Abstract: Sag in ceiling tiles is reduced by the present coated ceiling tile and method which decreases sag in the coated ceiling tiles. Calcined gypsum and water are combined to form a coating which is applied to the back side of a base ceiling tile in a thin layer of about 100 micrometer to about 1000 micrometers. The coating optionally includes a set time modifier. This method makes a coated ceiling tile from a base ceiling tile having a front side and a back side opposing the front side. The coating is applied to the back side of the base ceiling tile, the coating comprising an interlocking matrix of calcium sulfate dihydrate. Optionally, remnants of the set time modifier are present within interstices in the gypsum matrix. The remnants of the set time molecule include ions, molecules, particles or combinations thereof.

Abstract: A cross member for a narrow channel in a suspended ceiling grid comprising a carrier and a cover, the carrier having a web and a planar flange on a lower edge of the web, end connectors at opposite ends of the carrier web, the cover having a three-dimensional cross-section with an overall width generally equal to the width of the carrier flange and integral bendable tabs, the tabs being adjacent the ends of the cover and short in comparison to a length of the cover, the tabs being constructed to be manually folded over the flange of the carrier to lock the cover to the carrier.

Abstract: Provided is a mineral wool that includes recycled material. The mineral wool is characterized by an acid to base ratio within a specified range. Also provided is a method of manufacturing the mineral wool that includes selection of post-consumer or post-industrial recyclable materials. Application of the mineral wool to products such as an acoustical ceiling panel is also provided.

Abstract: Sag in ceiling tiles is reduced by the present coated ceiling tile and method which decreases sag in the coated ceiling tiles. Calcined gypsum and water are combined to form a coating which is applied to the back side of a base ceiling tile in a thin layer of about 100 micrometer to about 1000 micrometers. The coating optionally includes a set time modifier. This method makes a coated ceiling tile from a base ceiling tile having a front side and a back side opposing the front side. The coating is applied to the back side of the base ceiling tile, the coating comprising an interlocking matrix of calcium sulfate dihydrate. Optionally, remnants of the set time modifier are present within interstices in the gypsum matrix. The remnants of the set time molecule include ions, molecules, particles or combinations thereof.

Abstract: An abuse-resistant, cast acoustical ceiling tile having improved impact resistance and excellent sound absorption values. The ceiling tiles have aggregate particles applied to the surface of a wet pulp in the casting process and the particles are embedded in the pulp by compression with a roll and/or smooth plates. The aggregate particles have an average particle diameter of at least about 1,000 microns. The ceiling tiles have excellent sound absorption properties with a noise reduction coefficient (NRC) of at least about 0.50. Calcium carbonate is the preferred aggregate particle material.

Abstract: A suspended ceiling grid runner comprising separate parallel upper and lower chords, a plurality of identical web plates fixed between the chords and the plates having a height less than the height of the grid runner and a width, the chords being made of roll-formed sheet metal strips and symmetrical about a vertical plane, the chordal strips each having marginal sections folded parallel to one another and on opposite sides of the vertical plane, the web plates including vertical slots for receiving connectors of cross runners, the web plates being spaced at regular centers along the grid runner with a distance that is a small fraction of the nominal length of the grid runner, the gaps between adjacent web plates being longer than the height of the grid runner.

Abstract: An elongated grid runner, and its manufacture, comprising a pair of overlying metal strips roll-formed together into a shape suitable for use in a rectangular grid to support ceiling panels, one of said strips serving as a visible cap for concealing the other strip forming the main body of the grid runner when the grid member is employed in a completed ceiling, the strips being lanced at each end of the grid runner to lock the cap strip on the main body strip whereby when the overlying strips are simultaneously cut to a finish length prior to finish roll-forming, the ends of the strip are maintained in substantially overlying end-to-end registration where the cap is visible in a finished ceiling.

Abstract: An acoustic building material and method for manufacture incorporates a homogenously dispersed reactive silicone to improve water repellency and physical properties.

Abstract: A ceiling panel system includes a plurality of grid members that are operable to form a grid suspendable from a ceiling, the grid having grid member intersections; and a plurality of ceiling panels, each ceiling panel including a planar surface and a plurality of upturned edges arranged about the periphery of the planar surface. The upturned edges include a catch operable to attach the panels to the face of the grid intermediately to the intersections to form a ceiling surface.

Abstract: An elongated metal grid runner for a suspended ceiling, the grid runner having a cross-section with an upper hollow reinforcing bulb, a vertical web extending below the bulb, and lower flange elements extending laterally from opposite sides of the web, the length of the grid runner being less than about 9?, a permanent magnet disposed on each end of the grid runner at its flange elements, the magnet being adapted to overlie and be attracted to a horizontal leg of a steel wall angle to thereby releasably retain the grid runner in position on the wall angle.

