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1. (WO2013156985) CEILING PLANK
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CEILING PLANK

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] This invention is directed a ceiling plank for a plank ceiling installation, and more particularly to a novel ceiling plank that can be easily handled and installed by one person.

[0002] It is known to make ceiling planks with a highly elongated structure, typically measuring approximately 5 inches by 84 inches, the standard size of a ceiling plank. The known ceiling planks because of their length can be unwieldy to handle, especially on a ladder, and are often installed by one or more skilled installers working on ladders or scaffolding.

[0003] Some known ceiling planks have a wood composition core and may be subject to warpage which is exaggerated when the plank is 84 inches long. The known planks must thus be laid out on a flat surface to normalize or flatten such warpage before being installed at a ceiling.

[0004] A typical ceiling plank installation can have plural rows of 84 inch ceiling planks, wherein the planks in each row are placed end to end. Because most ceiling dimensions are not an even multiple of the standard 84 inch plank length it is often necessary to cut a full length ceiling plank to a size that may be much smaller than the 84 inch standard length of a full size ceiling plank. This end to end arrangement can create a disproportionate relationship between the standard full size ceiling plank and the cut ceiling plank, and may give the plank ceiling installation an irregular appearance.

[0005] In many known plank ceiling installations the adjacent planks are joined together at the sides and ends by tongue and grove engagement. Two edges of the plank are thus provided with a tongue structure and two edges are provided with a groove structure. Other known joining

arrangements can also be used to join the edges of adjacent ceiling planks.

[0006] However once a standard size ceiling plank is cut to a shorter length, the cut end is smooth and has no tongue or groove or other joining structure. The cut end of a ceiling plank is thus not engageable with the edge joining structure of an uncut plank. Therefore the cut end of a ceiling plank must be installed at the edge of a ceiling where the cut end does not abut the edge joining structure of an uncut ceiling plank.

[0007] Thus it is not feasible to locate the cut end of a cut ceiling plank away from the edge of a ceiling in a plank ceiling installation.

DESCRIPTION OF THE DRAWINGS

[0008] In the accompanying drawings,

[0009] Fig. 1 is a simplified schematic view representing a prior art plank ceiling installation with known highly elongated standard size ceiling planks;

[0010] Fig. 2 is a simplified schematic view representing a plank ceiling installation using a ceiling plank incorporating one embodiment of the present invention;

[0011] Figs. 3 and 4 are simplified schematic views representing different stages of a ceiling plank installation using the ceiling plank of the present invention;

[0012] Fig. 5 is a perspective view of a ceiling plank clip used in installing the ceiling planks of Figs. 2-4;

[0013] Fig. 6 is an enlarged detail view of the area 6 of Fig. 5; and,

[0014] Fig. 7 is a sectional view taken on the line 7-7 of Fig. 6.

[0015] Corresponding reference numbers indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

[0016] Referring to the drawings, a ceiling plank incorporating one embodiment of the invention is generally indicated by the reference number 10 in Fig. 2.

[0017] The ceiling plank 10 is generally rectangular, with a preferred size of approximately five inches by forty-eight inches such that the longer side of the plank 10 is preferably between nine and ten times the length of the shorter side of the plank 10. Thus the plank 10 has two opposite elongated edges 12 and 16 approximately forty-eight inches long, and two opposite end edges 14 and 18 approximately five inches wide. One of the forty-eight inch elongated edges 12 and one of the five inch end edges 14 of the plank 10 are formed with a known edge joining means such as a known tongue construction 15 and the other forty-eight inch elongated edge 16 and five inch end edge 18 are formed with a known complementary groove construction 19. Adjacent ceiling planks 10 in side-by-side and end-to-end arrangement in a plank ceiling installation can thus have a tongue and groove engagement.

[0018] The ceiling plank 10 can have a decorative surface 24 (Figs. 6 and 7), such as a wood grain surface, colored surface or any other suitable design. The peripheral edges 26 (Fig. 7) of the decorative surface are preferably beveled. The core of the ceiling plank 10 is preferably fire retardant class A hardboard.

[0019] In a plank ceiling installation, the ceiling planks 10 are usually secured to known furring strips 20 (Fig. 3) by ceiling clips 30 (Figs. 3 and 5). The furring strips 20 are usually joined to known ceiling joists 22 in any suitable known manner, such as by screwing or nailing. In some instances the furring strips 20 are secured directly to a finished ceiling surface.

