushes against the outer edge region320of adjacent upturned edge segment326of ceiling panel300C, causing the upturned edge segment326of ceiling panel300C to flex to create a deeper bend in the facing material304, as illustrated inFIG. 14. As a result, the ceiling panel300B is able to shift further to the right. Due to the resilience of the facing material304, the facing material304of ceiling panel300C absorbs the force applied by the facing material304of ceiling panel300B by flexing and the contact does not result in the ceiling panel300C being pushed off of the main tee grid runner12. As the ceiling panel300B is further shifted to the right, the tile base302of the opposing side308of the ceiling panel300B shifts clear of the flange34of main tee grid runner12and is then able to drop down. As the side308of the ceiling panel300B continues to drop, the facing material304of side306is removed from the space between the flange34of main tee grid runner12and the facing material304of ceiling panel300C and also is free to drop down such that panel300B can be removed. As the straightened upturned edge segment326of the facing material304of ceiling panel300B moves out of contact with the flange34, the resilient nature of the facing material304causes the upturned edge segment326to return to the original upturned shape. Likewise, as the upturned edge segment326of ceiling panel300C moves out of contact with the upturned edge segment326of ceiling panel300B, the upturned edge segment326releases from the deeper bend and returns to the original upturned shape.

Referring now toFIGS. 15-22, there is illustrated a fourth embodiment of a ceiling panel400to be used in the grid structure22ofFIG. 1. The ceiling panel of this embodiment comprises a frame402and a facing material404secured across the frame402. Again, both the frame402and the facing material404are shown as being generally rectangular in shape, although other shapes are contemplated. The facing material404generally functions to provide an aesthetically pleasing and generally monolithic ceiling appearance. The frame402provides a support structure to which the facing material404is secured and also provides the suspension structure for the ceiling panel400such that the ceiling panel400engages with and is supported by the grid22.

In this embodiment, the frame402generally comprises a base frame portion420having a first pair of opposing side wall segments406,408and a second pair of opposing side wall segments410,412. Referring now toFIG. 17, the frame402is preferably formed from a length436of roll-formed metal. The general profile of each side wall segment406,408,410,412is formed during the roll-forming process. The frame402is factory adjustable by making varying lengths436of the roll-formed metal such that varying widths and lengths of ceiling panels400can be produced. Notches430,432,434are then formed in the roll-formed length436such that the length436can be folded or bent at each notch430,432,434to assemble the frame402. As is illustrated in the corner detail shown inFIG. 18, each corner438may optionally have an overlapping tab440for spot welding to secure the frame402in its assembled form.

When assembled, the side wall segments406,408,410,412define a generally rectangular border frame to which the facing material404is secured. As illustrated inFIG. 16, the facing material404of this embodiment has center portion424having a generally rectangular configuration, with the center portion424being sized to generally match the size of the frame402. In addition, the facing material404includes flap portions418along each side of the center portion424. The center portion424of the facing material404extends across the bottom of the side wall segments406,408,410,412, and the flap portions418are then folded up along the side wall segments406,408,410,412and secured thereto. The flap portions418are secured to the side wall segments406,408,410,412using any suitable securing means, such as, for example, by chemically attaching the flap portions418using a glue or adhesive or any known mechanical means.

In this embodiment, the base frame portion420of the frame402has a first pair of top facing walls426extending generally transverse to side wall segments406,408and a second pair of top facing walls442extending generally transverse to side wall segments410,412. The first pair of top facing walls426each has a support extension422extending therefrom, with the support extension422extending from a rolled edge444of the top facing walls426and toward the outer side wall segments406,408. The support extension422extends over generally two-thirds of the top facing wall426and extends generally along the entire length of the top facing wall426. The support extension422has a stepped perimeter profile428for being supported by a main tee grid runner during suspension. By another optional approach, a plurality of shortened support extensions may be positioned along the length of the top facing wall426.

The stepped profile428of each support extension422is comprised of a horizontal support step414starting from the outermost end region of the support extension422. A horizontal positioning step416is formed below the support step414, with the horizontal positioning step416extending to the rolled edge444of the top facing wall426. The support step414of this embodiment generally functions to provide a suspension surface for the ceiling panel400, with the support step414being supported by the flange34of the main tee grid runner12during suspension of the ceiling panel400, as illustrated inFIGS. 19 and 20. The support step414also assists in accurately positioning the ceiling panel400on the grid flange34. As shown, the support step414has a height generally equal to the thickness of the flange34of the main tee grid runner12. The positioning step416allows for the lift and shift installation and/or removal of the ceiling panel400from the grid22.

