Patent Application
20160273217
The present invention relates to ceiling systems, and more particularly to ceiling systems having a monolithic seamless appearance.
A number of different materials have been used for creating seamless ceilings having a monolithic appearance. One such material is drywall. Drywall or wall board panels are surface mounted to a support surface or grid formed of wood or metal which are affixed to an overhead building structure to support the panels. Panels are affixed to the grid using fasteners. Highly visible seams formed between adjoining panels typically have relatively wide gaps which must be taped and spackled with drywall joint compound to cover the joints and fastener heads. This process is time consuming and expensive generally involving several iterations of spackling and sanding to achieve a smooth finish to conceal the joints. Furthermore, drying time must be allowed between coats of joint compound before sanding. The ceiling installation may take as long as five days in some cases and requires completion by skilled craftsman which increases installation costs. The finished joints and drywall are only now ready for applying a finish coat or paint.
The foregoing drywall ceiling installation also requires attachment of the ceiling panels to a rigid support surface or grid. Such monolithic ceiling systems are not suitable for attachment to suspended grid support systems, thereby limiting the number of applications in which drywall may be used. Moreover, drywall cannot deliver comparable acoustical performance to other ceiling materials such as acoustical ceiling tiles or panels which many times is desired in occupied spaces.
An improved monolithic ceiling system is therefore desired.
A ceiling system is provided which conceals the ceiling support surface or grid with ceiling panels having specially configured peripheral edges that overlay the bottom surface or face of the grid support members. The ceiling panels in certain embodiments may include edge portions configured to mount to and conceal the exposed ceiling support surface or grid faces. In certain non-limiting embodiments, the ceiling panels may be acoustical tiles or panels.
In one embodiment, the ceiling system includes ceiling panels having a composite hybrid peripheral edge detail including a combination of a tongue-and-groove and shiplap configurations. The hybrid edges of adjoining panels are configured to both interlock via the tongue-and-groove portion of the edge detail and hide the ceiling panel support surfaces or grid faces via the shiplap portion of the edge detail.
The ceiling panels may be perimeter mounted to the support surface or grid. In one implementation, lateral extensions of the ceiling panel define an upper shiplap edge profile and mounting flanges for direct surface mounting of the ceiling panel to and hiding the ceiling support surface or grid. When the panels are assembled together in the ceiling system, a lower shiplap edge profile formed on the peripheral edge of adjoining panels in turn conceals the mounting flanges, thereby hiding any exposed fastening elements that may be used to mount the ceiling panel to the support surface or grid. Advantageously, less than the total number of peripheral edges of the ceiling panel need to be affixed to the support surface or grid in some embodiments for properly supporting the ceiling panel; the remaining edges being supported by the tongue-and-groove interlock formed with adjoining panels. This saves both installation time and fastener costs.
In one embodiment, a ceiling system includes a ceiling support structure having a downward facing support surface, and a plurality of ceiling panels attached to the ceiling support structure. The ceiling panels each have a top surface facing the ceiling support structure, an opposing bottom surface, and a plurality of peripheral edges extending between the top and bottom surfaces. A pair of adjoining first and second ceiling panels is mutually engaged along first and second mating peripheral edges respectively, the first and second peripheral edges each having a hybrid edge detail including a tongue-and-groove portion and a shiplap portion. The shiplap portion of the first ceiling panel defines a laterally extending mounting flange attached to the ceiling support structure. The shiplap portion of the second ceiling panel covers the mounting flange of the first ceiling panel. The tongue-and-groove portions of the first and second ceiling panels are interlocked, wherein the second peripheral edge of the second ceiling panel is supported via the tongue-and-groove interlock with the first ceiling panel.
