WO2004099521A1

WO2004099521A1 - Ceiling system

Info

Publication number: WO2004099521A1
Application number: PCT/DK2004/000336
Authority: WO
Inventors: Ole Lund Clausen
Original assignee: Inexa AS
Current assignee: Inexa AS
Priority date: 2003-05-12
Filing date: 2004-05-12
Publication date: 2004-11-18
Anticipated expiration: 2005-11-12

Abstract

The present system relates to a ceiling system comprising ceiling elements and assembly elements of metal, said ceiling elements and assembly elements being, in cross section, configured essentially as a U having a bottom, side edges and end edges. The present invention also relates to a ceiling constructed via this ceiling system and a use of the ceiling in a maritime environment.

Description

Ceiling system

Field of the invention

The present invention relates to a ceiling system comprising ceiling elements and assembly elements of metal, said ceiling elements and assembly elements being, in cross section, configured essentially as a U having a bottom, side edges and end edges.

Background of the invention Conventionally, onboard a ship installation of a ceiling must take place at a certain distance from the steel structure that establishes the structural intermediate deck of the ship. The space between the ceiling and the intermediate deck is used to advantage for hiding various installations, such as electric cables or tubing systems for eg sprinkler installations. Conventional ceilings for this purpose consist of a number of adjoining identical ceiling elements that are arranged in a side-by-side relationship and are assembled along the side and end edges. Typically the joining is accomplished by the ceiling elements having an integrally formed male engagement means along the one side edge, whereas a female engagement means is integrally formed along the other side edge. Typically, the female engagement means is configured as a clamp that secures the male engagement means on the adjoining ceiling element.

It is a problem of the prior art ceilings that the distance between the ceiling and the intermediate deck has to be comparatively far in order to enable, by turning of the ceiling element, engagement of the male engagement means with the female engagement means on the ceiling element already mounted . It is also a problem of the prior art ceilings that it is necessary to configure the ceiling elements with particular reinforcements when the ceiling elements are to span large distances, eg if the walls of the room in the ship on which the end edges of the ceiling elements rest are located more than 3-4 meters apart. Thereby it is not possible to use standard plates for both short and long spans without an ensuing waste of material when the span is small. It is furthermore a problem of the prior art ceilings that span large distances that the own weight of the ceiling elements gives rise to small deflections that are perceived as imperfections from below.

In the light of the above, it is shown that there is a need for a ceiling system that is not associated with the above-referenced problems.

It is the object of the invention to provide a ceiling system that is not associated with the above-referenced problems.

Brief description of the invention

It has surprisingly been found that the above-mentioned objects are accomplished by a ceiling system comprising ceiling elements and assembly elements of metal, said ceiling elements and assembly elements being, in cross section, configured essentially as a U having a bottom, side edges and end edges, and which is characterised in that the side edges of the ceiling element comprise a downwardly bent flange portion which is oriented outwards relative to the bottom for providing a clamp portion between the flange and the adjoining side edge; that at least one end edge on the ceiling element and the assembly element contain a correspondingly downwardly bent flange portion which is also oriented outwards relative to the bottom; and that the one side edge of the assembly element is received in said clamp portion.

By the invention the above-mentioned problems are solved, as it is possible by use of only one type of ceiling elements to establish ceilings with different spans that can be suspended at a small distance from the intermediate deck of the ship, whereby the room height in the covered room is maximized while simultaneously deformations, if any, resulting from the own weight of the elements become difficult to detect visually by persons present in that room. Moreover, the invention enables particularly simple establishment of illumination means in the room.

Detailed description of the invention:

According to a first aspect the invention relates to a ceiling system comprising ceiling elements and assembly elements of metal, said ceiling elements and assembly elements being, in cross section, configured essentially as a U having a bottom, side edges and end edges, and being characterised in that

- the side edges of the ceiling element comprise a downwardly bent flange portion which is oriented outwards relative to the bottom for providing a clamp portion between the flange and the adjoining side edge; - that at least one end edge on the ceiling element and the assembly element contain a correspondingly downwardly bent flange portion which is also oriented outwards relative to the bottom; and

- that the one side edge of the assembly element is received in said clamp portion.

Preferably the ceiling system comprises a number of identical ceiling elements and a number of identical assembly elements. Use of identical ceiling elements and assembly elements enable construction of the ceiling in an inexpensive manner, only the length of the ceiling elements and assembly elements having to be adapted.

