GB2547239A

GB2547239A - Marine cabin and wall or ceiling element therefor

Info

Publication number: GB2547239A
Application number: GB1602482.0A
Authority: GB
Inventors: Charles Norman Andrew; John Royle Thomas
Original assignee: P E Composites Ltd
Current assignee: P E Composites Ltd
Priority date: 2016-02-11
Filing date: 2016-02-11
Publication date: 2017-08-16
Anticipated expiration: 2036-02-11
Also published as: GB201602482D0; GB2547239B

Abstract

A wall or ceiling element 2 for constructing a marine cabin comprises a structural body and a decorative finish thereon. The structural body comprises a core layer 4 which is covered on a major surface thereof by a decoration layer 6, 8 forming the decorative finish and having an outer decorative surface 10, 12. The core layer and the decoration layer are non-metallic, the core layer is composed of a non-combustible material and the decoration layer is composed of a fibre-reinforced resin matrix composite material.

Description

MARINE CABIN AND WALL OR CEILING ELEMENT THEREFOR

The present invention relates to a marine cabin and to a wall or ceiling element for constructing a marine cabin. The present invention particularly relates to cruise ship cabins, but more generally relates to other marine cabins for accommodating crew and/or passengers on marine vessels, which marine vessels may be adapted for civilian or military use.

Cruise ships are currently highly popular with holidaymakers and leisure travellers. The number of cruise ships being built around the world is increasing, The size of cruise ships Is increasing and customers increasingly require higher standards of accommodation,

Passengers of cruise ships are accommodated in individual cabins. The cabins are typically individually constructed as a cabin unit, and then the unit is fitted to a deck in the cruise ship, ihe cabin unit comprises the wails and ceiling of the cabin, which are assembled together. Typical modem cruise ships may incorporate many hundreds of cabins in order to accommodate thousands of passengers.

The International Maritime Organization (IMO), which includes a Maritime Safety Committee (MSC), established and administers die International Convention for the Safety of Life at Sea (SOLAS), which was enacted in 1974. The SOLAS Convention is generally regarded in.the maritime industry as the most important of all international treaties concerning the safety of merchant ships. The main objective of the SOLAS Convention is to specify minimum standards for the construction, equipment and operation of ships, compatible with their safety. Merchant vessels, such as cruise ships, are required to comply with these very strict safety regulations, and in particular the cabin structure must comply with SOLAS fire regulations which define the requirements for cabins as an “accommodation space”. The requirement varies according to where the cabin is located in the vessel and what is adjacent to it, but in general the requirement is for the cabin wall to pass a “BO” boundary test, for the cabin-to-cabin interface to pass a “B15” boundary test, and for a cabin-to~corridor wall, including any door, to pass a “B15” boundary test.

The current IMO Fire Test Procedure Code, the International Code for the Application of Fire Test Procedures (2010), dates from 2010 and is MSC.307(88), These regulations encompass the cabin and include (i) for the structure achieving a B0 or B15 boundary as tested to IMO

Fire Test Procedure Code (FTPC) Part 3-IMO A.754(18) and (ii) for the exposed surface materials achieving smoke and toxicity (IMG Resolution MSC 307(88); Annex 1, Part 2 (Smoke and Toxicity Test)), surface flammability (IMG Resolution MSC 307(88): Annex 1: Part 5 (Test for Surface Flammability)) and heat release (IMG Resolution MSC 307(88): Annex I: Pail 5 (Reaction to Fire Tests for Building Products, Determination of the Heat of Combustion, Calorific Value to be determined in accordance with ISO 1716:2010).

Currently, cruise ship cabins have a structure which is designed to meet the SOLAS Convention, in particular with regard to SOLAS fire regulations. The regulations governing the construction of SOLAS vessels prevent the use of materials for fire barriers (including cabin walls and ceilings) that are manufactured from combustible materials when tested in accordance with the specific SOLAS regulations summarised above.

The cabins on board cruise ships me typically made up of discrete metal panels composed of steel, typically galvanised steel, or alternatively aluminium alloy, over which a decorative covering, for example a vinyl film, is applied. The metal panel provides structural and fire resistant properties; the covering provides a decorative surface finish.

The cabin is constructed of an assembly of metal panels, typically in the form of tiles or planks, to provide a wall or ceiling, i.e. the deckhead, of a cabin. The metal panels typically have a width of from 100 to 800 mm and a length of up to 3000 mm. The adjacent metal panels are assembled by connecting together (e.g. by bolts or other fastenings) adjacent panel edges which are typically bent so as to be oriented orthogonal to the primary outer surface of the panel, with the bent edges typically being concealed inwardly of the outer surface of the resultant wall or ceiling. The assembly therefore provides a visual disturbance to the cabin walls and ceiling allocations where adjacent panels are joined together, typically every 100mm to 800mm. Even with the panels being individually covered by a decorative covering, the resultant wall or ceiling is not aesthetically pleasing because the joints between adjacent panels making up a single wall or ceiling are not covered by the decorative covering and so the joints are highly visible.