[0020] An initial run of the ceiling planks 10, such as the planks 10A and 10B in Fig. 3, are nailed or screwed directly to the furring strips 20 at one edge of a ceiling and the plank securement nails (not shown) are subsequently covered over with a known edge molding (not shown) at the edge of the ceiling. Subsequent rows of ceiling planks 10, such as IOC and 10D in Fig. 3, are joined to the planks 10A and 10B in side-by-side and end-to-end engagement. The metal ceiling clips 30 are secured to each furring strip 20 to engage the groove portions 19 of the planks in the ceiling plank assembly, and thus enable the grooved portions 19 to support the tongue portions 15 of adjacent planks.

[0021] The ceiling clip 30 (Fig. 5) has a base plate 32 with a bent prong portion 34 that defines a receiving space 36. The clip 30 also includes openings 40, 42, 44 and 46 which can be used to accommodate fasteners, such as screws, nails or staples in one or more of the openings 40, 42, 44 and 46 for fastening the clips 30 to the furring strips 20 as shown in Fig. 6. The ceiling clip 30 is thus positioned such that the prong 34 engages the groove portion 19 of a ceiling plank such as the plank 10A (Fig. 6) to secure the groove portion 19 to the furring strip 20. The groove portion 19 (Fig. 6) thus includes spaced sidewalls 60 and 62 that define a channel 64.

[0022] The ceiling clip prong 34 is accommodated into the channel 64 to engage the channel sidewall 60. The ceiling clip 30 thus sandwiches the channel sidewall 60 between the prong 34 and the base plate 32. The tongue 15 of another ceiling plank IOC can thus be interengaged in the groove portion 19 of the ceiling plank 10A (Figs. 3, 6 and 7).

[0023] In this manner the ceiling clip 30 secures the groove portion 19 of the ceiling plank 10A to the furring strip 20 to enable the groove portion

19 to receive and support the tongue portion 15 of a next installed ceiling plank IOC in adjacent relationship to the previously installed ceiling plank 10A.

[0024] Under this arrangement the plank ceiling installation is progressively installed as shown in Figs. 2 and 3. It will be noted from Fig. 2 that a cut ceiling plank 10, indicated by the reference number 10E, is installed at an edge of the ceiling. The cut end of the ceiling plank 10E is without a tongue or groove and is nailed or screwed directly to a furring strip

20 (not shown) at the edge of the ceiling. The uncut edge of the ceiling plank 10E with a tongue or groove profile is interengaged with the

complementary end of an uncut full size plank 10. The cut ceiling planks, such as the plank 10E, are of a smaller size than the uncut forty-eight inch ceiling plank 10.

[0025] The prior art ceiling plank installation as shown in Fig. 1 is representative of the known highly elongated eighty-four inch standard ceiling planks 50, with end cut ceiling planks 52 at the edge of the ceiling. It can been seen from Fig. 1 that the size of the cut ceiling planks 52 relative to the known uncut eighty-four inch ceiling planks 50 can be relatively small and disproportional to the uncut eighty-four inch length of the planks 50. In comparison, the cut ceiling planks 10E (Fig. 2) are usually more

proportional to the uncut forty-eight inch length of the ceiling planks 10 of the present invention. The cut ceiling planks 10E ( Fig. 2) are thus more proportional in size to the uncut forty-eight inch length ceiling planks 10 of the present invention than are the prior art cut planks 52 (Fig. 1) relative to the uncut eighty-four inch length of the known ceiling planks 50.

[0026] Furthermore, since the ceiling plank 10 of the present invention is preferably approximately forty-eight inches long as compared the known prior art standard plank length of eighty-four inches there is less likelihood of warpage in the plank 10 as compared to the known eighty-four inch plank 50.

[0027] In addition, the forty-eight inch ceiling plank 10 of the present invention, because it is substantially smaller in length than the known standard eighty-four inch ceiling plank 50 and is of less weight than the known ceiling plank 50, is more easily maneuverable and manipulable by one person than the known standard eighty-four inch ceiling plank 50. Thus a single individual do-it-yourselfer working without assistance can easily install a plank ceiling assembly with the forty-eight inch ceiling plank 10 of the present invention as compared with the known highly elongated eighty-four inch standard ceiling planks 50, which generally require one or more skilled installers.

[0028] As various changes can be made in the above constructions and methods without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a liming sense.