In one embodiment, a ceiling panel with hybrid edge detail includes a body including a top surface, a bottom surface, opposite first and second longitudinal sides extending between the top and bottom surfaces, and opposite third and fourth lateral sides extending between the top and bottom surfaces. The first longitudinal side has a first peripheral edge including a shiplap portion and a tongue-and-groove portion. The third lateral side has a third peripheral edge including a shiplap portion and a tongue-and-groove portion. The shiplap and tongue-and-groove portions of the first and third peripheral edges are arranged to engage complementary configured shiplap and tongue-and-groove portions of adjoining ceiling panels for forming an interlocked ceiling system.
A method for concealing a ceiling support structure is provided. The method includes: providing a plurality of ceiling panels each having a top surface and an opposing bottom surface, the panels each having opposing first and second peripheral sides, the first peripheral side having a hybrid edge detail comprising a tongue-and-groove feature and a laterally extending shiplap feature adjacent the top surface, the second peripheral side having a hybrid edge detail comprising a tongue-and-groove feature and a stepped shiplap feature; attaching the first ceiling panel to the ceiling support structure; engaging the tongue-and-groove of the second peripheral side of a second ceiling panel with the tongue-and-groove feature of the first peripheral side of the first ceiling panel; and engaging the stepped shiplap feature of the second peripheral side of the second ceiling panel with the laterally extending shiplap feature of the first peripheral side of the first ceiling panel; wherein the second peripheral side of the second ceiling panel is supported by first peripheral side of the first ceiling panel.
The features of the exemplary embodiments of the present invention will be described with reference to the following drawings, where like elements are labeled similarly, and in which:
All drawings are schematic and not necessarily to scale. Parts given a reference numerical designation in one figure may be considered to be the same parts where they appear in other figures without a numerical designation for brevity unless specifically labeled with a different part number and described herein.
The 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.
In the description of embodiments disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,”, “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivative thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise.
The present ceiling system 100 will now be described for convenience without limitation to a suspended type ceiling system having a grid-type ceiling panel support system which is hung from an overhead building structure. However, the ceiling system is not limited in its scope or applicability to such grid systems. Accordingly, the support grid may be directly surface mounted to the building structure in certain embodiments. Alternatively, the ceiling panels themselves may be directly surface mounted to the building structure or framing members (e.g. wood or metal joists, studs, or other elements). Therefore, the present invention is explicitly not restricted for use with suspended type ceiling systems alone.
Referring initially now to
Longitudinal and lateral grid support members 202, 204 are elongated in shape having a length greater than their respective width (e.g. at least twice), and in various embodiments lengths substantially greater than their widths (e.g. 3 times or more). Longitudinal grid support member 202 may have a substantially greater length than lateral grid support member 204 and form “runners” or “rails” which are maintained in a substantially parallel spaced apart relationship by the lateral grid support members. The lateral grid support members 204 may be attached to and between adjacent (but spaced apart) longitudinal grid support members 202 at appropriate intervals using any suitable permanent or detachable coupling means. The combination of interconnected longitudinal and lateral grid support members 202, 204 provides strength and lateral stability to the grid support system 200. In one non-limiting example, the grid support system 200 may be a metal drywall grid system or suspended grid system available from Armstrong World Industries.
In one embodiment, grid support members 202 and 204 may be horizontally oriented when installed. It will be appreciated, however, that other suitable mounted orientations of grid support members 202, 204 such as angled or sloped (i.e. between 0 and 90 degrees to horizontal) may be used. Accordingly, although support members 202, 204 may be described in one exemplary orientation herein as horizontal, the invention is not limited to this orientation alone and other orientations may be used.
Longitudinal and lateral grid support members 202, 204 intersect to form an array of grid openings 208 which receive and essentially are closed by ceiling tiles or panels 300 when positioned within the openings. In some embodiments, the grid support members 202, 204 may be arranged in an orthogonal pattern wherein the support members intersect at right angles (i.e. perpendicular) to form rectilinear grid openings 208 such as squares or rectangles (in top plan view).
The terminal ends 205 of the lateral grid support members 204 have end connections configured for permanent or detachable connection to the vertical webs 212 of the longitudinal grid support members 202 at right angles to form a rectilinear grid pattern (see, e.g.