The SOLAS Convention stipulates that the exposed surface materials must meet specific SOLAS regulations for decoration materials and other exposed surfaces, in particular with regard to smoke and toxicity (1MO Resolution MSC 307(88); Annex 1, Part 2 (Smoke and

Toxicity Test)), surface flammability (IMO Resolution MSC 307(88): Annex 1: Part 5 (lest for Surface Flammability)) and heat release (IMO Resolution MSC 307(88): Annex 1: Part 5 (Reaction to Fire Tests for Building Products, Determination of the Heat of Combustion, Calorific Value to be determined in accordance with ISO 1716:2010). These regulations are met by the use of a vinyl or other decorative film, which is very thin and flexible and is adhered over the surface of the structural metal panels. However, such a vinyl film does not conceal joints between adjacent panels.

Furthermore, cabin wall exposed surface materials which are required to meet these specified fire, smoke and toxicity (FST) requirements are currently typically being met by these polymeric based vinyl or other films. These materials are prone to being marked, scuffed, tom or otherwise damaged by the passage of people and luggage. This damage leaves marks or damages the current wall coverings, which makes repairs difficult or impossible to complete within the typical turn-around time of most cruise liners. Metal, e.g. steel, panels are hard to repair if dented and would typically be replaced, provided that the method of construction of the wall allows the replacement of an individual panel. Some known panel systems allow individual panel replacement. Tom or damaged decorative coverings need to be removed and replaced. At panel edges where the original covering film is bonded to the metal panel surface and disappears into the joint between adjacent panels, the film must be cut and the new film carefully run as far into the joint as possible. This is tricky and time consuming and requires skill to reinstate the original aesthetic finish.

There is a current desire to add further accommodation to cruise ships by retrofitting additional cabins to the cruise ship. The addition of additional cabins to a cruise ship typically results in additional weight being added above the metacentric height of the cruise ship. In order to compensate for tills de-stabilising effect, additional ballast in the hull of the ship is required.

Additional ballast in turn increases the vessel displacement, and hence the fuel efficiency of the vessel would be adversely affected. A current balcony cabin design typically weighs 1.6 Tonnes, excluding fit-out (e.g. bathroom sanitary ware and fittings, built-in furniture, etc.). The current high cabin weight can reduce the number of cabins that can be retro-fitted to the vessel and/or increase the operating costs of the refitted cruise ship.

The present invention aims at least partially to solve one o.r more of these problems with known marine (e.g. emise ship) cabins and the wail and ceiling dements used to manufacture such cabins.

In one aspect, the present invention aims to provide a marine (e.g, cruise ship) cabin, and wail and ceiling elements used to manufacture such cabins, which can exhibit an enhanced aesthetic appearance yet can comply with fire, smoke and toxicity (FST) requirements set out in the SOLAS Convention, In other words, the present invention aims in particular to provide SOLAS-eompliant cruise ship cabins, and wall and ceiling elements therefor, which have enhanced aesthetics as compared to known cruise ship cabins.

In another aspect, the present Invention aims to provide a marine (e.g, cruise ship) cabin, and wall and ceiling elements used to manufacture such marine cabins, which can exhibit an enhanced durability against typical wear and tear, and enhanced repairabiiity, yet can comply with fire, smoke and toxicity (FST) requirements set out in the SOLAS Convention, In other words, the present invention aims in particular to provide SOLAS-compliant cruise ship cabins, and wall and ceiling elements therefor, which have enhanced damage resistance and, if damaged, can be more easily repaired, as compared to known emise ship cabins.

In a further aspect, the present invention aims to provide a marine (e.g. cruise ship) cabin, and wall and ceiling elements used to manufacture such cabins, of reduced weight as compared to known cabins and wail and ceiling elements, yet can comply with fire, smoke and toxicity (FST) requirements set out in the SOLAS Convention. In other words, the present invention aims in particular to provide SOLAS-compliant cruise ship cabins, and wall and ceiling elements therefor, which have reduced weight as compared to known cruise ship cabins. Such reduced weight cabins can permit a greater number of cabins to be fitted, or retrofitted, to a cruise ship for a given total cabin weight, which in turn can increase the revenue generation tor the ship.

The present invention accordingly provides a wail or ceiling element for constructing a marine cabin, the element comprising a structural body and a decorative finish thereon, the structural body comprising a core layer, the core layer being covered on a major surface tnereoi by a decoration layer forming the decorative finish, and having an outer decorative surface, wherein the core layer and the decoration layer are non-metaliic, the core layer being composed oi a non-combustible material and the decoration layer being composed of a fibre-reinforced resin matrix, composite material.

The present invention is at least partly predicated on the finding by the present inventors that a composite material wail element or ceiling element can be provided which meets the SOLAS regulations by providing a panel decoration of non-metaUic fibre-reinforced resin matrix composite material which does not require to be non-combustible provided that the decoration constitutes only a decorative finish of the wall element or ceiling element. Such a decorative finish only needs to satisfy the requirements of the SOLAS Convention for decoration materials and other exposed surfaces, in particular with regard to smoke and toxicity (IMO Resolution MSC 307(88); Annex L Part 2 (Smoke and Toxicity Test)), surface flammability (IMO Resolution MSC 307(88): Annex 1: Part 5 (1'est for Surface Flammability)) and heat release (IMO Resolution MSC 307(88): Annex I: Part 5 (Reaction to Fire tests for Building Products, Determination of the Heat of Combustion, Calorific Value to be determined in accordance with ISO 1716:2010).

