CEILING SYSTEM COMPRISING PANELS

Abstract

An architectural structure includes a carrier having structural members and panels mounted to the structural members by way of one or more panel clips. Moreover, the panels are connected to one another by tongue and groove arrangements. Each panel further includes a clip slot, separate and apart from the groove, configured to receive the panel clips and mount to the panel to the carrier.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority to United States Provisional Patent Application No. 63/764,995, filed on Feb. 28, 2025, the entirety of which is incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to architectural systems, such as suspended ceiling systems, for example.

BACKGROUND

In various instances, a ceiling system comprises a carrier and panels attached to the carrier. In various instances, the panels can be mis-aligned or mis-oriented relative to one another. Disclosed herein is an improvement over the foregoing.

SUMMARY

The present invention provides, in one form, a panel configured to be attached to a carrier of a ceiling system, the panel comprising a longitudinal body, a tongue extending along a side of the longitudinal body, a groove extending along an opposite side of the longitudinal body configured to receive a tongue of an adjacent panel, and a clip slot extending along the opposite side of the longitudinal body configured to receive panel clips that hold the panel to the carrier.

The present invention provides, in one form, a ceiling system comprising a carrier, a first panel comprising a first longitudinal body, a first tongue extending along a side of the first longitudinal body, a first groove extending along an opposite side of the first longitudinal body, and a first clip slot extending along the opposite side of the first longitudinal body, a plurality of first clips extending into the first clip slot that mount the first panel to the carrier, a second panel comprising a second longitudinal body, a second tongue extending along a side of the second longitudinal body, wherein the second tongue extends into the first groove of the first panel, a second groove extending along an opposite side of the second longitudinal body, and a second clip slot extending along the opposite side of the second longitudinal body, and a plurality of second clips extending into the second clip slot that mount the second panel to the carrier.

The present invention provides, in one form, a method of assembling a ceiling system comprising attaching a carrier to a building structure, positioning a first panel relative to the carrier, attaching a first set of panel clips to the carrier, inserting the first set of panel clips into a first clip slot defined in the first panel, positioning a second panel relative to the carrier and adjacent to the first panel, positioning a tongue of the second panel into a groove of the first panel, attaching a second set of panel clips of the carrier, and inserting the second set of panel clips into a second clip slot defined in the second panel.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

FIG. 1 is a perspective view of a ceiling system including a carrier and panels assembled to the carrier via panel clips in accordance with at least one embodiment;

FIG. 2 is an exploded view of the carrier of FIG. 1;

FIG. 3 is a perspective view of a panel of FIG. 1;

FIG. 4 is an end view of the panel of FIG. 3;

FIG. 5 is a perspective view of a panel clip of FIG. 1;

FIGS. 6A-6D illustrate steps in assembling the panel clip of FIG. 5 to the carrier of FIG. 1 to mount the panel of FIG. 3 to the carrier;

FIGS. 7A-7C also illustrate steps in assembling the panel clip of FIG. 5 to the carrier of FIG. 1 to mount the panel of FIG. 3 to the carrier;

FIGS. 8A-8C illustrate steps in mounting the panels of FIG. 1 to the carrier of FIG. 1;

FIG. 9 is an end view of a panel of FIG. 1 that has been cut to accommodate an irregular, or odd-sized, opening in the ceiling system of FIG. 1;

FIG. 10 is a detail view of an interface between the ceiling system of FIG. 1 and a wall;

FIG. 11 is an end view of a panel in accordance with at least one alternative embodiment;

FIG. 12 is an end view of another panel in accordance with at least one alternative embodiment;

FIG. 13 is an end view of another panel in accordance with at least one alternative embodiment;

FIG. 14 is a partial perspective view of the panel of FIG. 13;

FIG. 15 illustrates the panel of FIG. 13 assembled to another panel of FIG. 13;

FIG. 16 illustrates assembled panels in accordance with at least one alternative embodiment;

FIG. 17 illustrates assembled panels in accordance with another alternative embodiment;

FIG. 18 is a detail view of an interface between a ceiling system including the panels of FIG. 15 and a wall;

FIG. 19 is an end view of a panel in accordance with at least one embodiment;

FIG. 20 is a partial elevational view of a ceiling system comprising the carrier of FIG. 1, panel clips as illustrated in FIG. 5, and panels as illustrated in FIG. 19;

FIG. 21 is a detail view of an interface between two adjacent panels in FIG. 20; and

FIG. 22 illustrates veneer stacks on the top and bottom surfaces of the panel of FIG. 3.

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

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.

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.

