WO2008030384A2

WO2008030384A2 - Ceiling tile assembly

Info

Publication number: WO2008030384A2
Application number: PCT/US2007/019095
Authority: WO
Inventors: Frederick A. Buck; Mohammed Tazi
Original assignee: Owens Corning Intellectual Capital, Llc
Priority date: 2006-09-01
Filing date: 2007-08-30
Publication date: 2008-03-13
Also published as: WO2008030384A3; US20070079562A1

Abstract

A ceiling tile assembly includes a sheet of ornamental facing and a support frame or a supporting member with a retaining element.

Description

CEILING TILE ASSEMBLY

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY The present invention relates generally to the suspended ceiling art and, more particularly, to a new and improved ceiling tile assembly.

BACKGROUND OF THE INVENTION

A number of different systems and structures have been developed for providing a drop or suspended ceiling in a room. As will be appreciated by those skilled in the art, suspended ceilings are formed from a primary overhead structure such as ceiling joists or the underside of a reinforced concrete structure for establishing a substantially level and more aesthetically pleasing ceiling for a finished space. Suspended ceilings provide improved flexibility for finishing a space over ceiling systems that are mounted directly to the primary overhead structure or furring strips or other attachment regions provided on the primary overhead structure. Suspended ceilings generally comprise a plurality of individual ceiling tiles with the individual tiles typically having a rectangular or square shape. The composition of the individual ceiling tiles utilized in such systems have also been manufactured from many different materials such as pressed fibrous materials or synthetic polymers and synthetic resins that may be cast to form the tile body. The ceiling tiles may also be produced with at least one embossed or textured surface for improving the aesthetic appearance and/or improved sound absorption. The present invention relates to an alternative type of ceiling tiles that are manufactured using a combination of a frame and a cover layer.

SUMMARY OF THE INVENTION In accordance with the purposes of the present invention as described herein, an improved ceiling tile assembly is provided. That ceiling tile assembly comprises a sheet of ornamental facing having a main body and a margin and a support frame engaging and holding that margin. The assembly is further characterized by constructing the sheet of ornamental facing from^' a fiberglass veil. More specifically describing the invention, the fiberglass veil includes between about 17 to about 30 weight percent glass fibers, about 6 to about 10 weight percent polymer binder and about 58 to about 78 weight percent filler. The glass fibers have a nominal diameter of between about 6.5 to about 11.0 microns and a length of between about 5.0 to about 7.0 mm. In addition the fiberglass veil has an areal weight of about 50 to about 200 gsm and a thickness of between about 1.0 to about 2.0 mm. The fiberglass veil is also characterized by a water hold number of greater than 180 seconds.

The filler may be a flame retardant. Typically the filler includes aluminum trihydrate, phosphorous compounds, antimony trioxide, borates, intumescent materials, or mixtures thereof. The polymer binder may be selected from a group of materials including, for example, polyvinyl alcohol, styrene-acrylate, melamine formaldehyde and mixtures thereof.

The support frame is constructed from a material selected from a group consisting of polypropylene, polystyrene, polyethylene, polyvinyl chloride, nylon, acrylic, polycarbonate and mixtures thereof. Typically the support frame has a tensile strength at yield of between about 15 to about 70 MPa as measured by ASTM test method D638 and a flexural modulus of between about 40 to about 100 MPa as measured by ASTM D790.

In accordance with additional aspects of the present invention, the margin and support frame are continuous and have a width of between about 1.5 to about 2.0 mm.

Further, the main body has a surface area of between about 3,100 to about 3,800 cm². The sheet of ornamental facing is unstretched and the main body spans between the support frame and is otherwise unsupported. The sheet of ornamental facing has a thickness of between about 1.0 to about 2.0 mm and the support frame has a thickness of between about 2.0 to about 5.0 mm. Further the main body is characterized by a sag of less than about 2.5 mm and more preferably about 2.0 mm as measured by ASTM test method

C367.

Tn one possible embodiment, the support frame is discontinuous. The support frame is also substantially c-shaped in cross section and defines a channel that holds a margin of the ornamental facing. Such a support frame may either be straight or form a corner.

