AU2007200031A1 - Perimeter panel for forming part of a ceiling - Google Patents

Description

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION NAME OF APPLICANT(S):: Justin Barry Bakes ADDRESS FOR SERVICE: DAVIES COLLISON CAVE Patent Attorneys 255 Elizabeth Street, Sydney, New South Wales, Australia, 2000 INVENTION TITLE: Perimeter panel for forming part of a ceiling The following statement is a full description of this invention, including the best method of performing it known to me/us:- 5102 PERIMETER PANEL FOR FORMING PART OF A CEILING Technical Field [001] The present invention generally relates to a panel able to be used to form part of a ceiling or a wall, and more particularly, to a panel able to be used to form at least part of a perimeter region of a ceiling, for example near a wall section. The present invention also generally relates to a method of installing at least part of a ceiling, for example a perimeter region, using such a panel.

Copyright Notice/Permission [002] A portion of the disclosure of this patent specification contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent specification or parts thereof as it appears in the file or records of a Patent Office, but otherwise reserves all copyrights whatsoever.

Background Art [003] Presently, various types of ceiling panels are known in the art. Different types of ceiling panels can provide sound absorption, decoration, light reflection and other functions. Ceiling panels are provided in various types of materials and sizes and can be fixed to or suspended from a number of suitable ceiling support structures.

[004] Ceiling panels have been fabricated from a variety of materials, for example gypsum-based plasterboard, mineral fibres, fibreglass, metals, etc., or composites or laminates thereof. Gypsum is a hydrated calcium sulphate mineral and occurs in five types being rock gypsum, gypsite, alabaster, satin spar or selenite. Gypsum-based plasterboard ceiling panels, for example those sold under the trade mark Gyprock® by CSR Limited, are a popular type of cost-effective ceiling panel for both residential and commercial markets.

Such ceiling panels can provide acoustic properties in addition to a decorative effect, such as, for example, a white vinyl face finish, a paper faced finish and a textured vinyl surface.

[005] Presently, to install a ceiling using known ceiling panels, difficulties are encountered in providing a satisfactory finish near the ceiling-wall junction or interface.

To obtain a modem-looking finish, it is presently known to use an angled strip of metal which maintains a small gap, for example 10 mm, between the ceiling and the wall. For example, the product known as ShadowlineTM sold by Rondo Building Services Pty Ltd is Sused in this manner. Shadowline is fixed at the perimeter of the ceiling-wall junction or Sinterface. However, in practice, Shadowline, once installed, then requires one or more filling substances or renders to be applied. For example, this may include a flexible gap sealant, sold under the trade mark No More GapsTM by Selleys Pty Ltd, being a white paste, applied to the leading edge of the Shadowline metal strip, which is relatively Sdifficult and time consuming to complete.

[006] In other forms of decoration known for a ceiling-wall interface, a timber trim, cornice or set beads can be attached, typically using a form of adhesive, to the already installed ceiling and wall to cover the ceiling-wall junction or interface.

[007] However, Shadowline strips, trims, cornices and setbeads are all required to be finished (eg. have a finish coating applied or be sanded) or painted after the complete ceiling is installed, or at least after the perimeter of the ceiling has already been installed.

For example, in the case where gypsum-based plasterboard ceiling panels have been used, the Shadowline strips, trims, cornices or setbeads are required to be finished and painted after the plasterboard has been installed, set and sanded. Specifically, Shadowline strips, which is a popular product in today's building market, takes a relatively large amount of time to paint, due to difficulties with the relatively small shadow gap, typically being about mm in width.

[008] Moreover, during installation, Shadowline strips first have to be stapled in place and then set by hand, typically using two coatings of render, plaster or masonry adhesive and a further top coating. The area then has to be sanded by hand, as it is not possible to adequately sand the area using a machine, thereby making the installation relatively expensive and labour intensive.

[009] All currently known ceiling-wall junction or interface finishes, trims or coverings are installed after ceiling panels have been fixed in place. This leaves the installer with the relatively more difficult and generally labour intensive task of producing a satisfactory finish in the ceiling-wall region, or similarly in other cornered or angled regions, such as near a door or window frame or jamb. This difficulty generally necessitates the use of a skilled tradesperson to produce a satisfactory finish.