It will be appreciated that some lateral grid support members 204 may be run the same direction between and parallel to main beam longitudinal grid support members 202, as shown for example in
The longitudinal and lateral grid support members 202, 204 each define a respective longitudinal axis LA and axial directions; the lateral grid support members 204 generally but not necessarily being arranged transversely thereto. In one implementation, bottom flange 210 is oriented substantially horizontally when in an installed hung position (see, e.g.
With continuing reference to
Grid support members 202, 204 may be made of any suitable metallic or non-metallic materials structured to support the dead weight or load of ceiling panels 300 without undue deflection. In some non-limiting embodiments, the grid support members may be made of metal including aluminum, titanium, steel, or other. In some non-limiting embodiments, the grid support members 202, 204 may be a standard heavy duty 15/16 inch aluminum T-rail having a 15/16 inch grid face or 9/16 inch T-rail having a narrow 9/16 inch grid face. Other types of grid support members may be used preferably with a sufficiently sized grid face for properly fastening or attaching the ceiling panels thereto.
Features of the ceiling panels mountable on the foregoing ceiling support grid will now be described in further detail. Referring generally to
Ceiling panels 300 may include grid-concealment features in one embodiment being configured and dimensioned to hide or conceal at least a portion of the ceiling support surface or grid face when mounted to the longitudinal and lateral grid support members 202, 204 of the grid support system 200. Accordingly, ceiling panels 300 may be used to provide a monolithic ceiling appearance which hides the ceiling support or grid surface when viewed from the occupied building space created below, as further described herein.
Referring now
For clarification, it bears noting that the ceiling panel shown in
In some embodiments, ceiling panels 300 may have a rectilinear shape, such as without limitation square or rectangular. Each ceiling panel 300 includes four corners 331 and peripheral edges 332 extending around the perimeter of the panel. Edges 334 define outward facing peripheral edge surfaces configured to interlock with adjoining ceiling panels 300 when mounted to the grid support system 200, as further described herein.
The ceiling panels 300 are configured and dimensioned to hide the grid face of the overhead support grid 209 (i.e. bottom surface 206 of the grid support members 202 and 204). Accordingly, referring to
Accordingly, when adjoining ceiling panels 300 are installed in the overhead support grid 209 which are configured and dimensioned in the foregoing manner, the peripheral edge portions 332 of the panels overlap and extend entirely beneath the flange bottom surfaces 206 of both the two opposing longitudinal grid support members 202 and two opposing lateral grid support members 204 surrounding each grid opening 208, thereby completely concealing the grid face. Perimeter regions of top surface 302 of each ceiling panel 300 define upward facing substantially planar peripheral top surfaces 335 which may either contact or fall in close proximity to bottom surfaces 206 of grid support members 202 and 204 when the ceiling panel is mounted therefrom (see, e.g.
The ceiling panels 300 may have a composite-structured hybrid peripheral edge detail including a combination of a tongue-and-groove and shiplap configurations. The hybrid edges of adjoining panels are configured to both interlock via the tongue-and-groove portion of the edge detail and hide the ceiling panel support surfaces or grid faces via the shiplap portion of the edge detail.
Referring to
In one exemplary non-limiting embodiment as shown, each ceiling panel 300 may include two peripheral edges 332 having a male upper shiplap feature 340 and two peripheral edges 332 having a female lower shiplap feature 350. In one configuration, the upper shiplap features 340 may be formed on two orthogonally adjoining peripheral edges 332 (i.e. oriented perpendicular to each other) which intersect at a first corner 331. Similarly, the lower shiplap feature 350 may be formed on two orthogonally adjoining peripheral edges (i.e. oriented perpendicular to each other) which intersect at a second corner 331 diagonally opposite to the first corner 331. The upper shiplap features 340 may be continuous in structure on the two adjoining peripheral edges 332 including at the first corner. Similarly, the lower shiplap features 350 may be continuous in structure on the two adjoining peripheral edges 332 including at the second corner.