The ceiling elements and the assembly elements are preferably formed by folding of a metal plate to the desired shape. Preferably the thickness of the metal plate is the same, irrespective of whether a ceiling element or an assembly element is manufactured. The ceiling elements and the assembly element are formed from a metal plate, where the metal is preferably selected from among the group consisting of galvanized steel, film-coated and painted steel, stainless steel or aluminium.

The ceiling elements and the assembly elements have a longitudinal expanse that considerably exceeds the transverse expanse.

The ceiling elements and assembly elements are, in cross section, configured essentially as a U having a bottom, side edges and end edges. According to a preferred embodiment, the height of the side edge of the ceiling element is comprised within the range of from 30 to 70 mm, preferably 45 mm; the width of the bottom of the ceiling element is comprised within the range of from 20 to 500 mm, preferably 270 mm; and the width of the bottom of the assembly element is comprised within the range of from 20 to 500 mm, preferably 30 mm.

According to an alternative, preferred embodiment, the ratio between the height of the side edge and the end edge of the assembly element relative to the height of the side edge and end edge of the ceiling element is comprised within the interval of from 1 :4 to 4:4, preferably 2:4 to 3:4.

According to a particularly preferred embodiment insulating material is arranged between the side edges of the ceiling element and/or the assembly element, preferably thermally and/or acoustically insulating material.

The ceiling system is characterised in that the side edges on the ceiling element contains a downwardly bent flange portion that is oriented outwards in relation to the bottom in order to provide a clamp portion between the flange and the adjoining side edge; at least one end edge on the ceiling element; and that the assembly element contains a corresponding downwardly bent flange portion that is oriented outwards in relation to the bottom; and that the one side edge of the assembly element is received in said clamp portion.

According to a preferred embodiment both end edges on the ceiling element or the assembly element comprise a downwardly bent flange portion which is outwardly oriented relative to the bottom for providing a clamp portion between the flange and the adjoining side edge. These ceiling elements or assembly elements are typically used as middle ceiling elements or intermediate assembly elements, ie ceiling elements or assembly elements that do not adjoin the wall.

According to a further preferred embodiment at least one end edge of the ceiling element or the assembly element comprises a flange portion that is oriented outwards relative to the bottom and is essentially perpendicular to the end edge. These ceiling elements or assembly elements are typically used as end ceiling elements or as end joining elements, the described flange portion adjoining the wall, optionally supported on the wall by means of a bracket.

Preferably the side edges on the assembly element contains a downwardly bent flange portion which is oriented inwards relative to the bottom for providing a higher degree of rigidity of the upper part of the side edge.

Preferably the flange portion on the ceiling element constitutes a first portion that extends downwards and approximately in parallel with the side edge; a second portion that extends inwards in relation to the bottom at an angle α relative to the first portion; and a third portion that extends downwards and outwards in relation to the bottom at an angle β in relation to the second portion. The preferred angle α is comprised between 5 and 35°, preferably between 10 and 25°, and the preferred angle β is comprised between 5 and 35°, preferably between 15 and 25°. The clamp portion according to the invention is configured for being able to produce a releasable locking engagement between the flange and the side edge; preferably produced by elastic deformation of the clamp portion.

Furthermore, the invention provides a particularly simple way in which to establish illumination in the room, the bottom of the ceiling element and/or the assembly element being perforated in a particular embodiment; and in that a light source, preferably a fluorescent tube, is arranged between the side edges of the assembly element.

In order to avoid damage to the ceiling elements or the assembly elements, eg during transport, it is preferred that the ceiling elements and assembly elements are coated with a film, preferably a plastics film.

According to a further aspect the invention relates to a ceiling system comprising ceiling elements and assembly elements of metal, which ceiling elements and assembly elements are, in cross section, configured essentially as a U having a bottom side edges and end edges, and being characterised in that

- the side edges of the assembly element comprise a downwardly bent flange portion which is oriented outwards relative to the bottom for providing a clamp portion between the flange and the adjoining side edge; - that at least one end edge on the ceiling element and the assembly element contain a correspondingly downwardly bent flange portion which is also oriented outwards relative to the bottom; and

- that the one side edge of the assembly element is received in said clamp portion. According to a third aspect the invention relates to a ceiling constructed by means of the ceiling system, and being characterised in that the assembly elements are arranged along two perpendicular directions; and that the ceiling elements are connected to the assembly elements along both of these directions in that the side edges of the assembly elements are received in respective clamp portions on the ceiling elements; or in that the side edges on the ceiling elements are received in respective clamp portions on the assembly elements.

Moreover, the invention relates to use of the described ceiling in a maritime environment.