[010] This identifies a need for a panel and/or a method of installing such which addresses or at least ameliorates problems inherent in the prior art.

[011] The reference in this specification to any prior publication (or information derived from the prior publication), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from the prior publication) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Disclosure Of Invention [012] Ceiling construction and/or installation costs are generally increasing due to increased costs of materials and labour. A panel and/or means of installing the panel to form part of a ceiling or a wall in an economical and efficient manner is desirable.

[013] In an exemplary embodiment, a prefabricated panel is relatively easily fixed or attached to a ceiling support structure. The prefabricated panel is fixed or attached to the ceiling support structure before known standard ceiling panels are fixed or attached to the ceiling support structure. The prefabricated panels provide an easier or simpler means of working with or forming a satisfactory ceiling-wall junction or interface.

[014] According to a first broad form, the present invention provides a panel, including an upper surface and a lower surface, a panel edge formed between the upper surface and the lower surface, and a wall edge formed between the upper surface and the lower surface opposite the panel edge.

[015] In a particular embodiment, the panel is used to form at least part of a perimeter of a ceiling.

[016] According to a further particular embodiment, in use, the panel is fixed adjacent to a wall, after which a ceiling panel is fixed adjacent to the panel.

[017] Preferably, in use, the panel edge is fixed adjacent to a ceiling panel edge of the ceiling panel.

[018] According to a further particular embodiment, in use, the wall edge is fixed adjacent to a surface of the wall.

[019] In a particular, but non-limiting, form, in use, part of the wall edge abuts or approaches the surface of the wall to define a cavity or recess between the panel and the wall.

[020] Optionally, but not necessarily, the wall edge is at least one of: an angled surface; a curved surface; and, a tapered surface.

[021] Also optionally, but not necessarily, the lower surface is provided with one or more lower surface features.

[022] In another particular, but non-limiting, form the panel tapers towards the panel edge.

[023] In yet another particular, but non-limiting, form the panel is prefabricated from one or more materials selected from the group of: gypsum; Gyprock®; wood; MDF timber; plastic; paper; foam; plaster; metal; and composites thereof.

[024] Preferably, the perimeter panel is removably fixed to the ceiling support structure.

[025] Optionally, but not necessarily, the perimeter panel and the ceiling panel are made of Gyprock®, and the ceiling panel edge and the panel edge provide a standard Gyprock® junction able to be set with a setting box and sanded by machine.

[026] According to a second broad form, the present invention provides a method of installing at least part of a ceiling near a wall using a perimeter panel, the perimeter panel including an upper surface and a lower surface, a panel edge formed between the upper surface and the lower surface, and a wall edge formed between the upper surface and the lower surface opposite the panel edge, the method including the steps of: fixing the perimeter panel to a ceiling support structure so that the wall edge is adjacent a surface of the wall; and then, fixing a ceiling panel to the ceiling support structure so that a ceiling panel edge of the ceiling panel is adjacent at least part of the panel edge.

[027] According to a third broad form, the present invention provides a method of installing at least part of a ceiling using two perimeter panels, each of the perimeter panels including an upper surface and a lower surface, a panel edge formed between the upper surface and the lower surface, and a wall edge formed between the upper surface and the lower surface opposite the panel edge, the method including the steps of: fixing a first perimeter panel to a ceiling support structure; fixing a second perimeter panel to the ceiling support structure so that the wall edge of the first perimeter panel is adjacent the wall edge of the second perimeter panel; fixing a first ceiling panel to the ceiling support structure so that a ceiling panel edge of the first ceiling panel is adjacent at least part of the panel edge of the first perimeter panel; and, fixing a second ceiling panel to the ceiling support structure so that a ceiling panel edge of the second ceiling panel is adjacent at least part of the panel edge of the second perimeter panel.

Brief Description Of Figures [028] An example embodiment of the present invention should become apparent from the following description, which is given by way of example only, of a preferred but nonlimiting embodiment, described in connection with the accompanying figures.

