Note: Descriptions are shown in the official language in which they were submitted.
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CEILING SYSTEM
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Patent Application No.
14/542,242
filed November 14, 2014, and U.S. Patent Application No. 14/542,077 filed
November 14,
2014, the entireties of which are incorporated herein by reference.
FIELD
[0002] The present invention relates to suspended ceiling systems with
concealed support
grids.
BACKGROUND
[0003] 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
[0004] A ceiling system is provided which conceals the ceiling support grid
with adjoining
facings or scrims between adjacent ceiling panels. Two approaches to facing
systems are
disclosed herein. A first embodiment of a facing system provides direct
mounting the facing
to the grid support members and ceiling panels for support to prevent sagging.
The ceiling
system incudes grid support members having an integral cutting guide groove to
permit tight
and straight seams to be made between the facings. A second embodiment
provides
suspended mounting of the facing directly to the grid support members without
reliance on
support on the ceiling panel for support to prevent sagging. The facings may
be coupled to
and supported by the support grid independently of the ceiling panels mounted
on the grid.
The facings in the second embodiment may be releasably secured to the support
grid and
removable without damaging the facings or ceiling panels for access to the
ceiling panels and
utilities above the grid. Each embodiment is further described herein.
[0005] In one embodiment of a ceiling system utilizing the first embodiment of
a facing
system described above, 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
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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.
[0006] 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.
[0007] 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.
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[0008] In one embodiment of a ceiling system utilizing the second embodiment
of a facing
system described above, a ceiling system includes: a longitudinally extending
grid support
member including a longitudinal axis and a substantially horizontal bottom
surface; a ceiling
panel supported by the grid support member; a first facing sheet having a
peripheral edge
portion; and a coupling mechanism that couples the peripheral edge portion of
the first facing
sheet to the bottom surface of the grid support member, the grid support
member supporting
the first facing sheet; wherein the bottom surface of the first grid support
member is at least
partially concealed by the peripheral edge portion of the first facing sheet.
[0009] In another embodiment, a ceiling system includes: a first
longitudinally-extending
grid support member and a second longitudinally-extending grid support member
spaced
apart from the first grid support member, each of the first and second grid
support members
defining a longitudinal axis and a substantially horizontal bottom surface; a
ceiling panel
extending between the first and second grid support members, the ceiling panel
supported by
the first and second grid support members; a first facing sheet spanning
between the first and
second grid support members, the first facing sheet coupled to and supported
from the bottom
surfaces of the first and second grid support members at peripheral edge
portions of the first
facing sheet; and a second facing sheet spanning between the first grid
support member and a
third grid support member spaced apart from the first grid support member, the
second facing
sheet coupled to and supported from the bottom surface of the first grid
support member at a
peripheral edge portion of the second facing sheet; the first and second
facing sheets having
respective adjacent edges positioned proximate to each other below the bottom
surface of the
first grid support member; wherein the bottom surface of the first grid
support member is
concealed by the peripheral edge portions of the first and second facing
sheets.
[0010] A method for concealing a grid support member of a ceiling system is
provided. The
method includes the steps of: providing a first longitudinally-extending grid
support member
and a second longitudinally-extending grid support member spaced apart from
the first grid
support member, each of the first and second grid support members including a
substantially
horizontal flange defining an upward facing top surface and a downward facing
bottom
surface; positioning a first ceiling panel on the top surfaces of the first
and second grid
support members, the first ceiling panel spanning between the first and second
grid support
members; and attaching a first facing sheet to the bottom surfaces of the
first and second grid
support members, the first facing sheet spanning between and supported by the
first and
second grid support members; wherein the first facing sheet at least partially
conceals the
bottom surfaces of the first and second grid support members.
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[0011] The method may further include: attaching a peripheral edge portion of
a second
facing sheet to the bottom surface of the first grid support member; and
positioning a linear
peripheral edge of the second facing sheet adjacent and proximate to the
linear edge of the
first facing sheet to form a substantially uniform narrow seam, wherein the
first and second
facing sheets conceal a majority of the bottom surface of the first grid
support member.
[0012] The method may further include: attaching a peripheral edge portion of
a second
facing sheet to the bottom surface of the first grid support member; and
positioning a linear
peripheral edge of the second facing sheet adjacent and proximate to the
linear edge of the
first facing sheet to form a substantially uniform narrow seam, wherein the
first and second
facing sheets conceal a majority of the bottom surface of the first grid
support member.