The ceiling tile assembly of the present invention may be alternatively described as comprising a sheet of ornamental facing and a support frame having an overall thickness of less than 7.0 mm and characterized by a sag of less than about 2.5 mm for an unsupported surface area of about 3716 cm² as measured by ASTM test method C367.

The ceiling tile assembly has a weight per unit area of between about 50 to about 200 gsm.

In accordance with yet another aspect of the present invention a method is provided for reducing shipping expenses relating to ceiling tiles. That method comprises producing ceiling tiles with an overall thickness of less than 7.0 mm and an overall weight per unit area of less than 200 gsm and then packing those ceiling tiles in a shipping vessel such as a carton, box, crate or the like.

In still another embodiment, the ceiling tile assembly comprises a sheet of ornamental facing and a supporting member. The ornamental facing has a main body and a margin. The supporting member includes a supporting flange and a retaining element. The retaining element is displaceable between open and closed positions. When closed, the margin of the ornamental facing is pressed and held between the supporting flange and the retaining element. In the following description there is shown and described several embodiments of this invention, simply by way of illustration of some 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.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

FIGS. IA and IB are a plan view and a cross sectional view along line A— A' of an exemplary ceiling tile construction according to the present invention;

FIGS. 1C and ID are plan views of two alternative embodiments wherein the support frame is discontinuous;

FIGS. 2A and 2B are a plan view and a cross sectional view along line A— A' of an exemplary ceiling tile construction generally corresponding to Figures IA and IB to which a trim piece has been added;

FIGS. 3 A and 3 B are a plan view and a cross sectional view along line A— A' of an exemplary ceiling tile construction generally corresponding to Figures 2A and 2B on which a portion of the original tile has been removed to prepare a customized ceiling tile; FIGS. 4 A and 4B are plan views of other exemplary customized ceiling tile configurations in which a portion of the original tile has been removed to prepare a customized ceiling tile;

FIGS. 5A and 5B are cross-sectional views of other exemplary ceiling tile configurations illustrating exemplary configurations for supporting the ceiling tiles from a supporting frame or grid;

FIGS. 6A-6F are cross-sectional views of other exemplary ceiling tile configurations;

FIGS. 7A-7C are cross-sectional views of other exemplary ceiling tile configurations illustrating exemplary configurations for accommodating the insertion of a trim piece for preparing a customized ceiling tile;

FIG. 8A is a perspective view of a straight support frame element that holds an ornamental facing;

FIG. 8B is an end elevational view of the support frame element of FIG. 8A holding an ornamental facing;

FIG. 8C is a top plan view of four support frame elements as illustrated in FTG 8 A attached to all four sides of an ornamental facing;

FIG. 9 A is a perspective view of a corner support frame element;

FIG. 9B is a top plan view of four corner support frame elements as illustrated in FIG. 9A holding an ornamental facing; and

FIG. 10 is an end elevational view illustrating a support member with a displaceable retaining element for holding an ornamental facing.

These drawings have been provided to assist in the understanding of the exemplary embodiments of the invention as described in more detail below and should not be construed as unduly limiting the invention. In particular, the relative spacing, positioning, sizing and dimensions of the various elements illustrated in the drawings are not drawn to scale and may have been exaggerated, reduced or otherwise modified for the purpose of improved clarity.

Those of ordinary skill in the art will also appreciate that a range of alternative configurations have been omitted simply to improve the clarity and reduce the number of drawings. Similarly, those of ordinary skill will appreciate that certain of the various structural elements illustrated in the exemplary embodiments shown in the drawing figures may be selectively and independently combined to form other configurations for preparing a ceiling tile configuration tailored specifically for an intended application.

. DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION

An exemplary ceiling tile assembly 100 according to the present invention is illustrated in FIG. IA and includes a peripheral support frame 102 surrounding a single opening and a cover layer or ornament facing 104 extending across the opening and attached to the peripheral frame. As illustrated in FIG. IB, a cross-sectional view along line A-A' of FIG. IA, the peripheral frame 102 may be attached to the ornamental facing 104 using an adhesive layer 106 or other suitable attachment means such as stitching, welding, stapling, crimping, pressing, retaining, clipping or other mechanical and/or frictional attachments (not shown). The cross-sectional configuration of the frame may have an "S" or "Z" configuration, or may utilize a more complex configuration, that includes an inwardly extending offset portion of the peripheral frame 102 that, in combination with the ornamental facing 104 or another protruding portion of the frame (not shown), forms a peripheral recess 103. It should also be appreciated that the frame could assume a simpler cross-sectional configuration such as a rectangle if desired. As illustrated in FIGS. 1C and ID the support frame 102 may also be made discontinuous. As illustrated in Fig. 1C, the discontinuous frame 102 may comprise a series of individual or separate corners 603. Alternatively, as illustrated in Fig. ID the frame 102 may comprise a series of individual straight sections 605. The discontinuous frames 102 illustrated in Figs. 1C or ID may be easily adapted and used to fit any size and shape of ornamental facing 104. More specifically, the corners 603 or straight sections 605 may be glued with adhesive to the margin M of the ornamental facing 104 and then used to support and hold that facing on the supporting members 200 in the ceiling grid.

As illustrated in FIG. 2 A, an exemplary ceiling tile assembly 100 may be modified using a trim element or piece 108 that extends from one portion of the peripheral frame 102 to another portion of the peripheral frame and extends at least partially into the recess 103 at both ends. As illustrated in FIG. 2B, the trim element 108 will typically be attached to the portion of the ornamental facing 104 that is covered by the trim element with an adhesive layer 110. Premanufactured trim elements 108 may include a double-sided adhesive tape with a cover layer that is removed before application to expose an adhesive surface. The adhesive layer 110 may also be field-applied and may or may not be continuous, but the adhesive means utilized will preferably be one that will not degrade the appearance of the exposed surface of the ornamental facing 104, i.e., will not discolor, seep or be extruded through the cover layer during application or during the anticipated useful life of the customized ceiling tile.

As illustrated in FIG. 3 A, once the trim element 108 is in place and attached to at least a portion of the underlying region of the ornamental facing 104, a portion of the peripheral frame 102 and the cover layer can be removed with the remaining portion of the peripheral frame 102a and the trim element defining the periphery of the modified or customized ceiling tile assembly 100a. As illustrated in FIG. 3 B, the trim element 108 and the adhesive layer 110 can provide substantially continuous support for the cut edge of the remaining portion of the ornamental facing 104a, thus reducing sagging or wrinkling that would tend to degrade the appearance of the remaining portion of the ceiling tile 100a. As illustrated in FIG. 4A, the trim element 108 may be configured for customizing a ceiling tile assembly 100a for placement around a generally rectangular obstruction. The trim element 108 may be formed by attaching two straight trim elements, as illustrated in FIG. 3 A, with mitered (shown), butt, overlapping or other attachment at the intersection of the two trim elements. Similarly, premanufactured trim elements defining one or more common angles, such as 30°, 45°, 60° or 90°, to reduce the need for and/or to simplify the field assembly of more complex trim elements for customizing the ceiling tiles. As illustrated in FIG. 4B, premanufactured trim elements 108 may be provided in curved, circular or arcuate configurations having an assortment of radii to reduce the need for and/or to simplify the field assembly of customized ceiling tiles for accommodating pipes, columns or other obstructions having a generally cylindrical or rounded surface.

As illustrated in FIG. 5 A, exemplary ceiling tile assemblies 100 according to the invention may be laid in a supporting structure or grid formed from a plurality of supporting members 200 that provide a supporting flange 202 on which an edge of the ceiling tile can rest. In the configuration illustrated in FIG. 5A, the supporting flange 202 has a surface 202a that is completely exposed when the ceiling tile assemblies 100 are in place. As also illustrated in FIG. 5 A, the end portion of trim element 108 may also be provided with a recess 109 that allows it to engage the offset portion of the peripheral frame 102 and thereby reinforce the attachment. FIG. 5 A also illustrates both the optional use of a lower inwardly protruding portion of the peripheral frame 102 to form at least a portion of the recess, thereby providing additional mechanical support for the end portion of the trim element 108, and the use of reinforced regions 108a provided on appropriate surfaces of the trim element that may, for example, improve the strength, durability and/or dimensional control of the ends of the trim elements.

