U.S. patent application number 10/206385 was filed with the patent office on 2004-01-29 for acoustical ceiling tile.
Invention is credited to Huebsch, Robert J., Hutmacher, Joerg F..
Application Number | 20040016184 10/206385 |
Document ID | / |
Family ID | 30770269 |
Filed Date | 2004-01-29 |
United States Patent
Application |
20040016184 |
Kind Code |
A1 |
Huebsch, Robert J. ; et
al. |
January 29, 2004 |
Acoustical ceiling tile
Abstract
A ceiling tile includes a first layer and a second layer. The
first layer includes first and second planar surfaces. The second
layer is comprised of at least ten (10) percent fiberglass by
weight and is joined adjacent to the first planar surface.
Inventors: |
Huebsch, Robert J.; (White
Bear Lake, MN) ; Hutmacher, Joerg F.; (Minneapolis,
MN) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Family ID: |
30770269 |
Appl. No.: |
10/206385 |
Filed: |
July 26, 2002 |
Current U.S.
Class: |
52/144 ;
52/506.07 |
Current CPC
Class: |
E04B 9/045 20130101;
E04B 2001/8461 20130101; E04B 9/001 20130101 |
Class at
Publication: |
52/144 ;
52/506.07 |
International
Class: |
E04B 001/82; E04B
002/00; E04B 005/00; E04B 009/00 |
Claims
1. A ceiling tile comprising: a first layer having first and second
planar surfaces; a second layer comprised of at least ten (10)
percent fiberglass by weight joined adjacent the first planar
surface.
2. The ceiling tile of claim 1, further including a third layer
comprised of at least ten (10) percent fiberglass by weight joined
adjacent the second planar surface.
3. The ceiling tile of claim 2, further including a first adhesive
layer between the second layer and the first planar surface and a
second adhesive layer between the third layer and the second planar
surface.
4. The ceiling tile of claim 3, wherein the adhesive is a
thermoplastic bonding agent.
5. The ceiling tile of claim 3, wherein the adhesive is a hot melt
adhesive.
6. The ceiling tile of claim 1, wherein the first layer comprises a
foam core.
7. The ceiling tile of claim 1, wherein the ceiling tile is less
than 0.6 inches thick.
8. The ceiling tile of claim 1, wherein the ceiling tile has a
first axis and a second axis, wherein the first axis is between
five (5) and eight (8) feet long and the second axis is between
three (3) and four (4) feet long.
9. The ceiling tile of claim 1, wherein the ceiling tile has a
first axis and a second axis, wherein the first axis is about eight
(8) feet long and the second axis is about four (4) feet long.
10. An acoustical ceiling tile comprising: a foam panel having
first and second surfaces, the foam panel comprised of an open-cell
melamine foam; and a first laminated layer impregnated with
fiberglass and joined to the first surface of the foam panel.
11. The acoustical ceiling tile of claim 10, further including a
second laminated layer impregnated with fiberglass and joined to
the second surface of the foam panel.
12. The acoustical ceiling tile of claim 10, wherein the first
laminated layer is joined to the first surface by an adhesive
therebetween.
13. The acoustical tile of claim 11, wherein the second laminated
layer is joined to the second surface by an adhesive
therebetween.
14. The acoustical tile of claim 13, wherein the adhesive is a hot
melt or a pressure sensitive adhesive.
15. The ceiling tile of claim 10, wherein the foam panel is less
than 0.6 inches thick.
16. The ceiling tile of claim 10, wherein the foam panel is about
0.4 inches thick.
17. The ceiling tile of claim 10, wherein the foam panel has a
first axis and a second axis, wherein the first axis is between
five (5) and eight (8) feet long and the second axis is between
three (3) and four (4) feet long.
18. The ceiling tile of claim 10, wherein the foam panel has a
first axis and a second axis, wherein the first axis is about
(eight) 8 feet long and the second axis is about four (4) feet
long.
19. A ceiling tile comprising: two opposed layers surrounding a
foam core made from an open-cell melamine foam, the two opposed
layers comprised of a material having at least ten (10) percent
fiberglass by weight.
20. The ceiling tile of claim 19, wherein the two layers are joined
to the foam core with an adhesive layer therebetween.
Description
FIELD OF THE INVENTION
[0001] This invention relates to ceiling tiles and, in particular,
to a high strength acoustical ceiling tile.
BACKGROUND
[0002] In the field of building construction, it is a common
practice to install suspended ceilings in new or existing
structures. Various alternative structural systems and methods are
used for hanging a support frame at the approximate level of the
desired ceiling and then affixing ceiling tiles, panels, or the
like to the frame. Such frames typically are formed from channels
that, in cross section, are in the shape of a "T", an "I", or other
suitable shape. They may be made from aluminum, steel, plastic or
other materials that are suitable for the intended use. The tiles,
panels and other surfacing materials commonly are made from
cellulose, plastic, glass, and other appropriate materials.
[0003] Many such ceiling systems are known and in common use.
However, many have shortcomings and difficulties that make them
difficult to install, unattractive, or otherwise unacceptable in
varying degrees. Therefore, improvements are desirable.