FIG. 1 depicts a ceiling system 1000 comprising a carrier 1100 and a plurality of panels 1200 mounted to the carrier 1100. Referring to FIGS. 1 and 2, the carrier 1100 comprises a plurality of first structural members, such as longitudinal main beams 1110, for example, and a plurality of second structural members, such as cross-beams 1120, for example, connecting the main beams 1110. The cross-beams 1120 are connected to the main beams 1110 at junctions 1130. In various instances, the junctions 1130 comprise fasteners, such as rivets and/or bolts, for example, and/or welds, for example, that connect the cross-beams 1120 to the main beams 1110. Each main beam 1110 is straight, or at least substantially straight, and extends along a longitudinal axis. Similarly, each cross-beam 1120 is straight, or at least substantially straight, and extends along a longitudinal axis. That said, the beams 1110, 1120 can comprise any suitable configuration, such as a curved configuration and/or a curvilinear configuration, for example. In various embodiments, each beam 1110, 1120 is comprised of stainless steel and comprises a substantially T-shaped cross-section. For instance, each main beam 1110 comprises a bottom flange 1115 extending along the length thereof. That being said, the beams 1110, 1120 can be comprised of any suitable material and can comprise any suitable configuration. For instance, the beams 1110, 1120 can be comprised of wood and/or aluminum, for example. In any event, the ceiling system 1000 further comprises cables and/or rods 1140 configured to suspend the carrier 1100 from the structure of a building, for example.

Referring to FIGS. 3 and 4, each panel 1200 comprises an elongate body 1210, ends 1220, and lateral sides 1230 and 1240 extending between the ends 1220. The panel 1200 further comprises a bottom face 1215, a top face 1217, and a thickness 1216 extending between the bottom face 1215 and the top face 1217. In various embodiments, the panels 1200 are comprised of particle board, for example. In various instances, the particle board is comprised of small wood particles, such as sawdust and/or shavings, for example, that are glued together using one or more resins under heat and/or pressure to create a wood-based composite. Moreover, the bottom face 1215 of each panel 1200 comprises a veneer attached to the wood-based composite having a pattern defined thereon that gives the appearance of wood grain, for example. In various instances, the veneer is also comprised of wood that is attached to the wood-based composite using one or more adhesives, such as a soy-based adhesive and/or a polyvinyl alcohol-based adhesive, for example. In some instances, the veneer is comprised of a polymer laminate attached to the wood-based composite using one or more adhesives, for example. In addition to or in lieu of the above, the panels 1200 can be comprised of solid wood, for example. Given the natural grain of the wood, applying a veneer thereto may be unnecessary, but can be possible in some instances.

Further to the above, referring to FIGS. 5, 6A-6D, and 7A-7C, the panels 1200 are mounted to the carrier 1100 via panel clips 1300. Each panel clip 1300 comprises a body 1310 comprised of a stainless steel plate, for example, that has been stamped into the shape seen in FIG. 5. Each panel clip 1300 further comprises two inwardly-extending lock tabs 1315 and a panel hook 1340. To assemble a panel clip 1300 to the carrier 1100, referring to FIGS. 6A and 6B, the panel clip 1300 is placed against the bottom flange 1115 of a main beam 1110 and then rotated about a clip axis 1320 extending orthogonally through the body 1310 of the clip 1300. As a result of this rotation, the bottom flange 1115 of the main beam 1110 is captured between the lock tabs 1315 and the body 1310 of the clip 1300. At such point, referring now to FIGS. 6C and 6D, the clip 1300 can be slid along the main beam 1110 to engage the clip 1300 with a panel 1200, as discussed in greater detail below. FIGS. 7A-7C illustrate a similar sequence when a clip 1300 is slid along a main beam 1110 and aligned with a junction 1130 of the carrier 1100. In various other embodiments, the panel clips 1300 could be attached to the cross beams 1120, for example.

As discussed above, referring again to FIG. 4, each panel 1200 comprises longitudinal sides 1230 and 1240 extending along the length thereof. The longitudinal side 1230 comprises a tongue 1235 extending laterally therefrom and the longitudinal side 1240 comprises a groove 1245 defined therein. Referring primarily to FIG. 6A, the groove 1245 of a first panel 1200 is configured to receive the tongue 1235 of an adjacent, or second, panel 1200, and so forth, as the panels 1200 are attached to the carrier 1100. FIGS. 8A-8C illustrate a plurality of panels 1200 mounted to the carrier 1100 with the tongue 1235 of each panel 1200 nested within the groove 1245 of an adjacent panel 1200. In various instances, each panel 1200 has a lateral width of four inches, for example, as measured from the lateral end of the tongue 1235 and the longitudinal side 1240 of the panel 1200. In other instances, each panel 1200 has a lateral width of six inches, for example. In the embodiment illustrated in FIGS. 8A-8C, each of the panels 1200 of the ceiling system 1000 has the same lateral width. In other embodiments, the panels 1200 of a ceiling system have different lateral widths. The above being said, the panels 1200 can have any suitable shapes and/or dimensions.