As illustrated in FIG. 5B, the peripheral frame 102 can be provided with extended portions 102c that extend across and below a portion of the exposed surface of the supporting flange 202. The peripheral frame can also be provided with resilient or otherwise biased retaining elements or members 112 that project generally upwardly from the peripheral frame and are configured for removably attaching the ceiling tile to the supporting grid. The retaining elements 112 may be configured to allow deflection or rotation, about either a horizontal or a vertical axis, between an attached position and a released position 112a to allow insertion and removal of the ceiling tile from the supporting grid. Openings may be provided in the peripheral frame 102 for inserting a tool or a finger through the frame to contact and deflect the retaining element 112. The openings may, in turn, be concealed using a plug or an insert 102d for concealing the openings until needed. As an alternative to the openings, the peripheral frame 102 may incorporate a simple mechanism 116 for deflecting the retaining element 112 through actuation of an exposed button, slide, tab, fastener or other structure. As also illustrated in FIG. 5B, the peripheral frame may incorporate projections 102b, which may extend from the extended portion 102c of the peripheral frame and may be positioned below and/or spaced inwardly from the supporting flange 202. As with the openings, a plug or cover element may be provided for concealing the exposed portion of the mechanism until access is needed for actuation.

As illustrated in FIG. 6A, an exemplary ceiling tile assembly according to the invention will tend to include certain structural elements and dimensions that may be adapted as necessary to provide the strength and sizing appropriate for an intended application. As indicated in FIG. 6A, the offset portion of the frame may have a characteristic length F and thickness To and be separated from the ornamental facing 104 by a recess height D. The supporting portion of the frame may have a characteristic length B and thickness Ts with the supporting portion of the frame and the offset portion of the frame being separated by a transitional or intermediate portion of length I. As illustrated in FIG. 6B₅ the peripheral frame 102 may be provided with one or more recesses 118 into which a corresponding attachment element 120 may be inserted or snapped to secure the ornamental facing 104 to the frame and/or improve the aesthetic appearance of the ceiling tile. As illustrated in FIG. 6C, the peripheral frame 102 may be provided with one or more reinforcing members 122 for increasing the strength and/or rigidity of the peripheral frame, thereby decreasing the quantity of material, typically a polymeric material, needed to obtain the desired strength and/or dimensions. Further, although, as illustrated in FIG. 5 A, the support surface, with or without a portion of the ornamental facing 104 can rest on the supporting flange 202, as illustrated in FIGS. 6C-6E, the peripheral frame 102 may be provided with an extended portion to provide a mounting surface 124 that is offset from the supporting surface, allowing the ornamental facing 104 to be positioned at different levels, i.e., above or below, relative to the supporting flange.

As illustrated in FIGS. 6E and 6F, although the primary plane of the ornamental facing 104 will typically be defined by the supporting surface(s) of the peripheral frame 102, or a modified peripheral frame 102a and one or more trim elements 108, the ornamental facing 104 may include an additional margin or peripheral portion 104b that extends beyond the support surface and can be attached to the peripheral frame along one or more remote surfaces 102e that are offset from the support surface. These configurations allow the ornamental facing 104 to conceal more of the peripheral frame and may be used to improve the appearance of the ceiling panel.