SUMMARY
[0004] In one aspect of the present invention, a ceiling tile is
disclosed. The ceiling tile includes a first layer and a second
layer. The first layer includes first and second planar surfaces.
The second layer is comprised of at least ten (10) percent
fiberglass by weight and is joined adjacent to the first planar
surface.
[0005] In another aspect of the present invention, an acoustical
ceiling tile includes a foam panel and a first laminated layer. The
foam panel has first and second surfaces and is comprised of an
open-cell melamine foam. The first laminated layer is impregnated
with fiberglass and joined to the first surface of the foam
panel.
[0006] In another aspect of the present invention, a ceiling tile
includes two opposed layers surrounding a foam core. The foam core
is made from an open-cell melamine foam. The two opposed layers
comprise a material having at least ten (10) percent fiberglass by
weight.
[0007] A more complete appreciation of the present invention and
its scope may be obtained from the accompanying drawings, that are
briefly described below, from the following detailed descriptions
of presently preferred embodiments of the invention and from the
appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The invention may be more completely understood in
consideration of the following detailed description of various
embodiments of the invention in connection with the accompanying
drawings, in which:
[0009] FIG. 1 is a perspective view of an example embodiment of a
ceiling tile according to the present disclosure.
[0010] FIG. 2 is a fragmented, perspective view of an example
embodiment of a suspended ceiling grid usable with the ceiling tile
of FIG. 1 according to the present disclosure.
[0011] FIG. 3 is a cross sectional view of the ceiling grid of FIG.
2, taken along lines 3-3, with the ceiling tile of FIG. 1 suspended
therein according to the present disclosure.
[0012] FIG. 4 is a cross-sectional view of an example embodiment of
the ceiling tile of FIG. 1 according to the present disclosure.
[0013] FIG. 5 is a cross-sectional view of another example
embodiment of a ceiling tile according to the present
disclosure.
[0014] While the invention is amenable to various modifications and
alternative forms, specifics thereof have been shown by way of
example in the drawings and will be described in detail. It should
be understood, however, that the intention is not to limit the
invention to the particular embodiments described. On the contrary,
the intention is to cover all modifications, equivalents, and
alternatives falling within the spirit and scope of the
invention.
DETAILED DESCRIPTION
[0015] In the following description of preferred embodiments of the
present disclosure, reference is made to the accompanying drawings
that form a part hereof, and in which is shown by way of
illustration specific embodiments in which the disclosure might be
practiced. It is understood that other embodiments may be utilized
and structural changes may be made without departing from the scope
of the present invention.
[0016] In general, the present disclosure discusses a ceiling tile
for use in a suspended ceiling grid system. The ceiling tile is a
lightweight, multi-layer ceiling tile that has a high strength and
other desirable properties.
[0017] FIG. 1 is a perspective view of a ceiling tile 10 usable in
a suspended ceiling grid system. The ceiling tile 10 has many
industrial applications, but is especially suited for suspended
ceilings that include a framework with individual ceiling tiles
suspended by flanges or lips in the framework.
[0018] FIG. 2 is a fragmented, perspective view of an example
embodiment of such a suspended ceiling grid system 20. The
suspended ceiling grid system 20 is an exposed grid system 22. The
exposed grid system 22 comprises first members 24 and second
members 26. Generally, the first members 24 and second members 26
are configured and arranged perpendicular to each other to form the
exposed grid system 26. Preferably, the first members are main
runners 28. Preferably, the second members are cross runners
30.
[0019] The exposed grid system 22 further comprises third members
32. The third members are typically configured and arranged
vertically and typically are attached to another structure above
the exposed grid system 22. Preferably, the third members 32 are
hangers 34. The suspended ceiling grid system 20 generally defines
rectangular areas 36. The rectangular areas 36 defined can be of
any suitable dimension. Typically the rectangular areas are formed
in standard sizes, for example, twenty-four (24) inches by
twenty-four (24) inches.
[0020] FIG. 3 is a cross-sectional view of a portion of the
suspended ceiling grid system 20 taken along lines 3-3. Typically,
the second members 26 and cross runners 30 have a T-shaped
cross-sectional area as illustrated in FIG. 3. However, any
suitable cross-sectional shape can be used. Likewise, the first
members 24 and main runners 28 typically have a T-shaped
cross-sectional area, although not shown, but can have any suitable
cross-sectional shape. Preferably, the ceiling tile 10 fits within
the rectangular area 36, described above, such that the ceiling
tile 10 is supported by the first and second members 24, 26.
[0021] FIG. 4 is a cross-sectional area of the ceiling tile 10 of
FIG. 1 taken along line 4-4. Preferably, the ceiling tile 10
includes a first layer 101, a second layer 102, and a third layer
103. In general, the second layer 102 is sandwiched, or placed
between, the first layer 101 and the third layer 103. Preferably,
the first layer 101 is attached, bonded, or joined to the second
layer 102. Likewise, the third layer 103 is attached, bonded, or
joined to the second layer 102 to form an unified ceiling tile
10.
