Patent Description:
A conventional suspended ceiling system normally comprises a grid of profiles supporting tile members arranged in openings formed by the grid of profiles. The tile members are typically adapted for sound absorption and may be formed by mineral wool.

The tile members may be provided with grooves along their side edges, which grooves are configured to receive supporting flanges of the grid of profiles.

The grooves may have a complex design in order to allow concealed mounting (i.e. such that the grid of profiles is not visible in the installed state of the suspended ceiling system) and/or to allow dismounting of a single tile element in an installed state of the suspended ceiling system. The grooves are conventionally formed in a milling/grinding/rebating process.

It has further become increasingly common to use woodwool in ceiling tiles, either alone or in combination with mineral wool. Woodwool is an organic material that may provide a desired aesthetic appearance and a reduced environmental impact for each manufactured tile element. However, provision of complex grooves in a tile element comprising woodwool drives cost and production time and it is difficult to achieve a groove allowing the desired properties of the tile member mentioned above. <CIT> describes an acoustical tile member.

In view of that stated above, the object of the present invention is to provide a tile member comprising woodwool that facilitates achieving a low production cost and reduced environmental impact. A further object is to provide a tile member comprising woodwool and having a groove configuration provided thereto that facilitates mounting and dismounting of the acoustical tile member.

To achieve at least one of the above objects and also other objects that will be evident from the following description, a tile member having the features defined in claim <NUM> is provided according to the present invention. Preferred embodiments of the device will be evident from the dependent claims.

More specifically, there is provided according to a first aspect an acoustical tile member having a front surface intended to face a room, an opposing rear surface and four side surfaces connecting the front surface and the rear surface. The acoustical tile member comprising a first layer and a second layer, the first layer being associated with the front surface and comprises woodwool. Each of at least two opposing side surfaces of the four side surfaces is provided with a groove configuration for mounting of the acoustical tile member and extending along the associated side surface, each groove configuration being formed by a first groove in the first layer and a second groove in the second layer. By providing a groove configuration comprising a groove in each of the first and second layers, a complex groove configuration can be achieved while allowing a large portion of the acoustical tile member to be made from wood wool. For instance, the acoustical tile member may be provided with a groove configuration allowing a single acoustical tile member to be dismounted, which is typically not allowed in prior art tile members comprising wood wool in a suspended ceiling system with concealed or semi concealed grid profiles. The acoustical tile member may thus be dismounted with easiness, low demounting height - i.e. with low upward vertical movement of the tile in order to release it from a supporting grid profile, with high accuracy and precision. Additionally, an acoustical tile member comprising wood wool may reduce the environmental impact in the manufacturing of the acoustical tile member.

The first groove may have a single step profile, providing reliable forming of the first groove in the wood wool material of the first layer. The single step profile can in combination with the second groove form a large variety of groove configurations.

The first layer may have a thickness of at least <NUM>.

The second layer may comprise a mineral fibre material such as mineral wool. The second layer can thus improve and complement the properties of the wood wool in the first layer, thus providing an acoustical tile member having desired acoustic properties.

The first layer may be arranged directly against the second layer.

The first layer may further be adhered to the second layer, for instance may the first layer and second layer be separately manufactured and subsequently adhered to each other with an adhesive such as glue. The first and second layer may further be mechanically adhered to each other. The manufacturing of each of the first and second layer can thus be performed without having to compromise due to restrictions of the material properties of the other layer and thus can an improved acoustical tile member be provided.

Each of the side surfaces may be provided with the groove configuration.

Two opposing side surfaces of the four side surfaces may be configured for unsupported mounting of the acoustical tile member.

Each groove configuration may be configured for concealed or semi concealed mounting of the tile member, thus hiding an associated support structure such as a grid of profiles from view from the room below the acoustical tile member.

Each second groove may comprise an abutment surface configured for engagement with a support structure, such as a grid of profiles.

All references to "a/an/the [element, device, component, means, step, etc]" are to be interpreted openly as referring to at least one instance of said element, device, component, means, step, etc., unless explicitly stated otherwise.