FIGS. 19-21show the installed condition of the ceiling panel400. The ceiling panel400of this embodiment is supported on opposing side walls406,408by the support extensions422hanging on the flange34of the main tee grid runners12,14, with the support step414of each support extension422engaging with the grid flange34. When suspended, the top facing wall420of the frame402extends under a side36,38of the grid flange34to partially conceal the main tee grid runner12. The frame402is then generally, if not fully, concealed by the facing material404secured thereto. As a result, when viewed from below, the main tee grid runners12,14are at least partially concealed by the facing material404to provide a more monolithic appearance.

FIG. 22illustrates a ceiling panel400of this embodiment being installed and/or removed from a suspended position within the grid22using a lift-and-shift motion. Adjacent parallel main tee grid runners12,14are shown with a series of three adjacent ceiling panels400A,400B, and400C. In this illustration, ceiling panel400B is being removed. As the ceiling panels are symmetrical in that there is a support extension422having a stepped profile428along opposing top facing walls of the frame402, it is understood that the installation and/or removal may be performed using the features of either support extension422.

To begin removal, the ceiling panel400B of this embodiment is lifted vertically until the top facing wall426contacts the flange34of each main tee grid runner34and the flange34is generally aligned with the positioning step416along side walls406,408. The ceiling panel400B is then shifted to the right toward ceiling panel400C. When the ceiling panel400B is shifted to the right, the flange34of main tee grid runner12is inserted into the positioning step416of the support extension422on side wall406. As the ceiling panel400B is further shifted to the right, the support extension422of side wall408shifts clear of the flange34of main tee grid runner14and is able to drop down. As the side wall408of the ceiling panel400B continues to drop, the facing material404of side wall406is removed from the space between the flange34of main tee grid runner12and the facing material404of ceiling panel400C and is also free to drop down such that panel400B can be removed.

With reference toFIGS. 23-32, there is illustrated a perspective view of a fifth embodiment of a ceiling panel500, to be used in the grid structure22ofFIG. 1. The ceiling panel500of this embodiment comprises a frame502and a facing material504secured across the frame502. The facing material504provides an aesthetically pleasing and generally monolithic ceiling appearance. The frame502provides support structure to which the facing material504is secured and also provides the suspension structure for the ceiling panel500such that the ceiling panel500engages with and is supported by the grid22.

The frame502of this embodiment generally comprises a first pair of opposing sides506,508and a second pair of opposing sides510,512. The sides506,508,510,512form a generally rectangular border frame to which the facing material504is secured. As illustrated inFIG. 24, the facing material504has a center portion524having a generally rectangular configuration, with the center portion524being sized to generally match the size of the frame502. In addition, the facing material504includes flap portions518along each side of the center portion524, which are secured to the frame502.

In this embodiment, the frame502has upstanding main walls516and base walls522along each side506,508,510,512that are generally perpendicular to the main walls516to form a generally L-shaped cross-section. A lip520extends away transversely from a distal end of the base wall522. The flap portions518of the facing material504are secured to the lip520of each side506,508,510,512. Along each side506,508, a pair of support flanges514are formed generally perpendicular to the main wall516. The support flanges514are each bent outwardly of the frame502, with the support flanges514being used to support the ceiling panel500during suspension. The support flange514extends generally parallel to the base wall522, with the base wall522extending further in length than the support flange514. Each support flange514on side506is generally aligned laterally with the support flanges514on the opposing side508. Each support flange514is positioned generally adjacent a corner538of the frame502, although other locations are contemplated. Although a pair of flanges514are shown on each side506,508, it should be noted that there may be any number of support flanges514along the sides506,508, with the support flanges514positioned anywhere along the length of the sides506,508. In addition, the support flanges514may be any length and, by one optional approach, a single support flange514may extend the length of a side506,508.

Referring now toFIG. 25, the frame502of this embodiment is preferably formed from a length536of roll-formed metal. The general profile of each side walls506,508,510,512is formed during the roll-forming process. The frame502is factory adjustable by making varying lengths536of the roll-formed metal such that varying widths and lengths of ceiling panels500can be produced. Support flanges514are then cut along the length536. Notches530,532,534are then formed in the roll-formed length536such that the length536can be hinged and folded or bent at each notch530,532,534to assemble the frame502. After folding, each corner538may optionally be spot welded to secure the frame502in its assembled form.