In order for the decoration layers, composed of a non-metallic fibre-reinforced resin matrix composite material to qualify as a decoration material (Le. decorative finish) rather than being considered (under the SOLAS Convention) as constituting part of the fire barrier or structural cabin wall, the structural layer of the wall element or ceiling element, which is comprised of the core layer or in the preferred embodiments consists of the core layer, must be structurally acceptable without the decoration layers, and also the structural layer (i.e. core layer) itself, independent of any decoration layers, must satisfy both the requirements of IMO Resolution MSC 307(88); Annex 1, Part 1 and also the B0 or B15 bulkhead test of the IMO Fire Test Procedure Code (FTPC), i.e. IMO Fire lest Procedure Code (FTPC) Part 3-IMO A,754(18) for the structure.

This finding of the inventors, which was contrary to conventional implementation of the SOLAS Convention, was critical to achieving a composite material cabin to be fully SOLAS compliant.

In hindsight, the provision of structural and non-combustible core provided with composite material non-structural decoration layers which do not require to be non-combustible is a technically simple concept, but however the determination, and associated testing, that confirmed that a SOLAS compliant composite materia! wa!!/celling panel of a marine cabin could be produced took extensive research and development to achieve.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a schematic cross-section through a wall or ceiling element for constructing a marine cabin in accordance with an embodiment of the present invention;

Figure 2 is a schematic perspective view of the wall dement as illustrated in Figure 1; fmd Figure 3 is a schematic perspective view of a cruise ship cabin constructed from an assembly of wall elements as illustrated in Figure 1, the cabin being in accordance with another embodiment of the present invention .

Referring to Figures 1 and 2, there is shown a schematic cross-section through a wail or ceiling element for constructing a marine cabin, in particular a cruise ship cabin, In accordance with an embodiment of the present invention. The schematic drawing is not to scale, and the layer thicknesses may be exaggerated for the purpose of clarity of illustration.

The present invention particularly relates to cruise ship cabins, but more generally relates to any marine cabin for accommodating crew and/or passengers on any type of marine vessel, which marine vessels may be adapted for civilian or military use,

The wall or ceiling element 2 comprises a structural body comprising, or preferably consisting of, a. central core layer 4 sandwiched between opposite outer decoration layers 6, 8 forming a decorative finish. The decoration layers 6, 8 cover a respective major surface of the core layer 4. Each outer decoration layer 6, 8 has a respective outer decorative surface 10, 12, and an inner surface 14, 16 bonded to a respective major outer surface 18, 20 of the central core layer 4, The core layer 4 and the decoration layers 6, 8 are non-metalllc, in contrast to the known steel panels used to assemble cabin walls ami ceilings in cruise ships,

The core layer 4 is non-combustible. In this specification, the term “non-combustible” means that the materia! does not combust when the material is tested according to the test protocol in BS EM ISO 1182:2010.

Typically, the opposite outer decoration layers 6, 8 are substantially identical in composition, thickness and mechanical properties. Alternatively, the opposite outer decoration layers 6, 8 may have different composition and/or different thickness and/or different mechanical properties and/or different appearance. For example, one outer decoration layer 6 may be configured to be a front “A” surface of the element 2 which is intended to be an exposed decorative surface of a cabin, whereas the opposite outer decoration layer 8 may be configured to be a rear “B” surface of the element. 2 which is intended to be hidden from view when assembled into a cabin, in which case although the “B-surface” layer 8 may be called herein a “decorative” the aesthetic appearance of the “B-surface” layer is less critical than for the opposite “A-surface” layer 6.

In the illustrated embodiment of the present invention, the central core layer 4 constitutes a structural body and the decoration layers 6, 8 constitute the decorative finish. In an alternative embodiment of the present invention, the core layer 4 is covered on only one major outer surface 18 by a respective decoration layer 6 forming the decorative finish, in such a case comprising an “A-surface” layer 6. In some embodiments of the present invention, the core layer 4 is a rear layer of the el ement 2 and there is one decoration layer 6 forming a front layer of the element 2, thereby providing an “A-surface” layer 6. In a further alternative embodiment of the present invention, the core layer 4 is a cen tral layer sandwiched between opposite outer front and rear layers of the element 2, the front layer being an “A-surface” decoration layer 6 forming the decorative finish and the rear layer comprising a reinforcing layer, which is not a decoration layer 6, for example being composed of a metal layer or a non-decorative composite material layer, on the central core layer 4.

The SOLAS regulations differentiate the required properties of the structural part of a wall or ceiling element 2 and decorative finish. The decoration layers 6, 8 do not contribute to the structural properties of the of the wall or ceiling element 2 and so the decoration layers 6, 8 are disregarded when determining whether or not the structural part meets the required SOLAS regulations with regard to fire barrier properties and structural properties.

The core layer 4 complies with SOLAS regulations for cabin bulkhead materials, in particular MO Resolution MSG 307(88); Annex 1, Part 1 and also the B i 5 bulkhead test of the IMO Fire Test Procedure Code (FTPC) Part 3-IMO A.754(18). The decoration layers 6, 8 satisfy the requirements of IMO Resolution MSC 307(88); Annex I, Parts 2 and 5 as identified above.

The core layer 4 has a thickness of from 10 to less than 30 mm, preferably .from 10 to 25 mm, further preferably from. 12 to 1? mm, typically about 15 mm. By providing a maximum core thickness of less than 30 mm, the total thickness of the wall element can be less than or no greater than the wall thickness of current steel panels, thereby permitting cabins to be mutually spaced no further apart, or preferably nearer, than the existing designs, facilitating the retrofit of the cabin of the embodiment into an existing cruise ship and providing a greater number of cabins per deck area in new cruise ships.