As discussed above, referring again to FIGS. 4 and 5, the groove 1245 of a first panel 1200 is configured to receive a tongue 1235 of a second, or adjacent, panel 1200. According to one method of assembly, a first panel 1200 is attached to the carrier 1100 and then a second panel 1200 is attached to the carrier 1100 such that the second panel 1200 abuts the first panel 1200. When mounting the first panel 1200 to the carrier 1100, further to the above, panel clips 1300 are assembled to the main beams 1110 of the carrier 1100 and then slid along the main beams 1110 such that the panel hooks 1340 of the panel clips 1300 are inserted into the groove 1245 of the first panel 1200. At such point, the tongue 1235 of the second panel 1200 is inserted into the groove 1245 of the first panel 1200. Thus, the groove 1245 of the first panel 1200 is sized and configured to receive both the tongue 1235 of the second panel 1200 and the panel hooks 1340 of the panel clips 1300 therein. To attach the second panel 1200 to the carrier 1100, a second set of panel clips 1300 are assembled to the main beams 1110 and then slid along the main beams 1110 such that the panel hooks 1340 thereof are inserted into the groove 1245 of the second panel 1200. This process can be repeated for a third panel 1200 and so forth.

Further to the above, referring again to FIG. 4, the groove 1245 of the panel 1200 is defined by sidewalls having a width 1246 therebetween. The sidewalls of the groove 1245 are parallel, or at least substantially parallel, to one another. Such sidewalls can be created when a longitudinal groove cut is made in the side 1240 of the panel 1200 by a saw blade having a width equal to, or at least substantially equal to, the width 1246 of the groove 1245, for example. The tongue 1235 of the panel 1200 is defined by a width 1236 that is less than the width 1246 of the tongue 1245. In various instances, the tongue 1235 can be created by making a first rabbet cut in the bottom surface 1215 of the panel 1200 and a second, or opposing, rabbet cut in the top surface 1217, for example. Referring again to FIG. 5, the panel hook 1340 of the panel clip 1300 comprises a leg 1341 extending from the body 1310, a support 1342 extending laterally from the leg 1341, and a bend 1343 connecting the support 1342 to the leg 1341. The support 1342 is defined by a width 1346 which is, essentially, the thickness of the sheet metal comprising the panel clip 1300. Further to the above, the width 1246 of the groove 1245 accommodates both the width 1236 of the tongue 1235 and the width 1346 of the panel clip supports 1342. The tongue 1235 and the panel clip supports 1342 are closely received in the groove 1245 and, in various instances, the tongue 1235 and the panel clip supports 1342 are compressed between the sidewalls of the groove 1245.

In various instances, the carrier 1100 is sized and dimensioned so as to mount a quantity, or array, of panels 1200 without having to modify, or cut, the panels 1200 to length and/or width. However, such instances may not always be possible owing to the configuration of a particular room, for example. In such instances, referring to FIGS. 9 and 10, one or more panels 1200 can be ripped, or cut longitudinally, with a saw along the length thereof so that the modified panels 1200’ are sized to fit within a smaller space, for instance, along the perimeter of the panel array. As illustrated in FIG. 9, the longitudinal side 1230 of a panel 1200 has been cut off to create the panel 1200’ depicted therein; however, a longitudinal side 1240 of a panel could be cut off to create another modified panel 1200’, for example.

Referring primarily again to FIGS. 1 and 8A-8C, the ceiling system 1000 further comprises springs 1500 positioned between, and compressed between, the array of panels 1200 and trim panels 1400 mounted to the walls W of the room surrounding the array of panels 1200. The springs 1500 are resiliently deformed between the outermost panels 1200 of the ceiling system 1000 and the trim panels 1400 so as to center the array of panels 1200 relative to the walls W of the room. Each spring 1500 comprises a curved, or leaf spring, configuration, for example, but can comprise any suitable configuration. Referring to FIGS. 8A-8C, a perimeter panel 1200’ can be assembled to the end of the panel array by rotating the perimeter panel 1200’ into position between the carrier 1100 and a trim panel 1400 (FIG. 8A), pushed laterally outwardly to compress a spring 1500 and make enough room for the perimeter panel 1200’ (FIG. 8B), and then slid laterally inwardly into engagement with an adjacent panel 1200 of the panel array (FIG. 8C) thereby partially decompressing the spring 1500. Once the array of panels 1200, and the perimeter panels 1200’, have been assembled, the springs 1500 positioned around the perimeter of the panel array hold the panels together such that there is little, if any, observable gap between adjacent panels. In various other instances, a ceiling system may not utilize such springs. In at least one instance, referring to FIGS. 6A and 6B, one or more adhesives 1600 can be used to attach the ends and/or longitudinal sides of the panels of a ceiling system.