As is illustrated in the corner details shown inFIGS. 26 and 27, the notches530,532,534formed along the frame length536form a corner538with a specific profile when folded.FIG. 26shows a top view of a corner of this embodiment, andFIG. 27shows a perspective view of a corner538. Corner angled walls526,528extend from the main wall516. The walls526,528are folded to seat flush against each other and each has an identical profile, including a rectangular wall540and a stepped wall544. The rectangular wall540and the stepped wall544are separated by a notch542.

FIGS. 28-30show the installed condition of the ceiling panel500. The ceiling panel500of this embodiment is supported on opposing side walls506,508by the support flanges514hanging on the flange34of the main tee grid runners12,14. When suspended, the base wall522of the frame502extends under a side36,38of the grid flange34to at least partially conceal the main tee grid runner12. The frame502is then fully concealed by the facing material504being secured thereto. In addition, the flap portion518secured to the lip520serves to fill the space between the lips520of the adjacent ceiling panels500A and500B to further conceal the main tee grid runner12. As a result, when viewed from below, the main tee grid runners12,14are at least partially concealed by the facing material504to provide a generally monolithic appearance. In addition, the base wall522of the frame502along opposing sides510,512conceals the cross tee grid runners in the same manner.

FIGS. 31-32illustrate a ceiling panel being removed from a suspended position within the grid22using a lift-and-shift motion. Adjacent parallel main tee grid runners12,14are shown with a series of three adjacent ceiling panels500A,500B, and500C. The removal of the ceiling panel500will be described, with the installation of the ceiling panel500being accomplished by the same series of steps being performed in reverse order and in the reverse directions.

To begin removal, the ceiling panel500B of this embodiment is lifted upward vertically until the lip520of side walls506,508contacts the flange34. The ceiling panel500B is then shifted to the right toward ceiling panel500C (although the removal may also be completed by shifting the ceiling panel500B to the left toward ceiling panel500A). When the ceiling panel500B is shifted to the right, the lip520on side wall506of ceiling panel500B is inserted in the space between the flange34of main tee grid runner12and the lip520of ceiling panel500C. As the ceiling panel500B is further shifted to the right, the support flange514of the opposing side wall508of the ceiling panel500B clears the flange34of main tee grid runner14and is able to drop down. As the side wall508of the ceiling panel500B continues to drop, the lip520of side wall506is removed from the space between the flange34and the lip520of panel500C and also is free to drop down such that the panel500B can be removed.

With reference toFIGS. 33-36, there is illustrated a sixth embodiment of a ceiling panel600, to be used in the grid structure22ofFIG. 1. The ceiling panel of this embodiment comprises a frame602and a facing material604secured across the frame602. The facing material604generally functions to provide an esthetically pleasing and generally monolithic ceiling appearance. The frame602provides support structure to which the facing material604is secured and also provides the suspension structure for the ceiling panel600such that the ceiling panel600engages with and is supported by the grid. The frame602is preferably formed from a length of roll-formed metal. When assembled, the frame602has a generally rectangular configuration, with the facing material604extending across the bottom of the frame602and secured thereto.

The frame602of this embodiment has a stepped perimeter profile628along a first pair of opposing sides606,608. A second pair of opposing sides610,612comprise upstanding sidewalls, although other profile options may be used. The stepped profile628is comprised of a vertical riser630extending to a horizontal support step614. A positioning step616is formed below the support step614, with the positioning step616extending horizontally deeper than the support step614to complete the stepped profile628. The support step614generally functions to provide a suspension surface for the ceiling panel600, with the support step614being supported by the flange34of the main tee grid runner12during suspension of the ceiling panel600, as shown inFIGS. 35 and 36. The support step614also assists in accurately positioning the ceiling panel600on the grid flange34. The positioning step616allows for the lift and shift installation and/or removal of the ceiling panel600from the grid22. A horizontal extension wall632extends from the back wall634of the positioning step614to a point beyond the riser630. The extension wall632preferably extends generally to a mid-point of the grid runner12web34such that the extension wall632conceals a side36or38of the flange34during suspension. The extension wall632connects to a lower face wall636. The lower face wall636extends below the extension wall632to a point beyond the back wall634of the positioning step614. The facing material604is secured to the lower face wall636using any suitable securing means, such as, for example, by chemically attaching the flap portions using a glue or adhesive or any known mechanical means.