Each decoration layer 6, 8 has a thickness of up to 2,5 mm, typically from 0.5 to 2.5 mm, more typically from 0.75 to 1.5 mm, for example about 1 mm.

Therefore the total thickness of the wall or ceiling element 2 is preferably from 11 to less than 30 mm, more preferably from 13 to 20 mm, yet more preferably from 15 to 19 mm, for example about 17 mm.

The core layer 4 is composed of a non-combustible fibre-reinioreed foam. The core layer 4 is composed of non-combustible fibres, for example glass fibres, in and/or on a loam matrix .

The glass fibres may be in the form or woven or non-woven fibres, for example in the form of a fabric or in the form of tows. The fibres may provide multiaxial, for example biaxial or triaxial, reinforcement to the core layer 4,

The foam comprises or consists of one or more mineral substances forming a foam matrix, and in particular- comprises a silicate foam, for example a. foam composed of at least one of an alkali metal silicate and an alkali earth metal silicate or any mixture thereof. The alkali metal silicate may comprise sodium silicate and/or potassium, silicate. I he alkali earth metal silicate may comprise calcium, silicate and/or magnesium silicate.

The manufacture of silicate foam is known to those skilled in the art. Silicate foam products are available in commerce, for example under the trade names Warotecu B15 available from Rudolf Rost Sperrholz Gmhh, Germany and Alsitek Mineral Polymer available from Alsitek

Limited, United Kingdom. The fibre-reinforcement and foam matrix are selected to provide particular properties to the core layer 4,

The core material in the core layer 4 has particular material and structural properties. The core material is non-combustible when tested under BS EN ISO 1182:2010. The density of the core material is .from 150 to 400 Kg/m3, preferably from 150 to 250 Kg/mJ, more preferably from 175 to 225 Kg/m3, typically about 200 Kg/rn3. With a typical core thickness of 15 mm, such a core density of about 200 Kg/m* provides a typical “core areal weight” of 3 Kg/m2. Preferably, the core areal weight is from 2 to 10 Kg/m2, optionally from 2 to 5 Kg/m2, further optionally from 2.5 to 4 Kg/rn2, yet further optionally about 3 Kg/m2.

The preferred embodiments of the present invention can provide a reduced areal weight of the wall or ceiling element as compared to conventional steel panels. For example, by providing a typical areal weight of less than 10 Kg/m2, in particular about 6.5 Kg/m2, for wall elements of preferred embodiments of the present invention, there is a typical 43 % weight saving per unit wall area as compared to current cabin wall constructions composed of steel sheet which typically have an areal weight of about 11.5 Kg/m2.

The core material density and structural properties can be selected in combination with a core thickness to provide a selected areal weight, which in turn affect the thickness and areal weight of the wall or ceiling element. For example, If the core has a density of about 200 Kg/m3, for example comprising the Warotec B15 silicate foam as identified above, the core material may have relatively low structural properties and may require decoration layers on opposite major surfaces of the core, and with a typical core thickness of 15 mm, the core areal weight would be about 3 Kg/m2 and the areal weight of the wall element would be about 6.5 Kg/nr. which is about 43% less than areal weight of conventional steel panels.

In contrast, for example, if the core has a density of about 400 Kg/m*, for example comprising the Alsitek Mineral Polymer as identified above, the core material may have relatively high structural properties and may require only one decoration layer, which in use would be on the front major surface of the core to comprise the decorative A-surface of the element, and with a typical core thickness of 20 mm, the core areal weight would be about 8 Kg/m·4 and the areal weight of the wall or ceiling element would be about 10 Kg/m2, which is about 15% less than areal weight of conventional steel panels. The use of a higher density and higher structural property core may provide the avoidance of a second decorative or other layer on the rear surface of the element and may provide additional associated weight savings as compare to conventional cabin panels.

The stiffness El of the wall or ceiling element Is calculated from (i) the average of the tensile and compressive in plane modulus of the core and (ii) the average of the tensile and compressive in plane modulus of the decoration layers in their respective geometric arrangements. The material properties are measured in accordance with the following test protocols: tensile modulus for the core ASTM D1623; compressive modulus for the core ASTM D1621-10; tensile modulus for the decoration layers ISO 527-4; compressive modulus for the decoration layers SACMA SRM1-94. The stiffness El of the wall or ceiling element 2 is preferably from 1 xIQ5 to 1.0 xl07 Nmm2/mm width, more preferably from 0.5 xl06to 5 xlO6 Nmnr/mm width, typically from 1.0 x 106 to 1.6 x 10s Nmm2/mm width, for example about 1.3 x 106 Nmirri/mm width. This stiffness is required to allow the wall element 2 to be self-supporting with the attached decoration layers 6, 8 and to support the weight of items up to IQKg being attached to the element 2 by means, for example, of bolts or other mechanical fittings or adhesive. The panel stiffness also avoids or minimises wall deflections in use, for example from extraneous vibrations.

The mean through-thickness compressive modulus (measured in accordance with ASTM D1621-2010) of the core layer 4 in the wall or ceiling element 2 is preferably from 20 to 1.30 MPa. If the through-thickness compressive modulus is too tow, the wall or ceiling element 2 may be easily inadvertently dented during use as a result of impacts, for example by luggage.

