METHOD FOR RENOVATING CEILING TILE

The present invention relates generally to the field of building construction and, more particularly, to a method for renovating ceiling tiles.

Suspended ceilings or "drop" ceilings are well known in the art. Typically a ceiling grid or lattice framework is hung by wires fixed to the building's overhead framing or mechanical components. Decorative ceiling tiles are then inserted into the grid. Suspended ceilings have a number of advantages over drywall ceilings. These include but are not limited to lower cost and the creation of less mess during installation. In addition, in the event of a water leak or other damage, the individual damaged tiles may be simply replaced without having to repair and/or repaint the entire ceiling as could be necessary with a drywall ceiling.

Over time the ceiling tiles may become dirty and worn. Some may be damaged if they are frequently lifted to access lighting fixtures, speakers or mechanical components above the supporting grid. Further, decorating tastes change over time and an individual may simply want to change the look of the ceiling tiles.

The present invention relates to a quick, convenient and inexpensive method for renovating ceiling tiles and providing a "new" suspended ceiling.

To achieve the foregoing and other objects and in accordance with the purposes of the present invention as described herein, an improved method is provided for renovating a ceiling tile and grid system. That method comprises the steps of lifting an old ceiling tile from the grid, placing a new ceiling tile in the grid where the old ceiling tile was positioned and placing the old ceiling tile on top of the new ceiling tile.

Where necessary, the method further includes the step of shaping the new ceiling tile prior to placing the new ceiling tile in the grid. The shaping step includes cutting the new ceiling tile to a proper size to fit the grid. The shaping also includes the step of cutting an opening in the new ceiling tile in order to accommodate an

obstruction such as a light fixture, speaker, smoke detector, pipe, sprinkler head or the like. Further the method includes the optional step of applying adhesive tape to the new ceiling tile prior to placing the new ceiling tile in the grid.

In the following description there is shown and described a preferred embodiment of this invention simply by way of illustration of one 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.

The 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:

Figure 1 is a bottom perspective view of a ceiling tile of the type utilized in the renovation method of the present invention;

Figures 2a-2d are schematical side elevational views illustrating the renovation method of the present invention including the lifting of an old ceiling tile from the grid in Figure 2b, the placing of a new ceiling tile in the grid in Figure 2c and the placing of the old ceiling tile on top of the new ceiling tile in Figure 2d.

Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings.

Reference is now made to Figure 1 illustrating a ceiling tile 10 such as utilized in the present method of renovating a ceiling tile and grid system. The ceiling tile 10 is preferably a stiff structure that will not bow or sag during its lifetime. The ceiling tile 10 may be built from a single glass veil or by a combination of layers.

In the case of a single glass veil, the ceiling tile 10 will include glass fibers and additional chemicals added by single side coating or full impregnation. ADVANTEX

glass fibers, manufactured and sold by Owens Corning may be utilized for this purpose. The thickness of the fibers may vary from about 6 microns to about 21 microns. The length of the glass fibers may vary from about 4 mm to about 38 mm. Additionally, it should be appreciated that other fibers like synthetic polymer (for example, polypropylene, polyethylene, polyester, polyethylene terephthalate, polybutylene terephthalate, aramid, nylon, rayon) or natural fibers (for example, cotton, hemp, kenaf, jute) may be utilized.

Typical chemicals used for coating and impregnating the ceiling tile include polyvinyl alcohol, synthetic polymer binders like polyacrylates, polyacetates, vinyl polymers, fillers like aluminum trihydrate, magnesium hydrate, calcium carbonate, synthetic microspheres, glass spheres, and flame retarding nitrogen and phosphor containing compounds. A ceiling board edge coating such as disclosed in U.S. Patent 4,559,377 to Gleeson et al. may also be utilized.

Where a combination of layers is used, the ceiling tile 10 will typically comprise a glass veil of composition as described above for aesthetic properties in combination with one or more additional glass veils, reinforcement scrims, thin panels of synthetic polymer material, metal, cardboard, paper, mineral wool, glass wool, wood pulp, gypsum or other hard minerals which form reinforcement layers. Layers may be combined or laminated together by means of gluing, heat welding or other means.

The renovation method of the present invention will now be described in detail with reference to Figures 2a-2d. The existing suspended ceiling system S is illustrated in Figure 2a. The suspended ceiling system S includes a grid or latticework G suspended from the building's overhead framing F by means of wires W in a manner well known in the art. The existing ceiling tiles T (only one illustrated in the drawing figure) fill the opening between adjacent grid members in order to provide an aesthetically pleasing ceiling surface. The existing ceiling tile T of the suspended ceiling system S may be quickly and easily replaced by first lifting the old ceiling tile T from the grid G (see Figure 2b). Next the new ceiling tile 10 is positioned in the grid G where the old ceiling tile T was previously positioned (see Figure 2c). This is then

followed by the step of placing the old ceiling tile T on top of the new ceiling tile 10. In this position the old ceiling tile T effectively holds the new ceiling tile 10 in the grid G. Where the new ceiling tile 10 includes margins 12, those margins rest on and engage the grid G when the ceiling tile is properly positioned in the grid.

It should be appreciated that the method also includes the shaping of the new ceiling tile prior to the positioning of the new ceiling tile in the grid G when shaping is necessary. Thus, shaping includes cutting the new ceiling tile 10 to a proper size to fit in the grid. This is often necessary adjacent a wall where a standard grid size will not fit the available space. Further, shaping includes cutting an opening in the new ceiling tile 10 in order to accommodate an obstruction such as a light fixture, speaker, smoke detector, sprinkler head, pipe or the like.

The method also includes the optional step of applying adhesive tape to the ceiling tile 10 prior to placing the ceiling tile in the grid G. Where the ceiling tile 10 includes margins 12 as illustrated, the two sided adhesive tape is positioned in the margin. The ceiling tile 10 is then positioned in the grid G and pressed down so that the adhesive tape adheres the ceiling tile 10 to the grid G. The weight of the old ceiling tile T on the new ceiling tile 10 helps to insure the integrity of the connection.

In summary, numerous benefits result from employing the concepts of the present invention. The present method provides a simple and convenient approach for renovating suspended ceiling systems and, more particularly, replacing ceiling tiles. Since the old ceiling tiles are maintained in the space above the new ceiling tiles 10, there is no mess created during renovation and the time and effort otherwise required to remove the old ceiling tiles and discard them is eliminated. Accordingly, installation costs are greatly reduced. Further, the new ceiling tiles 10 allow one to aesthetically upgrade any existing suspended ceiling independent of the ceiling type and design. Since the old ceiling tiles T remain in place on the grid G behind the new ceiling tiles 10, the original technical properties of the ceiling relating, for example, to fire rating and acoustical characteristics are at least maintained if not improved by the new ceiling tiles 10. Further, since the ceiling tiles T may be replaced without creating any

substantial mess and without necessitating their removal, renovation and replacement can be done in a normal work environment with minimal disruption to the work area.

The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. For example, the ceiling tile 10 could include a trim margin of reduced thickness which would engage the grid and allow the face of the panel to extend through the grid. In addition, instead of using two-sided adhesive tape, an appropriate adhesive may be applied directly to the ceiling tile and the ceiling tile then positioned in the grid. In yet another alternative, the ceiling tile itself may be made self adhesive along the margins that engage the grid.

The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiment do not and are not intended to limit the ordinary meaning of the claims and their fair and broad interpretation in any way.