U.S. patent application number 10/749085 was filed with the patent office on 2005-08-04 for ceiling tile.
Invention is credited to Grove, Dale A., Lee, Yien-Ming L., Morelissen, Jacob H..
Application Number | 20050166506 10/749085 |
Document ID | / |
Family ID | 34749286 |
Filed Date | 2005-08-04 |
United States Patent
Application |
20050166506 |
Kind Code |
A1 |
Morelissen, Jacob H. ; et
al. |
August 4, 2005 |
Ceiling tile
Abstract
The present invention is directed to a ceiling panel for use in
a suspended ceiling system. The ceiling panel includes a main frame
and at least two crossing members within said main frame. A facing
material is adhered to the main frame and crossing members.
Inventors: |
Morelissen, Jacob H.;
(Holland, OH) ; Lee, Yien-Ming L.; (Westerville,
OH) ; Grove, Dale A.; (Pataskala, OH) |
Correspondence
Address: |
OWENS CORNING
2790 COLUMBUS ROAD
GRANVILLE
OH
43023
US
|
Family ID: |
34749286 |
Appl. No.: |
10/749085 |
Filed: |
December 30, 2003 |
Current U.S.
Class: |
52/506.06 |
Current CPC
Class: |
E04B 9/0428 20130101;
E04B 2103/04 20130101 |
Class at
Publication: |
052/506.06 |
International
Class: |
E04B 002/00; E04B
005/00 |
Claims
What is claimed is:
1. A ceiling panel for use in a suspended ceiling system
comprising: a) a main frame; b) at least two crossing members
within said main frame; and c) a facing material adhered to said
main frame and said crossing members.
2. The ceiling panel of claim 1, wherein said main frame and said
crossing members a one-piece assembly.
3. The ceiling panel of claim 2, wherein said main frame and said
crossing members are made of a material selected from the group
consisting of injection molded plastic and extruded plastic.
4. The ceiling panel of claim 2, wherein said main frame and said
crossing members are made of a material selected from the group
consisting of aluminum, steel, and other roll-formable metals.
5. The ceiling panel of claim 3, wherein said main frame and said
crossing members are welded together.
6. The ceiling panel of claim 3, wherein said plastic is flame
retardant.
7. The ceiling panel of claim 6, wherein said plastic is selected
from the group consisting of rigid polyvinyl chloride and
polyphenylene sulfide.
8. The ceiling panel of claim 6, wherein said plastic is a plastic
made with a material selected from the group consisting of
halogenated additives/copolymers, antimony trioxide, antimony
pentoxide, nitrogen-phosphorous flame retardants, phosphates,
aluminum trihydrate, magnesium hydroxide, bauxite, and calcium
carbonate.
9. The ceiling panel of claim 3, wherein said plastic is reinforced
with a material selected from the group consisting of glass fibers,
carbon fibers, mica, wollastonite, and talc.
10. The ceiling panel of claim 1, wherein said facing material is a
veil.
11. The ceiling panel of claim 1, wherein said facing material is a
textile material.
12. The ceiling panel of claim 1, wherein said facing material is a
film.
13. The ceiling panel of claim 5, wherein said facing material is
adhered to said main frame and said first and second crossing
members by heat bonding or through adhesives applied either to the
frame or preapplied to the veil.
14. The ceiling panel of claim 1, wherein said main frame is square
or rectangular.
15. The ceiling panel of claim 14, wherein said crossing members
are arranged in an "X" shape or radiated outwardly from a centrally
located, circular connection point.
16. The method of making a ceiling panel for use in a suspended
ceiling system comprising the steps of: a. providing a main frame
b. providing first and second crossing members within said main
frame; c. providing a facing material; and d. affixing said facing
material to said main frame and said first and second crossing
members.
17. The method of claim 16, wherein said main frame and said
crossing members are a one-piece assembly.
18. The method of claim 17, wherein said main frame and said
crossing members are made of a material selected from the group
consisting of injection molded plastic and extruded plastic.
19. The method of claim 17, wherein said main frame and said
crossing members are made of a material selected from the group
consisting of aluminum, steel, and other roll-formable metals.
20. The method of claim 18, wherein said main frame and said
crossing members are welded together.
21. The method of claim 18, wherein said plastic is flame
retardant.
22. The method of claim 21, wherein said plastic is selected from
the group consisting of rigid polyvinyl chloride and polyphenylene
sulfide.
23. The method of claim 21, wherein said plastic is a plastic made
with a material selected from the group consisting of halogenated
additives/copolymers, antimony trioxide, antimony pentoxide,
nitrogen-phosphorous flame retardants, phosphates, aluminum
trihydrate, magnesium hydroxide, bauxite, and calcium
carbonate.
