EP2996932A1

EP2996932A1 - Ceiling arrangement of cabin module for ship or corresponding vessel

Info

Publication number: EP2996932A1
Application number: EP14797048.7A
Authority: EP
Inventors: Jarno SOINILA; Kari VÄLIMAA; Leszek Matwij
Original assignee: Lautex Oy AB
Current assignee: Lautex Oy AB
Priority date: 2013-05-14
Filing date: 2014-05-06
Publication date: 2016-03-23
Also published as: EP2996932A4; FI20135505A; WO2014184423A1; FI124710B

Abstract

The invention relates to a ceiling arrangement for a cabin module of a ship or corresponding vessel. The ceiling panel (10) comprises a rectangular first surface plate (12), a second surface plate (12'), an insulating layer (11) between the surface plates (12, 12'), which is made of fire-resistant material. The edges of the panels (10) are provided with different gripping formations (13 and 14) of the surface plate (12). The second surface plate (12') is similarly provided with gripping formations (13', 14'), which are identical to the gripping formations (13, 14) of the first surface plate (12). The gripping formations of two adjacent panels (10) form a tongue-and-groove joint. The second surface plate (12') is disposed with respect to the first surface plate (12) upside down on the opposite side of the insulating layer (11) in such a manner that identical gripping formations (13, 13' and 14, 14') of the surface plates (12, 12') are situated on opposite sides of the panel (10) at diagonally opposite corners. Each panel is supported only at its ends on brackets (2) arranged on the cabin module walls (20). The gripping formations include at least two opening surfaces (13a, 14a and 13a', 14a'), which allow opening of the tongue- and-groove joint between adjacent panels (10) when applying against the plane of the surface plates (12, 12') a substantially perpendicular force (F), and in that the gripping formations include blanking flanges (14c, 14c').

Description

CEILING ARRANGEMENT OF CABIN MODULE FOR SHIP OR CORRESPONDING VESSEL

The present invention relates to a ceiling arrangement for the cabin module of a ship or corresponding vessel, having ceiling panels, which ceiling panel comprises a rectangular first surface plate, a second rectangular surface plate, an insulating layer between the surface plates, which is made of fire-resistant material, wherein a first edge of the ceiling panel is provided with a first gripping formation of a first surface plate and the second, opposite edge of the ceiling panel, which is parallel to the first edge, is provided with a second gripping formation of the first surface plate, which is a different in shape than the first gripping formation, which second surface plate is provided with a first gripping formation and a second gripping formation, which are identical to the gripping formations of the first surface plate, wherein gripping formations of two adjacent ceiling panels form a tongue-and- groove joint, and which second surface plate is disposed with respect to the first surface plate upside down on the opposite side of the insulating layer in such a way that identically shaped gripping formations of the surface plates are situated on opposite edges of the ceiling panel at diagonally opposite corners. From prior art there are known ceiling (or wall) panels of the foregoing types which are also fire- resistant. One such panel is described in published patent EP 1426518 Bl. It describes panels to be connected together by using tongue-and-groove joints, wherein between two metal plates there is a fire-resistant insulating layer. The metal plates have at their opposite edges different inclinations which form the tongue-and-groove joint. Inclinations of the panel's metal plate are identical and are arranged typically as mirror image on both sides of the insulating layer. Thus, differently shaped edges of two adjacent panels can be brought together to the tongue-and-groove joint. To ensure the adequacy of fire properties of such a structure the edge sealing between two panels has to be made complicated. In other words, to be effective, the surface plates are provided with accurate additional inclinations. These are mainly used as intermediate floor and outer wall structure, which sets for the strength and engagement of the panel its own requirements. Such panels are also not suitable to be used in ceiling arrangement for cabin modules of a ship or corresponding vessel. Thicknesses of such panels are at least 40mm. As length and thickness are increasing, the weight also increases so that additional bearings and fixings to the frame structure are necessary in order that joints between the panels remain firmly in place. This kind of panels are also produced by, inter alia, Paroc Oy.

Also known are tongue-and-groove joints, which are more complex in structure, such as those wherein between two panels is needed a connection piece and/or mechanical fastening parts, such as screws, which are drilled at the junction point through the panels. Such structures are relatively difficult to install and panels can be generally installed just in one way as extensions of the preceding one. Also, these do not fit particularly well due to their size and weight as a fire-resistant (fire rated) lightweight structure, such as the ceiling cladding of ships.