Referring FIG. 10, a first side of a perimeter panel 1200’ is supported by wall trim 1400 mounted to a wall W. The wall trim 1400 is mounted to the wall W by fasteners 1450, such as screws, for example. A second side of the perimeter panel 1200’ is supported by one or more panel clips 1300 mounted to the carrier 1100. As described above, the panel clips 1300 are supported by a bottom flange 1115 of a main beam 1110 of the carrier 1100 and the carrier 1100 is supported by the building structure via suspension cables 1140. In various instances, the panel clips 1300 are affixed to the carrier 1100 by one more fasteners 1350. In at least one instance, each panel clip 1300 comprises an aperture 1330 defined therein that is configured to receive a sheet metal screw, for example, therethrough that threadably engages and gains purchase with the carrier 1100. As a result of the above, the weight of the perimeter panel 1200’ is supported by the wall W, via the wall trim 1400 and fasteners 1450, and the building structure, via the panel clips 1300, the carrier 1100, and the suspension cables 1140. Similarly, the other panels 1200 of the ceiling system 1000 are also supported on their two longitudinal sides. More specifically, the longitudinal side 1230 of each panel 1200, i.e., the side having a tongue 1235, is supported by an adjacent panel 1200 and the longitudinal side 1240 of each panel 1200, i.e., the side having a groove 1245, is supported by one or more panel clips 1300.

Referring again to FIGS. 6A-6D, 8A-8C, and 11, it is intended for the bottom surfaces 1215 of the panels 1200 of the ceiling system 1000 to be flush, or co-planar, with one another. Such an arrangement can provide a pleasant aesthetic effect. Owing to various manufacturing tolerances and/or assembly tolerances, however, the bottom surfaces 1215 of the panels 1200 may not be flush with one another. In such instances, an edge, or lip, can be created between adjacent panels 1200 that is noticeable and, in many instances, unaesthetic to an observer, especially when the panels 1200 are comprised of particle board and the longitudinal sides 1230 and 1240, for example, are not covered by a veneer. Moreover, referring again to FIG. 4, the panel 1200 comprises a square corner 1249 defined between the longitudinal side 1230 and the bottom surface 1215 and, similarly, a square corner 1249 defined between the longitudinal side 1240 and the bottom surface 1215. Although such square corners 1249 are suitable, if not desirable, in many instances, the square corners 1249 can exacerbate the creation of a lip, for example. Potential solutions to this problem are discussed further below.

A panel 2200 is illustrated in FIG. 11 and is usable interchangeably with the panels 1200 in the ceiling system 1000. The panel 2200 is similar to the panel 1200 in many respects. Notably, though, the panel 2200 comprises a notch 2235 defined between a bottom surface 2215 of the panel 2200 and the longitudinal side 1230 of the panel 2200. In the event that the bottom surfaces 2215 of adjacent panels 2200 are not aligned with one another, as described above, the notch 2235 defines a flat recess at the interface between the two panels 2200 instead of a lip. Moreover, a panel 3200 is illustrated in FIG. 12 and is usable interchangeably with the panels 1200, and/or the panels 2200, in the ceiling system 1000. The panel 3200 is similar to the panel 1200 in many respects. Notably, though, the panel 3200 comprises bevel cuts 3235, 3245 defined between a bottom surface 3215 of the panel 3200 and the longitudinal sides 1230 and 1240 of the panel 3200, respectively. The bevel cuts 3235, 3245 can provide an aesthetic effect, especially when that the bevel cuts 3235, 3245 of adjacent panels 3200 are aligned with one another to form a V-shaped groove at the interface between the adjacent panels 3200.

A panel 4200 is illustrated in FIGS. 14 and 15 and is usable with the carrier 1100 and the panel clips 1300 described above as part of a ceiling system 4000 illustrated in FIG. 18, for example. The panel 4200 is similar to the panel 1200 in many respects. The panel 4200 comprises a longitudinal body 4210, a longitudinal side 4230 extending along one side of the longitudinal body 4210, and a longitudinal side 4240 extending along an opposite side of the longitudinal body 4210. Similar to the longitudinal side 1230 of the panel 1200, the longitudinal side 4230 of the panel 4200 comprises a tongue 4235. The tongue 4235 has the same shape and configuration as the tongue 1235. For instance, the tongue 4235 is defined by a tongue width 4236 which is equal to the width 1236 of the tongue 1235. That said, the tongue 4235 can have any suitable shape. Notably, though, the tongue 4235 is closer to the bottom surface 1215 of the panel 4200 than the tongue 1235 is to the bottom surface 1215 of the panel 1200. As illustrated in FIG. 13, the panel 4200 defines a midline 1219 midway between the bottom surface 1215 and the top surface 1217 of the panel 4200 and the tongue 4235 is positioned entirely on the bottom side of the midline 1219. That said, the tongue 4235 can be positioned at any suitable location on the longitudinal side 4230.