24. The method of claim 18, wherein said plastic is reinforced with
a material selected from the group consisting of glass fibers,
carbon fibers, mica, wollastonite, and talc.
25. The method of claim 16, wherein said facing material is a
veil.
26. The method of claim 16, wherein said facing material is a
textile material.
27. The method of claim 16, wherein said facing material is a
film.
28. The method of claim 20, wherein said facing material is adhered
to said main frame and said first and second crossing members by
heat bonding or through adhesives applied either to the frame or
preapplied to the veil.
29. The method of claim 16, wherein said main frame is square or
rectangular.
30. The method of claim 29, wherein said crossing members are
arranged in an "X" shape or radiated outwardly from a centrally
located, circular connection point.
Description
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0001] This invention relates to suspended ceiling tiles which are
fitted into a conventional ceiling grid system.
BACKGROUND OF THE INVENTION
[0002] U.S. Pat. No. 3,782,495 discloses a thin, lightweight
suspended ceiling tile. The tile includes a wire frame over which a
thin skin, i.e., aluminum foil or thin plastic film, is applied.
The edges of the skin are wrapped around the wire frame and are
secured by adhesive.
[0003] U.S. Pat. No. 6,499,262 illustrates a suspended ceiling
structure including a rectangular grid and a plurality of panels
supported on the grid. The panels are assemblies of a rigid
perimeter frame, a fabric sheet, sound absorbing material, and
sound transmission attenuating material. The fabric sheet forms the
visible face of the panel when it is installed in the ceiling grid.
The frame includes side members which are preferably formed as
extrusions of thermoplastic material, such as polyvinyl chloride.
Suitable materials for the fabric include polyester, polyolefin,
vinyl-coated fabric or acrylic fabric.
[0004] U.S. Pat. No. 4,580,387 illustrates a corrosion resistant
grid construction for suspended ceiling. A portion of two cross
members are joined by a junction clip to either side of main
members. The main and cross members are formed in an inverted T
configuration. A flange extends from either side of a base web
which support ceiling panels. Main and cross members also support
the ceiling members.
[0005] U.S. Pat. No. 3,186,129 discloses a ceiling structure having
a plurality of rectangular panels each having two layers of
translucent polyvinyl chloride plastic material which are stretched
over the upper and lower edges of a rectangular sheet metal frame.
The panels are supported on a strip-metal gridwork having
rectangular openings. The metal strips on the grid are of a T-shape
to that the panels can be easily located on the horizontal
surfaces.
[0006] U.S. Pat. No. 3,460,299 illustrates a suspended ceiling
having a plurality of rectangular window openings, constructed of
wood or metal, bounded by wood or metal flanges for receiving and
supporting the edges of luminous ceiling panels. The ceiling panels
are made of a translucent material which diffuses light such as
flexible plastic films made of polyester, vinyl, acrylic,
polyethylene, or terephthalate.
[0007] In the past, suspended ceilings have been constructed of
wood or metal materials, which are heavy and high in cost. There is
a need for an improved, low-cost, suspended ceiling panel system
constructed of lightweight materials that permit easy installation
while providing an aesthetically pleasing appearance.
SUMMARY OF THE INVENTION
[0008] These needs are met by the present invention, wherein an
improved ceiling panel for a suspended is provided. The ceiling
panel includes a main frame having at least two crossing members
within said main frame. The ceiling panel is preferably constructed
of injected molded plastic and is a one-piece design. A facing
material, preferably a veil, fabric or textile, is adhered to the
main frame and crossing members. The ceiling panel fits in a
conventional suspended ceiling grid system and hides pipes, cables
and unfinished ceilings.
[0009] It is an object of the present invention to provide a
ceiling panel that is lightweight providing for easy handling and
installation.
[0010] It is another object of the present invention to provide a
ceiling panel for a suspended ceiling system that is low in cost
without impacting aesthetics.
[0011] It is another object of the present invention to provide a
ceiling panel that is easy to manufacture.
[0012] It is another object of the present invention to provide a
ceiling panel that provides acoustical benefits to a suspended
ceiling system.
[0013] Other objects and advantages of the present invention will
become apparent upon considering the following detailed description
and appended claims, and upon reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is plan view of the support frame for a ceiling panel
of the present invention
[0015] FIG. 2 is a plan view of the ceiling panel of the present
invention.
[0016] FIG. 3 is a side view of the ceiling panel of the present
invention
[0017] FIG. 4 is a side view of another embodiment of the ceiling
panel of the present invention.
DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION
[0018] The present invention is directed to a ceiling panel for use
in a suspended ceiling system. The ceiling panel includes a main
frame and at least two crossing members within said main frame. A
facing material is adhered to the main frame and crossing
members.