<FIG> discloses a perspective view of an acoustical tile member <NUM> according to an embodiment of the teachings herein. The tile member <NUM> is configured to be mounted to a support structure, preferably to a grid of profiles <NUM> (shown in <FIG>). Typically, the grid of profiles <NUM> form rectangular openings into which a respective tile member <NUM> may be arranged supported by the grid of profiles <NUM> on at least two sides of the tile member <NUM>. The tile member <NUM> may thus form part of a suspended ceiling system which may provide functions such as sound absorption, concealment of building equipment and wiring and provision of an aesthetically pleasing interior ceiling.

The acoustical tile member <NUM> has a front surface <NUM> intended to face a room <NUM>. The front surface <NUM> may be provided with an additional layer, for instance for providing a desired appearance to the acoustical tile member <NUM>. The acoustical tile member <NUM> further comprises a rear surface <NUM> facing opposite the front surface <NUM>.

The tile member <NUM> further comprises four side surfaces <NUM>, 110a connecting the front surface <NUM> and the rear surface <NUM>. Preferably, the tile member <NUM> has a rectangular shape.

The acoustical tile member <NUM> comprises a first layer <NUM> and a second layer <NUM>, the first layer <NUM> being associated with the front surface <NUM> and comprises a wood fibre material, preferably wood wool. The wood wool may comprise a binder such as a cement based binder or geopolymer based binder. The first layer <NUM> may thus be exposed to the room <NUM> below the tile member <NUM>, thus providing a desired aesthetic appearance to the tile member <NUM>. The first layer <NUM> preferably has a thickness of at least <NUM>.

The second layer <NUM> may comprise a mineral fibre material such as stone wool and/or glass wool. The second layer <NUM> may thus complement the first layer <NUM> in providing a desired acoustic property to the acoustical tile member <NUM>, for instance in terms of providing improved sound absorption for certain sound frequencies or sound reflection/scattering etc..

It is to be realized that the acoustical tile member <NUM> may comprise additional layers to those mentioned above, even intermediately between the first layer <NUM> and the second layer <NUM>.

Preferably however, the first and second layer <NUM>, <NUM> are arranged superimposed and adjacent to each other.

Each of at least two opposing side surfaces <NUM> of the four side surfaces <NUM>, 110a of the acoustical tile member <NUM> is provided with a groove configuration <NUM> for mounting of the acoustical tile member <NUM> and extending along the associated side surface <NUM>. Each groove configuration <NUM> is formed by a first groove <NUM> in the first layer <NUM> and a second groove <NUM> in the second layer <NUM> as illustrated in for example <FIG>. The groove configuration <NUM> may be formed in a suitable manufacturing process such as a milling operation in which both the first groove <NUM> and the second groove <NUM>, and thus the entire groove configuration <NUM>, is formed simultaneously in one manufacturing process.

Alternatively, the first groove <NUM> and the second groove <NUM> may be formed in separate manufacturing processes, whereby the groove configuration <NUM> is formed as the first layer <NUM> and the second layer <NUM> are attached to one another.

Providing a groove configuration <NUM> formed in two separate layers <NUM>, <NUM> of the acoustical tile member <NUM> reduces the limiting effect of the wood wool of the first layer <NUM> on the type of groove configuration that can be provided to the acoustical tile member <NUM>.

The first layer <NUM> and the second layer <NUM> may be attached to each other for instance by means of an adhesive. The first layer <NUM> and second layer <NUM> may further be mechanically adhered to each other, for instance by means of nails, clips or similar.

Turning to <FIG> in which a side view is shown of two acoustical tile members <NUM> which are supported by a support structure in the form of a grid of profiles <NUM>. The grid of profiles <NUM> may as is shown comprise a profile having two laterally extending flanges <NUM> and an upstanding web <NUM> provided with a bulb <NUM> at its free end. The groove configuration <NUM> forms vertical support for the associated acoustical tile member <NUM> by abutting against the lateral flanges <NUM> of the grid of profiles <NUM>. The groove configuration <NUM> may further allow dismounting of a single tile element.

The first groove <NUM> may have a single step profile, as illustrated in <FIG> and further shown in <FIG>. The single step profile of the first groove <NUM> facilitates manufacturing of the acoustical tile member <NUM>. It is generally difficult to form complex grooves in wood wool due to the characteristics of the material, however single step profiles have been proven to allow being reliably formed in wood wool. In combination with the second groove <NUM> in the second layer <NUM>, which may be of a more complex shape as allowed by the material of the second layer <NUM>, the groove configuration <NUM> can be provided with a large variation of shapes.