It will be appreciated that other arrangements of the shiplap features on different peripheral edges may be used in other embodiments. Accordingly, the ceiling panel is not limited to the shiplap arrangement shown herein.
In one embodiment, each upper shiplap feature 340 may be defined by a cantilevered lateral extension 341 of a respective first ceiling panel edge 332 (reference
Upper shiplap feature 340 includes a laterally outward facing upper end surface 342 and downward facing bottom surface 344 arranged to engage a mating lower shiplap feature 350 of an adjoining ceiling panel 300. Bottom surface 344 may be oriented substantially parallel to top surface 302 of ceiling panel 300. In other embodiments, bottom surface 344 may be obliquely oriented to top surface 302. The lateral extension 341 preferably has a width sufficient to cover and at least a portion of the grid bottom flange 210 (i.e. grid face or surface 206) to which the ceiling panel is attached. In one embodiment, end surface 342 may be vertically aligned approximately with the web 212 of the grid support member 202 or 204 to which it attached (see, e.g.
In one configuration, the lateral extension 341 further defines a mounting flange 343 for attachment to the grid bottom flange 210 (see, e.g.
With continuing reference to
Stop wall 354 may be oriented perpendicular to and intersects top surface 302 of the ceiling panel 300 at one end. At the other end, stop wall 354 intersects and may be oriented perpendicular to seating surface 352 as best shown in
The tongue-and-groove portion of the ceiling panel edge detail will now be further described. In one embodiment, the peripheral edges 332 including a lower shiplap feature 350 may further include a male shiplap feature comprising a laterally outward projecting cantilevered tongue 360 configured for insertion into a mating female shiplap feature comprising a laterally open groove 370 formed in an adjoining ceiling panel peripheral edge 332 (see, e.g.
Lateral groove 370 defines a recessed vertical stop wall 371 arranged to abut the tongue 360 of an adjoining panel, and more particularly the end surface 355 of the tongue as shown in
In one embodiment, the lateral extension 341 (and mounting flange 343 defined by the extension) may have an L-shaped configuration as show in the bottom plan view of
The protruding tongue 360 portions of the ceiling panels 300 may have also an L-shaped configuration in bottom plan view. The tongues 360 may have a length substantially equal to the length of the peripheral edge 332 on which they are disposed (see, e.g.
Referring to
Advantageously, when the shiplap features of the ceiling panels 300a, 300b are joined, the lower shiplap feature 350 is arranged to completely conceal the otherwise exposed heads of the fasteners 380, thereby eliminating the need to spackle or otherwise hide the head of the fastener for forming a monolithic ceiling appearance.
With respect to the tongue-and-groove portion of the hybrid edge details, tongue 360 of ceiling panel 300a is inserted in and engaged with lateral groove 370 of ceiling panel 300b. End surface 355 of tongue 360 abuttingly contacts or alternatively may be disposed preferably at least proximate to recessed stop wall 371 in groove 370 to provide secure interlocked engagement between the adjoining peripheral edges 332 of each panel. Lower end surface 372 of ceiling panel 300b abuttingly contacts or alternatively may be disposed preferably at least proximate to lower stop wall 362 of ceiling panel 300a.
It should be noted that the remaining peripheral edge 332 (right) of the central ceiling panel 300b is supported only by tongue-and-groove engagement with ceiling panel 300c, thereby eliminating the need to fasten this peripheral side 306 of ceiling panel 300b to the support grid. The same joint configuration and arrangement as described above is used for joining the longitudinal peripheral sides 306b of ceiling panel 300b to adjoining ceiling panels (see, e.g.