[029] Figure 1 illustrates a perspective view looking downwards on part of a ceiling installed using a panel according to an embodiment of the present invention; [030] Figure 2 illustrates cross-sectional views of steps A, B and C showing installation of the panel and an adjacent ceiling panel; [031] Figure 3 illustrates an expanded cross-sectional view of Figure 2C; [032] Figure 4 illustrates a cross-sectional view of part of a ceiling using the panel in conjunction with a stud wall; [033] Figure 5 illustrates an alternate use of the panel when two panels are used adjacent each other near a control joint; [034] Figure 6 illustrates a possible use of panels about a door frame or jamb; [035] Figure 7 illustrates cross-sectional views of various example panels having a variety of surface features; and [036] Figure 8 illustrates cross-sectional views of further various example panels having a variety of surface features.

Modes for Carrying Out The Invention [037] The following modes, given by way of example only, are described in order to provide a more precise understanding of the subject matter of a preferred embodiment or embodiments.

[038] In the figures, incorporated to illustrate features of an example embodiment, like reference numerals are used to identify like parts throughout the figures.

[039] Referring to Fig. 1, there is illustrated a panel 10 including an upper surface 12 and a lower surface 14. Between upper surface 12 and lower surface 14 a panel edge 16 is formed, and a wall edge 18 is formed between upper surface 12 and lower surface 14 opposite panel edge 16.

[040] Preferably, though not necessarily as other uses are possible, panel 10 is a perimeter panel used to form at least part of a perimeter of a ceiling. Part of the ceiling is formed by perimeter panel 10 and a standard ceiling panel 20. In use, perimeter panel is fixed adjacent to a wall 22 as a first step. Then, after perimeter panel 10 is fixed adjacent wall 22, ceiling panel 20 is fixed adjacent perimeter panel [041] Perimeter panel 10 is secured to ceiling joist 24. Perimeter panel 10 could be fixed directly to ceiling joist 24, or as is illustrated in Fig. 1, perimeter panel 10 is fixed to metallic or wood ceiling batten (or rail) 26, which is in turn fixed to ceiling joist 24 via bracket 28. Ceiling joist 24, ceiling batten 26 and bracket 28 define part of a ceiling support structure.

[042] Upper surface 12 of perimeter panel 10 can, in use, a least partially abut the ceiling support structure, for example by contacting ceiling batten 26. Preferably, lower surface 14 of perimeter panel 10, in use, at least partially provides part of the visible ceiling.

[043] After perimeter panel 10 is fixed in place, ceiling panel 20 is fixed adjacent perimeter panel 10 so that a ceiling panel edge 30 of ceiling panel 20 is adjacent, in the vicinity of, or abuts, panel edge 16 of perimeter panel 10. In use, wall edge 20 is fixed adjacent to a surface of wall 22, and preferably, though not necessarily, at least part of wall edge 18 abuts or closely approaches the surface of wall 22 to define a cavity or recess between perimeter panel 10 and wall 22.

[044] Referring to Fig. 2, there is illustrated a series of installation stages A, B and C. In Fig. 2A, only wall 22, ceiling joist 24 and ceiling batten 26 are in place. In Fig. 2B, perimeter panel 10 is fixed to part of the ceiling support structure (ceiling joist 24 and/or ceiling batten 26), so that wall edge 18 abuts, nearly abuts or approaches, surface of wall 22. If a gap is to be left between the closest point of wall edge 18 and the surface of wall 22, this gap can be varied according to specific requirements or intentions of the installer.

It should be appreciated that it is not essential to leave such a gap. Referring to Fig. 2C, ceiling panel 20 is then fixed adjacent perimeter panel 10 so that ceiling panel edge contacts or is in the vicinity of panel edge 16. Plaster 32, or any other suitable material such as other forms of render, adhesive or sealant, can then be applied as one or more coatings over the join region formed by ceiling panel edge 30 and panel edge 16.

[045] Referring to Fig. 3, there is illustrated an expanded view of the region near perimeter panel 10 and wall 22 junction. Wall edge 18 is shown as an angled surface so that a cavity or recess is defined between perimeter panel 10 and wall 22. Wall edge 18 could alternatively be a curved surface or a tapered surface, or at least partially angled, curved or tapered. In another form, wall edge 18 could be stepped so that part of wall edge 18 might be flush with or approach wall 22 while another part of wall edge 18 could define Sa cavity or recess. It should be noted, however, that wall edge 18 need not be angled, Scurved, tapered or stepped. It is possible that wall edge 18 could define a surface that is substantially parallel to a surface of wall 22.