As illustrated in FIG. 7A, an exemplary embodiment of a customized ceiling panel will include an end portion of a trim element 108 that extends into the recess defined between the offset portion of the peripheral frame 102 and the ornamental facing 104 and may be attached to the cover layer using an adhesive layer 110. As illustrated in FIG. 7B, the basic embodiment of FIG. 7 A may be modified to incorporate stopping structures 126 for controlling the depth of the insertion of the trim element into the recess 103 and projecting structures such as teeth or ridges 128 for improving the retention of the trim element within the recess. As illustrated in FIG. 7C, the basic embodiment of FIG. 7A may also be modified to include a weakened or more resilient portion 130 that will allow the projecting portion of the offset portion of the peripheral frame 102 to be deflected to increase the sizing of the recess to simplify insertion of the end portion of the trim element

108 after which the offset portion can return to its original position. As illustrated in FIGS. 8A-8C the support frame 300 may comprise multiple, discontinuous elements 302. In the embodiment illustrated in. FIGS. 8A-8C, each element 302 comprises a straight body that is substantially C-shaped or U-shaped in cross section. The element 302 includes a channel 304 that receives and holds the margin 306 of an ornamental facing 104. One element 302 may be provided anywhere along each side of the ornamental facing 104 (FIG. 8C). The elements 302 are positioned to rest upon the supporting flange 202 of a supporting member 200 of the type illustrated in FIG. 5A and serve to hold an ornamental facing in position in a ceiling grid.

As illustrated in FIGS. 9A-9B, the support frame 400 may comprise multiple, discontinuous elements 402. Each element 402 comprises a substantially L-shaped body that forms a corner. Each leg of the element 402 is substantially C-shaped or U-shaped in cross sections and includes a channel 404 that receives and holds the margin 406 of an ornamental facing 104. One element 402 may be provided at each comer of the ornamental facing 104 (see FIG. 9B). The elements 402 are positioned to rest upon the supporting flange 202 of a supporting member 200 of the type illustrated in FIG. 5A and serve to hold an ornamental facing in position in a ceiling grid.

The channels 304 and 404 in the respective support frames 300, 400 are sized and shaped to securely hold the ornamental facing 104 without the use of adhesive. More specifically, the elements 302, 402 engage the ornamental facing 104 and are made from a material with sufficient resiliency to provide the desired friction fit.

In either embodiment, the support frame 300, 400 is suited to hold an ornamental facing 104 of substantially any size and shape in a ceiling grid without cutting or gluing of the support frame. Thus, the frames 300, 400 are particularly versatile and suited "out-of- the-box" for substantially any application. Yet another embodiment of a ceiling tile assembly 500 is illustrated in FIG. 10.

The assembly 500 includes a supporting member 200 with a supporting flange 202. An ornamental facing 104 is carried on the supporting member 200 with the margin thereof resting on the supporting flange 202. A retaining element 502 is pivotably mounted to supporting element 200 by a pivot pin 504. The retaining element 502 is displaceable between an open position illustrated in phantom line and a closed position illustrated in full line. When the retaining element 502 is open, one may easily position the margin 506 of the ornamental facing 104 on the supporting flange 202. The retaining element 502 is then closed to engage the margin 506 between the retaining element and the supporting flange 202 and thereby hold the ornamental facing in. position in the ceiling grid. A biasing element such as a torsion spring (not shown) may be connected between the body of the supporting member 200 and the retaining element 502 to bias the retaining element into the closed position. While not shown, it should be appreciated that a series of supporting members 200 are provided perpendicular to each other at spaced locations in order to provide a ceiling grid. A retaining element 502 is provided on each supporting member 200 along all four sides of the ornamental facing 104. When properly secured in position in the grid, the ornamental facing 104 is, therefore, positively secured on all four sides by retaining elements 502. An important aspect of the present invention is the thin profile and lightweight of the ceiling tile assembly 100. As a consequence, a large number of ceiling tile assemblies 100 may be packaged together for shipping at reduced cost. Specifically, the resulting package is both lighter in weight and less bulky than would be true if shipping ceiling tiles of prior art design. More specifically, the ornamental facing 104 of the ceiling tile assembly 100 is constructed from a fiberglass veil. That fiberglass veil includes between about 17 to about 30 weight percent glass fibers, about 6 to about 10 weight percent polymer binder and about 58 to about 78 weight percent filler. The glass fibers have a nominal diameter of between about 6.5 to about 11.0 microns and a length of between about 5.0 to about 7.0 mm. Further the fiberglass veil has an areal weight of between about 50 to about 200 gsm and a thickness of between about 1.0 to about 2.0 mm.