FIGS. 35 and 36show the installed condition of the ceiling panel600of this embodiment. The ceiling panel is supported on opposing sides by the support step614hanging on the flange34of the main tee grid runners12,14. When suspended, the lower face wall636of the frame602extends under a side36,38of the grid flange34to conceal the main tee grid runner12. The frame602is then substantially, if not fully, concealed by the facing material604secured thereto. As a result, when viewed from below, the main tee grid runners12,14are at least partially concealed, and preferably fully concealed, by the facing material604to provide a monolithic appearance.

FIG. 36illustrates a ceiling panel600being installed and/or removed from a suspended position within the grid22using a lift-and-shift motion. Adjacent parallel main tee grid runners12,14are shown with a series of three adjacent ceiling panels600A,600B, and600C. In this illustration, ceiling panel600B is being removed. As the ceiling panels are symmetrical in that there is a stepped profile628along opposing edge regions606,608, it is understood that the installation and/or removal may be performed using the stepped profile628feature along either side.

To begin removal, the ceiling panel600B of this embodiment is lifted vertically until the extension wall632along sides606,608is generally adjacent the flanges34of main tee grid runners12,14and the flanges34are generally aligned with the positioning step616. The ceiling panel is then shifted to the left toward ceiling panel600A. When the ceiling panel600B is shifted to the left, the extension wall632, lower face wall636, and the facing material604secured thereto on side608of the ceiling panel600B is inserted in the space between flange34of main tee grid runner14and the extension wall632of ceiling panel600C. In addition, side38of the main tee grid runner14is positioned within the positioning step616of side608of the ceiling panel600B. As the ceiling panel600B is further shifted to the left, the support step614of side606of the ceiling panel600B shifts clear of the flange34of main tee grid runner12and is able to drop down. As the side608of the ceiling panel600B continues to drop, the extension wall632, lower face wall636, and the facing material604secured thereto on side608is removed from the space between the flange34of main tee grid runner14and the extension wall632of ceiling panel600C and is also free to drop down such that panel600B can be removed.

With reference toFIGS. 37-40, there is illustrated a seventh embodiment of a ceiling panel700, to be used in the grid structure22ofFIG. 1. The ceiling panel of this embodiment comprises a frame702and a facing material704secured across the frame702. The facing material704generally functions to provide an aesthetically pleasing and generally monolithic ceiling appearance. The frame702provides support structure to which the facing material704is secured and also provides the suspension structure for the ceiling panel700such that the ceiling panel700engages with and is supported by the grid. The frame702is preferably formed from a length of roll-formed metal. When assembled, the frame702has a generally rectangular configuration, with the facing material704extended across the bottom of the frame702and secured thereto.

The frame702of this embodiment has a stepped upper profile728connected to an angled wall730along a first pair of opposing sides706,708. A second pair of opposing sides710,712comprise upstanding sidewalls, although other profile options may be used. The stepped profile728is comprised of a horizontal support step714and a positioning step716formed below the support step714, with the positioning step716extending horizontally deeper than the support step714to complete the stepped profile728. The support step714generally functions to provide a suspension surface for the ceiling panel700, with the support step714being supported by the flange34of the main tee grid runner12during suspension of the ceiling panel700, as shown inFIGS. 39 and 40. The support step714also assists in accurately positioning the ceiling panel700on the grid flange34. A top facing wall734optionally extends over the support step714to provide rigidity and support to the support step714being suspended from the flange34. An angled wall730extends from the positioning step716, and angles downwardly toward the center of the flange34during suspension. The angled wall730has a curved lip732at a terminal end thereof. The lip732hems over the facing material704to catch the facing material704and secure the facing material704to the frame702. The stepped profile728and angled wall730allow for the lift and shift installation and/or removal of the ceiling panel700from the grid22.

FIGS. 39 and 40show the installed condition of the ceiling panel700. The ceiling panel700is supported on opposing sides706,708by the support step716hanging on the flange34of the main tee grid runners12,14. When suspended, a portion of the angled wall730and the curved lip732of the frame extend under side36,38of the grid flange34to partially conceal the main tee grid runner12. The frame702is then fully concealed by the facing material704secured thereto. As a result, when viewed from below, the main tee grid runners12,14are at least partially concealed by the facing material704.