[0019] Referring now to FIG. 1, support frame 2 includes main frame
4 and crossing members 6 and 8. Crossing member supports 10 provide
stability where crossing members 6 and 8 contact the frame 4. It is
preferable for the support frame 2 to be a one-piece frame,
however, frame 4 and crossing members 6 and 8 may be manufactured
separately, assembled in two or more pieces and then welded
together by a plastic or metal welding process.
[0020] FIG. 1 shows a square support frame, however, the support
frame may be any shape suitable for use in a suspended ceiling
system. For example, the support frame may be circular,
rectangular, triangular, etc. FIG. 1 shows two crossing members 6
and 8. In certain instances, there may be more than two or several
crossing members depending on the size of the ceiling panel. The
crossing members are not limited to an "X" shape, as shown in FIG.
1. For example, crossing members may cross one other in a "T"
shape.
[0021] Support frame 2 is preferably made of plastic and formed by
an injection molding process or an extrusion process. Suitable
materials for the support frame include, but are not limited to,
polyethylene, polyvinyl chloride, polypropylene, polystyrene,
nylon, acrylic, polycarbonate and other plastics. The support frame
2 may be constructed of a plastic reinforced with other materials
such as glass fibers, carbon fibers, mica, wollastonite and talc
and may comprise a binder such as an acrylic or styrene based
binder.
[0022] Support frame 2 may also be made by an air or gas assisted
injection-molding process. The typical process involves gas or air
being injected into the hot core of the plastic melt through a
nozzle, or directly into the molding cavity of the frame via one or
more gas needles. Due to an almost constant pressure in all areas
with gas penetration, a good and even pressure distribution and
transmission is guaranteed across the molded part. After the end of
the gassing phase, the pressure is released either by gas recycling
or blowing the gas into the atmosphere. As soon as ambient pressure
is reached, the molded frame can be ejected. Hollow pockets in the
frame, created by this process, maintain flexural stiffness of the
frame and, in turn, provide substantial cost savings.
[0023] It is preferable for the plastic to contain a flame
retardant material such as halogenated additives/copolymers,
antimony trioxide, antimony pentoxide, nitrogen-phosphorous,
phosphates, aluminum trihydrate, magnesium hydroxide, bauxite or
calcium carbonate.
[0024] Alternatively, the support frame 2 and crossing members 6
and 8 may be constructed of roll-formable metals including, but not
limited to, aluminum, steel, copper, tin or coated metals such as
clad, galvanized, prefinished, preplated, prepainted, vinyl
laminated and tin plated coated metals.
[0025] Referring now to FIG. 2, ceiling panel 12 is shown including
support frame 2 including main frame 4, crossing members 6 and 8
and facing 14 which covers support frame 2. Preferably, facing 14
is a veil, textile, fabric, polymeric film, foils, laminates or
other non-woven or woven facer. The facing 14 may contain glass
wool or glass fibers to provide acoustical benefits to the
ceiling.
[0026] In an alternative embodiment, the ceiling panel 12 may be
made in one piece, including the frame and the facing material. The
ceiling panel 12 is formed from a multi-layer product including an
insulating layer and a structural layer, the structural layer
comprising a reinforced composite. The insulating layers preferably
contain a phenolic binder. The layers are laminated together via a
standard compression molding process. The resulting product
includes a lofted facing for insulating against the transmission of
sound and heat energy and the frame, i.e., the structural layer.
Preferably, the multi-layer material used is Acoustimax.TM.
material manufactured by Owens Corning, Toledo, Ohio.
[0027] Referring now to FIG. 3, a side view of the support frame 16
and facing 18 is shown. Facing 18 extends across the entire length
of support frame 16 and is preferably affixed to the support frame
by heat bonding. In the heat bonding process, one side of support
frame 16 is heated and softened. The facing 18 is then affixed to
the softened side of the support frame 16 and, upon cooling, the
facing 18 is firmly adhered to the support frame 16.
[0028] Adhesives can also be used to affix the facing 18 to the
support frame 16. Adhesive may be applied to either the facing 18,
the support frame 16 or both. Common adhesives include epoxy
adhesives, polyurethane and hot melt adhesives.
[0029] FIG. 3 illustrates a ceiling tile having a support frame 16,
which is substantially flat and can be easily fit into a suspended
ceiling frame system. FIG. 4 shows an alternative support frame 20
having edges 24, 26 which can be fitted into a suspended ceiling
system. Facing 28 is affixed to extending portion 28 of support
frame 20.
[0030] While the invention has been described in terms of preferred
embodiments, it will be understood, of course, that the invention
is not limited thereto since modifications may be made by those
skilled in the art, particularly in light of the foregoing
teachings.
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