[0022] In the example embodiment shown in FIG. 4, the first layer
101 is attached to the second layer 103 by a fourth layer 104.
Preferably, the fourth layer 104 comprises an adhesive like
material. Likewise, the third layer 103 is attached to the second
layer 102 by a fifth layer 105. Preferably, the fifth layer 105
comprises an adhesive like material. It is noted that the first
layer 101 could be chemically bonded to the second layer 102
without the need for the fourth layer 104. Likewise, the third
layer 103 could be chemically bonded to the second layer 102
without the need for the fifth layer 105.
[0023] Typically, the second layer 102 comprises a foam core 110
and includes first and second planar surfaces 112, 114. One example
of suitable foam core 110 is preferably made from an open-cell
melamine material, such as WILLTEC.RTM. foam, available from
Illbruck Architectural Products in Minneapolis, Minn. Of course,
any suitable material for the second layer 102 can be used. The
first layer 101 is joined adjacent the first surface 112 of the
second layer 102 and the third layer 103 is joined adjacent the
second surface 114 of the second layer 102.
[0024] The first and third layers 101, 103 are preferably a white
fleece material, although any suitable material might be used.
Preferably, the white fleece material includes at least ten (10)
percent fiberglass by weight. Typically, the white fleece material
includes between sixty-five (65) and seventy (75) percent
fiberglass by weight. More preferably, the first and third layers
101, 103 are made from a fiberglass mat with adhesive, such as
MICROLITH.RTM. glass fiber mat available from Johns Manville,
Corp., as Type SM-H 50/34 B51. This preferred material combines the
first and fourth layers 101, 104 into one fiberglass mat with
adhesive, and the third and fifth layers 103, 105 into one
fiberglass mat with adhesive. The adhesive can be, for example, a
thermoplastic bonding agent.
[0025] The first and third layers 101, 103 are advantageous. One
advantage is that the first layer and third layers 101, 103 add
strength to the ceiling tile 10, which might otherwise sag under
its own weight. The first and third layers 101, 103 also add a
pleasing aesthetic appearance to the ceiling tile 10 when it is
installed.
[0026] While the example embodiment shown includes two layers 101,
103 surrounding the second layer 102, it is possible to have only
one layer on either side of the second layer 102. FIG. 5
illustrates another example embodiment in which only one adjacent
layer is used in a ceiling tile 200. Referring now to FIG. 5, if
only one layer 220 is used, it is preferably on a surface 212 of a
second layer 210 oriented downwards as the ceiling tile 200 is
placed in the framework of the suspended ceiling described
previously herein. In this orientation, the layer 220 is in tension
and tends to keep the second layer 210 from sagging, and the layer
220 also presents an aesthetically pleasing appearance. Of course,
the ceiling tile 200 could also be oriented upwards, or in the
reverse direction. The layer 220 is joined to the second layer 210
by an adhesive zone 230 therebetween. Of course, the layer 220
could be joined to the second layer by chemical bonding.
[0027] Referring back to FIG. 4, the first and third layers 101,
103 are preferably laminated to the second layer 102 by adhesive
layers 104, 105, respectively, between the first and third layers
101, 103 and the corresponding surface 112, 114 to which they are
attached. Preferably, a hot melt or pressure sensitive adhesive is
used to join the first and third layers 101, 103 to the second
layer 102. The first and third layers 101, 103 might also be
attached to the second layer 102 by coating or impregnating the
first and third layers 101, 103 with a hot-melt adhesive.
[0028] The second layer 102, along with the first and third layers
101, 103, is then run through a heated nip roller assembly, not
shown. The heated roller melts the adhesive on the first and third
layers 101, 103 as the arrangement passes through the nip roller,
thus joining the first and third layers 101, 103 to their
respective surface 112, 114 of the second layer 102.
[0029] The ceiling tile of the present disclosure can be made
thinner than a typical ceiling tile, due to its high strength and
improved acoustical properties. For example, a twenty-four (24)
inch square tile can be made 0.4 inches thick. The ceiling tile of
the present disclosure can also be made into tiles ranging from
twenty-four (24) inches by forty-eight (48) inches up to
forty-eight (48) inches by ninety-six (96) inches that are 0.6
inches thick. The tile can be made to other dimensions in both
thickness and length and width, and the example dimensions are used
to demonstrate the high strength of the ceiling tile 10 of the
present disclosure. The ceiling tile 10 of the present disclosure
can be made as thin as 0.04 inches thick. The tiles generally have
a first axis and a second axis, and the tile is typically longer
along the first axis than along the second axis. The first axis is
preferably between five (5) feet and eight (8) feet and the second
axis is preferably between three (3) feet and four (4) feet.
[0030] The present invention should not be considered limited to
the particular examples described above, but rather should be
understood to cover all aspects of the invention as fairly set out
in the attached claims. Various modifications, equivalent
processes, as well as numerous structures to which the present
invention may be applicable will be readily apparent to those of
skill in the art to which the present invention is directed upon
review of the instant specification.
* * * * *