Further to the above, referring again to FIG. 13, the longitudinal side 4240 of the panel 4200 comprises a groove 4245 which is defined by a groove width 4246. Similar to the groove 1245 of the panel 1200, the groove 4245 has parallel, or at least substantially parallel, sidewalls that can be created by making a groove cut in the longitudinal side 4240 of the panel 4200 using a saw blade having a width equal to, or at least substantially equal to, the groove width 4246. Notably, though, the groove width 4246 of the groove 4245 is narrower than the groove width 1246 of the groove 1245. Referring to FIG. 15, the groove 4245 is sized and configured to closely receive the tongue 4235 of an adjacent panel 4200 therein but not, however, the panel hooks 1340 of the panel clips 1300, as described in greater detail below. In various instances, a slight clearance gap, such as .005”, for example, is present between the tongue 4235 and the sidewalls of the groove 4245. In other instances, the tongue 4235 is in a line-to-line fit between the sidewalls of the groove 4245. In certain instances, a slight press-fit is present between the tongue 4235 and the sidewalls of the groove 4245. Similar to the tongue 4235, the groove 4245 is closer to the bottom surface 1215 of the panel 4200 than the groove 1245 is to the bottom surface 1215 of the panel 1200. As illustrated in FIG. 14, the groove 1245 is positioned entirely on the bottom side of the midline 1219. That said, the groove 4245 can be positioned at any suitable location on the longitudinal side 4240.

Further to the above, the longitudinal side 4240 of the panel 4200 further comprises a clip slot 4242 defined therein that is configured to receive the panel hooks 1340 of the panel clips 1300 that are slid into contact with the panel 4200. The clip slot 4242 is positioned vertically above the groove 4245 and is positioned entirely on the top side of the midline 1219 of the panel 4200; however, the clip slot 4242 can be positioned in any suitable location in the longitudinal side 4240. The clip slot 4242 comprises parallel, or at least substantially parallel, lateral sidewalls that define a slot width 4243 therebetween that can be created by making a groove cut in the longitudinal side 4240 of the panel 4200 using a saw blade having a width equal to, or at least substantially equal to, the slot width 4243. The clip slot 4242 is sized and configured to receive the panel clip supports 1342 of one or more panel hooks 1340 therein with a clearance fit therebetween that permits the panel clips 1300 to be assembled to the panel 4200. To accommodate this arrangement, the slot width 4243 of the clip slot 4242 is wider than the width 1346 of the panel clip support 1342.

As discussed above, the groove 1245 of each panel 1200 is configured to receive both the tongue 1235 of an adjacent panel 1200 and the panel hooks 1340 of one or more panel clips 1300 therein. In some instances, however, a tolerance issue, or a maximum material condition, can arise in which the groove 1245 is not wide enough to properly accommodate both the tongue 1235 and the panel hooks 1340 therein without the panel 1200 and/or adjacent panels 1200 becoming crooked or mis-aligned with one another, for example. In such instances, as discussed above, an unaesthetic lip can be present between the panels 1200. The panels 4200, however, can avoid this problem as the clip slot 4242 and the groove 4245 can be independently sized and configured to accommodate, respectively and separately, the panel hooks 1342 of one or more panel clips 1340 and the tongue 4235 of an adjacent panel 4200. For instance, the groove 4245 of a first panel 4200 can closely receive the tongue 4235 of a second, or adjacent, panel 4200 therein such that there is little, if any, relative movement between the tongue 4235 and the sidewalls of the groove 1245 while, on the other hand, a substantial clearance fit can be present between the sidewalls of the clip slot 4242 and the panel hooks 1342. In such an arrangement, referring generally to FIG. 18, the panels 4200 can rest on the panel hooks 1340 such that the weight of the panels 4200 is substantially supported by the panel clips 1300 and, moreover, the space between adjacent panels 4200 is at least partially held closed by the interaction between the tongues 4235 and the sidewalls of the grooves 4245 of the panels 4200. More specifically, referring to FIG. 15, the tongues 4235 and the sidewalls of the grooves 4245 can hold adjacent panels 4200 together such that a bottom surface 4237 of the longitudinal side 4230 of a first panel 4200 is held in contact with, or at least in close proximity to, a bottom surface 4247 on the longitudinal side 4240 of a second, or adjacent, panel 4200.