[0013] In one embodiment, a facing sheet for concealing a grid support of a
ceiling system
includes: a substantially flat body having a rectilinear shape and four
corners; a pair of first
and second spacers; the first spacer attached to the facing sheet at a first
corner on a first
peripheral side of the facing sheet; the second spacer attached to the facing
sheet at a second
corner on the first peripheral side of the facing sheet; and a resiliently
deformable tensioning
rod having a first end coupled to the first spacer and a second end coupled to
the second
spacer, the tensioning rod being at least partially deflected to force the
first and second
corners apart and draw the facing sheet taut between the first and second
comers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] 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:
[0015] FIG. 1 is a side elevation cross-sectional view of a ceiling system
according to a first
embodiment comprising grid support members and ceiling panels;
[0016] FIG. 2 is an enlarged side elevation cross-sectional view of a
peripheral side or end
portion of the ceiling panel;
[0017] FIG. 3 is a transverse cross-section of the ceiling panel taken along
line 3-3 in FIG. 2
and showing one embodiment of a core structure of the ceiling panel;
[0018] FIG. 4 is an enlarged front elevation cross-sectional view of the grid
support member;
[0019] FIG. 5 is a cross-sectional bottom perspective view thereof;
[0020] FIGS. 6-9 show front elevation cross-sectional views of a grid support
member and
ceiling panels illustrating sequential steps in a method for installing the
ceiling system of
FIG. 1 to conceal the grid support member;
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[0021] FIG. 10 is a side elevation cross-sectional view of the ceiling system
showing an
alternative construction of the ceiling panel;
[0022] FIG. 11 is a side elevation cross-sectional view of a ceiling system
accordingly to a
second embodiment comprising grid support members and ceiling panels;
[0023] FIG. 12 is an enlarged view from FIG. 11;
[0024] FIG. 13 is a transverse cross-section of the ceiling panel showing one
embodiment of
a core structure of the ceiling panel;
[0025] FIG. 14 is a cross-sectional bottom perspective view of the grid
support member;
[0026] FIG. 15 is a top plan view of a bottom facing sheet with tensioning rod
system;
[0027] FIG. 16 is a side elevation cross-sectional view of a second embodiment
of a ceiling
system having alternating height facings;
[0028] FIG. 17 is an enlarged view from FIG. 16;
[0029] FIG. 18 is a side elevation cross-sectional view of a third embodiment
of a ceiling
system showing an alternative construction of the ceiling panel; and
[0030] FIG. 19 is a side elevation cross-sectional view of a fourth embodiment
of a ceiling
system showing an alternative construction of the ceiling panel including a
spacer panel.
[0031] 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
[0032] 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.
[0033] 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
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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.
Direct Mount Facing System
[0034] FIG. 1 depicts an exemplary embodiment of a first embodiment of a
ceiling system
100 with a first embodiment of a facing system according to the present
disclosure. The
ceiling system 100 includes an overhead support grid 200 including a plurality
of overhead
longitudinal grid support members 202 and ceiling panels 300 supported by the
grid support
members. The grid support members 202 are mountable in a suspended manner from
an
overhead building support structure.
[0035] Referring to FIGS. 1, 4, and 5, grid support members 202 are 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
members 202 may form "runners" or "rails" and are laterally spaced apart and
oriented
parallel to each other as shown in FIG. 1 to position a ceiling panel 300
therebetween. In
some embodiments, the longitudinal grid support members 202 may 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 members
202 at
appropriate intervals using any suitable permanent or detachable manner of
coupling.
[0036] In one embodiment, grid support members 202 may be horizontally
oriented when
installed. It will be appreciated, however, that other suitable mounted
orientations of grid
support members 202 such as angled or sloped (i.e. between 0 and 90 degrees to
horizontal)
may be used. Accordingly, although support members 202 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.
[0037] With continuing reference to FIGS. 1, 4, and 5, grid support members
202 may 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 members 202 may 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.
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[0038] Grid support members 202 may each include a longitudinally-extending
horizontal
bottom flange 210, an enlarged top stiffening channel 220, and a vertical web
212 extending
upwards from the flange to the stiffening channel. In some embodiments, the
top stiffening
channel 220 may be omitted. The grid support members 202 each define a
respective
longitudinal axis LA and axial directions. Bottom flange 210 has opposing
portions which
extend laterally outwards from web 212 and terminate in opposed longitudinally
extending
edges 214. Web 212 may be centered between the edges 214 and vertically
aligned with the
centerline CL1 of the grid support member in one non-limiting embodiment. In
other
embodiments, the web 212 may be laterally offset from centerline CL1. Bottom
flange 210
further defines a bottom surface 206 facing downwards away from the flange and
towards a
room or space below the support grid 200. Bottom surface 206 defines a
horizontal ceiling
reference plane for the overhead support grid 200. Flange 210 further defines
a top surface
216 for positioning and supporting the ceiling panel 300 thereon.
[0039] Grid support members 202 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 one embodiment, the
grid support
members 202 may be a standard heavy duty 15/16 inch aluminum T-rail.
[0040] Referring now FIGS. 1-3, ceiling panel 300 may have a generally
flattened body with
a substantially greater horizontal width and length than vertical thickness as
shown. Ceiling
panel 300 includes a top surface 302, bottom surface 304, and lateral sides
306 extending
therebetween along four sides of the panel. Sides 306 define peripheral
surfaces which may
be oriented substantially parallel to the vertical centerline CL2 of the
ceiling panel 300. In
some embodiments, the peripheral surfaces may be angled or sloped, or have a
stepped edge
profile or configuration. Top and bottom surfaces 302, 304 may be generally
planar and
arranged substantially parallel to each other in one non-limiting embodiment.
[0041] Ceiling panels 300 may 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 panels 300
may have any
suitable dimensions and shapes (in top plan view) including without limitation
square or
rectangular.
[0042] In one embodiment, ceiling panels 300 may have an inner core 301
comprising a
honeycomb structure formed from a plurality of interconnected cell walls 308
that define a
plurality of open cells 310 (best shown in FIG. 3). The cell walls 308 are
oriented
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perpendicular to the top and bottom surfaces 302, 304 of the ceiling panels
300 and extend
vertically between the top and bottom surfaces. Any suitable shape of cells
310 (in top plan
view) may be used, including hexagon, triangular, square, circular, etc. as
some non-limiting
examples.
[0043] In one embodiment, the core 301 may be formed by paper cell walls 308.