[046] Also illustrated in Fig. 3 are example surface features 34 forming part of lower Ssurface 14 of perimeter panel 10. Surface features 34 can be provided in a wide variety of Stypes, configurations or geometries to produce decorative or stylistic effects.

[047] It is also preferable, though not essential, that perimeter panel 10 generally tapers towards panel edge 16. The degree of tapering can vary and can assist in producing a clean finish after application of plaster coatings 32 or other suitable materials.

[048] Perimeter panel 10 is preferably prefabricated as a gypsum-based plasterboard product. However, perimeter panel 10 could be prefabricated or moulded from a wide variety of materials, for example, gypsum, Gyprock®, wood, MDF timber, plastic, paper, foam, plaster and/or combinations or laminates thereof.

[049] Also preferably, perimeter panel 10 is removably fixed to the ceiling support structure, for example, by screws or the like. By being removably fixed, an installer can see the visual effect of the ceiling perimeter, and if not satisfactory, remove or adjust perimeter panels if desired. This also allows the installer to make any desired adjustments to the level of the ceiling, or part of the ceiling, and the straightness of walls, or part of walls, before the complete ceiling is fixed into place.

[050] Use of panel 10 provides an easier method of installing a ceiling (or section of wall), which could also likely be achieved by a much broader range of persons than prior art devices which typically require a skilled tradesperson for a satisfactory finish. The perimeter panels readily provide a clean finish for the edge of a ceiling against a wide variety of walls, for example, tiles in a bathroom, face brick walls, pre-painted walls, door frames or jambs, window frames or jambs, tops of partition walls against T-lock ceilings, glass walls, bottoms of walls instead of skirting, or stair treads and stair runners.

[051] Importantly, it should be appreciated that although reference to installation of a Sceiling has been made to describe the use of perimeter panels 10, a variety of other Sapplications are possible. For example, as indicated above, perimeter panels 10 may be used as part of a wall, for example, a lower or an upper portion of a decorative finish on a wall to replace traditional skirting. Perimeter panels could also be used in a back-to-back fashion over control joints or other types of joints in a ceiling.

S[052] The cavity or recess defined by wall edge 18 and wall 22 provides a specific N allowance for a filling substance or material to be easily applied against the finished rNleading edge in an efficient manner. For example, the filling substance may be a flexible gap sealant, such as No More Gaps T M sold by Selleys Pty Ltd. A variety of other filling substances could be used.

[053] Preferably, although not necessarily, perimeter panel 10 can be pre-painted, or otherwise provided ready for final display without requiring additional coatings or finishes, before perimeter panel 10 is installed, to thus providing efficiency in painting a ceiling/wall. This also avoids a problem in the prior art in respect of the use of Shadowline strips, for which great care has to be taken in respect of paint in the shadow region or line, typically being a 10 mm shadow.

[054] Furthermore, once perimeter panel 10 and ceiling panel 20 are fixed relative to each other, a standard junction, for example a standard Gyprock® junction if both perimeter panel and ceiling panel are made of Gyprock®, is formed. This is highly beneficial as such a standard junction can be set with setting boxes and sanded by machine to produce a satisfactory coating layer.

[055] Referring to Fig. 4, an application of perimeter panel 10 is illustrated where perimeter panel 10 defines a region of a perimeter finish to the top or bottom of a stud wall 36.

[056] Referring to Fig. 5, there is illustrated an alternate use of perimeter panel 10a and In this application, perimeter panels 10a,10b, are fixed in a back-to-back fashion near a control joint 38.

[057] Referring to Fig. 6, an alternate application is illustrated where perimeter panels and 10b provide a finish to a door frame or jamb 40. Standard panels 20a and 20b can then be fixed adjacent perimeter panels 10a and 10b respectively.

[058] Referring to Figs. 7 and 8, there are illustrated cross-sectional views of a variety of perimeter panels with different example surface features. A variety of surface features 34a to 34p are shown. A wide variety of surface features can be produced as part of prefabrication or moulding of a panel to produce a range of functional, decorative or stylistic effects.