In addition, a Norwegian company called "Norac" produces lightweight ceiling panels, for example under the brand name "B-600/40" and "Sigma 300", the former also being 40 mm in thickness and which surface plate is formed having a cross- section which completely surrounds the insulating layer. The surface plate does not form a tongue-and-groove joint at the edges of the panel, but the edges of adjacent panels rest freely on tabs formed at the edges of the panels, and therefore the joint is not very durable and tight. This model is not suitable to be used as wall panel either. The "Sigma 300" panel in turn comprises a surface plate only at one side of the insulating layer. The surface plate in question is shaped with gripping clips on panel edges, wherein a space is left between adjacent panels, with no insulating layer. Thickness of the panel is, in order to achieve the fire resistance, relatively high, i.e at least 50mm. In addition, disconnection of two adjacent plates is relatively difficult. Disconnection is possible by pulling the other panel downward (or holding vertically in position) and at the same time pushing the next panel upward, which can be done with a special tool and by choosing the right panel, to push and pull.

The purpose of the present invention is to provide a ceiling panel arrangement that permits us to eliminate or at least substantially reduce the above presented disadvantages of prior art solutions. The aim is to provide a ship's cabin module arrangement with ceiling panels that have a tongue-and-groove joint provided in a simple way, which allows easier installation and removal and re-installation of ceiling made of panels during maintenance works. In addition one aim is to provide a fire- rated ceiling panel, wherein the ceiling can be made with reduced thickness compared to prior art and to achieve benefits through the whole ship scale.

In order to achieve the abovementioned goal the present invention is characterized by the fact that each ceiling panel is supported only at its ends on brackets arranged on cabin module walls, that gripping formations of the first surface plate and the second surface plate include at least two opening surfaces, which in connection with a tongue-and-groove joint between two adjacent ceiling panels are cooperating with each other to allow opening of the tongue-and-groove joint between said two adjacent ceiling panels in substantially perpendicular direction against the plane of the surface plates when applying at the tongue-and-groove joint point a substantially perpendicular force against the plane of the surface plates, and that the gripping formations include blanking flanges, which form between said two adjacent ceiling panels a double surface plate layer extending along the whole length of the tongue-and-groove joint.

With the ceiling arrangement according to the invention, it is possible to form with a new simple structure ceiling panel edges for a tongue-and-groove joint, which are identical. In other words, the two surface plates are identical in edge formation, such as panels known per se, but their edges are shaped so that when attached according to the invention to the insulation board they form tongue-and-groove joint edges of a panel similar in shape. Accordingly, the surface plates may also be formed to be identical in shape. This will not only facilitate the manufacture of the panels by reducing the number of different pieces, but also their installation. A tongue-and-groove joint having according to the invention a sealed and structure- reinforcing double surface plate layer made of blanking flanges and extending along the whole length of the tongue-and-groove joint, and at each of the edges at least two opening surfaces, enables manufacturing of a fire-rated ceiling panel of reduced thickness and which is self-supporting compared to prior art. This has considerable advantages in accordance with the purposes of the invention throughout the ship (vessel) scale. In particular, the prior art supporting grids between the ceiling walls of the cabin module can be dispensed with entirely, because the panels can be placed in between opposing walls of the cabin module. This in turn, enables, along with the ceiling panel structure having partly reduced thickness, the height of the cabin module (and therefore the entire height and the mass/mass centre of the ship) to be reduced by several centimeters per floor. This also achieves substantial savings in the ship's hull structure material, and further costs.

In addition, similar edges of the panel (tongue-and-groove joints) allow the panel to be mounted on either surface plate exposed. On the other hand, if the surfaces of the surface plates are similar (same color), the panel, or even the ceiling or partition wall made of panels, can be turned so that the other completely new surface will be exposed. With this feature, the panel's service life can in principle be doubled. The panel surface plates can also be of different colors, and the panel can be installed either way according to color choice. This structure allows the edges to be formed in such a way that the structure of the ceiling formed of panels is easily opened from any point.

Preferred embodiments according to the present invention are disclosed in the appended dependent claims.