Paper used
to construct cell walls 308 may be at least 20 pound haft paper, and in some
embodiments 20
to 80 pound haft 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.
[0044] With continuing reference to FIGS. 1-3, ceiling panel 300 further
includes a top
facing sheet 320 and bottom facing sheet 330. The facing sheets 320, 330 may
be directly or
indirectly coupled to the core 310 thereby forming part of the ceiling panel
structure. The
facing sheets 320, 330 may be permanently bonded to core 301 using a suitable
industrial
adhesive 35 which is applied to the exposed upper and lower edges of the core
cell walls 308,
thereby closing the upper and lower ends of the cells 310. Industrial
adhesives which may be
used include Swift tak from H.B. Fuller Company and others. The combination of
core 301
and the top and bottom facing sheets 320, 330 collectively form a relatively
rigid composite
structure which resists sagging when installed in the support grid 200.
[0045] In some embodiments, the bottom facing layer 330 may 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 sheets 320, 330 and are available from suppliers such as Owens Corning,
Lyda11,
Ahlstrom and Johns Manville. Such materials may include films, sheets, woven
materials
and open cell foamed materials are all suitable
[0046] Ceiling panel 300 may further include a spacer panel 325 in some
embodiments as
shown in FIGS. 1 and 2. Bottom facing sheet 330 is permanently attached to the
spacer panel
325, which in turn is permanently attached to the bottom of ceiling panel 300.
In some
embodiments, the attachment may be made via a suitable industrial adhesive
(e.g. Swift tak
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adhesive from H.B. Fuller Company and others). Spacer panel 325 may 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 core 301 and
bottom surface
206 of grid support member 202, as best shown in FIG. 1 (which substantially
equates to the
thickness of the flange 210). This locates the bottom facing sheet 330 in a
vertical position
that is substantially flush with the bottom surface 206 on the grid support
member bottom
flange 210. Spacer panel 325 has a horizontal width dimensioned to fit and
extend between
opposed edges 214 of a pair of grid support members 300 (see, e.g. FIG. 1).
When a ceiling
panel 300 having a honeycomb core 301 is used, the spacer panel 325 may
provide a
convenient and cost-effective means to fill the gap between the grid support
member flanges
210 rather 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.
[0047] In alternative embodiments as shown in FIG. 10, the ceiling panel 300
however may
have a sufficient vertical thickness between the sides 306 and an integral
stepped side edge
profile or configuration (in transverse cross section) so that the bottom
facing sheet 330 is in
a vertical position that is substantially flush with the bottom surface 206 on
the grid support
member bottom flange 210 without the need for a spacer panel 325. This
construction may
be convenient particularly with non-honeycomb core ceiling panels.
[0048] Either construction of FIGS. 1 or 10 essentially forms a tegular
ceiling panel 300
having a stepped side edge profile (see also FIG. 2) so that the ceiling panel
may be seated on
and supported by the top surface 216 of the grid support member's bottom
flange 210. This
stepped edge profile also helps to properly horizontally position and secure
the ceiling panels
300 between the grid support members 202.
[0049] Referring to FIGS. 1 and 2, the bottom facing sheet 330 in one
embodiment has an
extension that projects or extends laterally in a horizontal direction beyond
the sides 306 of
the ceiling panel 300 by a distance Dl. Accordingly, bottom facing sheet 330
has a
horizontal width that is larger than the horizontal width of the ceiling panel
core 301
measured between opposite lateral sides 306. This creates free or cantilevered
peripheral
edge portions 332 that allow the bottom facing sheet 330 to extend underneath
and at least
partially across the face or bottom surface 206 of the grid support member 202
for concealing
the support grid, as further described herein. A peripheral slot 322 is formed
between the
ceiling panel core 301 and bottom facing sheet 310 that extends horizontally
along at least
two sides 306 of the ceiling panel as shown in FIG. 1. The slot 322 allows
insertion of the
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grid support member bottom flange 210 therein when mounting the ceiling panel
300 to the
grid support members 202.
[0050] In one embodiment with reference to FIGS. 4 and 5, a linear cutting
guide groove 250
is provided to facilitate neatly trimming adjacent bottom facing sheets 330 of
two ceiling
panels 300 to conceal the grid support member 202 from building occupants for
creating a
monolithic ceiling appearance. Groove 250 is formed in bottom surface 206 of
the grid
support member 202. The groove 250 extends linearly in an axial direction
along and parallel
to the longitudinal axis of the grid support member 202. In one embodiment,
the groove 250
may be vertically aligned with the web 212 and centerline CL1 of the grid
support member
202, thereby centering the groove between the longitudinally extending edges
214 of flange
210. The cutting guide groove 250 has a depth which is less than the vertical
thickness of the
grid support member flange 210. The depth need only be sufficient to engage a
cutting tool
which may be slid along the length of the groove 250 for trimming the facings
330, as further
described herein.
[0051] A method for concealing a grid support member 202 of a ceiling system
100 will now
be described. FIGS. 6-9 illustrate sequential steps in the process.
[0052] Referring to FIG. 6, a grid support member 202 is provided which may be
hung from
an overhead ceiling support structure. The grid support member 202 includes
cutting guide
groove 250 formed in the downward facing bottom surface 206 as described
herein. For
securing the bottom facing sheet 330 to the grid support member 202, a pair of
longitudinally-extending adhesive strips 240 may be provided on the bottom
surface 206 of
the grid support member. The strips 240 extend axially along and parallel to
the longitudinal
axis of the grid support member 202. The adhesive strips 240 may have a length
that extends
for substantially the entire portion of the grid support member to which the
bottom facing
sheets 330 will come into contact when the ceiling panel 300 is mounted. In
one
embodiment, a continuous length of adhesive strip 240 may be used for this
purpose. In
alternative embodiments, however, intermittent gaps may be formed between
multiple pieces
of adhesive strips 240.