The invention will now be described in further detail with reference to the drawing, wherein

Figure 1 shows a ceiling according to the invention seen from below in a room, eg a ship's cabin;

Figures 2a and 2b show cross sectional views seen along lines 2a and 2b in Figure 1 ;

Figure 3 shows a section of Figure 2a, seen in an enlarged scale;

Figures 4a-4d are perspective views of opposite ends of two components that are constituents of the ceiling shown in Figure 1 ;

Figure 4e shows a joint between the two components shown in Figures 4a- 4d; seen in a perspective view;

Figure 5 is a sectional view of a detail of the component shown in Figure 4a, seen in a cross sectional view; Figures 6a-6d are cross sectional views seen along lines a, b, c, d in Figure 1; and

Figure 7 is a view corresponding to that of Figure 2a, outlining the mounting procedure.

The ceiling 10 shown in Figure 1 is preferably intended for being established at a small distance from a fixed intermediate deck of a ship for forming the visible ceiling element of a cabin or any other room onboard the ship. Albeit in the following the ceiling 10 is described as being mounted onboard a ship, nothing prevents the ceiling from being mounted eg underneath the concrete deck of a house.

The ceiling 10 is constructed by means of the ceiling system according to the invention, the ceiling system comprising a number of essentially identical ceiling elements 20 and a number of essentially identical assembly elements 50, 50' that will be described in further detail in the following. The ceiling elements 20 and the assembly elements 50, 50' have a longitudinal expanse, that considerably exceeds its transverse expanse; to the left in Figure 1 ceiling elements are shown that have a length of 4 meters along the side walls of the room and a width of 0.8 meter, while the ceiling elements 20 shown to the right have a shorter length, but the same cross sectional shape. Use of essentially identical ceiling elements and assembly elements enables less costly construction of the ceiling 10.

As will appear the ceiling 10 is constructed such that the assembly elements 50, 50' intersect. In that context it is noted that the transverse assembly element 50' extends uninterruptedly along with those end edges of the ceiling elements 20 that are connected to the assembly element 50', shown to the right and to the left in the drawing. Moreover, the transversal assembly element 50' is supported by the side walls of the room, whereby the assembly element 50 forms a beam that takes up a part of the own weight of the adjoining ceiling elements 20 and assembly elements 50.

Figure 2a is a cross sectional view through the ceiling elements 20 and the assembly elements 50 and further shows how the ceiling 10 can be supported on the walls 1 in the room by means of brackets 5. It will appear from the drawing that the ceiling elements 20 and the assembly elements 50 have a generally U-shaped cross section. Figure 2b shows a cross section through the ceiling elements 20 along a transversal direction, and a cross section through the assembly element 50'. As will appear the ceiling elements 20 have protruding support faces along opposed end edges, whereby ceiling elements 20 are able to rest on said brackets 5. The ceiling elements 20 and the assembly elements 50, 50' are preferably formed by bending of a metal plate to the desired shape. The thickness of the metal plate is preferably the same, irrespective of whether a ceiling element or an assembly element is manufactured.

As shown -in Figure 3, the ceiling elements 20 more specifically -have a bottom 22 that can be perforated and optionally carry a sound-insulating material. The bottom 22 is integrally connected to upwardly oriented side edges 24, 34 that form the longitudinally extending sides of the ceiling elements 20. Besides, the side edges 24, 34 have a flange portion 26, 36 for providing a clamp portion between the flange and the adjoining side edge. The flange portion is formed by flexing of a part of the material outwards in a direction away from the bottom 22 and downwards. Hereby a receiving slot for the assembly elements 50 is established, the shape of the flange portion

26, 36 and the plate thickness of the assembly elements 50 being selected such that it is possible to establish a securing force between the ceiling elements 20 and the assembly elements 50 when a section of the assembly elements 50 is conveyed into the receiving slot as shown in Figure 3. Preferably, the assembly element 50 shown in Figure 3 has the same cross sectional shape as the transversal assembly element 50' shown in Figure 1 and thus comprises a bottom 52 that is integrally connected to upwardly oriented side edges 54, 56 that form the longitudinally extending sides of the assembly elements 50. The upper section of the side edges 54, 56 are intended for being introduced into said receiving slot on the ceiling elements 20. Preferably, the transversal assembly element 50' has a cross section that is identical with the cross section of the assembly elements 50, including also the same element thickness. .

