U.S. patent application number 10/000045 was filed with the patent office on 2002-07-04 for ceiling panel.
Invention is credited to Ostenfeldt, Johnny.
Application Number | 20020083672 10/000045 |
Document ID | / |
Family ID | 8094495 |
Filed Date | 2002-07-04 |
United States Patent
Application |
20020083672 |
Kind Code |
A1 |
Ostenfeldt, Johnny |
July 4, 2002 |
Ceiling panel
Abstract
The invention relates to a metal ceiling panel having flange
portions with complementary engagement areas formed such that two
juxtaposed panels can be interconnected in a tight manner. The
shape of the flange portions corresponds to the contour of an
inclined S whereby the joint between two such panels becomes even
tighter in the event of a substantial increase of the temperature
in the space below the ceiling panel. The shape of the flange
portions also brigs about an increased stability of an underside
covering for a ceiling formed by a plurality of such panels when
exposed to a fire.
Inventors: |
Ostenfeldt, Johnny; (Odense
C, DK) |
Correspondence
Address: |
ALTERA LAW GROUP, LLC
6500 CITY WEST PARKWAY
SUITE 100
MINNEAPOLIS
MN
55344
US
|
Family ID: |
8094495 |
Appl. No.: |
10/000045 |
Filed: |
October 18, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10000045 |
Oct 18, 2001 |
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PCT/DK00/00198 |
Apr 18, 2000 |
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Current U.S.
Class: |
52/536 ;
52/506.06; 52/539; 52/588.1 |
Current CPC
Class: |
E04B 2103/06 20130101;
E04B 9/363 20130101; E04D 3/362 20130101; E04B 9/0478 20130101 |
Class at
Publication: |
52/536 ; 52/539;
52/588.1; 52/506.06 |
International
Class: |
E04D 001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 19, 1999 |
DK |
PA 1999 00521 |
Claims
1. A ceiling panel (1) of metal intended to form an underside
covering for a ceiling upon assembly with a plurality of
corresponding ceiling panels, said ceiling panel comprising: a web
portion (5) which defines a main extent plane for the ceiling panel
(1), and which is adapted to face the underlying room in the
mounted state of the ceiling panel, said web portion (5) having a
first longitudinal edge side (9), a second longitudinal edge side
(8) and transverse edge sides, a first longitudinal flange portion
(40) connected with the web portion (5) at the first longitudinal
edge side (9), a second longitudinal flange portion (20) connected
with the web portion (5) at the second longitudinal edge side (8),
said flange portions (20, 40) comprising complementary engagement
areas (21, 41) adapted to generate a releasable locking engagement
between the flange portions (20, 40) on two juxtaposed ceiling
panels (1), characterized in that the first longitudinal flange
portion (40) exhibits: a first part (42), which extends upwards and
outwards away from the central area of the web portion (5) at an
acute angle .alpha. relative to a normal to the main extent plane,
and which merges into a second part (44), which extends downwards
back in a direction toward the central area of the web portion (5)
at an angle .theta. relative to a normal to the main extent plane,
and which merges into a third part (46), which extends upwards and
outwards away from the central area of the web portion (5) at an
acute angle .beta. relative to a normal to the main extent plane,
and which merges into a fourth part (48), which extends upwards and
outwards away from the central area of the web portion (5) at an
angle .phi. relative to a normal to the main extent plane, and that
the second flange portion (20) exhibits: a first part (22), which
extends upwards and inwards toward the central area of the web
portion (5) at an acute angle of about .alpha. relative to a normal
to the main extent plane, and which merges into a second part (24),
which extends downwards in a direction away from the central area
of the web portion (5) at an angle of about .theta. relative to a
normal to the main extent plane, and which merges into third part
(26), which extends upwards and inwards toward the central area of
the web portion (5) at an acute angle of about .beta. relative to a
normal to the main extent plane.
2. A ceiling panel according to claim 1, characterized in that the
first flange portion (40) comprises a longitudinal locking section
(50), which extends from the engagement area (41) upwards and
outwards away from the central area of the web portion (5) at an
acute angle .gamma. relative to a normal to the main extent plane,
and which has a free edge arranged at the greatest distance from
the web portion (5) relative to the rest of the flange portion
(40), whereby the longitudinal locking section (50) by folding
deformation provides an obstacle to the release of said locking
engagement.
3. A ceiling panel according to claim 1 or 2, characterized in that
it applies to the first longitudinal flange portion (40): that the
angle .alpha. is between 5.degree. and 30.degree., preferably
between 10.degree. and 15.degree., that the angle .theta. is
between about 110.degree. and 130.degree., that the angle .beta. is
between 5.degree. and 30.degree., preferably between 10.degree. and
15.degree., that the angle .phi. is between 55.degree. and
85.degree., preferably between 65.degree. and 80.degree..
4. A ceiling panel according to one of the preceding claims,
characterized in that said third part (26) of the second flange
portion (20) merges into a fourth part (29), which, via a bend
(28), extends downwards approximately in parallel with said third
part (26) on the side thereof facing the web portion (5).
5. A ceiling panel according to one of the preceding claims,
characterized in that the releasable engagement is produced by
cooperation between the fourth part (48) of the first flange
portion (40) and the third part (26) of the second flange portion
(20).
6. A ceiling panel according to any one of the preceding claims,
characterized in that the web portion (5) and the first (40) and
the second (20) flange portions are formed in one piece by bending
of a plate.
