Ceiling system

Abstract

A ceiling system in one embodiment conceals the ceiling support structure to provide a monolithic ceiling appearance. The system includes the support structure and ceiling panels each having a top surface, bottom surface, and peripheral edges. In one embodiment, the peripheral edges of the panels may have a hybrid edge detail including a tongue-and-groove portion and a shiplap portion. The hybrid edges of adjoining panels are configured to both interlock via the tongue-and-groove edge features and hide the ceiling support structure via the shiplap edge features. This eliminates the need to secure all peripheral edges to the support structure for proper support. In one implementation, some but less than all peripheral edges may include mounting flanges for direct surface mounting of the panels to and hiding the support structure.

1 . A ceiling system comprising:
 a ceiling support structure having a downward facing support surface;   a plurality of ceiling panels attached to the ceiling support structure, the ceiling panels each having a top surface facing the ceiling support structure, an opposing bottom surface, and a plurality of peripheral edges extending between the top and bottom surfaces;   a pair of adjoining first and second ceiling panels mutually engaged along first and second mating peripheral edges respectively, the first and second peripheral edges each having a hybrid edge detail including a tongue-and-groove portion and a shiplap portion;   the shiplap portion of the first ceiling panel defining a laterally extending mounting flange attached to the ceiling support structure;   the shiplap portion of the second ceiling panel covering the mounting flange of the first ceiling panel; and   the tongue-and-groove portions of the first and second ceiling panels being interlocked;   wherein the second peripheral edge of the second ceiling panel is supported via the tongue-and-groove interlock with the first ceiling panel;   wherein the second ceiling panel has a third peripheral edge having a hybrid edge detail comprising a tongue-and-groove portion and a shiplap portion defining a laterally extending mounting flange;   wherein the mounting flange of the third peripheral edge of the second ceiling panel has a terminal end which is offset from a corner of the third peripheral edge to form a corner notch which receives a portion of the mounting flange of the first ceiling panel therein.   
     
     
         2 . The ceiling system according to  claim 1 , wherein the mounting flange of the first ceiling panel is attached to and covers a portion of the support surface of the ceiling support structure. 
     
     
         3 . The ceiling system according to  claim 2 , wherein the support surface is a grid face defined by a grid support member suspended from the ceiling support structure. 
     
     
         4 . The ceiling system according to  claim 2 , wherein the top surface of the second ceiling panel covers an adjoining portion of the support surface covered by the mounting flange. 
     
     
         5 . The ceiling system according to  claim 1 , wherein the second peripheral edge of the second ceiling panel does not have a mounting flange. 
     
     
         6 . The ceiling system according to  claim 1 , wherein the tongue-and-groove portion of the first ceiling panel includes a groove and the tongue-and-groove of the second ceiling panel includes a tongue engaging the groove. 
     
     
         7 . The ceiling system according to  claim 1 , wherein the first ceiling panel includes a fourth peripheral edge which orthogonally adjoins the first peripheral edge, the fourth peripheral edge having hybrid edge detail not including a mounting flange. 
     
     
         8 . The ceiling system according to  claim 1 , wherein the mounting flange of the first ceiling panel is attached to a bottom flange of the ceiling support structure. 
     
     
         9 . The ceiling system according to  claim 1 , wherein the ceiling support structure is selected from the group consisting of a grid support member suspended from a building structure, a grid support member surface mounted to a building structure, and a flat surface of a building structure. 
     
     
         10 . The ceiling system according to  claim 1 , wherein the ceiling support structure comprises a plurality of orthogonally intersecting grid support members that define an array of grid openings, each grid support member including a vertical centerline and a bottom flange forming a grid face that defines the support surface. 
     
     
         11 . The ceiling system according to  claim 10 , wherein the mounting flange of the first ceiling panel extends partially across the grid face of a first grid support member. 
     
     
         12 . The ceiling system according to  claim 11 , wherein the second ceiling panel extends completely across the grid face of the first support member below the mounting flange 
     
     
         13 . A ceiling panel with hybrid edge detail, the ceiling panel comprising:
 a body including a top surface, a bottom surface, opposite first and second longitudinal sides extending between the top and bottom surfaces, and opposite third and fourth lateral sides extending between the top and bottom surfaces;   the first longitudinal side having a first peripheral edge including a shiplap portion defining a mounting flange extending outwards from the first peripheral edge and a tongue-and-groove portion, the mounting flange having a terminal end which is offset from a corner of the first peripheral edge to form a corner notch which receives a portion of a mounting flange of an adjoining second ceiling panel therein when the ceiling panel is mounted to an overhead support structure;   the third lateral side having a second peripheral edge including a shiplap portion defining a second mounting flange extending outwards from the second peripheral edge and a tongue-and-groove portion, the second mounting flange having a terminal end which is offset from a corner of the second peripheral edge to form a corner notch which receives a portion of a mounting flange of an adjoining third ceiling panel therein when the ceiling panel is mounted to the overhead support structure;   wherein the shiplap and tongue-and-groove portions of the first and third peripheral edges are arranged to engage complementary configured shiplap and tongue-and-groove portions of the adjoining second and third ceiling panels for forming an interlocked ceiling system.   
     
