Ceiling tile of expanded polystyrene laminated with embossed vinyl sheet

The method of making a drop-in ceiling tile or the like comprising the steps of

• a. expanding polystyrene to form a cellular block with dimensions at least one foot by two feet by four feet,
• b. using a hot-wire cutter to cut said block into substrate sheets approximately one inch by two feet by four feet,
• c. applying a water solvent adhesive to said substrate sheets,
• d. adhering a thin plastic sheet on each substrate sheet to cover a face thereof, and
• e. allowing each said combined substrate sheet and facer sheet to cure in an atmosphere above 30.degree. F. for at least one-half hour.

The method of making a drop-in ceiling tile or the like comprising the steps of

• a. using a hot-wire cutter to cut a block of expanded polystyrene foam into substrate sheets approximately one inch by two feet by four feet,
• b. preparing a thin plastic sheet for use as a facer on each of said substrte sheets by perforating the plastic sheet at intervals less than one inch with apertures of less than one-quarter inch in their greatest transverse dimension,
• c. applying an adhesive to at least one of said plastic sheets and said substrate sheets, and
• d. adhering each said plastic sheet on a face of one of said substrate sheets.

A drop-in ceiling tile or the like made by the method of

• a. expanding polystyrene to form a cellular block with dimensions at least about two inches by two feet by four feet,
• b. using a hot-wire cutter to cut said expanded polystyrene block into substrate sheets approximately one inch by two feet by four feet,
• c. preparing a thin vinyl textured plastic sheet for use as a facer on each of said substrate sheets by perforating the plastic sheet at intervals of less than about one inch with apertures less than one-half inch in their greatest transverse dimension,
• d. applying an adhesive to at least one of said plastic sheets and said substrate sheets, and
• e. adhering each said plastic sheet on a face of one of substrate sheets.