Further to the above, referring again to FIG. 14, the clip slot 4242 is defined by a depth 4248 that is sufficient to receive the entirety of the panel clip supports 1342 therein. The groove 4245, however, has a depth that is shallower than the depth 4248. Moreover, the clip slot 4242 defines a clip slot axis 4244 that is parallel to, or at least substantially parallel to, a groove axis 4249 defined by the groove 4245. That said, other embodiments are envisioned in which the clip slot axis 4244 and the groove axis 4249 are not parallel to one another. The above being said, the clip slot 4242 and/or the groove 4245 can have any suitable width, depth, and/or configuration. Notably, though, a wall 4244 is present between the clip slot 4242 and the groove 4245 that needs to be strong enough to structurally accommodate any loads transmitted therethrough.

Referring again to FIG. 15, a slot 4250 is defined between adjacent first and second panels 4200 that is sized and configured to accommodate the panel hooks 1340 supporting the first panel 4200. The slot 4250 is defined by a top surface 4241 defined on the longitudinal side 4240 on the first panel 4200 and a top surface 4231 defined on the longitudinal side 2430 on the second panel 4200. The legs 1341 of the panel hooks 1340 extend between the top surfaces 4231 and 4241 such that panel supports 1342 of the panel hooks 1340 can extend inwardly into the clip slot 4242 defined in the first panel 4200. Such an arrangement is also present between a third panel 4200 and the second panel 4200, and so forth.

Further to the above, a panel 5200 is illustrated in FIG. 16 and is usable interchangeably with the panels 4200 in the ceiling system 4000. The panel 5200 is similar to the panel 4200 in many respects. Notably, though, the panel 5200 comprises a bevel cut 5235 defined between a bottom surface of the panel 5200 and the longitudinal side 5230 and a bevel cut 5245 defined between the bottom surface and the longitudinal side 5240 of the panel 5200. The bevel cuts 5235, 5245 can provide an aesthetic effect, especially when that the bevel cuts 5235, 5245 of adjacent panels 5200 are aligned with one another to form a V-shaped groove at the interface between the adjacent panels 5200. Moreover, a panel 6200 is illustrated in FIG. 17 and is usable interchangeably with the panels 4200, and/or the panels 5200, in the ceiling system 4000. The panel 6200 is similar to the panel 4200 in many respects. Notably, though, the panel 6200 comprises a notch 6235 defined between a bottom surface of the panel 6200 and the longitudinal sides 6230 of the panel 2200. In the event that the bottom surfaces of adjacent panels 6200 are not aligned with one another, as described above, the notches 6235 define a flat recess at the interface between the two panels 6200 instead of a lip.

Further to the above, a panel 7200 is illustrated in FIG. 19 that is similar to the panel 1200 in many respects. The panel 7200 comprises a first longitudinal side including a tongue 7235 and a second longitudinal side including a groove 7245 configured to receive the tongue 7235 of an adjacent panel 7200, as illustrated in FIG. 20. Similar to the groove 1245 defined in the panel 1200, the groove 7245 is also configured to receive a panel hook 1340 therein to support the panel 7200. That said, referring primarily to FIG. 21, the groove 7245 has two portions – a lower groove portion 7246 configured to receive the tongue 7235 of an adjacent panel 7200 and an upper groove portion 7247 configured to receive the panel hook 1340. Notably, the lower groove portion 7246 is deeper than the upper groove portion 7247; however, the groove portions 7246 and 7247 can have any suitable depth. Also, notably, the lower groove portion 7246 is wider than the upper groove portion 7247; that said, the groove portions 7246 and 7247 can have any suitable width. In at least one way, the groove 7245 comprises a double notch configuration – the lower groove portion 7246 comprising the first notch and the upper groove portion 7247 comprising the second notch. In various instances, the groove portions 7246 and 7247 are sized and configured such that there is clearance between the tongue 7235 and the panel hook 1340 positioned in the groove 1245. In other instances, the groove portions 7246 and 7247 are sized and configured such that the tongue 7235 and the panel hook 1340 are in contact with one another in the groove 1245. In either case, the groove portions 7246 and 7247 are sized and configured such that the presence of the tongue 7235 and the panel hook 1340 in the groove 7245 does not upset the desired co-planarity of the bottom surfaces 1215 of the panels 7200 in the ceiling system.

Further to the above, the bottom surfaces, the top surfaces, and/or any other suitable surfaces of the panels disclosed herein can comprise a veneer or veneer stack attached to the substrate of the panel. For instance, referring to FIG. 22, the bottom surface 1215 and the top surface 1217 of the panel 1200 each comprise a veneer stack attached to the particle board substrate of the panel 1200. In at least one instance, the veneer stack comprises a sheet of veneer attached to the particle board substrate via one or more adhesives, such as a soy-based adhesive and/or a poly-vinyl alcohol-based adhesive, for example. Moreover, in at least one instance, the veneer stack comprises one or more fills and/or one or more topcoats on the sheet of veneer that protects the sheet of veneer from moisture and/or ultraviolet light, for example.