     
         14 . The ceiling panel according to  claim 13 , wherein the tongue-and-groove portion of the first peripheral edge includes a laterally open recess configured to receive a tongue of an adjoining ceiling panel. 
     
     
         15 . The ceiling panel according to  claim 14 , wherein the shiplap portion of the first peripheral edge includes an upper shiplap feature comprising a lateral extension disposed along the top surface of the ceiling panel, the lateral extension defining the mounting flange. 
     
     
         16 . The ceiling panel according to  claim 13 , wherein the second longitudinal side has a third peripheral edge including a shiplap portion and a tongue-and-groove portion, the tongue-and-groove portion including a laterally protruding tongue configured for insertion into a recess of an adjoining ceiling panel. 
     
     
         17 . The ceiling panel according to  claim 16 , wherein the shiplap portion of the third peripheral edge includes a lower shiplap feature comprising an upward facing seating surface spaced apart from the top surface of the ceiling panel forming a stepped top surface configuration. 
     
     
         18 . The ceiling panel according to  claim 13 , wherein the tongue-and-groove portion of the second peripheral edge includes a laterally open recess configured to receive a tongue of an adjoining ceiling panel. 
     
     
         19 . The ceiling panel according to  claim 18 , wherein the shiplap portion of the second peripheral edge includes an upper shiplap feature comprising a lateral extension disposed along the top surface of the ceiling panel that defines the second mounting flange. 
     
     
         20 . The ceiling panel according to  claim 13 , wherein the fourth lateral side has a fourth peripheral edge including a shiplap portion and a tongue-and-groove portion, the tongue-and-groove portion including a laterally protruding tongue configured for insertion into a recess of an adjoining ceiling panel. 
     
     
         21 . The ceiling panel according to  claim 20 , wherein the shiplap portion of the fourth peripheral edge includes a lower shiplap feature comprising an upward facing seating surface spaced apart from the top surface of the ceiling panel forming a stepped top surface configuration. 
     
     
         22 . The ceiling panel according to  claim 13 , the first longitudinal side and the third lateral side each define a mounting flange configured for attachment to a ceiling support surface. 
     
     
         23 . The ceiling panel according to  claim 22 , wherein the first longitudinal side and the third lateral side are orthogonally adjoining and the mounting flanges form an L-shaped configuration. 
     
     
         24 . A method for concealing a ceiling support structure, the method comprising:
 providing a plurality of ceiling panels each having a top surface and an opposing bottom surface, the panels each having opposing first and second peripheral sides, the first peripheral side having a hybrid edge detail comprising a tongue-and-groove feature and a laterally extending shiplap feature adjacent the top surface, the second peripheral side having a hybrid edge detail comprising a tongue-and-groove feature and a stepped shiplap feature;   attaching the first ceiling panel to the ceiling support structure;   engaging the tongue-and-groove of the second peripheral side of a second ceiling panel with the tongue-and-groove feature of the first peripheral side of the first ceiling panel; and   engaging the stepped shiplap feature of the second peripheral side of the second ceiling panel with the laterally extending shiplap feature of the first peripheral side of the first ceiling panel;   wherein the second peripheral side of the second ceiling panel is supported by the first peripheral side of the first ceiling panel;   wherein the second ceiling panel has third peripheral side having a hybrid edge detail comprising a tongue-and-groove feature and a laterally extending shiplap feature adjacent the top surface;   wherein the laterally extending shiplap feature of the third peripheral side of the second ceiling panel has a terminal end which is offset from a corner of the third peripheral side to form a corner notch which receives a portion of the laterally extending shiplap feature of the first ceiling panel therein.   
     
     
         25 . The method according to  claim 24 , wherein the tongue-and-groove feature of the first peripheral side comprises a groove and the tongue-and-groove feature of the second peripheral side comprises a laterally projecting tongue. 
     
     
         26 . The method according to  claim 24 , wherein the first ceiling panel is attached to the ceiling support structure by the laterally extending shiplap feature of the first peripheral side. 
     
     
         27 . The method according to  claim 26 , wherein the laterally extending shiplap feature is attached to the ceiling support structure with a fastener. 
     
     
         28 . The method according to  claim 27 , wherein the stepped shiplap feature of the second peripheral side of the second ceiling panel covers and conceals the fastener.