Ceiling panels 300 may be constructed of any suitable material or combinations of different materials, which in certain embodiments preferably have acoustical properties. Some non-limiting examples of ceiling panel materials that may be used include, without limitation, mineral fiber board, fiberglass, metals, polymers, wood, composites, combinations thereof, or other. Embodiments of ceiling panels 300 have a sufficiently high noise reduction coefficient (NRC) to be characterized as an acoustical substrate in contrast to gypsum-based drywall having substantially lower NRCs (e.g. 0.05) characteristic of sound reflecting, not absorbing materials. An NRC rating of 0.00 is a perfect sound reflection material. An NRC rating of 1.00 is a perfect sound absorption material. In some embodiments, ceiling panels 300 may have an NRC of at least 0.50 or higher. In a certain embodiment, the NRC rating may be at least 0.70. The shiplap and tongue-in-groove edge details may be formed by any fabrication process or combination of processes capable of making the details. Non-limiting examples include cutting, routing, milling, casting, molding, etc.
In some embodiments contemplated, ceiling panels 300 may be composite structures formed from two or more separately formed layers or sheets of material which are bonded or joined together to form a complete panel. For example, referring to
An exemplary method for installing a ceiling system that conceals the ceiling support structure will now be described. In order to form a monolithic appearance for ceiling system 100, the ceiling panels 300 are mounted and assembled in an alternating sequence using the mounting flanges 342, and tongue-and-groove and shiplap edge details disclosed herein.
The grid support system 200 is first installed using a combination of longitudinal and lateral grid support members 202, 204 in the manner described herein and shown in
The present method begins with first installing a row of ceiling panels 300 along the longitudinal direction between pairs of lateral grid support members 204. For a suspended ceiling system, the grid support members are first hung from an overhead building structure. Alternatively, in some embodiments, the grid support members may be surface mounted directly to the building structure, or alternatively the surface of the building structure itself may be used for direct attachment of the ceiling panels 300 if the surface is sufficiently flat. The present method, however, will be described for convenience without limitation to a suspended-type ceiling system. The grid support members 202, 204 are installed in an arrangement similar to
Referring now to
A second ceiling panel 300b is next installed in step (2) and connected to ceiling panel 300c (see
It bears noting that the foregoing single step (2) achieves several objectives. First, referring to
Additional ceiling panels may then continue to be installed in the same longitudinal row (direction) using the same process described and shown in steps (1) and (2). Following completion of the longitudinal row of tiles, a second longitudinal row of laterally adjacent ceiling panels is next illustrated in the present installation process. It will be appreciated however that a full longitudinal row of ceiling panels need not be installed until adjacent longitudinal row ceiling panels can be installed. Alternatively, lateral rows of ceiling panels may be installed first. Furthermore, various select sections of ceiling panels may be installed by mounting panels in the both the longitudinal and lateral directions, as illustrated below.
Referring now to
A fourth ceiling panel 300d may next be installed in step (4) by connecting the panel to both previously-mounted ceiling panels 300b and 300e. The longitudinal and lateral tongues 360 of panel 300d are inserted into the longitudinal and lateral grooves 370 of ceiling panels 300b and 300e, respectively. The longitudinal and lateral mounting flanges 343 of panel 300d are positioned beneath and then attached along two peripheral sides 306 to bottom flanges 210 of intersecting longitudinal and lateral grid support members 202, 204 (see also
It will be appreciated that ceiling panels preferably are installed in an order or sequence in which there is always a previously-mounted ceiling panel having an exposed mounting flange 343 available. This is because the mounting flanges cannot be fastened to the support grid 209 if there already is an installed panel covering the grid face due to the shiplap edge detail. Ceiling panels may be cut or otherwise factory formed to allow installation along the perimeter of the ceiling system 100 adjacent the vertical walls of the building space where the normal installation method and sequence using the hybrid edge details cannot be fully used.
Although ceiling panels 300 are disclosed herein in one non-limiting embodiment as having a hybrid peripheral edge detail, it will be appreciated that other types of edge details and combinations of different type edge details may be used including edge details such as without limitation butt-joint, shiplap, tongue-and-groove, etc. The present invention is therefore not limited to panels having hybrid edge details alone.
As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls
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.