The invention will now be described in more detail with reference to the

accompanying drawings, wherein: Figure 1 shows an axonometric view of the ceiling arrangement formed of ceiling panels according to a preferred embodiment of the invention,

Figure 1A shows a longitudinal and cross-sectional view of the ceiling panel and an embodiment of the supporting of ends,

Figure 2 shows a cross-sectional view of a single ceiling panel shown in Figure

1,

Figure 3 shows a cross-section of a tongue-and-groove joint between two

ceiling panels shown in Figure 1 and 2, and

Figure 4 shows the opening of the tongue-and-groove joint between two ceiling panels shown in Figure 3. In Figure 1, therein is shown a ceiling arrangement for a cabin module of ship or corresponding vessel, formed of ceiling panels according to a preferred embodiment of the invention. Figure 2 shows a cross-section of a single ceiling panel according to a preferred embodiment, which is indicated by reference number 10. For simplification, the ceiling panel 10 is hereinafter referred to as panel 10 and its more detailed structure is described in the following.

The panel 10 comprises a mainly rectangular first surface plate 12 and a similar, rectangular second surface plate 12', which is preferably identical in shape to the surface plate 12. Between the surface plates 12 and 12' is arranged an insulating layer 11 formed of fire-resistant material. The principal shape of the insulating layer 11 follows the shape of the surface plates 12 and 12'. The surface plates preferably have a thickness of 0.5-1 mm. The surface plates 12 and 12' are mounted from their surface abutting the insulating layer 11, for example by gluing. The material of the surface plates is preferably metal and the insulating layer is therefore of some fire-resistant material, such as rock wool, mineral wool or glass wool. This establishes a so-called sandwich structure.

Looking at Figure 2, from the cross-section of panel 10 it is seen that the panel 10 has two edges, a first edge and a second edge, which are provided with gripping formations allowing a tongue-and-groove joint of two adjacent panels 10. Gripping formations are situated at corners (four corners) of the panel 10 cross-sectioned in Figure 2. The gripping formations include a gripping formation 13 of a first edge of the first surface plate 12 and a gripping formation 14 of a second edge of the first surface plate 12, which is different in shape in relation to the gripping edge 13 of the first edge. More detailed description of the gripping formations is presented below.

Further, the second surface plate 12' is provided with a first gripping formation 13' and a second gripping formation 14', which are identical to gripping formations 13, 14 of the first surface plate 12. From Figure 2 is seen that the second surface plate 12' is positioned in relation to the first surface plate 12 upside down on the opposite side of the insulating layer 11 in such a way that identically shaped gripping formations 13, 13' and 14, 14' of the surface plates 12, 12' are situated on opposite edges of the ceiling and wall panel 10 at diagonally opposite corners. Gripping formations are therefore shaped in such a way that on both edges of the panel 10 there are formed similar formations which provide a tongue-and-groove joint (between two adjacent panels 10). This facilitates the installation of the panel 10 as compared to known tongue-and-groove joint solutions which have different panel edges. In this embodiment, the above-disclosed formations allow both edges of the panel to be provided with three tabs 13c, 13d, 14b' and respectively 13c', 13d', 14b and two grooves 15, 16'; 15', 16 between them.

Preferably, from these panels 10 may be formed, particularly in the embodiments shown in Figures 1 and 1A, light ceilings or so-called false ceilings or similar claddings. Panels 10 are supported at both ends, for example in Figure 1, with two brackets 2, such as L-molding 2, or as shown in Figure 1A, with brackets 2 connected at the top of the walls 20 and are connected to each other by means of the above-described tongue-and-groove joints formed along long edges. Thus, the ceiling panels 10 according to the invention can be fitted between two walls 20 without the additional supports and couplings of the prior art. The L-molding preferably has a reinforced structure, for example an additional flanking, which makes a tight connection between the ceiling panel 10 and the wall and ensures a sufficient fire resistance to the ceiling arrangement.

The long connection seam 100 must then be made sufficiently rigid in order that the self-supporting structure does not bend in a longitudinal direction at the center part, at least not of its own weight. For this purpose, the edges of the panels 10 insulating layers 11 are formed with tabs 11a extending to the tongue-and-groove joints. They are formed overlapping at a tongue-and-groove joint of adjacent panels 10. Overlapping tabs 11a also contribute to joining together of two panels 10 in such a way that at least the panels' 10 own weight cannot open the connection seam 100 between two panels 10. Another advantage of overlapping tabs 11a of insulating layers 11 is that it connects insulating layers 11 of two adjacent panels as a unitary structure. This structure also improves the fire resistance.

Further, the ceiling arrangement for a cabin module of a ship or corresponding vessel according to the invention comprises blanking flanges 14c and 14c' which are part of the gripping formations. Blanking flanges 14c and 14c' are in this case inclinations formed as an extension of the opening surfaces 14a, 14a' of the surface plates 12 and 12', which are positioned against tabs 13c and 13c' of the adjacent panel. Thus, between two panels 10 is formed a double surface plate layer extending along the whole length of the tongue-and-groove joint as seen in Figure 3.