Figures 4a and 4d show the one transversal end of the ceiling elements 20 and the assembly elements 50. That end is intended for resting on a bracket 5 arranged along the end walls of the room, said ceiling elements 20 having a deflected flange portion 42 that abuts on the bracket 5. Conversely, Figures 4b and 4c show the opposite end of the ceiling elements 20 and the assembly elements 50, respectively. At that end the ceiling elements 20 and the assembly elements 50 are configured such that they can be connected to the transversal assembly element 50' shown in Figure 1 and 2b. More specifically, this is enabled by forming clamp portions 70, 46 that are- preferably configured in the same manner as the flange portions 26, 36 along the longitudinally extending sides of the ceiling elements 20. Figure 4d also shows that the side edges 54, 56 of the assembly elements 50, 50' may, if necessary, be provided with a deflection at the free edges to provide a higher degree of rigidity of the assembly elements 50, 50'.

During construction of the ceiling 10 in Figure 1 , the connection between the ceiling elements 20, the longitudinally extending assembly elements 50 and the transversal assembly element 50' is accomplished in the same manner as was described in the context of Figure 3 in that the clamp portions 46 and 70 receive the upwardly oriented side edges 54, 56 of the assembly element 50'. Owing to that connection it is possible to partially transfer the own weight of the ceiling elements 20 to the transversally extending assembly element 50' and to secure the ceiling elements 20 to the transversal assembly element 50'. Hereby it is possible to mount the ceiling 10 without using straps or the like, the ceiling being exclusively supported by the walls that delimit the room.

In Figure 5 the flange portions 26, 36, 46, 70 are shown in larger scale, and it will appear how the receiving slot has a reduced clearance width at the mouthing, and that the plate as such is bent in a conventional manner, whereby the flange to be introduced into the receiving slot will to a certain extent be caught and by wedging effect expand the receiving slot during its introduction. The figure further shows that the flange portion constitutes a first part that extends downwards and approximately in parallel with the side edge; a second portion that extends inwardly relative to the first part; and a third part that extends downwards and outwards relative to the bottom at an angle β in relation to the second part.

Figures 6a-d show how the ceiling elements 20 and the assembly elements 50 are connected to a bracket 5 and to the transversal assembly element 50'-, respectively.

Figure 7a shows how the ceiling system according to the invention is constructed; beginning by laying out a longitudinally extending assembly element 50, following which a ceiling element 20 is connected to the assembly element 50 laid out by moving the ceiling element 20 slightly upwards in relation to the assembly element 50 corresponding to the receiving slot on the ceiling element 20 being, by a subsequent downwardly oriented movement of the ceiling element 20, able to receive the one side edge 54 of the assembly element 50. For comparison, Figure 7b shows a conventional ceiling, and it will appear that in order to connect the ceiling elements to each other it is necessary to arrange the ceiling element in an inclined position, and thus it is necessary to have a larger distance between the ceiling and the superjacent ship's deck.

It is a particular advantage of the invention that, as needed, it is possible to arrange a light source, such as a fluorescent tube, in some of the assembly elements 50, 50' immediately above the bottom 52, the bottom of the assembly element being, at the location intended for the light source, provided with openings that allow illumination of the room underneath the ceiling.

The invention is not limited to the above figures. It is within the scope of the invention that the side edges on the assembly element can also comprise a downwardly bent flange portion which is outwardly oriented in relation to the bottom for providing a clamp portion between the flange and the adjoining side edge; and that the ceiling element is configured without said flange portion.

Claims

C l a i m s

1. A ceiling system comprising ceiling elements and assembly elements of metal, said ceiling elements and assembly elements being, in cross section, configured essentially as a U having a bottom, side edges and end edges, characterised in that

- the side edges on the ceiling elements comprise a downwardly bent flange portion which is outwardly oriented in relation to the bottom for providing a clamp portion between the flange and the adjoining side edge;

- at least one end edge on the ceiling element and the assembly element comprise a corresponding downwardly bent flange portion which is outwardly oriented in relation to the bottom; and - the one side edge of the assembly element is received in said clamp portion.

2. A ceiling system according to claim 1 , characterised in that both side edges of the ceiling element or the assembly element comprise a downwardly bent flange portion which is outwardly oriented relative to the bottom for providing a clamp portion between the flange and the adjoining side edge.

3. A ceiling system according to claim 1 , characterised in that at least one end edge on the ceiling element or the assembly element comprises a flange portion which is outwardly oriented in relation to the bottom and being approximately perpendicular to the end edge.

4. A ceiling system according to any one of claims 1-3, characterised in that the side edges on the assembly element contains a flange portion which is downwardly bent along the side edge and inwardly oriented in relation to the bottom for providing a higher degree of rigidity of the upper part of the side edge.

