EP3218554A1

EP3218554A1 - Ceiling system

Info

Publication number: EP3218554A1
Application number: EP15801600.6A
Authority: EP
Inventors: Christopher David Gaydos; Brian L. Springer; Lori Jo L. Shearer
Original assignee: Armstrong World Industries Inc
Current assignee: Armstrong World Industries Inc
Priority date: 2014-11-14
Filing date: 2015-11-13
Publication date: 2017-09-20
Also published as: AU2015346135A1; RU2017120191A; CN107109844B; RU2705700C2; AU2015346135B2; BR112017009944A2; CA2967366A1; WO2016077753A1; RU2017120191A3; CL2017001206A1; CN107109844A; MX2017006251A

Abstract

A ceiling system in one embodiment includes a grid member including a flange with bottom surface and a ceiling panel supported by the grid member. A first facing sheet includes a peripheral edge portion attached to the grid member and has an edge axially aligned with a cutting groove. A second ceiling panel includes a second facing sheet including a peripheral edge portion cut using the groove so its edge axially aligns with the groove and falls adjacent the first facing sheet edge. Another embodiment of a ceiling system includes a first facing sheet having a peripheral edge portion coupled to and supported by the grid member independently of the ceiling panel. A second facing sheet has a peripheral edge portion coupled to the grid member in a similar manner. The first and second facing sheets in either embodiment substantially conceal the grid support member. Related installation methods are disclosed.

Description

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 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. [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. [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 corners.

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; [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 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. [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 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 kraft paper, and in some embodiments 20 to 80 pound kraft 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, Lydall, 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 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 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 CLl 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 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 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 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 CL1 of the grid support member in one non-limiting embodiment. In other embodiments, the web 1212 may be laterally offset from centerline CL1. 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. [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 kraft 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 kraft paper, and in some embodiments 20 to 80 pound kraft 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 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 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 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 corners 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 corner 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 corner 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. [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 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 corners 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 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 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 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.

Claims

1. A ceiling system comprising:

a longitudinally extending grid support member including a longitudinal axis and a bottom flange defining a bottom surface;

a ceiling panel supported by the grid support member;

a first facing sheet having a peripheral edge portion attached to the grid support member; and

an integral cutting guide groove formed in the bottom surface of the grid support member, the groove extending linearly along the longitudinal axis;

wherein the peripheral edge portion of first facing sheet includes an edge which is axially aligned with the groove.

2. The ceiling system according to claim 1, wherein the first facing sheet is adhesively coupled to the grid support member.

3. The ceiling system according to claim 2, further comprising double-sided adhesive strips which adhesively couple the first facing sheet to the grid support member.

4. The ceiling system according to any one of claims 1 to 3, wherein the ceiling panel has a honeycomb core structure.

5. The ceiling system according to any one of claims 1 to 4, wherein the first facing sheet is coupled to the bottom surface of the ceiling panel.

6. The ceiling system according to any one of claims 1 to 4, wherein the first facing sheet is attached to a spacer panel disposed between the bottom surface of the ceiling panel and the first facing sheet.

7. The ceiling system according to claim 6, wherein the spacer panel has a bottom surface located substantially flush with the bottom surface of the grid support member.

8. The ceiling system according to claim 1, wherein the grid support member is T- shaped.

9. The ceiling system according to claim 1, wherein the ceiling panel is a tegular panel having a stepped side edge profile.

10. The ceiling system according to claim 1, further comprising a second facing sheet of a second ceiling panel supported by the grid support member, the second facing sheet having an edge which is axially aligned with the groove and disposed adjacent the edge of the first facing sheet.

11. A ceiling system comprising:

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 including 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 extending between the first and second grid support members, the ceiling panel supported by the first and second grid support members; and

a first facing sheet disposed below the ceiling panel and attached to the first and second grid support members;

wherein 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.

12. The ceiling system according to claim 11, further comprising a second facing sheet having an edge axially aligned with the groove of the first grid support member and disposed adjacent to the first edge of the first facing sheet.

13. The ceiling system according to claim 11 or claim 12, wherein the first facing sheet is adhesively coupled to the grid support member.

14. The ceiling system according to claim 13, further comprising double-sided adhesive strips which adhesively couple the first facing sheet to the grid support member.

15. The ceiling system according to any one of claims 11 to 14, wherein the ceiling panel has a honeycomb core structure.

16. The ceiling system according to any one of claims 11 to 15, wherein the first facing sheet is supported by the ceiling panel.

17. The ceiling system according to claim 16, wherein the first facing sheet is attached to a spacer panel disposed between a bottom surface of the ceiling panel and the first facing sheet.

18. The ceiling system according to claim 11, wherein the grid support member is T- shaped.

19. The ceiling system according to claim 11, wherein the ceiling panel is a tegular panel having a stepped side edge profile.

20. A method for concealing a grid support member of a ceiling system, the method comprising:

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;

wherein the grid support member is concealed by the overlapping peripheral edge portions of the bottom facing sheets of the first and second ceiling panels.