Each outer decoration layer 6, 8 comprises a fibre-reinforced resin matrix composite material, in which a fibrous reinforcement is in a resin matrix (i.e. is a fibre reinforced polymer (FRP) composition). The composite material of the outer decoration layers 6, 8 has particular material and structural properties. In particular, the fibrous reinforcement typically comprises one, I.e. a single, layer of fibrous material, or alternatively the fibrous reinforcement may comprise more than one layer of fibrous material Typically the fibrous material is woven, to provide a muitiaxia! structure, for example a biaxial or biaxial fabric. Typically the fibrous material comprises glass fibres, although additionally or alternatively other reinforcement materials could be used, such as aramid, basalt and/or carbon fibres, provided that the resultant fibrous material or blend provided the properties required by the SOLAS Convention and its associated regulations. The fibrous material typically is a fabric having a fibre weight of from 400 to 800 g/m2, preferably from 500 to 700 g/m2, for example about 600 g/mfi In the preferred embodiments the same weight of fibrous reinforcement is used in each outer decoration layer 6, 8, and consequently on each opposite surface 18. 20 of the core layer 4.

In alternative embodiments, the fibrous reinforcement of the outer decoration layers 6, 8 may comprise a plurality of fibrous layers, and in particular a plurality of layers of a fibrous material having a lighter fabric weight than the fabric weights specified above in order to provide a total weight of the fibrous reinforcement which increases the total weight of glass or other fibrous reinforcement used for the decoration layers 6. 8, thereby increasing the durability of the decoration layers 6,8 and increasing resistance to puncture. Alternatively, a lighter fabric weight fibrous reinforcement could be used to reduce the weight of the wall element 2, although lower fabric weight would tend to provide reduced panel durability. Alternatively, different fabric weight fibrous reinforcement could be used for each decoration layer 6 and 8. thereby allowing panel durability to be tuned to specific application or design requirements.

Each outer decoration layer 6. 8 complies with the SOLAS regulations for decoration materials, in particular for smoke and toxicity (IMO Resolution MSC 307(88); Annex L Part 2 (Smoke and Toxicity Test)), surface flammability (IMO Resolution MSC 307(88): Annex 1: Part 5 (Test for Surface Flammability)) and heat release (IMO Resolution MSC 307(88): Annex 1: Part 5 (Reaction to Fire tests for Building Products, Determination of the Heat of Combustion, Calorific Value to be determined in accordance with ISO 1716:2010)). The resin matrix of the fibre-reinforced resin matrix composite material comprises a polymer resin which can provide such compliance. Polymer resins exhibiting resistance to fire, smoke and toxicity (FST) are known in the art. For example, the following resins are known in the art as being capable of being formulated, with known additives, in order to exhibit FST properties: furan resins, cyanate ester resins, phenolic resins, epoxy resins, vinyl ester resins and polyester resins, although other suitable resins formulated to exhibit FST properties are known to those skilled in the art. A particularly preferred resin matrix of the fibre-reinforced resin matrix composite material which complies with the SOLAS regulations for decoration materials is a poly (furfuryl alcohol) bioresin which enables the decoration layers 6, 8, comprising the fibrous (e.g, glass fibre) material in the poly (forfuryl alcohol) bioresin matrix, to exhibit FST properties.

Typically, the resin matrix comprises from 30 to 50 wt% resin and from 70 ίο 50 wt% fibre, preferably from 35 to 45 wt% resin and from 65 to 55 wt% fibre, tor example about 40 wt% resin and about 60 wt% fibre.

The outer decoration layers 6, 8 have respective outer surfaces 10, 12 which are aesthetically pleasing and decorative. For example, the outer surfaces 10,12 may be smooth and continuous, typically exhibiting a smoothness corresponding to a typical plastered wall surtace. Alternatively, the outer surfaces 10,12 may have a texture, for example a regular pattern or an irregular texture, typically similar to texture provided by known wall coverings. The surface configuration of the outer surfaces 10, 12 may be achieved during formation and curing of the resin matrix of the composite material, for example by consolidation of the fibre-reinforced resin matrix composite material of the outer decoration layers 6, 8 against a mould surface conforming to the final desired appearance for the visible outer surfaces 10, 12 of the wall element 2. A particular advantage of using outer decoration layers 6, 8 of fibre-reinforced resin matrix composite material for the wall or ceiling element 2 is that the outer surfaces 10, 12 can be painted directly using conventional wall and ceiling paints, for example water-based emulsion paints. If the outer surfaces 10, 12 are marked or scuffed during use, the surfaces 10, 12 can quickly and readily be cleaned and restored by simple overpainting. In contrast, in known cabins in which the wall is covered with a decorative, and optionally coloured, vinyl film, the vinyl film may require replacement in the event of inadvertent marking or scuffing during use.

Furthermore, the outer decoration layers 6, 8 of fibre-reinforced resin matrix composite material provide a durable surface which is resistance to impact, tearing and scraping, and so is much less likely to be damaged than a known vinyl film which is easily tom. The decorati ve outer decoration layers 6, 8 typically have a Shore D type D hardness reading of from 70 to 100, optionally from 80 to 90, according to ASTM D2240. In the event of a dent or scrape in the outer decoration layers 6, 8, the damaged surface can readily be filled with a repair resin material, which can then be cured, optionally by rapid curing of a curable resin incorporating a photosensitive curing agent, using ultraviolet radiation.