[059] Optional embodiments of the present invention may also be said to broadly consist in the parts, elements and features referred to or indicated herein, individually or collectively, in any or all combinations of two or more of the parts, elements or features, and wherein specific integers are mentioned herein which have known equivalents in the art to which the invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

[060] Although a preferred embodiment has been described in detail, it should be understood that various changes, substitutions, and alterations can be made by one of ordinary skill in the art without departing from the scope of the present invention.

Claims (16)

1. A panel, including an upper surface and a lower surface, a panel edge formed between the upper surface and the lower surface, and a wall edge formed between the upper surface and the lower surface opposite the panel edge, wherein the panel is used to form at least part of a perimeter of a ceiling.

2. The panel as claimed in claim 1, whereby, in use, the panel is fixed adjacent to a wall, after which a ceiling panel is fixed adjacent to the panel.

3. The panel as claimed in claim 1, wherein the panel is able to be secured to a ceiling support structure.

4. The panel as claimed in claim 3, wherein, in use, the upper surface at least partially abuts the ceiling support structure. The panel as claimed in claim 1, wherein, in use, the lower surface at least partially provides part of a ceiling.

6. The panel as claimed in claim 2, wherein, in use, the panel edge is fixed adjacent to a ceiling panel edge of the ceiling panel.

7. The panel as claimed in claim 2, wherein, in use, the wall edge is fixed adjacent to a surface of the wall.

8. The panel as claimed in claim 7, wherein, in use, part of the wall edge abuts or closely approaches the surface of the wall to define a cavity between the panel and the wall.

9. The panel as claimed in claim 1, wherein the wall edge is at least one of: an angled surface; a curved surface; and, a tapered surface. -12- The panel as claimed in claim 1, wherein the lower surface is provided with one or more lower surface features.

11. The panel as claimed in claim 1, wherein the panel tapers towards the panel edge.

12. The panel as claimed in claim 1, wherein the panel is pre-fabricated from one or more materials selected from the group of: gypsum; Gyprock®; MDF timber; plastic; paper; foam; and plaster.

13. A method of installing at least part of a ceiling near a wall using a perimeter panel, the perimeter panel including an upper surface and a lower surface, a panel edge formed between the upper surface and the lower surface, and a wall edge formed between the upper surface and the lower surface opposite the panel edge, the method including the steps of: fixing the perimeter panel to a ceiling support structure so that the wall edge is adjacent a surface of the wall; and then, fixing a ceiling panel to the ceiling support structure so that a ceiling panel edge of the ceiling panel is adjacent at least part of the panel edge.

14. The method as claimed in claim 13, wherein the wall edge is at least one of: an angled surface; a curved surface; and, a tapered surface, and at least part of the wall edge abuts the wall. The method as claimed in claim 14, wherein fixing the perimeter panel to the ceiling support structure leaves a recess between the wall edge of the perimeter panel and the wall, the method including filling the recess with a filling substance.

16. The method as claimed in claim 13, wherein the perimeter panel is removably fixed to the ceiling support structure.

17. The method as claimed in claim 14, wherein the perimeter panel and the ceiling panel are made of Gyprock®, and the ceiling panel edge and the panel edge provide a standard Gyprock®joint able to be set with a setting box and sanded by machine.

18. The method as claimed in claim 14, wherein at least part of the ceiling perimeter is visible before fixing the ceiling panel to the ceiling support structure.

19. A method of installing at least part of a ceiling using two perimeter panels, each of the perimeter panels including an upper surface and a lower surface, a panel edge formed between the upper surface and the lower surface, and a wall edge formed between the upper surface and the lower surface opposite the panel edge, the method including the steps of: fixing a first perimeter panel to a ceiling support structure; fixing a second perimeter panel to the ceiling support structure so that the wall edge of the first perimeter panel is adjacent the wall edge of the second perimeter panel; fixing a first ceiling panel to the ceiling support structure so that a ceiling panel edge of the first ceiling panel is adjacent at least part of the panel edge of the first perimeter panel; and, fixing a second ceiling panel to the ceiling support structure so that a ceiling panel edge of the second ceiling panel is adjacent at least part of the panel edge of the second perimeter panel. A panel, substantially as hereinbefore described with reference to the accompanying figures.