[0053] The adhesive strips 240 are placed laterally adjacent and proximate to
the cutting
guide groove 250 on both sides to form a neat seam between peripheral edges
334 of
adjacent bottom facing sheets 330 beneath the grid support member 202. 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 sheet
330. In some
embodiments, a releasable type adhesive may be used to allow the ceiling
panels 300 and
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facing sheets to be cleanly removed and replaced if temporary access is needed
to utilities
above the ceiling system 100. In alternative embodiments, a spray adhesive may
be used
instead which is applied to the bottom surface 206 of the grid support member
202 to 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 member 202 and the other piece is attached to the upper surface
of the peripheral
edge portion 332 of the ceiling panel bottom facing sheet 330. 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.
[0054] Referring to FIG. 7, a first ceiling panel 300 (e.g. the right panel
shown in dashed
lines for clarity) is installed on one side of the grid support member 202.
The peripheral edge
portion 332 of the bottom facing sheet 330 is laterally inserted and
positioned beneath the
bottom surface 206 of the bottom flange 210 by a sufficient distance that
extends across and
over the cutting guide groove 250. This locates the peripheral edge 334
defined by the
peripheral edge portion 332 of the bottom facing sheet 330 on the opposite
(e.g. left) side of
the cutting guide groove 250. The free or cantilevered peripheral edge portion
332 provides
sufficient flexibility to allow the bottom facing sheet 330 to deflect
slightly to accomplish this
placement. During the placement, the peripheral edge portion 332 may be
pressed upwards
against the exposed tacky side of the near side adhesive strip 240 for
attachment after the
edge portion is properly positioned.
[0055] In a similar manner, a second ceiling panel 300 (e.g. the left panel
shown in dashed
lines for clarity) is next installed on the opposite side of the grid support
member 202. The
peripheral edge portion 332 of the bottom facing sheet 330 is laterally
inserted and positioned
beneath the bottom surface 206 of the bottom flange 210 by a sufficient
distance that extends
across and over the cutting guide groove 250. This locates the peripheral edge
334 of the
bottom facing sheet 330 of the second ceiling panel 300 on the opposite side
(e.g. right) of
the cutting guide groove 250. The peripheral edge portion 334 of the second
ceiling panel
preferably overlaps the peripheral edge portion 334 of the first ceiling panel
300 by a distance
D2 (see FIG. 7).
[0056] The next step in the ceiling panel installation process to conceal the
grid support
member 202 is cutting and trimming the overlapped peripheral edges portions of
the first and
second ceiling panels 300 using the cutting guide groove 250 to form a tight
and neat seam
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therebetween. Referring to FIG. 8, a cutting tool such as a razor knife may be
used for
trimming the overlapping bottom facing sheets 330. The tip of the blade 252
may be first
placed at least partially into the groove 250 near one end of the overlapped
peripheral edge
portions 332 at a first axial position. The blade 252 may then be run or slid
along the length
of the cutting guide groove 250 and longitudinal axis LA to a second spaced
apart axial
position towards the opposite end of the overlapped bottom facings peripheral
edge portions
332. Using the cutting guide groove, a straight linear cut through the edge
portions 332 can
be made, thereby trimming or cutting the overlapped peripheral edge portions
332 off to form
a straight seam therebetween as shown in FIG. 9. The peripheral edge portion
332 of the
second ceiling panel 300 may then be pressed firmly upwards against the
remaining adhesive
strip 240 to complete the installation. The peripheral edge portions 332 of
the first and
second ceiling panels 300 are now each adhesively bonded to the bottom surface
206 of the
grid support member 202. Advantageously, the combination of straight-cut
adjoining bottom
facing edges 334 between adjacent ceiling panels 300 and adhesive bonding of
their
respective bottom facing sheets to the grid support member 202 contribute to
creating a neat,
tight abutment seam.
[0057] It will be appreciated that numerous variations in the foregoing
ceiling panel
installation process and sequence are possible.
Suspended Mount Facing System
[0058] FIGS. 11 and 12 depict an exemplary embodiment of a ceiling system 1100
according
to the present disclosure. The ceiling system 1100 generally includes an
overhead support
grid 1200 including a plurality of overhead longitudinal grid support members
1202, ceiling
panels 1300 supported by the grid support members, and bottom facing sheets
1330. The
bottom facing sheets 1330 are separate components and may be supported from
the grid
support member independently of the ceiling panels 1300.
[0059] Referring to FIGS. 11, 12, and 14, the grid support members 1202 are
mountable in a
suspended manner from an overhead building support structure. Grid support
members 1202
are 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 members 1202 may form "runners" or "rails" and are laterally
spaced apart
and oriented parallel to each other as shown in FIG. 11 to position a ceiling
panel 1300
therebetween. In some embodiments, the longitudinal grid support members 1202
may 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
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members 1202 at appropriate intervals using any suitable permanent or
detachable manner of
coupling.
[0060] In one embodiment, grid support members 1202 may be horizontally
oriented when
installed. It will be appreciated, however, that other suitable mounted
orientations of grid
support members 1202 such as angled or sloped (i.e. between 0 and 90 degrees
to horizontal)
may be used. Accordingly, although support members 1202 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.