Accordingly as compared to the known steel/vinyl coated cruise ship cabin walls and ceilings, the wall and ceiling element 2 of the preferred embodiments of the present invention can be easily and quickly repaired in the event of damage occurring during normal usage, for example wear and tear. A further advantage of using outer decoration layers 6, 8 of fibre-reinforced resin matrix composite materia! for the wall or ceiling element 2 is that the outer surfaces 10,12 can provide, as compared to the known steel/vinyl coated cruise ship cabin walls and ceilings, a far greater range of surface finishes, both with regard to texture, appearance and colour, to the inside of the cabin and can provide a more attractive, up-market appearance to the finished cabin.

Referring in particular to Figure 2, the core layer 4 of the wall or ceiling element 2 comprises an assembly of a plurality of core panels 40 which abut along mutually adjacent edges 42. Typically, the assembly comprises a series of substantially rectangular core panels 40. The core panels 40 are assembled together in an abutting relationship and are bonded together along their mutually adjacent edges. The outer decoration layers 6, 8 extend over the assembly of the plurality of core panels 40 to provide a unitary decoration layer 6, § on a respective side face, in use respective front and rear surfaces, of the wall or ceiling element 2, The outer decoration layers 6, 8 each conceal the adjacent edges 42 of the core panels 40, so that a visual inspection of the wall or ceiling element 2 after installation to form a cabin would reveal a single unbroken surface, which is seamless, with a consistent and uniform visual appearance extending over the surface of the entire element 2.

Typically the outer decoration layers 6, 8 each have an area of at least 3 m2, typically from 5 to 14 m2 and have a length in a direction orthogonal to the adjacent edges 42 of the core panels 40 which is at least 2 m, typically from 2,6 to 7 m. Typically, each core panel 40 is substantially rectangular and the element has a width between successive adjacent edges 42 of from 0.6 to 1.2 m. Typically the element 2 incorporates at least 2 core panels 40, optionally from 5 to 8 core panels 40 for a typical cabin length, assembled together between the two opposed outer decoration layers 6, 8.

Referring to Figure 3, there is shown a schematic perspective view of a cruise ship cabin 50 constructed from an assembly of wall elements as illustrated in Figure 1. For clarity of illustration the ceiling is not illustrated, although the ceiling would be formed of the same element structure as the structure of the element used to form the walls of the cabin 50 and would be fitted to the walls in the same manner as the walls are fitted to each other.

The cabin is constructed from wall and ceiling elements 2 which are dimensioned and shaped in order to fit the cruise ship construction and arrangement. The walls and ceiling provide a B15 boundary as tested to IMG FTPC Part 3-IMG A.754(18).

The cabin 50 comprises opposed side walls 22,24 interconnected by an end wall 26 and a front wall 30, the front and end walls 30, 26 being mutually opposite. The end wall 26 incorporates a window opening 28, although in alternative embodiments the end wall 26 may be an internal wail without any window or the end wall may include a door opening onto an external balcony. The front wall 30 incorporates a door leaf 32 in a door opening. The walls 22, 24, 26, 30 are bonded together at their edges and comers by bonding devices, such as elongate angled sections 46 which are fitted across the adjacent edges of the walls 22, 26, 24, 30 and bonded in place. The angled sections 46 typically extend along substantially the entire length of the adjacent edges of the walls 22, 26, 24, 30. The angled sections 46 typically have two mutually orthogonal arms 48 of length from 50 to 150 mm, for example about 75 mm. The angled sections 46 are concealed in the final cabin assembly. The ceiling is correspondingly fitted to the walls by angled sections (not shown). As illustrated in Figure 1, the lower edges of the walls and exposed edges of the ceiling may be reinforced using U-shaped channel sections 54, for exampl e of metal or polymer, which receive an end edge of the panel.

In ahemaiive embodiments, the end wall 26 Is omitted, or a part end wall is provided, and the side walls 22, 24 are wholly or partly fixed directly to the inside of the hull of the ship, for example by a seal to provide resistance against fire, smoke and toxicity. A balcony door may accordingly be installed into the side of the ship.

The walls 22,24,26, 30 may include penetrations for electrical cabling, light switches, power outlets, etc. Such penetrations may be easily made through the decoration layers 6, 8 and core layer 4 using conventional tools and methodology. The non-metallic wall and ceiling elements are not electrically conductive, unlike the conventional steel/vinyl coated panels, and the electrical non-conductivity of the wall and ceiling elements makes electrical installations more straightforward and safer. The wall structure is capable of supporting the usual point and other loads associated with the interior fit-out of cabins. Items such as 1V attachment points may be bolted through the wail element. Bolt sleeves may be placed in the core layer 4 between the decorative decoration layers 6, 8 and a composite material or metal plate may be bonded to the back decorative cabin lining face if additional reinforcement is required, A bathroom unit 36, also known in the art as a wet unit, is assembled together with the cabin walls, for example by bathroom walls 34, 38 being fitted to walls 24, 30, Again, the bathroom walls 34, 38 and the walls 24, 30 may be bonded together by bonding devices, such as angled sections 46. The bathroom walls are also composed of composite material, for example the same wall element as used for the main cabin walls.

