Coated ceiling structure and method of forming

Abstract

A ceiling system including a base ceiling structure for suspending from a structural member of a building, a substrate attached to the base ceiling structure, and a sprayable reinforcing material adhered to the substrate. The sprayable reinforcing material and the substrate together form a self-supporting composite material. A method of forming the coated ceiling structure includes the steps of providing a base ceiling structure having an outer surface, applying a foam material in a fluid state to the outer surface of the base ceiling structure, and solidifying the foam material to form a rigid reinforcing layer on the base ceiling structure. Alternatively, the base ceiling structure is a non-self-supporting material, and a reinforcing material is sprayed onto an outer surface of the base ceiling structure. The reinforcing material and the non-self-supporting material together form a self-supporting composite structure.

1 . Method of forming a coated ceiling structure comprising the steps of: 
 providing a base ceiling structure having an outer surface;    applying a foam material in a fluid state to the outer surface of the base ceiling structure; and    solidifying the foam material to form a rigid reinforcing layer on the base ceiling structure.    
   
   
       2 . The method according to  claim 1 , wherein the base ceilings structure comprises a non-self-supporting material, and wherein the foam material bonds to the non-self-supporting material to form a self-supporting composite structure.  
   
   
       3 . The method according to  claim 1 , wherein the foam material comprises polyurethane.  
   
   
       4 . The method according to  claim 1 , wherein the step of applying comprises spraying the foam material.  
   
   
       5 . The method according to  claim 1 , wherein the base ceiling structure comprises a self-supporting grid structure.  
   
   
       6 . The method according to  claim 5 , wherein the base ceiling structure further comprises a plurality of self-supporting panels supported in the grid structure and wherein the outer surface of the base ceiling structure comprises outer surfaces of the plurality of panels.  
   
   
       7 . The method according to  claim 5 , wherein the base ceiling structure further comprises a layer of non-self-supporting material attached to the grid structure.  
   
   
       8 . The method according to  claim 1 , further comprising the step of applying an outer coating to the rigid reinforcing layer.  
   
   
       9 . Method of forming a ceiling structure comprising the steps of: 
 providing a base ceiling structure comprising a non-self-supporting material; and    spraying a reinforcing material onto an outer surface of the base ceiling structure,    wherein the reinforcing material and the non-self-supporting material together form a self-supporting composite structure.    
   
   
       10 . Method according to  claim 9 , wherein the reinforcing material comprises polyurethane.  
   
   
       11 . Method according to  claim 9 , wherein the reinforcing material is a foam material that is sprayed onto the base ceiling structure in a fluid state.  
   
   
       12 . Method according to  claim 9 , further comprising the step of solidifying the reinforcing material, wherein the reinforcing material bonds to the non-self-supporting material to form the self-supporting composite structure.  
   
   
       13 . Method according to  claim 9 , wherein the base ceiling structure further comprises a self-supporting frame to which the non-self-supporting material is attached.  
   
   
       14 . Method according to  claim 12 , further comprising the step of applying a protective coating to the self-supporting composite structure.  
   
   
       15 . A ceiling system comprising: 
 a base ceiling structure for suspending from a structural member of a building;    a substrate attached to the base ceiling structure; and    a sprayable reinforcing material adhered to the substrate, wherein the sprayable reinforcing material and the substrate together form a self-supporting composite material.    
   
   
       16 . The ceiling system of  claim 15 , wherein the sprayable reinforcing material comprises a foam material.  
   
   
       17 . The ceiling system of  claim 15 , wherein the substrate comprises a non-self-supporting material.  
   
   
       18 . The ceiling system of  claim 15 , wherein the substrate comprises a plurality of self-supporting panels.  
   
   
       19 . The ceiling system of  claim 15 , wherein the sprayable reinforcing material provides a ceiling surface having a seamless appearance.  
   
   
       20 . The ceiling system of  claim 15 , further comprising a protective coating adhered to the self-supporting composite material.  
   
   
       21 . The ceiling system of  claim 15 , wherein the base ceiling structure comprises a grid structure.