Ceiling tile assembly
A ceiling tile assembly includes a sheet of ornamental facing and a support frame or a supporting member with a retaining element.
This is a continuation-in-part of U.S. Utility patent application Ser. No. 10/749,085, filed on Dec. 30, 2003 and is also a continuation-in-part of U.S. Utility patent application Ser. No. 11/047,313 filed on Jan. 31, 2005.
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITYThe present invention relates generally to the suspended ceiling art and, more particularly, to a new and improved ceiling tile assembly.
BACKGROUND OF THE INVENTIONA number of different systems and structures have been developed for providing a drop or suspended ceiling in a room. As will be appreciated by those skilled in the art, suspended ceilings are formed from a primary overhead structure such as ceiling joists or the underside of a reinforced concrete structure for establishing a substantially level and more aesthetically pleasing ceiling for a finished space. Suspended ceilings provide improved flexibility for finishing a space over ceiling systems that are mounted directly to the primary overhead structure or furring strips or other attachment regions provided on the primary overhead structure. Suspended ceilings generally comprise a plurality of individual ceiling tiles with the individual tiles typically having a rectangular or square shape. The composition of the individual ceiling tiles utilized in such systems have also been manufactured from many different materials such as pressed fibrous materials or synthetic polymers and synthetic resins that may be cast to form the tile body. The ceiling tiles may also be produced with at least one embossed or textured surface for improving the aesthetic appearance and/or improved sound absorption. The present invention relates to an alternative type of ceiling tiles that are manufactured using a combination of a frame and a cover layer.
SUMMARY OF THE INVENTIONIn accordance with the purposes of the present invention as described herein, an improved ceiling tile assembly is provided. That ceiling tile assembly comprises a sheet of ornamental facing having a main body and a margin and a support frame engaging and holding that margin. The assembly is further characterized by constructing the sheet of ornamental facing from a fiberglass veil.
More specifically describing the invention, the fiberglass veil includes between about 17 to about 30 weight percent glass fibers, about 6 to about 10 weight percent polymer binder and about 58 to about 78 weight percent filler. The glass fibers have a nominal diameter of between about 6.5 to about 11.0 microns and a length of between about 5.0 to about 7.0 mm. In addition the fiberglass veil has an areal weight of about 50 to about 200 gsm and a thickness of between about 1.0 to about 2.0 mm. The fiberglass veil is also characterized by a water hold number of greater than 180 seconds.
The filler may be a flame retardant. Typically the filler includes aluminum trihydrate, phosphorous compounds, antimony trioxide, borates, intumescent materials, or mixtures thereof. The polymer binder may be selected from a group of materials including, for example, polyvinyl alcohol, styrene-acrylate, melamine formaldehyde and mixtures thereof.
The support frame is constructed from a material selected from a group consisting of polypropylene, polystyrene, polyethylene, polyvinyl chloride, nylon, acrylic, polycarbonate and mixtures thereof. Typically the support frame has a tensile strength at yield of between about 15 to about 70 MPa as measured by ASTM test method D638 and a flexural modulus of between about 40 to about 100 MPa as measured by ASTM D790.
In accordance with additional aspects of the present invention, the margin and support frame are continuous and have a width of between about 1.5 to about 2.0 mm. Further, the main body has a surface area of between about 3,100 to about 3,800 cm2. The sheet of ornamental facing is unstretched and the main body spans between the support frame and is otherwise unsupported. The sheet of ornamental facing has a thickness of between about 1.0 to about 2.0 mm and the support frame has a thickness of between about 2.0 to about 5.0 mm. Further the main body is characterized by a sag of less than about 2.5 mm and more preferably about 2.0 mm as measured by ASTM test method C367.
In one possible embodiment, the support frame is discontinuous. The support frame is also substantially c-shaped in cross section and defines a channel that holds a margin of the ornamental facing. Such a support frame may either be straight or form a corner.
The ceiling tile assembly of the present invention may be alternatively described as comprising a sheet of ornamental facing and a support frame having an overall thickness of less than 7.0 mm and characterized by a sag of less than about 2.5 mm for an unsupported surface area of about 3716 cm2 as measured by ASTM test method C367. The ceiling tile assembly has a weight per unit area of between about 50 to about 200 gsm.
In accordance with yet another aspect of the present invention a method is provided for reducing shipping expenses relating to ceiling tiles. That method comprises producing ceiling tiles with an overall thickness of less than about 7.0 mm and an overall weight per unit area of less than about 200 gsm and then packing those ceiling tiles in a shipping vessel such as a carton, box, crate or the like.
In still another embodiment, the ceiling tile assembly comprises a sheet of ornamental facing and a supporting member. The ornamental facing has a main body and a margin. The supporting member includes a supporting flange and a retaining element. The retaining element is displaceable between open and closed positions. When closed, the margin of the ornamental facing is pressed and held between the supporting flange and the retaining element.