The cabin 50 is installed on a deck 44 of a cruise ship. Adjacent cabins 50 (not shown) may be fitted on to the opposite sides of the cabin 50 in a modular assembly of a plurality of cabins on a common deck 44. 1'he adjacent cabins may be installed with an air gap therebetween for enhanced acoustic attenuation between adjacent cabins, for example an air gap of from 10 to 50 mm, typically from 15 to 25 mm.

The finished wall and ceiling panels may be pre-assembled to form cabins prior to loading on a ship or alternatively may be delivered flat packed for subsequent installation in-situ on the deck 44,

In the cabin 50, each wall 22,24, 26,30 and each bathroom wall 34,38 may comprise a unitary and seamless wall element 2. The resultant assembled cabin 50 is constructed from a minimum number of wall elements, one for each wail, with an integrated bathroom, and each wall has a high aesthetic appeal as it is seamless.

Such a cabin construction in accordance with the preferred embodiments of the present invention can provide a SOLAS compliant cabin which is 55% lighter than a known caoin oi corresponding dimensions constructed from conventional steel/vinyl coated panels, Tnis significant weight saving, as a result of manufacture and assembly ol a cabin from non-metalli.c composite materials for the main wails and ceiling, and furthermore incorporation of a non-metallic composite material wet unit, results in a very large cumulative weight saving in a cruise ship which may be fitted with many hundreds of modular cabins.

Accordingly the preferred embodiments of the present invention can provide a cruise ship cabin, and wall and ceiling dements used to manufacture sucb cruise ship cabins, which can exhibit an enhanced aesthetic appearance yet can comply with fire, smoke and toxicity (FST) requirements set out in the SOLAS Convention, thereby to provide SOLAS-compHant cruise ship cabins, and wall and ceiling elements therefor, which have enhanced aesthetics as compared to known cruise ship cabins.

The preferred embodiments of the present invention can also provide a cruise ship cabin, and wall and ceiling elements used to manufacture such cruise ship cabins, which can exhibit an enhanced durability against typical wear and tear, and enhanced repairability, yet can comply with fire, smoke and toxicity (FST) requirements set out in the SOLAS Convention, thereby to provide SGLAS-compliant cruise ship cabins, and wall and ceiling elements therefor, which have enhanced damage resistance and. if damaged, can be more easily repaired, as compared to known cruise ship cabins.

In particular, the construction of the cabin walls and ceiling from an assembly of core panels with a unitary decoration of fibre reinforced polymer bonded on each side of the core panels can provide a seamless surface on to which decoration can he applied. The continuous surface of fibre reinforced polymer which meets the SOLAS lining regulations, offers a surface that is suitable for a paint finish, is more resistant to scrapes and indentations and in the case of damage can be repaired within 30 to 60 minutes by most capable crew members. The paint finish also offers the interior designer a large range of colours to complement the interior decor, 'The preferred embodiments of the present invention can further provide a cruise ship cabin, and wall and ceiling elements used to manufacture such cruise ship cabins, of reduced weight as compared to known cabins and wall and ceiling elements, yet can comply with fire, smoke and toxicity (FST) requirements set out in the SOLAS Convention. These embodiments can provide SOLAS-eompliant cruise ship cabins, and wail and ceiling elements therefor, which have reduced weight as compared to known cruise ship cabins. Such reduced weight cabins can permit a greater number of cabins to be fitted, or retrofitted, to a cruise ship for a given total cabin weight, which in turn can reduce the operating costs of the vessel.

Claims

1. A wall or ceiling element for constructing a marine cabin, the element comprising a structural body and a decorative finish thereon, the structural body comprising a core layer, the core layer being covered on a major surface thereof by a decoration layer forming the decorative finish and having an outer decorative surface, wherein the core layer and the decoration layer are non-metallic, the core layer being composed of a noncombustible material and the decoration layer being composed of a fibre-reinforced resin matrix composite material.

2. A wall or ceiling element according to claim 1 wherein the core layer is a central layer sandwiched between opposite outer decoration layers forming the decorative finish on opposite major surfaces of the core layer.

3. A wall or ceiling element according to claim 2 wherein the opposite outer decoration layers have different composition and/or different thickness and/or different appearance and/or different mechanical properties.

4. A wall or ceiling element according to claim 1 wherein the core layer is a rear layer of the element and the decoration layer forms a front layer of the element.

5. A wall or ceiling element according to any foregoing claim wherein the core layer has a thickness of from 10 to less than 30 mm, optionally from 10 to 25 mm, further optionally from 12 to 17 mm, yet further optionally about 15 mm.

6. A wall or celling element according to any foregoing claim wherein the decoration layer has a thickness of up to 2.5 mm, optionally from 0.5 to 2.5 mm, further optionally from 0.75 to 1.5 mm, yet further optionally about 1 mm.

7. A wall or ceiling element according to any foregoing claim wherein the total thickness of the element is from 11 to less than 30 mm, optionally from 13 to 20 mm, further optionally from 15 to 19 mm, yet further optionally about 17 mm.

8. A wall or ceiling element according to any foregoing claim wherein the core layer is composed of a non-combustible foam material.

9. A wall or ceiling element according to claim 8 wherein the loam material is a fibre-reinforced foam, optionally including non-combustible fibres, further optionally glass fibres, in and/or on a 'foam matrix of the foam.