Typically a flame retardant is used as the filler. Thus, the filler may be made from a material selected from a group including, for example, alumina trihydrate, phosphorous compounds, antimony trioxide, borates, intumescent materials and mixtures thereof. Substantially any other flame retardant known in the art may be utilized. Typically the polymer binder is selected from a group of materials consisting of polyvinyl alcohol, styrene-acrylate, melamine formaldehyde and mixtures thereof. In addition the fiberglass veil is characterized by a water hold number of greater than 180 seconds. The water hold test comprises dripping one drop of water from a height of 5 cm onto the veil surface and measuring the time for full absorption at room temperature. The peripheral support frame 102, 300, 400 may be constructed from substantially any appropriate material including, for example, polypropylene, polystyrene, polyethylene, polyvinyl chloride, nylon, acrylic, polycarbonate and mixtures thereof. The support frame 102, 300, 400 has a tensile strength at yield of between about 15 to about 70 MPa as measured by ASTM test method D638 and a flexural modulus of between about 40 to about 100 MPa as measured by ASTM test method D790.

A typical ceiling tile assembly 100 will have a length and width of approximately 60.96 cm. As best illustrated in FIG. IB, the ornamental facing 104 includes a main body B and a margin M. The margin M extends all the way around the ornamental facing 104 and is secured by adhesive 106 to the peripheral support frame 102. The main body B spans across the opening in the support frame 102 and may typically have a surface area of between about 3,100 to about 3,800 cm²" The fiberglass veil forming the ornamental facing 104 is cut to the size and shape of the peripheral support frame 102. The facing 104 is fixed to the frame 102 in an unstretched condition. The main body B spanning the opening in the support frame 102 is otherwise unsupported. The support frame 102 has a thickness of between about 2.0 to about 5.0 mm. As noted above the ornamental facing 104 has a thickness of between about 1.0 to about 2.0 mm. Accordingly, the entire ceiling tile assembly 100 has a thickness of less than 7.0 mm and as little as 3.0 mm. This allows a great many assemblies to be stacked together in a small shipping vessel such as a carton, box or crate.

The fiberglass veil from which the ornamental facing 104 is constructed is characterized by remarkable dimensional stability. Since the ornamental facing 104 is not stretched prior to adhering to the support frame 102, the material is not in tension and thus will not stretch or elongate over time as would be typical of a stretched facing material. Similarly, glass veils have a very low elongation, less than some tenths of a percent and, accordingly, the ornamental facing 104 will not stretch and sag under heat. As noted above, the fiberglass veil of the ornamental facing 104 absorbs very little water and, therefore, again has no tendency to stretch due to absorbed water weight even in relatively high humidity environments. In fact, the fiberglass veil used for the ornamental facing 104 is characterized by a sag of less than about 2.5 mm as measured by ASTM test method C367. More preferred embodiments of the present invention are characterized by a sag of less than about 2.0 mm as measured by ASTM test method C367. Suitable veil material is available from Owens Corning, Toledo, OH. By forming the ornamental facing 104 from a fiberglass veil, other benefits are also provided. Specifically, the veil is flexible, resilient and breathable. Thus, sound passes freely through the veil. Consequently, a speaker may be positioned out of sight behind the ceiling tile assembly 100 yet the sound passes freely through the veil to those in the room. Advantageously, this provides a more aesthetically pleasing, continuous ceiling surface and eliminates the need for an installer to customize a ceiling tile assembly 100 by cutting around and exposing a speaker.

Although the invention has been described in connection with certain exemplary embodiments, it will be evident to those of ordinary skill in the art that many alternatives, modifications, and variations may be made to the disclosed structures and methods in a manner consistent with the detailed description provided above. Also, it will be apparent to those of ordinary skill in the art that certain aspects of the various disclosed exemplary embodiments could be used in combination with aspects of any of the other disclosed embodiments or their alternatives to produce additional, but not herein illustrated, embodiments incorporating the claimed invention but more closely adapted for an intended use or performance requirements. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A ceiling tile assembly, comprising: a sheet of ornamental facing having a main body and a margin; and a support frame engaging and holding at. least a portion of said margin; said assembly being characterized by constructing said sheet of ornamental facing from a fiberglass veil.