In the following description there is shown and described several embodiments of this invention, simply by way of illustration of some of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGSThe accompanying drawings incorporated in and forming a part of this specification, illustrate several aspects of the present invention, and together with the description serve to explain certain principles of the invention. In the drawings:
These drawings have been provided to assist in the understanding of the exemplary embodiments of the invention as described in more detail below and should not be construed as unduly limiting the invention. In particular, the relative spacing, positioning, sizing and dimensions of the various elements illustrated in the drawings are not drawn to scale and may have been exaggerated, reduced or otherwise modified for the purpose of improved clarity.
Those of ordinary skill in the art will also appreciate that a range of alternative configurations have been omitted simply to improve the clarity and reduce the number of drawings. Similarly, those of ordinary skill will appreciate that certain of the various structural elements illustrated in the exemplary embodiments shown in the drawing figures may be selectively and independently combined to form other configurations for preparing a ceiling tile configuration tailored specifically for an intended application.
DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION An exemplary ceiling tile assembly 100 according to the present invention is illustrated in
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Openings may be provided in the peripheral frame 102 for inserting a tool or a finger through the frame to contact and deflect the retaining element 112. The openings may, in turn, be concealed using a plug or an insert 102d for concealing the openings until needed. As an alternative to the openings, the peripheral frame 102 may incorporate a simple mechanism 116 for deflecting the retaining element 112 through actuation of an exposed button, slide, tab, fastener or other structure. As also illustrated in
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The channels 304 and 404 in the respective support frames 300, 400 are sized and shaped to securely hold the ornamental facing 104 without the use of adhesive. More specifically, the elements 302, 402 engage the ornamental facing 104 and are made from a material with sufficient resiliency to provide the desired friction fit.
In either embodiment, the support frame 300, 400 is suited to hold an ornamental facing 104 of substantially any size and shape in a ceiling grid without cutting or gluing of the support frame. Thus, the frames 300, 400 are particularly versatile and suited “out-of-the-box” for substantially any application.
Yet another embodiment of a ceiling tile assembly 500 is illustrated in
An important aspect of the present invention is the thin profile and lightweight of the ceiling tile assembly 100. As a consequence, a large number of ceiling tile assemblies 100 may be packaged together for shipping at reduced cost. Specifically, the resulting package is both lighter in weight and less bulky than would be true if shipping ceiling tiles of prior art design. More specifically, the ornamental facing 104 of the ceiling tile assembly 100 is constructed from a fiberglass veil. That fiberglass veil includes between about 17 to about 30 weight percent glass fibers, about 6 to about 10 weight percent polymer binder and about 58 to about 78 weight percent filler. The glass fibers have a nominal diameter of between about 6.5 to about 11.0 microns and a length of between about 5.0 to about 7.0 mm. Further the fiberglass veil has an areal weight of between about 50 to about 200 gsm and a thickness of between about 1.0 to about 2.0 mm.
Typically a flame retardant is used as the filler. Thus, the filler may be made from a material selected from a group including, for example, alumina trihydrate, phosphorous compounds, antimony trioxide, borates, intumescent materials and mixtures thereof. Substantially any other flame retardant known in the art may be utilized. Typically the polymer binder is selected from a group of materials consisting of polyvinyl alcohol, styrene-acrylate, melamine formaldehyde and mixtures thereof. In addition the fiberglass veil is characterized by a water hold number of greater than 180 seconds. The water hold test comprises dripping one drop of water from a height of 5 cm onto the veil surface and measuring the time for full absorption at room temperature.
The peripheral support frame 102, 300, 400 may be constructed from substantially any appropriate material including, for example, polypropylene, polystyrene, polyethylene, polyvinyl chloride, nylon, acrylic, polycarbonate and mixtures thereof. The support frame 102, 300, 400 has a tensile strength at yield of between about 15 to about 70 MPa as measured by ASTM test method D638 and a flexural modulus of between about 40 to about 100 MPa as measured by ASTM test method D790.
A typical ceiling tile assembly 100 will have a length and width of approximately 60.96 cm. As best illustrated in
The fiberglass veil from which the ornamental facing 104 is constructed is characterized by remarkable dimensional stability. Since the ornamental facing 104 is not stretched prior to adhering to the support frame 102, the material is not in tension and thus will not stretch or elongate over time as would be typical of a stretched facing material. Similarly, glass veils have a very low elongation, less than some tenths of a percent and, accordingly, the ornamental facing 104 will not stretch and sag under heat. As noted above, the fiberglass veil of the ornamental facing 104 absorbs very little water and, therefore, again has no tendency to stretch due to absorbed water weight even in relatively high humidity environments. In fact, the fiberglass veil used for the ornamental facing 104 is characterized by a sag of less than about 2.5 mm as measured by ASTM test method C367. More preferred embodiments of the present invention are characterized by a sag of less than about 2.0 mm as measured by ASTM test method C367. Suitable veil material is available from Owens Corning, Toledo, Ohio.
By forming the ornamental facing 104 from a fiberglass veil, other benefits are also provided. Specifically, the veil is flexible, resilient and breathable. Thus, sound passes freely through the veil. Consequently, a speaker may be positioned out of sight behind the ceiling tile assembly 100 yet the sound passes freely through the veil to those in the room. Advantageously, this provides a more aesthetically pleasing, continuous ceiling surface and eliminates the need for an installer to customize a ceiling tile assembly 100 by cutting around and exposing a speaker.
