XPS covering tile for suspended grid ceilings with stone paper surface and spring mounting capability

Abstract

With the rapid advancement of technology, greater comfort has been provided for people. However, traditional building materials sometimes lead to energy loss. To address this issue, covering tiles are used for ceilings and walls. Our invention introduces an extruded polystyrene (XPS) suspended ceiling tile with a stone paper surface and spring installation capability. The structure of this tile allows for larger dimensions while maintaining minimal weight, reducing the amount of structural material required and enhancing seismic resistance. The system consists of the following components: • A layer of extruded polystyrene (XPS) • Water-based acrylic adhesive • Stone paper This product is suitable for use in government and private buildings, hospitals, and schools, contributing to energy efficiency in suspended ceilings.

Description

[0001] Description of the Invention

[0002] Invention Title (as mentioned in the declaration):

[0003] XPS Covering Tile for Suspended Grid Ceilings with Stone Paper Surface and Spring Mounting Capability

[0004] Technical Field of the Invention:

[0005] The field of the invention pertains to civil engineering and building structures.

[0006] Technical Problem and Objectives of the Invention:

[0007] False ceilings are used as a covering for the main ceiling. They contribute to aesthetics, concealment of utilities and wiring, as well as improving insulation and correcting ceiling defects. False ceilings are typically divided into two types: the first type is a fixed and seamless ceiling made of materials such as gypsum board (knauf), and the second type is a grid ceiling made from ceiling tiles and visible Armstrong click structures. False grid ceilings are available in gypsum and PVC options.

[0008] As is evident, the gypsum-based false ceiling has issues such as high sensitivity to moisture, excessive weight, and small size (60x60 cm). Although the moisture sensitivity issue is resolved in PVC ceilings, they still face the problem of being small (60x60 cm) in size and heavy in weight. The click structures are not able to accommodate changes in size, and any attempt to thicken and strengthen the click structures to support larger tiles leads to high costs and lacks economic justification. Moreover, this process also adds to the dead load of the building.

[0009] In our design, we have produced an XPS grid tile with a stone paper surface that is larger in size and lighter in weight. This tile reduces the material consumption by up to 50%, decreases the dead load, and offers better stability during earthquakes, as it does not shatter during seismic events.

[0010] This design and production process meets the growing demand for easy and practical-to-use ceiling tiles, ensuring a strong market presence in construction supply stores. State of the Art and Background of the Invention:

[0011] In global markets, grid ceilings have been designed and implemented for many years. Typically, these ceilings are installed by first setting up visible structures (Armstrong), after which ceiling tiles are placed within them. Initially, gypsum tiles were used, but they were heavy and highly sensitive to moisture. Subsequently, PVC tiles were introduced, offering a lighter, moisture-resistant solution. However, these PVC tiles still faced limitations: they were produced in a small size and could not be resized or enlarged, due to their inherent structure.

[0012] What is XPS Foam?

[0013] In today’s world, energy conservation, particularly in terms of non-renewable energy sources, has pushed construction material manufacturers toward new approaches. The more energy consumption is reduced, the less greenhouse gas emissions occur, which can help prevent global warming.

[0014] XPS foam is essentially a layer of extruded polystyrene, a very lightweight material with the primary capability of maintaining low temperatures while being able to withstand high pressure.

[0015] How is XPS Foam Manufactured?

[0016] XPS foam is used in the construction of walls, ceilings, building foundations, and basements. The product is made by melting polystyrene and adding carbon dioxide. The mixture of these two materials is placed into a mold and formed into sheets with thicknesses ranging from 20 to 200 millimeters.

[0017] What Are the Applications of XPS Foam?

[0018] XPS foam is commonly used in prefabricated construction materials, serving as both a thermal and moisture insulator. However, it has not yet been used in grid ceiling tiles. Its applications so far include:

[0019] • Insulated walls, ceilings, cold storage, and basement insulation.

[0020] • Exterior building cladding.

[0021] • Insulation for sloped or flat roofs.