In relation to the shape of the first groove <NUM>, single step profile may be interpreted as that the first layer <NUM> comprises two laterally offset surfaces <NUM>, <NUM> formed along at least two opposite side surfaces <NUM> of the tile member <NUM>. The first groove <NUM> may thus be essentially rectangular.

Preferably, the first groove <NUM> is formed such that a lip <NUM> is formed adjacent to the front surface <NUM> of the tile member <NUM>. The lip <NUM> may extend such that a gap <NUM> is formed between two adjacent tile members <NUM>. The lip <NUM> may extend such that it is vertically aligned with the lateral side of the second layer <NUM>.

An upper gap <NUM> is preferably formed between the lateral side of the second layer <NUM> between side surfaces <NUM>, 110a of two adjacent tile members <NUM> in order to accommodate the grid of profiles <NUM>.

The first groove <NUM> may as mentioned be an essentially rectangular groove formed formed along the periphery of the first layer <NUM> along at least two opposite side surfaces <NUM> of the tile member <NUM>. The first groove <NUM> is formed on the side of the first layer <NUM> opposite the front surface <NUM>, preferably adjacent to the second layer <NUM>.

The second groove <NUM> may be provided with an abutment surface <NUM> facing towards the front surface <NUM> and preferably in a downwardly direction. the abutment surface <NUM> may have a lateral extension and be configured to be horizontally arranged when the acoustical tile member <NUM> is mounted to the support structure. The abutment surface <NUM> forming the contact between the lateral flange <NUM> of the grid of profiles <NUM> and the acoustical tile member <NUM>.

The abutment surface <NUM> being formed in the second layer <NUM> is beneficial as the second layer <NUM> may be formed from a mineral fiber material having higher structural strength, for instance being less fragile or brittle, than the wood wool of the first layer <NUM>, thus reducing the risk of the tile member <NUM> falling of the grid of profiles <NUM> or that the groove configuration <NUM> is damaged during mounting/demounting. Moreover, as mentioned in the foregoing, the material of the second layer <NUM> allows a higher freedom in terms of the allowed shape of the groove therein.

An inclined surface <NUM> may also be provided in the second groove <NUM>, the inclined surface <NUM> being arranged adjacent to the abutment surface <NUM> and closer to the centre/proximally of the acoustical tile member <NUM> than the abutment surface <NUM>. The inclined surface <NUM> facilitates mounting of the acoustical tile member <NUM> as the inclined surface <NUM> will slide against the lateral flange <NUM> of the grid of profiles <NUM> by the force of gravity until the lateral flange <NUM> abuts against the abutment surface <NUM>. The acoustical tile member <NUM> is thus correctly positioned in relation to the grid of profiles <NUM>.

It is also to be realized that each of the side surfaces <NUM> of the acoustical tile member <NUM> may be provided with the groove configuration <NUM>.

Moreover, it is to be realized that both acoustical tile members <NUM> shown in each of <FIG> may be considered identical and thus that a single acoustical tile member <NUM> may be provided with a groove configuration <NUM> as illustrated on the left acoustical tile member on one side surface <NUM> and a groove configuration <NUM> as illustrated on the right acoustical tile member <NUM> on the opposite side surface <NUM>.

<FIG> discloses a side view of acoustical tile members <NUM> which are supported by a grid of profiles <NUM>. The embodiment in <FIG> is identical to that shown in <FIG> with the exception of the extension of the lip <NUM>. In <FIG>, the lip <NUM> is provided with a lateral extension that is such that the lip <NUM> is in the proximity of the lip on the adjacent tile member <NUM>. The lateral extension of the lip <NUM> may be such that the lip <NUM> is abutting against the lip on the adjacent tile member <NUM>. The gap <NUM> between the adjacent tile members <NUM> may thus be very small or non-existent.

The lip <NUM> may extend laterally past the side surface <NUM> formed by the second layer <NUM>, i.e. the lateral side/distal surface of the second layer <NUM>.