[0061] With continuing reference to FIGS. 11, 12, and 14, grid support members
1202 may
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 members 1202 may 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.
[0062] Grid support members 1202 may each include a longitudinally-extending
horizontal
bottom flange 1210, an enlarged top stiffening channel 1220, and a vertical
web 1212
extending upwards from the flange to the stiffening channel. In some
embodiments, the top
stiffening channel 1220 may be omitted. The grid support members 1202 each
define a
respective longitudinal axis LA and axial directions. Bottom flange 1210 has
opposing
portions which extend laterally outwards from web 1212 and terminate in
opposed
longitudinally extending edges 1214. Web 1212 may be centered between the
edges 1214
and vertically aligned with the centerline CLI of the grid support member in
one non-limiting
embodiment. In other embodiments, the web 1212 may be laterally offset from
centerline
CLI. Bottom flange 1210 further defines a bottom surface 1206 facing downwards
away
from the flange and towards a room or space below the support grid 1200.
Bottom surface
1206 defines a horizontal ceiling reference plane for the overhead support
grid 1200. Flange
1210 further defines a top surface 1216 for positioning and supporting the
ceiling panel 1300
thereon.
[0063] Grid support members 1202 may be made of any suitable metallic or non-
metallic
materials structured to support the dead weight or load of ceiling panels 1300
without 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
members 1202 may be a standard heavy duty 15/16 inch aluminum T-rail.
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[0064] Referring now FIGS. 11-13, ceiling panel 1300 may have a generally
flattened body
with a substantially greater horizontal width and length than vertical
thickness as shown.
Ceiling panel 1300 includes a top surface 1302, bottom surface 1304, and
lateral sides 1306
extending therebetween along four sides of the panel. Sides 1306 define
outward facing
peripheral surfaces which may be oriented substantially parallel to the
vertical centerline CL2
of the ceiling panel 1300. In some embodiments, the peripheral surfaces may be
angled or
sloped, or have a stepped (tegular) edge profile or configuration. Top and
bottom surfaces
1302, 1304 may be generally planar and arranged substantially parallel to each
other in one
non-limiting embodiment.
[0065] Ceiling panels 1300 may be constructed of any suitable material
including without
limitation mineral fiber board, fiberglass, jute fiber, metals, polymers,
wood, composites,
resin impregnated haft paper, or other. In addition, the ceiling panels 1300
may have any
suitable dimensions and shapes (in top plan view) including without limitation
square or
rectangular.
[0066] In one embodiment, ceiling panels 1300 may have an inner core 1301
comprising a
honeycomb structure formed from a plurality of interconnected cell walls 1308
that define a
plurality of open cells 1310 (best shown in FIG. 13). The cell walls 1308 are
oriented
perpendicular to the top and bottom surfaces 1302, 1304 of the ceiling panels
1300 and
extend vertically between the top and bottom surfaces. Any suitable shape of
cells 1310 (in
top plan view) may be used, including hexagon, triangular, square, circular,
etc. as some non-
limiting examples.
[0067] In one embodiment, the core 1301 may be formed by paper cell walls
1308. Paper
used to construct cell walls 1308 may be at least 20 pound haft paper, and in
some
embodiments 20 to 80 pound haft 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.
[0068] With continuing reference to FIGS. 11-13, ceiling panel 1300 may
further include a
top facing sheet 1320. The facing sheet 1320 may be directly or indirectly
coupled to the
core 1310 thereby forming part of the ceiling panel structure. The facing
sheet 1320may be
permanently bonded to core 1301 using a suitable industrial adhesive 35 which
is applied to
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the exposed upper edges of the core cell walls 1308, thereby closing the upper
ends of the
cells 1310. Industrial adhesives which may be used include Swift tak from H.B.
Fuller
Company and others. The combination of core 1301 and the top facing sheet 1320
collectively form a relatively rigid composite structure which resists sagging
when installed
in the support grid 1200.
[0069] Ceiling panel 1300 may further include a spacer panel 1325 in some
embodiments as
shown in FIG. 19. Spacer panel 1325 may be permanently attached to the bottom
of ceiling
panel 1300. 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
panel 1325
may 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
core 1301 and bottom surface 1206 of grid support member 1202 (which
substantially
equates to the thickness of the flange 1210). This locates the bottom facing
sheet 1330 in a
vertical position that is substantially flush with the bottom surface 1206 on
the grid support
member bottom flange 1210. Spacer panel 1325 has a horizontal width
dimensioned to fit
and extend between opposed edges 1214 of a pair of grid support members 1300.
When a
ceiling panel 1300 having a honeycomb core 1301 is used, the spacer panel 1325
may
provide a convenient and cost-effective means to fill the gap between the grid
support
member flanges 1210 rather than cutting of the open-celled honeycomb core to
form a
stepped side edge profile at the sides of the ceiling panel. In addition, the
spacer panel 1325
structurally reinforces the ceiling panel 1300 providing additional rigidity
to the composite
construction.
[0070] In alternative embodiments as shown in FIG. 18, the ceiling panel 1300
may have a
sufficient vertical thickness between the sides 1306 and an integral stepped
or tegular side
edge profile or configuration (in transverse cross section) so that the bottom
facing sheet
1330 contacts, but is not necessarily attached to the ceiling panel. In some
embodiments, the
bottom facing sheet 1330 may be attached to the bottom 1304 of the ceiling
panel.