The connection seam 100 can be further stiffened with reinforcement portions 13b and 13b' formed on gripping formations. In this embodiment, the reinforcement portions 13b and 13b' are formed by double-folding a tab forming the metallic surface plate 12, 12', preferably along the direction of the surface plate plane.

These reinforcements (reinforcement portions and blanking flanges) allow the outer dimensions of the panel, i.e. the length and the width, to be kept high, while the thickness can be reduced compared to the prior art (about 40mm) and to be much smaller, about 30 to 31 mm. As an example it may be mentioned that a fire- resistant panel having an insulating layer 30 mm thick and 3 meters long (a typical panel mounted on a cabin module ceiling has a length of about 2.6 to 3 meters, with an insulation layer thickness of 40 mm) may be formed with a width of 600 millimeters while the connection seam 100, however, withstands the stresses caused by the weight of the panels without bending. When dimensioning the panel, which makes part of the self-supporting ceiling arrangement according to the invention, up to 80% of the ceiling panels of the cabin modules may be covered. In fire-rated ceiling or cladding solutions of the prior art, used without exception is an insulating layer about 40 mm thick or additional reinforcements of the ceiling arrangement that are not integral with panel's gripping formations.

Further, Figure 3 and 4 show in greater detail a preferred embodiment of the panel shown in Figure 2, wherein two interconnected panels 10 have means for assisting in opening of the connection. These means comprise opening surfaces 13a, 14a and 13a', 14a' which are arranged on gripping formations of the first surface plate 12 and the second surface plate 12'. Opening surfaces are preferably inclined surfaces 13a, 14a formed on gripping formations 13, 14 and arranged at an angle relative to the level of surface plate 12 as well as inclined surfaces 13a', 14a' formed on gripping formations 13', 14' and arranged at an angle relative to the level of surface plate 12' . Thus, there are at least two opening surfaces per edge. Therefore, the abovementioned grooves 15, 16'; 15', 16 are tapering towards the bottom and the tongues 13c, 13d, 14b'; 13c', 13d', 14b are tapering from the base towards the head. The opening surfaces of the two adjacent panels 10 (see Figures 3 and 4) are arranged in connection to each other in such a way that the inclined surface 13a formed on the first gripping formation 13 of the first surface plate 12 of the first edge of the panel 10 (in Figures 3 and 4, left panel) abuts on the inclined surface formed on the second gripping formation 14 of the first surface plate 12 of the second edge of the next panel 10 (right panel). Similarly, the inclined surface 14a' formed on the second gripping formation 14' of the second surface plate 12' of the first edge of the first panel 10 abuts on the first gripping formation 13a' of the second surface plate 12' of the second edge of the next panel. This forms at the same time a double surface plate layer of a tongue-and-groove joint of

interconnected panels.

Such matching opening surfaces 13a, 14a, 13a', 14' allow the simple disconnection of ceiling panels 10 shown particularly in Figure 4. Disconnection is effected by applying at the tongue-and-groove joint point (connection seam 100) a force F substantially perpendicular to the direction of the level of the surface plates 12, 12'. Such a force F can be achieved for example by pushing manually upwards (in the cases of Figure 3 and 4) at the tongue-and-groove joint point. Since the tongue- and-groove joint is always similar regardless of which side of the panel is folded, the force F may also, in accordance with the invention, be applied to the same tongue- and-groove joint from the opposite direction, i.e. in Figures 3 and 4 the force may be applied downward (from the opposite side of the ceiling arrangement). If force F is strong enough, the opposing edges of the panels rise in the direction of force F, as shown in Figure 4, but without breaking the tongues and grooves forming the tongue-and-groove joint of the edges. At the same time the opposing edges of the panels 10 separate from each other so that one of the panels may be dislocated. Opening of the tongue-and-groove joint thus is effected without tools and simply by applying a force in one direction.

It is clear that the correct and secure operation of the ceiling arrangement requires the structure of the panel 10 to have very precise tolerances. Sufficiently precise panel tolerances are preferably accomplished if the material of the insulating layer is milled rock wool. Thanks to the opening surfaces 13a, 14a and 13a', 14a' a single panel located between two panels can be easily separated without tools, which facilitates and simplifies considerably the access above the panel ceiling. For example, a suspended ceiling formed of panels according to the invention does not need to be provided with separate doors, since the ceiling can be opened at a desired point, for example for repair or maintenance purposes of fittings (pipes, wires, transformers) situated between the false ceiling and the actual intermediate floor (or roof).