Although the invention has been described in connection with certain exemplary embodiments, it will be evident to those of ordinary skill in the art that many alternatives, modifications, and variations may be made to the disclosed structures and methods in a manner consistent with the detailed description provided above. Also, it will be apparent to those of ordinary skill in the art that certain aspects of the various disclosed exemplary embodiments could be used in combination with aspects of any of the other disclosed embodiments or their alternatives to produce additional, but not herein illustrated, embodiments incorporating the claimed invention but more closely adapted for an intended use or performance requirements. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
Claims
1. A ceiling tile assembly, comprising:
- a sheet of ornamental facing having a main body and a margin; and
- a support frame engaging and holding at least a portion of said margin;
- said assembly being characterized by constructing said sheet of ornamental facing from a fiberglass veil.
2. The assembly of claim 1, wherein said fiberglass veil includes between about 17 to about 30 weight percent glass fibers, about 6 to about 10 weight percent polymer binder and about 58 to about 78 weight percent filler.
3. The assembly of claim 2, wherein said glass fibers have a nominal diameter of between about 6.5 to about 11.0 microns and a length of between about 5.0 to about 7.0 mm.
4. The assembly of claim 2, wherein said fiberglass veil has an areal weight of between about 50 to about 200 gsm and a thickness of between about 1.0 to about 2.0 mm.
5. The assembly of claim 4, wherein said filler is a flame retardant.
6. The assembly of claim 5, wherein said filler includes materials selected from a group consisting of alumina trihydrate, phosphorous compounds, antimony trioxide, borates, intumescent materials, and mixtures thereof.
7. The assembly of claim 2, wherein said polymer binder is selected from a group of materials consisting of polyvinyl alcohol, styrene-acrylate, melamine formaldehyde and mixtures thereof.
8. The assembly of claim 1, wherein said support frame is constructed from a material selected from a group consisting of polypropylene, polystyrene, polyethylene, polyvinyl chloride, nylon, acrylic, polycarbonate and mixtures thereof.
9. The assembly of claim 8, wherein said support frame has a tensile strength at yield of between about 15 to about 70 MPa as measured by ASTM test method D638 and a flexural modulus of between about 40 to about 100 MPa as measured by ASTM test method D790.
10. The assembly of claim 1, wherein said fiberglass veil is characterized by a water hold number of greater than 180 seconds.
11. The assembly of claim 1, wherein said margin and said support frame are continuous and have a width of between about 1.5 to about 2.0 mm.
12. The assembly of claim 11, wherein said main body has a surface area of between about 3,800 to about 3,800 cm2.
13. The assembly of claim 12, wherein said sheet of ornamental facing is unstretched and said main body spans across an opening in said support frame and is otherwise unsupported.
14. The assembly of claim 13, wherein said sheet of ornamental facing has a thickness of between about 1.0 to about 2.0 mm, said support frame has a thickness of between about 2.0 to about 5.0 mm.
15. The assembly of claim 14, wherein said main body is characterized by a sag of less than about 2.5 mm as measured by ASTM test method C367.
16. The assembly of claim 14, wherein said main body is characterized by a sag of less than about 2.0 mm as measured by ASTM test method C367.
17. The assembly of claim 1 wherein said support frame is discontinuous.
18. The assembly of claim 17, wherein said support frame is substantially C-shaped in cross section and defines a channel holding said margin.
19. The assembly of claim 18, wherein said support frame defines a corner.
20. The assembly of claim 18, wherein said support frame is straight.
21. A ceiling tile assembly, comprising:
- a sheet of ornamental facing and a support frame having an overall thickness of less than 7.0 mm and characterized by a sag of less than about 2.5 mm for an unsupported surface area of about 3716 cm2 as measured by ASTM test method C367.
22. The ceiling tile assembly of claim 21, wherein said ceiling tile assembly has a weight per unit surface area of between about 50 to about 200 gsm.
23. A ceiling tile assembly, comprising:
- a facing sheet of breathable material and a support frame having an overall thickness of less than 7.0 mm.
24. The ceiling tile assembly of claim 23 having an overall thickness of less than 5.0 mm.
25. A method of reducing shipping expenses relating to ceiling tiles, comprising:
- producing ceiling tiles with an overall thickness of less than 7.0 mm and an overall weight per unit area of less than 200 gsm; and
- packing those ceiling tiles in a shipping vessel.
26. A ceiling tile assembly, comprising:
- a sheet of ornamental facing having a main body and a margin; and
- a supporting member including a retaining element engaging said ornamental facing.
27. The assembly of claim 26, wherein said supporting member includes a supporting flange and said retaining element is displaceable between an open position and a closed position.
28. The assembly of claim 27, wherein in said closed position said margin of said ornamental facing is engaged between said supporting flange and said retaining element.
Type: Application
Filed: Sep 1, 2006
Publication Date: Apr 12, 2007
Inventors: Frederick Buck (New Albany, OH), Mohammed Tazi (New Albany, OH)
Application Number: 11/514,465
International Classification: E04H 15/00 (20060101);