[0071] Either construction of FIGS. 11 or 18 essentially forms a tegular
ceiling panel 1300
having a stepped side edge profile (see also FIG. 12) so that the ceiling
panel may be seated
on and supported by the top surface 1216 of the grid support member's bottom
flange 1210.
This stepped edge profile also helps to properly horizontally position and
secure the ceiling
panels 1300 between the grid support members 1202.
[0072] FIG. 15 is a top plan view of a bottom facing sheet 1330, which is not
part of the
ceiling panel 1300, but rather is a separate discrete component not attached
directly thereto in
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one embodiment. When supported solely from the grid support member 1202 as
further
described herein therefore, a vertical gap G may be formed between the bottom
surface 1304
of the ceiling panel 1300 and the bottom facing sheet 1330 as shown in FIGS.
11 and 12.
[0073] Bottom facing sheets 1330 are formed of a thin, substantially flat
material with a
transverse thickness substantially less than the width or length of the sheet.
In some
representative non-limiting embodiments, bottom facing sheets 1330 may have a
thickness
ranging from 0.05 mm to 25 mm or more such as with polymeric non-woven
materials.
[0074] Bottom facing sheets 1330 may be made of any suitable material of rigid
or semi-rigid
construction sufficient to remain relatively flat without undue deflection
when mounted
between a pair of spaced apart grid support members 1202 (see, e.g. FIG. 11).
In some
embodiments, facing sheets 1330 may be made of a non-woven material which
optionally
may be treated such as with a porous coating to reduce reverberated sound. Non-
wovens
including open cell foams may include small cavities to attenuate sound.
Bottom facing
sheet 1330 may be site painted in the field or pre-painted in various
embodiments.
[0075] Representative but non-limiting examples of facing materials that may
be used
include non-woven veils or scrim (e.g. fiberglass or polymeric), perforated
films or sheets,
open cell foamed panels, woven fabrics, and wet or dry laid built up fibrous
panels. These
materials can offer sufficient opaqueness and flatness for a uniform and
acceptable
appearance.
[0076] In some embodiment, bottom facing sheet 1330 may have a rectilinear
shape as
shown in FIG. 15, such as without limitation square or rectangular. In those
examples, each
bottom facing sheet 1330 includes four corners 1331 and linear peripheral edge
portions 1332
extending around the perimeter of the sheet that defines corresponding
peripheral edges 1334.
Other suitable shapes of bottom facing sheets 1330 may be provided depending
on the pattern
or layout of the grid support members 1202 from which the sheets 1330 are
mounted and
supported.
[0077] Although FIG. 15 shows bottom facing sheet 1330 in a discrete panel or
tile-like form
with predetermined fixed width and length, it will be appreciated that in
other embodiments a
roll of material may instead be used having a fixed width but variable
longitudinal length
which can be cut in the field to suit the specific installation requirements.
[0078] Depending on the material selected for bottom facing sheet 1330, the
sheet may have
tendency to unduly sag or deflect in the unsupported span between the grid
supports members
1202 (see, e.g. FIG. 11) because the sheet is supported at only the peripheral
edge portions
1332. To help maintain and enhance the flatness of the bottom facing sheet
1300 in some
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embodiments where the material used may have some degree of flexibility and
tendency to
sag, tensioning rods 1360 may optionally be provided as shown in FIG. 15.
[0079] Referring to FIG. 15, the opposite ends 1362 of each tensioning rods
1360 may be
attached between adjacent (i.e. non-diagonal) corners 1331 of the bottom
facing sheet 1330.
The tensioning rods 1360 may be formed of a suitable resiliently deformable
metal having
material properties which create an elastic memory. In one exemplary
embodiment, the
tensioning rods 1360 may be made of spring steel. The rods 1360 may have wire-
like
structure in one embodiment with a modicum of stiffness, but sufficient
flexibility to allow
the rods to be elastically deformed. This allows the rods 1360 to act as
spring members
creating opposing forces F that bias adjacent comers 1331 of the bottom facing
sheet 1330
apart in opposite directions (see force arrows in FIG. 15 corresponding to
said directions).
Tensioning rods 1360 are shown in an elastically deformed and deflected
condition in which
the rods may assume an arcuately curved shape in top plan view.
[0080] The tensioning rods 1360 may be attached to the corners 1331 of bottom
facing sheet
1330 via any suitable mounting element 1350 configured to capture the ends
1362 of the
rods. In one non-limiting embodiment, the mounting element 1350 may be spacer
1120
which also functions to space the bottom facing sheet 1330 vertically apart
from the bottom
surface 1206 of grid support member 1202 by a distance D2 (see also FIGS. 11
and 12). In
one embodiment, the spacers 1120 may have laterally facing sockets which are
configured
and arranged to receive the ends 1362 of the tensioning rods 1360 as shown in
FIG. 15.
[0081] In the undeformed condition, the tension rods 1360 may have a generally
straight
shape in the unassembled deactivated condition. To assemble the rods 1360 to
the spacers
1120, one end of the rod may first be engaged with a first spacer on one comer
1331 of
bottom facing sheet 1330. The tension rod 1360 may then be slightly
bent/deflected to allow
the second end of the rod to be engaged with a second spacer 1120 in an
adjacent comer 1331
(see FIG. 15). This deformation activates the elastic spring properties of the
tensioning rod
1360 which now assumes the arcuately curved shape shown. Preferably, the
length L of the
tensioning rods 1360 is larger than the distance D3 between the adjacent
spacers 1120 in
order activate the biasing force of the rods.