Exemplary Claims

The present disclosure may be further characterized by the following exemplary claims:

Exemplary Claim 1. A ceiling system, comprising: a carrier; a first panel, comprising: a first longitudinal body; a first tongue extending along a side of the first longitudinal body; a first groove extending along an opposite side of the first longitudinal body; and a first clip slot extending along the opposite side of the first longitudinal body; a plurality of first clips extending into the first clip slot that mount the first panel to the carrier; a second panel, comprising: a second longitudinal body; a second tongue extending along a side of the second longitudinal body, wherein the second tongue extends into the first groove of the first panel; a second groove extending along an opposite side of the second longitudinal body; and a second clip slot extending along the opposite side of the second longitudinal body; and a plurality of second clips extending into the second clip slot that mount the second panel to the carrier.

Exemplary Claim 2. The ceiling system of Exemplary Claim 1, wherein the first clips do not extend into the first groove, and wherein the second clips do not extend into the second groove.

Exemplary Claim 3. The ceiling system of Exemplary Claim 1 or 2, wherein the first panel comprises a first bottom surface and a first top surface, wherein the second panel comprises a second bottom surface and a second top surface, and wherein the first clips and the second clips co-operatively hold the first bottom surface in plane with the second plane surface.

Exemplary Claim 4. The ceiling system of Exemplary Claim 3, wherein the first clip slot is vertically above the first groove, and wherein the second clip slot is vertically above the second groove.

Exemplary Claim 5. The ceiling system of Exemplary Claim 3 or 4, wherein the first panel has a panel thickness extending between the first bottom surface and the first top surface, wherein the first clip slot is positioned on one side of a midline of the panel thickness, and wherein the first groove is positioned on the opposite side of the midline.

Exemplary Claim 6. The ceiling system of any one of Exemplary Claims 1-5, wherein the first panel and the second panel are comprised of particle board.

Exemplary Claim 7. The ceiling system of Exemplary Claim 6, further comprising a veneer sheet adhered to the particle board.

Exemplary Claim 8. The ceiling system of any one of Exemplary Claims 1-5, wherein the first panel and the second panel are comprised of solid wood.

Exemplary Claim 9. The ceiling system of any one of Exemplary Claims 1-8, wherein the first groove comprises a groove depth, and wherein the first clip slot comprises a slot depth that is different than the groove depth.

Exemplary Claim 10. The ceiling system of Exemplary Claim 9, wherein the slot depth is deeper than the groove depth.

Exemplary Claim 11. The ceiling system of any one of Exemplary Claims 1-10, wherein the first groove defines a groove axis, wherein the first clip slot defines a slot axis, and wherein the groove axis is parallel to the slot axis.

Exemplary Claim 12. The ceiling system of any one of Exemplary Claims 1-10, wherein the first groove defines a groove axis, wherein the first clip slot defines a slot axis, and wherein the groove axis is not parallel to the slot axis.

Exemplary Claim 13. The ceiling system of any one of Exemplary Claims 1-12, wherein the first groove comprises a groove width, and wherein the first clip slot comprises a slot width that is different than the groove depth.

Exemplary Claim 14. The ceiling system of Exemplary Claim 13, wherein the groove width is wider than the slot width.

Exemplary Claim 15. A panel configured to be attached to a carrier of a ceiling system, the panel comprising: a longitudinal body; a tongue extending along a side of the longitudinal body; a groove extending along an opposite side of the longitudinal body configured to receive a tongue of an adjacent panel; and a clip slot extending along the opposite side of the longitudinal body configured to receive at least one panel clip that holds the panel to the carrier.

Exemplary Claim 16. The panel of Exemplary Claim 15, wherein the clip slot is vertically above the groove when the panel is attached to the carrier system.

Exemplary Claim 17. The panel of Exemplary Claim 15 or 16, further comprising: a bottom surface; a top surface; a panel thickness extending between the bottom surface and the top surface; and a midline defined midway between the bottom surface and the top surface, wherein the clip slot is positioned on one side of the midline and the groove is positioned on the opposite side of the midline.

Exemplary Claim 18. The panel of Exemplary Claim 17, wherein the clip slot is positioned entirely above the midline and the groove is positioned entirely below the midline.

Exemplary Claim 19. The panel of any one of Exemplary Claims 15-18, wherein the panel is comprised of particle board and a veneer attached to the particle board.

Exemplary Claim 20. The panel of any one of Exemplary Claims 15-18, wherein the panel is comprised of solid wood.