10. A wall or ceiling element according to claim 8 or claim 9 wherein the foam material comprises or consists of one or more mineral substances forming a foam matrix.

11. A wall or ceiling element according to claim 10 wherein the foam material comprises or consists of a silicate foam composed of at least one of an alkali metal silicate and an alkali earth metal silicate or any mixture thereof.

12. A wall or ceiling element according to claim 11 wherein the alkali metal silicate comprises at least one of sodium silicate and potassium silicate, or a mixture thereof, and the alkali earth metal silicate comprises at least one of calcium silicate and magnesium silicate, or a mixture thereof.

13. A wall or ceiling element according to any foregoing claim wherein the density of the core layer is from 150 to 400 Kg/m3, optionally from 150 to 250 Kg/m3, further optionally from 175 to 225 Kg/m3, yet further optionally about 200 Kg/m3,

14. A wall or ceiling element according to any foregoing claim wherein the areal weight of the core layer is from 2 to 10 Kg/m2, optionally from 2 to 5 Kg/m2, further optionally from 2.5 to 4 Kg/m2, yet further optionally about 3 Kg/m2.

15. A wall or ceiling element according to any foregoing claim wherein the stiffiiess El of the wall or ceiling element is from 1 xl05to 1.0 xl07Nmm2/mm width, optionally from 0.5 xl06to 5 xlQ6Nmm2/mm width, further optionally from 1.0 x 10* to 1.6 x 10s Nmm2/mm width, yet further optionally about 1.3 x 10* NmnrVmm width.

16. A wall or ceiling element according to any foregoing claim wherein the mean throughthickness compressive modulus of the core layer is from 20 to 130 MPa.

17. A wall or ceiling element according to any foregoing claim wherein in the decoration layer the fibre-reinforced resin matrix composite material comprises a fibrous reinforcement in a resin matrix,

18. A wall or ceiling element according to claim 17 wherein the fibrous reinforcement comprises one or more layers of fibrous material.

19. A wall or ceiling element according to claim 17 or claim 18 wherein the fibrous reinforcement comprises a woven fabric.

20. A wall or ceiling element according to any one of claims 17 to 19 wherein the fibrous reinforcement comprises glass fibres,

21. A wall or ceiling element according to any one of claims 17 to 20 wherein the fibrous reinforcement is a fabric having a fibre weight of from 400 to 800 g/m2, optionally from 500 to 700 g/m2, further optionally about 600 g/m2.

22. A wall or ceiling element according to any one of claims 17 to 21 when appendant on claim 2 wherein the same weight of fibrous reinforcement is used in each decoration layer.

23. A wall or ceiling element according to any one of claims 17 to 22 wherein the decoration layer complies with SOLAS regulations tor cabin decoration materials, in particular for smoke and toxicity (IMO Resolution MSC 307(88); Annex L Part 2 (Smoke and Toxicity Test)), surface flammability (IMO Resolution MSC 307(88): Annex 1: Part 5 (Test for Surface Flammability)) and heat release (IMO Resolution MSC 307(88): Annex I: Part 5 (Reaction to Fire tests for Building Products, Determination of the Heat of Combustion, Calorific Value to be determined in accordance with ISO 1716:2010).

24. A wall or ceiling element according to any one of claims 17 to 23 wherein in the or each decoration layer the resin matrix comprises or consists of a poly (furfuryl alcohol) bioresin.

25. A wall or ceiling element according to any one of claims 17 to 24 wherein the composite material comprises from 30 to 50 wt% resin matrix and from 70 to 50 wt% fibrous reinforcement, optionally from 35 to 45 wt% resin matrix and from 65 to 55 wt% fibrous reinforcement, further optionally about 40 wt% resin matrix and about 60 wt% fibrous reinforcement.

26. A wall or ceiling element according to any foregoing claim wherem the decoration layer has an outer decorative surface,

27. A wall or ceiling element according to claim 26 wherein the outer decorative surface of the decoration layer is smooth and continuous.

28. A wall or ceiling element according to claim 26 wherein the outer decorative surface of the decoration layer is textured, optionally with a regular pattern or an irregular texture.

29. A wall or ceiling element according to any one of claims 26 to 28 wherein the outer decorative surface of the decoration layer is moulded during formation and curing of a resin matrix of the composite material, optionally by consolidation of the fibre-reinforced resin matrix composite material of the decoration layer agamst a mould surface, conforming to a final desired appearance for the outer surface of the element.

30. A wall or ceiling element according to any foregoing claim wherein the decoration layer has a Shore hardness Type D measurement of from 70 to 100, optionally from 80 to 90, according to ASTM D2240.

31. A wall or ceiling element according to any foregoing claim wherein the decoration layer is painted, optionally with a water-based emulsion paint, to provide a final decorative finish.

32. A wall or ceiling element according to any foregoing claim wherein the core layer complies with SOLAS regulations for cabin bulkhead materials, in particular ΪΜΟ Resolution MSC 307(88); Annex 1, Part 1 and also the B15 bulkhead test of the IMO Fire Test Procedure Code (FTPC) Part 3-IMO A.754(18).

33. A marine cabin, for example a cruise ship cabin, comprising a plurality of wall dements and a ceiling element fitted together to form a cabin module, wherein the wall elements and the ceiling element comprise an element according to any foregoing claim.