[0022] • As the core layer in ceiling and wall panels. Stone Paper:

[0023] Stone paper is a paper-like product made primarily from calcium carbonate combined with high-density polyethylene. Its main advantages include high resistance, waterproof properties, and flexibility. This product is typically used in stationery, posters, books, magazines, and, in general, packaging and writing industries. It has not been used in suspended ceiling tiles.

[0024] Review of My Invention in Comparison to International and Domestic Patents

[0025] • Patent No. 390030542: This patent relates to the production of suspended ceiling tiles using a thermal vacuum process with soft PVC sheets, which are attached to wooden, metallic, or polystyrene frames. The production process involves using a custom mold designed with a CNC machine, where only the frame is vacuumed to adhere to the PVC foil. The mold design remains in place for multiple uses, and the frame is used to reinforce the foil and maintain its shape.

[0026] As mentioned in the above patent description, the material of the product is made from PVC foil, which has smaller thickness and dimensions compared to our invention. Additionally, this invention is not heat-insulating, lacks flexibility, and does not allow for the installation of springs. In contrast, our design is not only heatinsulating but also completely flexible and capable of installing springs.

[0027] Composite structure for exterior insulation applications of outside wall with registration number CN102159774B

[0028] This invention pertains to a composite structure comprising an extruded polystyrene layer, a mortar layer, and a primer layer, wherein at least one surface of the extruded polystyrene layer is shaved, and the mortar layer is made from a mixture of mortar composed of re-dispersible powder, cellulose ether, one or more viscosity modifiers, one or more hydraulic binders, and one or more aggregates. A method for manufacturing such a composite structure is also provided.

[0029] Analysis and Comparison:

[0030] • The above invention relates to a foam layer that is shaved on one side, where a layer of material is applied using a coating process. In contrast, our invention does not involve any shaving of the foam surface. The foam used in our design is 90*120 cm with a perfectly smooth surface. It consists of an XPS foam layer, an adhesive middle layer, and a stone paper coating. Due to the structure and soft texture of the stone paper, it perfectly aligns with the XPS foam, ensuring no wrinkles or detachment when the foam bends. Ceiling tiles and acoustic aluminum tiles with a thickness of 0.5 mm and dimensions of 40x40 cm, 50x50 cm, and 60x60 cm with concealed and exposed grids with registration number 38172:

[0031] • The above invention describes a ceiling tile made from aluminum with dimensions of 60x60 cm.

[0032] • This invention is entirely different from our design, as it uses aluminum as the material, with a smaller thickness and dimensions compared to our design. Additionally, it is not heat-insulating, lacks flexibility, and cannot accommodate spring installation. In contrast, our design is heat-insulating, highly flexible, and supports the installation of springs.

[0033] Summary of Key Differences:

[0034] In general, our design differs from XPS panels and other available panels in the following ways:

[0035] • XPS panels are typically used as a replacement for gypsum board (e.g., Knauf) in suspended ceilings. Other panels are installed either raw or coated with materials and then screwed onto structures to create decorative or boxed ceilings. However, our design is specifically for suspended grid ceilings, and no screwing is required to secure the tiles. They are simply placed onto the grid structure and can be easily removed or repositioned.

[0036] • The flexible tiles we have designed are secured within the grid using an internal spring system. This removes the need for painting, joint filling, and other post-installation processes.

[0037] • The stone paper coating ensures that, like XPS foam, the tile remains highly flexible and does not wrinkle when bent. Furthermore, its smooth matte white surface allows for easy cleaning with bleach, removing the need for painting after installation.

[0038] Solution for the Existing Technical Problem, Along with a Detailed and Unified Explanation of the Invention

[0039] In recent years, due to the increasing pace of daily life, social life has shifted towards enhancing the efficiency of products, leading to significant progress across various industries, including construction and its related factors. Our design, in general, aims to improve different materials used in prefabricated structures and suspended ceilings, featuring a simple yet highly functional structure. The overall process comprises several key components, which are as follows:

[0040] • An extruded polystyrene layer

[0041] • Water-based acrylic adhesive

[0042] • Stone paper

[0043] It should be clarified that the manufacturing method for this covering tile is as follows: First, a layer of stone paper is bonded to an extruded polystyrene layer with a thickness of 2 to 3 centimeters and dimensions of 120x90 cm and 120x120 cm, using a water-based acrylic adhesive applied on both sides.