Exemplary Claim 21. A method of assembling a ceiling system, comprising: attaching a carrier to a building structure; positioning a first panel relative to the carrier; attaching a first set of panel clips to the carrier; inserting the first set of panel clips into a first clip slot defined in the first panel; positioning a second panel relative to the carrier and adjacent to the first panel; positioning a tongue of the second panel into a groove of the first panel; attaching a second set of panel clips of the carrier; and inserting the second set of panel clips into a second clip slot defined in the second panel.

Exemplary Claim 22. A panel configured to be attached to a carrier of a ceiling system, the panel comprising: a longitudinal body; a tongue extending along a side of the longitudinal body; and a groove extending along an opposite side of the longitudinal body, comprising: a lower groove portion configured to receive a tongue of an adjacent panel; and an upper groove portion configured to receive at least one panel clip that holds the panel to the carrier.

Exemplary Claim 23. The panel of Exemplary Claim 22, wherein the lower groove portion has a first depth, wherein the upper groove portion has a second depth, and wherein the first depth is deeper than the second depth.

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 carrier;

a first panel, comprising: a first longitudinal body; a first tongue extending along a side of the first longitudinal body; a first groove extending along an opposite side of the first longitudinal body; and a first clip slot extending along the opposite side of the first longitudinal body;

a plurality of first clips extending into the first clip slot that mount the first panel to the carrier;

a second panel, comprising: a second longitudinal body; a second tongue extending along a side of the second longitudinal body, wherein the second tongue extends into the first groove of the first panel; a second groove extending along an opposite side of the second longitudinal body; and a second clip slot extending along the opposite side of the second longitudinal body; and a plurality of second clips extending into the second clip slot that mount the second panel to the carrier.

2. The ceiling system of claim 1, wherein the first clips do not extend into the first groove, and wherein the second clips do not extend into the second groove.

3. The ceiling system of claim 1, wherein the first panel comprises a first bottom surface and a first top surface, wherein the second panel comprises a second bottom surface and a second top surface, and wherein the first clips and the second clips co-operatively hold the first bottom surface in plane with the second plane surface.

4. The ceiling system of claim 3, wherein the first clip slot is vertically above the first groove, and wherein the second clip slot is vertically above the second groove.

5. The ceiling system of claim 3, wherein the first panel has a panel thickness extending between the first bottom surface and the first top surface, wherein the first clip slot is positioned on one side of a midline of the panel thickness, and wherein the first groove is positioned on the opposite side of the midline.

6. The ceiling system of claim 1, wherein the first panel and the second panel are comprised of particle board.

7. The ceiling system of claim 6, further comprising a veneer sheet adhered to the particle board.

8. The ceiling system of claim 1, wherein the first panel and the second panel are comprised of solid wood.

9. The ceiling system of claim 1, wherein the first groove comprises a groove depth, and wherein the first clip slot comprises a slot depth that is different than the groove depth.

10. The ceiling system of claim 9, wherein the slot depth is deeper than the groove depth.

11. The ceiling system of claim 1, wherein the first groove defines a groove axis, wherein the first clip slot defines a slot axis, and wherein the groove axis is parallel to the slot axis.

12. The ceiling system of claim 1, wherein the first groove defines a groove axis, wherein the first clip slot defines a slot axis, and wherein the groove axis is not parallel to the slot axis.

13. The ceiling system of claim 1, wherein the first groove comprises a groove width, and wherein the first clip slot comprises a slot width that is different than the groove depth.

14. The ceiling system of claim 13, wherein the groove width is wider than the slot width.

15. A panel configured to be attached to a carrier of a ceiling system, the panel comprising:

a longitudinal body;

a tongue extending along a side of the longitudinal body;

a groove extending along an opposite side of the longitudinal body configured to receive a tongue of an adjacent panel; and

a clip slot extending along the opposite side of the longitudinal body configured to receive at least one panel clip that holds the panel to the carrier.

16. The panel of claim 15, wherein the clip slot is vertically above the groove when the panel is attached to the carrier system.

17. The panel of claim 15, further comprising:

a bottom surface;

a top surface;

a panel thickness extending between the bottom surface and the top surface; and

a midline defined midway between the bottom surface and the top surface, wherein the clip slot is positioned on one side of the midline and the groove is positioned on the opposite side of the midline.

18. The panel of claim 17, wherein the clip slot is positioned entirely above the midline and the groove is positioned entirely below the midline.

19. The panel of claim 15, wherein the panel is comprised of particle board and a veneer attached to the particle board.

20. A method of assembling a ceiling system, comprising:

attaching a carrier to a building structure;

positioning a first panel relative to the carrier;

attaching a first set of panel clips to the carrier;

inserting the first set of panel clips into a first clip slot defined in the first panel;

positioning a second panel relative to the carrier and adjacent to the first panel;

positioning a tongue of the second panel into a groove of the first panel;

attaching a second set of panel clips of the carrier; and

inserting the second set of panel clips into a second clip slot defined in the second panel.