5. A ceiling system according to any one of claims 1-3, characterised in that the flange portion constitutes a first portion that extends downwards and approximately in parallel with the side edge; a second portion that extends inwards in relation to the bottom at an angle α in relation to the first portion; and a third portion that extends downwards and outwards in relation to the bottom at an angle β in relation to the second portion.

6. A ceiling system according to claim 5, characterised in that the angle α is between 5 and 35°, preferably between 10 and 25°; and that the angle β is between 5 and 35°, preferably between 15 and 25°.

7. A ceiling system according to any one of the preceding claims, characterised in that the clamp portion is configured to be able to produce a releasable locking engagement between the flange and the side edge.

8. A ceiling system according to claim 7, characterised in that the locking engagement is provided by elastic deformation of the clamp portion.

9. A ceiling system according to any one of the preceding claims, characterised in that the height of the side edge and the end edge of the ceiling element is comprised within the interval of from 30 to 70 mm, preferably 45 mm.

10. A ceiling system according to any one of the preceding claims, characterised in that the ratio of the height of the side edge and the end edge of the assembly element to the height of the side edge and the end edge of the ceiling element is comprised within the range of from 1 :4 to 4:4, preferably 2:4 to 3:4.

11. A ceiling system according to any one of the preceding claims, characterised in that the width of the bottom of the ceiling element is comprised within the interval of from 20 to 500 mm, preferably 270 mm.

12. A ceiling system according to any one of the preceding claims, characterised in that the width of the bottom of the assembly element is comprised within the interval of from 20 to 500 mm, preferably 30 mm.

13. A ceiling system according to any one of the preceding claims, characterised in that the bottom of the ceiling element and/or assembly element is perforated.

14. A ceiling system according to any one of the preceding claims, characterised in that, between the side edges of the assembly element, a sight source is arranged, preferably a fluorescent tube.

15. A ceiling system according to any one of the preceding claims, characterised in that, between the side edges of the ceiling element „and/or the assembly element, insulating material is arranged, preferably thermal, fire- and/or acoustically insulating material.

16. A ceiling system according to any one of the preceding claims, characterised in that the ceiling elements and the assembly elements are coated with a film, preferably a plastics film.

17. A ceiling system according to any one of the preceding claims, characterised in that the metal is selected from among the group consisting of galvanized steel, film-coated and painted steel, stainless steel or aluminium.

18. A ceiling system comprising ceiling elements and assembly elements of metal, said ceiling elements and assembly elements being, in cross section, configured essentially as a U having a bottom, side edges, and end edges, characterised in that

- the side edges on the assembly element comprise a downwardly bent flange portion which is outwardly oriented in relation to the bottom for providing a clamp portion between the flange and the adjoining side edge; - at least one end edge on the ceiling element and the assembly element comprise a corresponding downwardly bent flange portion which is outwardly oriented in relation to the bottom; and

- the one side edge of the assembly element is received in said clamp portion.

19. A ceiling system according to claim 18, characterised in that both side edges of the ceiling element or the assembly element comprise a downwardly bent flange portion which is outwardly oriented relative to the bottom for providing a clamp portion between the flange and the adjoining side edge.

20. A ceiling system according to claim 18, characterised in that at least one end edge on the ceiling element or the assembly element comprises a flange portion which is outwardly oriented in relation to the bottom and being approximately perpendicular to the end edge.

21. A ceiling system according to any one of claims 18-20, characterised in that the side edges on the assembly element contains a flange portion which is downwardly bent along the side edge and inwardly oriented in relation to the bottom for providing a higher degree of rigidity of the upper part of the side edge.

22. A ceiling system according to any one of claims 18-21 , characterised in that the flange portion constitutes a first portion that extends downwards and approximately in parallel with the side edge; a second portion that extends inwards in relation to the bottom at an angle α in relation to the first portion; and a third portion that extends downwards and outwards in relation to the bottom at an angle β in relation to the second portion.

23. A ceiling system according to claim 22, characterised in that the angle α is between 5 and 35°, preferably between 10 and 25°; and that the angle β is between 5 and 35°, preferably between 15 and 25°.

24. A ceiling constructed via a ceiling system according to any one of claims 1-17, characterised in that the assembly elements are arranged along two perpendicular directions; and that the ceiling elements are connected to the assembly elements along both of these directions in that the side edges of the assembly elements are received in respective clamp portions on the ceiling elements.

25. A ceiling constructed via a ceiling system according to claims 18-23, characterised in that the assembly elements are arranged along two perpendicular directions; and that the ceiling elements are connected to the assembly elements along both of these directions in that the side edges of the assembly elements are received in respective clamp portions on the ceiling elements.

26. Use of a ceiling according to claim 24 or 25 in a maritime environment.