[0082] It will be appreciated that other suitable cross-sectional shapes of
tensioning rods
1360 other than circular may be used, including without limitation square or
rectangular
strap-like shapes. In addition, other arrangements and attachment of the
tensioning rods 1360
to the corners of the bottom facing sheet 1330 are possible.
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[0083] Coupling of bottom facing sheets 1330 to adjacent spaced apart grid
support members
1202 will now be further described. Referring initially to FIGS. 11 and 12,
the bottom facing
sheets 1330 in one embodiment each span between the grid bottom facing sheet
1330 and
may be coupled only to the grid support members for support. Accordingly, the
bottom
facing sheets 1330 are structurally discrete elements supported by the grid
independently of
the ceiling panels also mounted thereon.
[0084] Each bottom facing sheet 1330 may be directly or indirectly coupled to
the grid
support members 1202 via an intermediate structure. An indirect coupling
arrangement will
first be described with continuing reference to FIGS. 11 and 12. For securing
the bottom
facing sheet 1330 to the grid support member 1202, a coupling mechanism is
provided which
is disposed between the bottom surface 1206 of the grid support member and
peripheral edge
portion 1332 of the facing sheet. The coupling mechanism may include a spacer
1120 and
fastening elements 1120 which attach the spacer in turn to both the bottom
facing sheet 1330
and bottom surface 1206 of the grid support member 1202 via fastening elements
1130. Any
suitable fastening element 1130 may be used. In one embodiment, the fastening
elements
1130 may be adhesives such as spray or liquid adhesives (such as those
described herein or
other), or double-sided adhesive tape of suitable shape and dimensions. In
other
embodiments, the fastening elements(s) 1130 may be hook and loop closures such
as
Velcro . In yet other possible embodiments, the fastening elements 1130 may be
magnetic
such as without limitation magnetic strips. In the latter embodiment, the
spacer 1120 may
itself be a magnet which is attached to the top surface of the bottom facing
sheet 1330 via a
fastening element 1130 at the bottom end and coupled directly to a ferritic
grid support
member 1202 at the top end via magnetic force without a separate fastening
element. It will
be appreciated that various combinations of the foregoing adhesive, magnetic,
or hook and
loop fastening elements 1130 may be used together in some embodiments where
top and
bottom fastening elements are required for mounting the spacer 1120 and bottom
facing sheet
1330. Various types of fastening elements 1130 other than the foregoing non-
limiting
examples may alternatively be used.
[0085] As noted above and shown in FIGS 11 and 12, the spacers 1120 of the
coupling
mechanism function to space the bottom facing sheet 1330 vertically apart from
the bottom
surface 1206 of grid support member 1202 by a distance D2. In some embodiment,
the
spacers 1120 may have a height making D2 greater than the thicknesses of the
bottom facing
sheet 1330 and/or bottom flange 1210 of the grid support members 1202,
alternatively greater
than twice or three times the thicknesses of the facing sheet and/or bottom
flange. The
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spacers 1120 also distance the bottom facing sheet 1330 from the bottom
surface of the
ceiling panel 1300 as shown.
[0086] The spacers 1120 may have any suitable configuration. In some
embodiments, the
spacers 1120 may be round in top plan view as depicted for example in FIG. 15
showing dual
purpose mounting elements 1350 which may also be spacers 1120. In other
configurations,
the spacers 1120 may have polygonal or rectilinear shapes of any suitable size
and length.
[0087] Any suitable number of spacers 1120 may be provided to support the
bottom facing
sheets 1330 by the peripheral edge portions 1332 without undue sagging or
deflection
therebetween to maintain tautness and relative flatness of the sheets. In the
embodiment
shown in FIG. 15 for example, four spacers 1120 disposed at the comers of a
sheet or tile-like
bottom facing sheet 1330 may be provided. In embodiments where the bottom
facing sheet
1330 may be provided in a roll of material for field cutting, more than four
spacers 1120 may
be provided as needed to maintain tautness of the facing sheet along the
length of the grid
support members 1202.
[0088] Spacers 1120 may be formed of any suitable material, including for
example without
limitation metallic, polymeric, magnetic, foamed, and single or multiple
layers of non-woven
materials. In some embodiments, the spacers 1120 may be a mechanical clip or
part of the
fastener.
[0089] FIGS. 11 and 12 depict a first embodiment of a ceiling system 1100
formed using
spacers 1120. In this arrangement, the mating peripheral edges 1334 of the two
adjacent
bottom facing sheets 1330 lie approximately in the same horizontal plane
(accounting for
installation variances/tolerances). The two adjacent edges 1334 are
substantially flush in a
horizontal plane and distanced substantially uniformly by distance D2 with
respect to the
horizontal bottom surface 1206 of the grid support member 1202. A relatively
tight (close)
seam or joint may be formed between the mating peripheral edges 1334 with any
visible gap
being left as is, filled with caulking and/or painted over as desired. In
other possible
embodiment, a wider gap may intentionally be formed at the joint between the
peripheral
edges if desired for specific visual effects.
[0090] FIGS. 16 and 17 depict a second embodiment of a ceiling system 1100. In
this
embodiment, one bottom facing sheet 1330 is indirectly coupled to a grid
support member
1202 using spacers 1120 while the adjacent second bottom facing sheet 1330 is
directly
coupled attached to the same grid support member using a single fastening
element 1130.
