Faced ceiling system

Patent metadata

Field	Value
Publication number	US-9938717-B2
Application number	US-201514661413-A
Country	US
Kind code	B2
Filing date	Mar 18, 2015
Priority date	Mar 18, 2015
Publication date	Apr 10, 2018
Grant date	Apr 10, 2018

Abstract

A ceiling system in one embodiment conceals joints between adjoining ceiling panels to provide a monolithic ceiling appearance. The system includes the support structure and ceiling panels each having a top surface, bottom surface, and peripheral edges. In one embodiment, the peripheral edges of the panels may have a hybrid edge detail including a first edge profile and a second edge profile different than the first. A facing material, bonded to the bottom surfaces of ceiling panels after securement to the support structure, has a continuous uninterrupted extent to cover and conceal multiple panels and joints. The facing may be adhesively bonded to the panels.

First claim

What is claimed is:

1. A faced ceiling system comprising:
a ceiling support structure comprising a T-bar having a bottom flange, the bottom flange including an upward facing top surface that is opposite a downward facing bottom support surface;
a plurality of acoustic ceiling panels each having a width, a length, a top surface facing the ceiling support structure, an opposing bottom surface facing an interior space below the ceiling panels, and a plurality of peripheral edges extending between the top and bottom surfaces, the plurality of peripheral edges comprising:
a first edge having a groove, the first edge comprising a first mounting flange having a top surface opposite a bottom surface and an end surface extending therebetween, the bottom surface of the first mounting flange forming a ceiling of the groove, the end surface extending beyond the bottom surface of the ceiling panel, and the top surface of the ceiling panel comprising the top surface of the first mounting flange and the top surface of the first mounting flange abuttingly engaging and attached to the downward facing bottom surface of the ceiling support structure, and
a second edge opposite the first edge, the second edge having a tongue configured to be inserted into the groove of the first edge;

a plurality of laterally spaced apart joints formed between mating the first and second edges of adjoining ceiling panels;
a facing sheet adhesively bonded to the bottom surfaces of at least two ceiling panels, the facing sheet extending continuously across the bottom surfaces of the at least two ceiling panels to conceal the joint formed therebetween, the facing sheet extending a distance that is larger than a lateral width of the at least two ceiling panels combined; and
a fastener extending between the top and bottom surfaces of the first mounting flange and into the T-bar such that the fastener extends beyond the upward facing top surface of the bottom flange of the T-bar.

2. The ceiling system according to claim 1 , wherein the facing sheet covers at least two joints formed between adjoining ceiling panels.

3. The ceiling system according to claim 1 , wherein the facing sheet covers substantially the entire bottom surfaces of the at least two ceiling panels.

4. The ceiling system according to claim 1 , wherein the facing sheet is formed of a material selected from the group consisting of nonwoven filled material, nonwoven pre-painted material, a fabric, and a perforated material.

5. The system according to claim 1 , wherein the top surface of the first mounting flange is flush and coextensive with the top surface of the ceiling panel.

6. The system according to claim 1 , wherein the first edge of each ceiling panel comprises a second mounting flange having a top surface opposite a bottom surface and an end surface extending therebetween, wherein the top surface of the second mounting flange forms a floor of the groove.

7. The system according to claim 6 , wherein the bottom surface of the second mounting flange is flush and coextensive with the bottom surface of the ceiling panel.

8. The system according to claim 6 , wherein the end surface of the first mounting flange extends beyond the end surface of the second mounting flange.

9. The system according to claim 6 , wherein the groove comprises a stop wall that extends from the bottom surface of the first mounting flange to the top surface of the second mounting flange.

10. The system according to claim 9 , wherein the end surface of both the first and second mounting flanges extend beyond the stop wall of the groove.

11. The system according to claim 1 , wherein the acoustic ceiling panel comprises mineral fiber.

12. The system according to claim 11 , wherein for two adjoining ceiling panels, the tongue of a first ceiling panel conceals the fastener extending through the second ceiling panel.

13. A ceiling system comprising:
a grid support system comprising a plurality of intersecting grid support members, the grid support members each comprising a T-bar having a bottom flange, the bottom flange including an upward facing top surface that is opposite a downward facing bottom support surface;
a plurality of acoustic ceiling panels attached to the downward facing bottom support surfaces of the grid support system, each ceiling panel including a pair of opposed peripheral edges extending between an upper surface and a lower surface, the pair of opposed peripheral edges including a tongue-and-groove portion and a shiplap portion;
a plurality of laterally spaced apart joints formed between mating and interlocking the tongue-and-groove portions of the opposed peripheral edges of adjoining ceiling panels; and
a facing sheet adhesively bonded to the lower bottom surfaces of a plurality of ceiling panels, the facing sheet extending continuously across the bottom surfaces of at
least two ceiling panels to conceal the joint formed therebetween, the facing sheet extending a distance that is larger than a lateral width of the at least two ceiling panels combined,
wherein an airflow resistance as measured from the facing sheet to the upper surface of the ceiling panels is at least 0.5 NRC; and
a fastener extending between the top and bottom surfaces of the first mounting flange and into the T-bar such that the fastener extends beyond the upward facing top surface of the bottom flange of the T-bar.

14. The ceiling system according to claim 13 , wherein the facing sheet is formed of a material selected from the group consisting of nonwoven filled material, nonwoven pre-painted material, a fabric, and a perforated material.

15. The system according to claim 13 , wherein the top surface of the ceiling panel abuttingly engages and attaches to the downward facing bottom support surface of one of the grid support members.

16. The system according to claim 13 , wherein the facing sheet has a thickness in a range from about 10 mils to about 15 mils.

Assignees

• Armstrong World Ind Inc
• Awi Licensing Llc

Inventors

• Gaydos Christopher D
• Springer Brian L
• Shearer Lori Jo L
• Huntzinger Scott L

Classifications

• E04B9/04

  comprising slabs, {panels,} sheets or the like · CPC title

• E04F13/042

  Joint tapes · CPC title

• E04F13/0837

  extending completely through the covering elements · CPC title

• E04F13/0889

  characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections · CPC title

• E04B9/245

  by means of screws, bolts or clamping strips held against the underside of the supporting construction (E04B9/26 takes precedence) · CPC title