The grid of profiles <NUM> can thus be hidden from view from the room <NUM> below the tile member <NUM>, i.e. the tile element <NUM> can be configured for concealed mounting. It is to be realized that the features described in relation to <FIG> can be freely combined with the other embodiments disclosed herein.

<FIG> discloses a side view of two acoustical tile members <NUM> which are supported by a grid of profiles <NUM>. As is illustrated in <FIG>, the lip <NUM> on opposite sides of the tile member <NUM> may extend laterally to different lengths such that the gap <NUM> is offset in relation to the centre of the upper gap <NUM> betwenn the second layer <NUM> of two adjacent tile members <NUM>. The gap <NUM> may further be configured to be laterally offset from a plane defined by of the web <NUM> of the grid of profiles <NUM>. This may faciliate mounting of the acoustical tile member <NUM> and further facilitate concealed mounting of the acoustical tile member <NUM> on the grid of profiles <NUM> such that the grid of profiles <NUM> is hidden from from view from the room <NUM> below the tile member <NUM>.

The first groove <NUM> in the groove configuration <NUM> on opposite side surfaces <NUM> of the tile member <NUM> may further be provided with different dimensions. For instance may the groove configuration <NUM> on one side be configured for placing against the grid of profiles <NUM> first, while the opposite side groove configuration <NUM> is configured to be placed on the grid of profiles <NUM> secondly by pivoting the tile member <NUM> around the contact point between the groove configuration <NUM>, more specifically the abutment surface <NUM> thereof, and the grid of profiles on the opposite side of the tile member <NUM>.

Moreover, the second groove <NUM> may be formed differently in the groove configuration <NUM> on opposite side surfaces <NUM> of the acoustical tile member <NUM>. The second groove <NUM> on one side may comprise a slot forming the abutment surface <NUM>, wherein the surface in the slot opposite the abutment surface <NUM> is inclined such that the slot tapers laterally from the side surface <NUM> towards the proximal side/bottom of the slot. Such a second groove <NUM> facilitates that the acoustical tile member <NUM> can be pivoted in at least a downwardly direction around a contact point between the abutment surface <NUM> and the lateral flange <NUM> of the grid of profiles.

The second groove <NUM> on the opposite side may be identical to that described in the foregoing or as is shown in <FIG> be provided with a different shape e.g. the shape of the second groove <NUM> described in conjunction with <FIG>.

<FIG> discloses a side view of an acoustical tile member <NUM> being arranged adjacent to a grid of profiles <NUM>. The acoustical tile member <NUM> shown in <FIG> is configured for unsupported mounting as two opposing side surfaces 110a of the four side surfaces <NUM>, 110a are configured for unsupported mounting by not being provided with an abutment surface <NUM>. Preferably however, the side surfaces 110a are configured to be arranged in close proximity of the lateral flanges <NUM> of the grid of profiles <NUM>, thus providing lateral stability to the suspended ceiling which the acoustical tile member <NUM> and the grid of profiles <NUM> may form part of.

As is also illustrated in <FIG>, the opposing side surfaces 110a of the acoustical tile member <NUM> that are configured for unsupported mounting may comprise a first groove <NUM> as described above and thus a lip <NUM> also as described in the foregoing. The lateral extension of the lip <NUM> may be varied accordingly, in order to for instance achieve a concealed mounting of the acoustical tile member <NUM>.

Claim 1:
An acoustical tile member (<NUM>) having a front surface (<NUM>) intended to face a room (<NUM>), an opposing rear surface (<NUM>) and four side surfaces (<NUM>, <NUM>0a) connecting the front surface (<NUM>) and the rear surface (<NUM>), the acoustical tile member (<NUM>) comprising a first layer (<NUM>) and a second layer (<NUM>), the first layer (<NUM>) being associated with the front surface (<NUM>) and comprises woodwool, wherein each of at least two opposing side surfaces (<NUM>) of the four side surfaces (<NUM>, 110a) is provided with a groove configuration (<NUM>) for mounting of the acoustical tile member (<NUM>) and extending along the associated side surface (<NUM>), wherein each groove configuration (<NUM>) is formed by a first groove (<NUM>) in the first layer (<NUM>) and a second groove (<NUM>) in the second layer (<NUM>).