This vertically offsets the two adjacent peripheral edges 1334 of the bottom
facing sheets
1,330 beneath the flange bottom surface 1206 of the grid support member 1202
by a distance
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Dl. This creates a different stepped visual appearance of the joint or seam
formed between
the two adjacent bottom facing sheets 1330 than the substantially flush bottom
facing sheets
shown in FIGS. 11 and 12. The discontinuous or different heights of the bottom
facing sheets
1330 may aid in concealing alignment, installation, or other squareness or
lapping issues.
Any of the foregoing types of fastening elements 1130 described above or
others may be used
to directly couple the bottom facing sheet 1330 lying substantially flush with
the bottom
surface 1206 of the grid support member 1202 (left side) to the grid support
member.
[0091] A method for concealing a grid support member 1202 of a ceiling system
1100 will
now be described with initial reference to FIGS. 11 and 12.
[0092] A first and second grid support member 1202 are provided and hung from
an
overhead ceiling support structure in the arrangement shown in FIG. 11. The
grid support
members 1202 are horizontally spaced apart. The bottom flanges 1210
substantially lie in a
common horizontal plane.
[0093] A first ceiling panel 1300 is positioned on the top surfaces 1216 of
bottom flanges
1210 of the first and second grid support members 1202, as further shown in
FIG. 12 in
greater detail. The peripheral edge portions of the ceiling panel adjacent the
lateral sides
1306 are seated atop the flanges 1210. The ceiling panel 1300 spans between
the first and
second grid support members 1202 and is unsupported between the peripheral
edge portions.
The ceiling panel 1300 may have any of the configurations, construction, and
edge details
disclosed herein or others.
[0094] A first bottom facing sheet 1330 is provided ("first facing sheet"
hereafter for
brevity). In the present embodiment being described, the first facing sheet
1330 is configured
as shown in FIG. 15 and includes spacers 1120 conveniently pre-mounted thereon
in the
peripheral edge portions 1332 at the four corners via a fastening element
1130. In other
possible embodiments, the spacers may instead be mounted separately on the
flanges 1210 of
the grid support members 1202 if the precise horizontal spacing between all
the grid support
members 1202 is not known or may vary (e.g. retrofit installations). Either
arrangement is
acceptable.
[0095] Next, the first facing sheet 1330 is attached to the grid support
member 1202.
Assuming the spacers 1120 are pre-mounted on the facing sheet (FIG. 15), the
first facing
sheet 1330 is mounted on the bottom surface 1206 of the first grid support
member 1202
using a fastening element 1130. This mounts the peripheral edge portion 1332
on a first
lateral side of the first facing sheet 1330 to the first grid support member
1202. The
peripheral edge portion 1332 on the opposite lateral side of the first facing
sheet 1330 is also
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mounted on the second grid support member 1202 in a similar manner. The first
spacing
sheet 1330 thus spans between the first and second grid support members 1202
and is
supported from the bottom surface 1206 of the grid support member flange 1210,
independently of the first ceiling panel 1300.
[0096] The linear peripheral edge 1334 of first facing sheet 1330 is
positioned between the
longitudinal edges 1214 of the grid support member 1202, thereby extending at
least partially
across and partially concealing the bottom surface 1206 of the first grid
support member (see
FIG. 12). In one embodiment, the peripheral edge 1334 is positioned
approximately at the
midpoint between the opposing longitudinal edges 1214 of the first grid
support member
1202 and vertically aligned approximately with the vertical web 1212 of the
support. In one
embodiment, approximately 1/2 of the grid support member bottom surface 1206
is
concealed by the first facing sheet 1330. The peripheral edge 1334 and
peripheral edge
portion 1332 of the first facing sheet 1330 is spaced vertically from the
bottom surface 1206
of the first grid support member 1202 by vertical distance D2 by the spacer
1120 disposed
therebetween.
[0097] To fully conceal the first grid support member 1202, a peripheral edge
portion 1332
of a second facing sheet 1330 is attached to the bottom surface 1206 of the
first grid support
member in a similar manner to the first facing sheet 1330 as described above.
The linear
peripheral edge 1334 of the second facing sheet 1330 is positioned adjacent
and proximate to
the linear edge 1334 of the first facing sheet 1330 to form a substantially
uniform narrow
seam. The peripheral edge portion 1332 of second facing sheet 1330 extends
across the
bottom surface 1206 of the first grid support member 1202 with its peripheral
edge 1334
terminating at the mating peripheral edge 1334 of the first facing sheet 1330.
The entire
bottom surface 1206 of the first grid support member 1202 is now completely
concealed by
the peripheral edge portions 1332 of the first and second facing sheets 1330,
except for the
narrow seam or joint formed therebetween which preferably is narrow enough to
not be
visible or can be caulked or painted over to complete the concealment as
needed. A
monolithic ceiling appearance is created.
[0098] It will be appreciated that the same forgoing installation method may
be used for
facing sheet arrangements/layouts with a stepped appearance as shown in FIGS.
16 and 17.
In that embodiment, the only variation is that the second facing sheet 1330
(left one) does not
include a spacer 1120 so that the facing sheet is directly attached to the
bottom surface 1206
of the first grid support member 1202 using a fastening element 1130 as shown.
The first
facing sheet 1330 (right) lies in a horizontal plane different and lower than
the second facing
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sheet (left) 1330 being offset by vertical distance Dl. It should be noted
that the ceiling
system 1100 may use any combination of the foregoing mounting methods using
spacers or
no spacers to raise or lower various sections of the installed ceiling to
create different visual
effects.
[0099] 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.
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