Abstract: A water felted base mat for a suspended ceiling tile comprising on a weight basis about ½ mineral wool, starch binder, limited to about ?, newsprint, limited to about ?, and about ¼ expanded glass beads.

Abstract: A suspended ceiling comprising a grid formed of intersecting grid runners and snap-up panels supported on the grid runners, the grid runners dividing a ceiling area into standard modules, the pans being formed of sheet material and each having its sides sized to cover the module size while leaving a space at visible faces thereof between adjacent panels when in an installed position on the grid, at least one adjacent pair of panels being displaceable from their installed positions, the gap between a pair of displaceable panels being closed by a removable runner or the displaceable panels so that when the displaceable panels are displaced from their installed position and any removable runner is removed, an access opening of twice the standard module is made available for accessing the area above the ceiling while adjacent panels at longitudinal ends of the gap between the displaceable panels can remain in respective installed positions.

Abstract: A wall molding for a suspended ceiling comprising a roll-formed sheet metal body having a generally upright component to be fixed to a wall and a projecting component extending generally transversely to the upright component and adapted to underlie and support the edges of ceiling tiles and ends of grid runners, the projecting component in a free state extending across a plane defined by the upright component to a line adapted to abut the wall when the upright component is drawn towards the wall.

Abstract: An interior surface panel such as a ceiling tile is free of PVC materials and otherwise possesses desirable properties that make it suitable for installation in a variety of environments including schools, household and commercial kitchens and healthcare facilities. The panel can include a base mat and a facing material of a polyolefin or polyester polymer or copolymer bonded to the base mat. The facing material is resistant to ultraviolet light and possesses superior scrubbability. The PVC-free facing has a preferred thickness, opacity and surface roughness and a texture pattern that is non-directional and discontinuous. In an embodiment in which the PVC-free facing is white, it has a preferred light reflectance. The PVC-free facing is resistant to deformation under tension. In addition, the facing has low anisotropy; that is, the facing exhibits minimal differences in its physical properties in different directions. The facing also has good dimensional stability.

Abstract: A panel includes about 0.1% to about 95% by weight of a ground renewable component. In an embodiment, the panel has at least one core comprising: from about 0.1% to about 95% by weight of the ground renewable component; from about 0.1% to about 95% by weight of one or more fibers; and from about 1% to about 30% by weight of one or more binders, all based on dry panel weight. In an embodiment, the ground renewable component has a particle size distribution whereby less than 5% of the particles are retained by a mesh screen with openings of about 0.312 inches and less than 5% of the particles pass through a mesh screen with openings of about 0.059 inches. A method for manufacturing such panels is also provided.

Abstract: A roll-formed grid runner comprising a sheet metal strip folded into an upper hollow single wall reinforcing bulb, a double wall web below the bulb, a channel extending laterally from both sides of a lower end of the web to a bend and upwardly from the bend to a panel supporting elevation, the bend on each side of the web existing at a longitudinally extending score line where a thickness of the strip is locally reduced.

Abstract: A clip for a suspended ceiling grid to join a pair of grid runners intersecting a third grid runner from opposite sides of the third grid runner, the clip being bendable sheet metal symmetrical about a vertical plane, having a saddle portion with a seat and generally planar flaps depending from opposite sides of the seat, including a pair of generally planar wings each cantilevered from a respective one of the flaps; the seat width corresponding to a hollow reinforcing bulb of a grid runner, the flaps extend over the sides of the reinforcing bulb and web of the third grid runner, a flap and wing joined at a vertical bend line, weaker than each adjacent area of the flap and wing whereby the wing can be manually bent to a desired angle relative to the flap.

Abstract: An acoustical building panel and method of manufacturing it are disclosed. Embodiments of the panel include a porous nonwoven scrim, a coating deposited on the scrim, a base mat, and an adhesive deposited on either the base mat or the scrim in a discrete form such as in droplets. Embodiments of the method of manufacture include steps of perforating the base mat, applying the adhesive to the base mat in the discrete form, laminating the scrim onto the base mat, and applying the coating to the scrim surface.

Abstract: The invention, provides a curable, formaldehyde free coating composition comprising a composition comprising a polyacid copolymer crosslinked with a hydroxyl group-containing compound and calcium aluminosilicate powder, panels coated with the coating composition, and a method of coating a panel with the coating composition.

Abstract: A panel includes about 0.1% to about 95% by weight of a renewable component. The panel has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. A method for manufacturing such panels is also provided.