FIG. 40illustrates a ceiling panel700of this embodiment being installed and/or removed from a suspended position within the grid22using a lift-and-shift motion. Adjacent parallel main tee grid runners12,14are shown with a series of three adjacent ceiling panels700A,700B, and700C. In this illustration, ceiling panel700B is being removed. As the ceiling panels are symmetrical in that there is a stepped profile728along both opposing edge regions706,708, it is understood that the installation and/or removal may be performed using the stepped profile728feature along either side.

To begin removal, the ceiling panel700B of this embodiment is lifted vertically until the flange34of main tee grid runners12,14is aligned with the positioning step716. The ceiling panel700B is then shifted to the left toward ceiling panel700A. When the ceiling panel700B is shifted to the left, the lip732and the facing material704secured thereto on side708of the ceiling panel700B is inserted in the space between flange34of main tee grid runner14and the lip732of ceiling panel700A. In addition side38of the main tee grid runner14is positioned within the positioning step716of side708of the ceiling panel700B. As the ceiling panel700B is further shifted to the left, the support step714of side706of the ceiling panel700B shifts clear of the flange34of the main tee grid runner12and is able to drop down. As the side708of the ceiling panel700B continues to drop, the lip732and the facing material704secured thereto on side708is removed from the space between the flange34of main tee grid runner14and the lip732of ceiling panel700C and is also free to drop down such that panel700B can be removed.

With reference toFIGS. 41-44, there is illustrated an eighth embodiment of a ceiling panel800to be used in the grid structure22ofFIG. 1. The ceiling panel of this embodiment comprises a frame802and a facing material804secured across the frame802. The facing material804generally functions to provide an aesthetically pleasing and generally monolithic ceiling appearance. The facing material804has a center portion824having a generally rectangular configuration, with the center portion824being sized to generally match the size of the frame804. In addition, the facing material804includes flap portions818along each side of the center portion824, which are secured to the frame802. The frame802provides support structure to which the facing material804is secured and also provides the suspension structure for the ceiling panel800such that the ceiling panel800engages with and is supported by the grid22. The frame802is preferably formed from a length of roll-formed metal. When assembled, the frame802has a generally rectangular configuration, with the facing material804extended across the bottom of the frame802and secured thereto.

The frame802of this embodiment has a first pair of opposing angled side walls806,808and a second pair of opposing angled side walls810,812. An upstanding lip820extends from a terminal end of the angled side walls806,808,810,812. The flap portions818of the facing material804are secured to the lip820of each angled side806,808,810,812. Angled side walls806,808connect to top facing wall822and angled side walls810,812connect to top facing wall826. The top facing wall826overlays the top facing wall822in the corner regions836of the frame802. In addition, top facing wall826has a support flange814extending from each end thereof over angled side walls806,808. The support flange814is elevated above the plane of the top facing wall826by a riser816. Although a pair of support flanges814are shown extending over each angled side wall806,808, it should be noted that there may be any number of support flanges814extending over angled side walls806,808, with the support flanges814positioned anywhere along the length of the angled side walls806,808. In addition, the support flanges814may be any length.

FIG. 43shows the installed condition of ceiling panels800A and800B of this embodiment. The ceiling panels800A,800B are supported by the support flanges814hanging on the flange34of the main tee grid runner12. When suspended, the angled walls806,808extend under a side36,38of the flange34to at least partially conceal the main tee grid runner12. The frame802is then fully concealed by the facing material804being secured thereto. In addition, the flap portion818secured to the lip820serves to fill the space between the lips820of the adjacent ceiling panels800A and800B to further conceal the main tee grid runner12. As a result, when viewed from below, the main tee grid runner12is at least partially concealed by the facing material804to provide a generally monolithic appearance. In addition, the angled walls810,812conceal the cross tee grid runners in the same manner.

To begin removal, the ceiling panel800B of this embodiment is lifted vertically until the lip820is generally adjacent the flange34of main tee grid runners12,14and aligned with the space between the flange34and the lip820of ceiling panel800A. The ceiling panel800B is then shifted to the left toward ceiling panel800A. When the ceiling panel800B is shifted to the left, the lip820and the facing material804secured thereto on side808of the ceiling panel800B is inserted in the space between flange34of main tee grid runner14and the lip820of ceiling panel800A. As the ceiling panel800B is further shifted to the left, the support flange814adjacent side808of the ceiling panel800B shifts clear of the flange34of the main tee grid runner12and is able to drop down. As the side808of the ceiling panel800B continues to drop, the lip820and the facing material804secured thereto on side808is removed from the space between the flange34of main tee grid runner14and the lip820of ceiling panel800C and is also free to drop down such that panel800B can be removed.