2. The assembly of claim I₅ wherein said fiberglass veil includes between about 17 to about 30 weight percent glass fibers, about 6 to about 10 weight percent polymer binder and about 58 to about 78 weight percent filler.

3. The assembly of claim 2, wherein said glass fibers have a nominal diameter of between about 6.5 to about 11.0 microns and a length of between about 5.0 to about 7.0 mm.

4. The assembly of claim 2, wherein said fiberglass veil has an areal weight of between about 50 to about 200 gsm and a thickness of between about 1.0 to about 2.0 mm.

5. The assembly of claim 4, wherein said filler is a flame retardant.

6. The assembly of claim 5, wherein said filler includes materials selected from a group consisting of alumina trihydrate, phosphorous compounds, antimony trioxide, borates, intumescent materials, and mixtures thereof.

7. The assembly of claim 2, wherein said polymer binder is selected from a group of materials consisting of polyvinyl alcohol, styrene-acrylate, melamine formaldehyde and mixtures thereof.

8. The assembly of claim 1 , wherein said support frame is constructed from a material selected from a group consisting of polypropylene, polystyrene, polyethylene, polyvinyl chloride, nylon, acrylic, polycarbonate and mixtures thereof.

9. The assembly of claim 8, wherein said support frame has a tensile strength at yield of between about 15 to about 70 MPa as measured by ASTM test method D638 and a flexural modulus of between about 40 to about 100 MPa as measured by ASTM test method D790.

10. The assembly of claim 1 , wherein said fiberglass veil is characterized by a water hold number of greater than 180 seconds.

11. The assembly of claim 1 , wherein said margin and said support frame are continuous and have a width of between about 1.5 to about 2.0 mm.

12. The assembly of claim 11₅ wherein said main body has a surface area of between about 3,800 to about 3,800 cm².

13. The assembly of claim 12, wherein said sheet of ornamental facing is unstretched and said main body spans across an opening in said support frame and is otherwise unsupported.

14. The assembly of claim 13, wherein said sheet of ornamental facing has a thickness of between about 1.0 to about 2.0 mm, said support frame has a thickness of between about 2.0 to about 5.0 mm.

15. The assembly of claim 14, wherein said main body is characterized by a sag of less than about 2.5 mm as measured by ASTM test method C367.

16. The assembly of claim 14, wherein said main body is characterized by a sag of less than about 2.0 mm as measured by ASTM test method C367.

17. The assembly of claim 1 wherein said support frame is discontinuous.

18. The assembly of claim 17, wherein said support frame is substantially C-shaped in cross section and defines a channel holding said margin.

19. The assembly of claim 18, wherein said support frame defines a corner.

20. The assembly of claim 18, wherein said support frame is straight.

21. A ceiling tile assembly, comprising: a sheet of ornamental facing and a support frame having an overall thickness of less than 7.0 mm and characterized by a sag of less than about 2.5 mm for an unsupported surface area of about 3716 cm² as measured by ASTM test method C367.

22. The ceiling tile assembly of claim 21, wherein said ceiling tile assembly has a weight per unit surface area of between about 50 to about 200 gsm.

23. A ceiling tile assembly, comprising a facing sheet of breathable material and a support frame having an overall thickness of less than 7.0 mm.

24. The ceiling tile assembly of claim 23 having an overall thickness of less than 5.0 mm.

25. A method of reducing shipping expenses relating to ceiling tiles, comprising: producing ceiling tiles with an overall thickness of less than 7.0 mm and an overall weight per unit area of less than 200 gsm; and packing those ceiling tiles in a shipping vessel.

26. A ceiling tile assembly, comprising a sheet of ornamental facing having a main body and a margin; and a supporting member including a retaining element engaging said ornamental facing.

27. The assembly of claim 26, wherein said supporting member includes a supporting flange and said retaining element is displaceable between an open position and a closed position.

28. The assembly of claim 27, wherein in said closed position said margin of said ornamental facing is engaged between said supporting flange and said retaining element.