Similarly, a single panel can be easily replaced. Further, the ceiling arrangement according to the invention avoids use of prior art supporting grids between ceiling walls of cabin modules, which in turn will result in major savings in the cabin module and the whole ship's scale, as has already been shown.

Surface plates 12 and 12' of the panel 10 according to a preferred embodiment of the invention have outer surfaces of different colors. Such panels easily permit using for example, special effect colorings for the wall and ceiling or that two completely different surfaces may be provided with similar panels.

The present invention is not limited to the disclosed embodiment. It can be applied in many ways within the scope defined by the appended claims. For example, the thicknesses of the panels may be according to the application larger than the 30 millimeters shown, and their edge formations may be shaped in numerous ways within the scope defined by the claims to meet the required strength. For example, there may be more than two opening surfaces.

Claims

1. Ceiling arrangement for cabin module of a ship or corresponding vessel, having ceiling panels (10), the ceiling panel (10) comprising a rectangular first surface plate (12), a second rectangular surface plate (12'), an insulating layer (11) between the surface plates (12, 12'), which is made of fire-resistant material, wherein the first edge of the ceiling panel (10) is provided with the first gripping formation (13) of the first surface plate (12) and the second, opposite edge of the ceiling panel (10), which is parallel to the first edge, is provided with the second gripping formation (14) of the first surface plate (12), which is different in shape than the first gripping formation, which second surface plate (12') is provided with the first gripping formation (13 and the second gripping formation (14'), which are identical to gripping formations (13, 14) of the first surface plate (12), wherein gripping formations of two adjacent ceiling panels (10) form a tongue-and-groove joint, and which second surface plate (12') is disposed with respect to the first surface plate (12) upside down on the opposite side of the insulating layer (11) in such a manner that identically shaped gripping formations (13, 13' and 14, 14') of the surface plates (12, 12') are situated on opposite edges of the ceiling panel (10) at diagonally opposite corners, characterized in that each ceiling panel is supported only at its ends on brackets (2) arranged on the cabin module walls (20), that the gripping formations of the first surface plate (12) and the second surface plate (12') include at least two opening surfaces (13a, 14a and 13a', 14a'), which in connection with the tongue-and-groove joint between two adjacent ceiling panels (10) are cooperating with each other to allow opening of the tongue-and-groove joint between said two adjacent ceiling panels (10) in a substantially perpendicular direction against the level of the surface plates (12, 12') when applying at the tongue-and-groove joint point a force (F) substantially perpendicular to the plane of the surface plates (12, 12'), and that the gripping formations include blanking flanges (14c, 14c'), wherein a double surface plate layer is formed between said two adjacent ceiling panels (10) extending along the entire length of the tongue-and- groove joint.

2. Ceiling arrangement according to claim 1, characterized in that the edges of the insulating layers (11) of the ceiling panels (10) are formed with tabs (11a) extending to the tongue-and-groove joints which are overlapping at the tongue- and-groove joint of adjacent ceiling panels (10).

3. Ceiling arrangement according to claim 1 or 2, characterized in that the gripping formations of the first surface plate (12) and/or the second surface plate (12') include reinforcing portions (13b, 13b'), which provide stiffening of the tongue- and-groove joint between two adjacent ceiling panels (10).

4. Ceiling arrangement according to claim 3, characterized in that the surface plates (12, 12') are made of metal and the reinforcing portions (13b, 13b') are formed by double-folding one edge of a metallic surface plate (12, 12').

5. Ceiling arrangement according to any one of the preceding claims 1-4,

characterized in that the first surface plate (12) and the second surface plate (12') have outer surfaces of the same color or different colors.

6. Ceiling arrangement according to any one of the preceding claims 1-5,

characterized in that both edges of the panel (10) include three tabs (13c, 13d, 14b'; 13c', 13d', 14b) and two grooves (15, 16'; 15', 16) between them.

7. Ceiling arrangement according to claim 6, characterized in that grooves (15, 16'; 15', 16) are tapering toward the bottom, and tabs (13c, 13d, 14b'; 13c', 13d', 14b) are tapering from the base towards the head.

8. Ceiling arrangement according to any one of the preceding claims 1-7,

characterized in that the first surface plate (12) and the second surface plate (12') are identical in shape.

9. Ceiling arrangement according to any one of the preceding claims 1-8,

characterized in that the material of the insulating layer (11) is milled rock wool.