21. The method according to claim 20, wherein the step of laterally positioning the peripheral edge portion of the first ceiling panel includes locating a peripheral edge defined by the peripheral edge portion on a side of the cutting guide groove opposite the first ceiling panel.

22. The method according to claim 21, wherein the step of laterally positioning the peripheral edge portion of the second ceiling panel includes locating a peripheral edge defined by the peripheral edge portion on a side of the cutting guide groove opposite the second ceiling panel.

23. The method according to claim 22, wherein the peripheral edges of the first and second ceiling panels are adjacent each other and substantially axially aligned with the cutting guide groove after the trimming step.

24. The method according to claim 21, further comprising adhesively bonding the peripheral edge portions of the first and second ceiling panels to the bottom surface of the grid support member.

25. The method according to claim 24, wherein the peripheral edge portions are adhesively bonded with adhesive strips.

26. A ceiling system comprising:

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.

27. The ceiling system of claim 26, wherein the first facing sheet is supported from the grid support member independently of the ceiling panel.

28. The ceiling system of claims 26 or 27, wherein the coupling mechanism is selected from a group consisting of adhesives, magnets, and hook and loop closures.

29. The ceiling system of claim 28, wherein the coupling mechanism comprises double- sided adhesive tape.

30. The ceiling system of any of claims 26-29, wherein the first facing sheet is releasably coupled to the grid support member.

31. The ceiling system of any of claims 26-30, further comprising a first spacer disposed between the first facing sheet and the bottom surface of the grid support member, the first spacer spacing the first facing sheet from the bottom surface by a first vertical distance.

32. The ceiling system of claim 31, wherein the first facing sheet has a rectilinear shape and the first spacer is attached to a first corner of the first facing sheet.

33. The ceiling system of claims 32, further comprising a second spacer attached to a second corner of the first facing sheet.

34. The ceiling system of claim 33, further comprising a resilient tensioning rod coupled between the first and second spacers, the tensioning rod urging the first and second corners apart to draw the first facing sheet taut and substantially flat.

35. The ceiling system of claim 26, wherein the ceiling panel has a honeycomb core structure.

36. The ceiling system of any of claims 26-35, wherein the first facing sheet is unattached to the ceiling panel.

37. The ceiling system of claim 26, wherein the grid support member is T-shaped and includes a bottom flange that defines the bottom surface.

38. A ceiling system comprising:

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.

39. The ceiling system of claim 38 further comprising a coupling mechanism that couples the peripheral edge portions of the first and second facing sheets to the bottom surface of the first grid support member, the coupling mechanism selected from a group consisting of adhesive coupling, magnetic coupling, and hook and loop coupling.

40. The ceiling system of claims 38 or 39, wherein the first facing sheet is unattached to the ceiling panel and only supported from the bottom surface of the grid support member.

41. The ceiling system of any of claims 38-40, wherein the first and second facing sheets are releasably coupled to the bottom surface of the first grid support member.

42. The ceiling system of claim 39, wherein the coupling mechanism further includes a first spacer disposed between the first facing sheet and the bottom surface of the first grid support member, the first spacer spacing the first facing sheet from the bottom surface by a first vertical distance.

43. The ceiling system of claim 42, wherein: the coupling mechanism includes a second spacer disposed between the second facing sheet and the bottom surface of the first grid support member, the second spacer spacing the second facing sheet from the bottom surface by the first vertical distance;

wherein a peripheral edge of the second facing sheet is substantially flush with an adjacent peripheral edge of the first facing sheet beneath the first grid support member.

44. The ceiling system of claim 42, wherein the second facing sheet is directly coupled to the bottom surface of the first grid support member, a peripheral edge of the second facing sheet being vertically offset from an adjacent peripheral edge of the first facing sheet beneath the first grid support member to form a stepped configuration.

45. The ceiling system of any of claims 42 or 43, wherein the first spacer is fixedly attached to the first facing sheet.

46. The ceiling system of any of claims 38 to 45, wherein the ceiling panel has a honeycomb core structure.

47. A method for concealing a grid support member of a ceiling system, the method comprising:

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.

48. The method of claim 47, wherein the attaching step includes attaching a peripheral edge portion of the first facing sheet to the bottom surfaces of the first and second grid support members.

49. The method of claims 47 or 48, further comprising positioning a linear peripheral edge of first facing sheet at least partially across the bottom surface of the first grid support member.

50. The method of claim 47, further comprising:

attaching a peripheral edge portion of a second facing sheet to the bottom surface of the first grid support member;

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.

51. The method of claim 50, further comprising positioning a spacer between the first facing sheet and the bottom surface of the first grid support member, the spacer spacing the first facing sheet apart from the bottom surface of the first grid support member by a vertical distance.

52. The method of claim 51, wherein the peripheral edge of the first facing sheet is vertically offset from the peripheral edge of the second facing sheet.

53. A facing sheet for concealing a grid support of a ceiling system, the facing sheet comprising:

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 corners.