[0044] Description of Diagrams, Maps, and Charts:

[0045] 1 . Stone paper

[0046] 2. Water-based acrylic adhesive

[0047] 3. An extruded polystyrene layer

[0048] Clear and Accurate Description of the Advantages of the Claimed Invention Compared to Previous Inventions:

[0049] This process, in its entirety, is based on internal research and development while being highly practical. It incorporates unique advantages and goals that transparently showcase the capabilities of this method. Some of these advantages and goals are as follows:

[0050] • Increased dimensions and aesthetic appeal

[0051] • Reduced weight

[0052] • Usable in all buildings and offices

[0053] • Reduced structure requirements

[0054] • Greater thickness

[0055] • Increased flexibility

[0056] • Easy and convenient handling

[0057] • Semi-acoustic properties

[0058] • Waterproof and antibacterial

[0059] • Heat and cold insulation Ability to install springs

[0060] High-speed execution

[0061] Description of at Least One Execution Method for Implementing the Invention:

[0062] Due to its larger dimensions, the use of this invention accelerates the installation process. Initially, the click ceiling structures with dimensions of 120x90 cm and 120x120 cm are installed. Then, the XPS covering tiles, designed with a stone paper surface, are placed on the click structures. Following this, a special steel spring is installed between the structure and the back of the tile.

[0063] Explicit Industrial Application of the Invention:

[0064] This invention has significant industrial applications in building structures, particularly for suspended ceiling tiles. It is suitable for use in office buildings, schools, universities, as well as public facilities such as hospitals. Due to its water resistance, sound reduction properties, and complete insulation for energy conservation, it can be effectively utilized in these environments.

[0065] Abstract

[0066] With the rapid advancement of technology, greater comfort has been provided for people. However, traditional building materials sometimes lead to energy loss. To address this issue, covering tiles are used for ceilings and walls.

[0067] Our invention introduces an extruded polystyrene (XPS) suspended ceiling tile with a stone paper surface and spring installation capability. The structure of this tile allows for larger dimensions while maintaining minimal weight, reducing the amount of structural material required and enhancing seismic resistance.

[0068] The system consists of the following components:

[0069] • A layer of extruded polystyrene (XPS)

[0070] • Water-based acrylic adhesive

[0071] • Stone paper

[0072] This product is suitable for use in government and private buildings, hospitals, and schools, contributing to energy efficiency in suspended ceilings.

Claims

ClaimsWhat is claimed:Claim 1 :The present invention relates to an extruded polystyrene (XPS) ceiling tile designed for Armstrong (suspended grid) ceilings. This innovative design incorporates a stone paper surface and a spring installation mechanism, which results in increased tile dimensions, reduced weight, and minimized structural framework requirements. The invention comprises the following components:• A layer of extruded polystyrene (XPS)• Water-based acrylic adhesive• Stone paper coveringClaim 2:According to Claim 1 , a flexible stone paper layer is applied to the top surface of the tile, with its underside coated in acrylic adhesive.Claim 3:According to Claims 1 and 2, the underside of the stone paper layer is fully impregnated with an acrylic adhesive layer, ensuring strong adhesion and durability.Claim 4:According to Claims 1 and 3, a 2 to 3 cm thick extruded polystyrene (XPS) core, with dimensions of 120x90 cm or 120x120 cm, is securely bonded beneath the stone paper layer using acrylic adhesive.Claim 5:According to Claim 4, the assembled ceiling tile is designed for direct installation onto Armstrong (suspended grid) ceiling click-frame structures, ensuring seamless integration.Claim 6:According to Claim 5, a specialized stainless steel spring mechanism is positioned between the tile and the ceiling grid structure, enhancing stability, ease of installation, and structural integrity.

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