7. A ceiling panel according to any one of the preceding claims,
characterized in that the locking engagement is provided by elastic
deformation of at least one of the flange portions (20, 40).
8. A ceiling panel according to any one of the preceding claims,
characterized in that it applies to the second flange portion (20)
that the angles .alpha., .beta. and .theta. differ from the
corresponding angles of the first flange portion (40) by
.+-.2.degree..
9. A ceiling panel according to the preceding claim, characterized
in that the angle (x) between the first part (42) and the second
part (44) of the first flange portion (40) is greater than the
angle (x') between the first part (22) and the second part (24) of
the second flange portion (20), and that the angle (y) between the
second part (44) and the third part (46) of the first flange
portion (40) is smaller than the angle (y') between the second part
(24) and the third part (26) of the second flange portion (20) to
provide a clamping force in the assembly of two ceiling panels
(1).
10. A ceiling panel according to any one of the preceding claims
1-7, characterized in that it applies to the second flange portion
(20) that the angles .alpha., .beta. and .theta. are equal to the
corresponding angles of the first flange portion (40).
11. A ceiling panel according to any one of the preceding claims,
characterized in that the angle .alpha. is equal to the angle
.beta..
12. An underside covering produced by assembling a plurality of
ceiling panels according to claims 1-11 arranged side by side.
Description
[0001] The present invention relates to a ceiling panel of the type
defined in the introductory portion of claim 1.
[0002] U.S. Pat. Nos 3,462,906 and 4,223,503 as well as British
Patent No 1249765, among others, disclose examples of such ceiling
panels, which are mounted side by side, and which form an underside
covering for a ceiling over a room in the interconnected state. The
individual panels are made of a metal material which has been
machined by bending or rolling. The underside covering is typically
supported by a supporting structure in the form of a system of
supporting strips, which are arranged on the walls defining the
room. The underside covering may moreover be adapted to carry a
suitable thermal and/or acoustic insulation, e.g. in the form of
insulation batts which are placed on the surface of the panels
facing the ceiling.
[0003] A common property of the known ceiling panels underlying the
invention is that they are self-supporting and that they may be
interconnected via complementary and elastically deformable
engagement areas arranged along the longitudinal edge sides of the
panels. When the panels are self-supporting and interconnected, the
own weight of each panel can also be transferred partly to the
supporting structure via the adjoining panels. As the engagement
areas extend in the full length of the longitudinal edge sides of
the panels, it is moreover possible to ensure a desired tightness
of the underside covering against flame penetration and passage of
smoke or other gases, which may e.g. be emitted from burning
objects in the room below the underside covering. In the known
underside coverings, however, it is frequently difficult to remove
one or more of the ceiling panels, when so required, without
damaging the adjoining ceiling panels, or without having to loosen
screws or similar fasteners. Such removal of some of the ceiling
panels may be desired e.g. to obtain access to installations in the
space between the ceiling and the underside covering.
[0004] In the construction of ceiling panels allowance must of
course be made for the static impacts on the panels because of e.g.
the own weight and because of the weight of overlying insulation
batts, if any, which might necessitate reinforcement of the panels
with ribs or the like. Furthermore, allowance must be made for the
special conditions that may occur in connection with a fire in the
room below the underside covering. In addition to the fact that the
panels must constructively be arranged to prevent penetration of
flames and smoke in the engagement areas, as mentioned, they must
also be constructed such that the stability and integrity of the
underside covering can be maintained at elevated temperatures for a
given period of time. It will be appreciated that the fire load
thereby also make demands on the strength of the locking engagement
between the flange portions, as this locking engagement must not
only ensure the continued tightness, but must also ensure that
forces because of own weight and insulation material, if any, can
still be transferred from one ceiling panel to the next one and
further to the supporting structure which supports the underside
covering.
[0005] With the previously known underside coverings, however, it
has been difficult to satisfy modern legislative requirements as
regards the time during which the underside covering is tight.
[0006] The object of the present invention is to provide an
improved ceiling panel which inter alia provides concurrent
favourable properties as regards all the below-mentioned
aspects:
[0007] the engagement areas allow transfer of forces from one
ceiling panel to the next one
[0008] the joint between the panels is extremely tight in normal
use
[0009] a panel may be removed and mounted again without also having
to remove one or more of the other panels
[0010] the load-bearing capacity and integrity of the underside
covering may be maintained for a relatively long time at high
temperatures
[0011] the tightness of the covering may be maintained for a
relatively long time at high temperatures.
[0012] This is achieved according to the invention as defined in
the characterizing portion of claim 1.
[0013] When the first and second flange portions exhibit a
respective inclined first part, it has surprisingly been found that
the above specifications may be observed. In a fire, the entire
flange portion will thus try to turn down toward the web portion of
the ceiling panels. This provides a very reliable tightness of the
joint, as at least the complementary engagement areas adjoining the
web portion will be kept in intimate mutual contact. Moreover,
according to the invention, it is still possible, in the normal
state, to release a single panel from the other panels by affecting
the panel concerned by an upwardly directed pressure impact that
releases the locking engagement, e.g. to generate an elastic
deformation of the flange portions whereby the locking engagement
at one longitudinal side edge may be released.
[0014] When, as stated in claim 2, the one flange portion is formed
with a locking section having a free edge extending along the edge
side at a maximum distance from the web portion of the panel,
improved interlocking of two adjoining ceiling panels is achieved,
as the stability of the locking section when subjected to the
impact of a fire will tend to fail, i.e. the locking section will
tend to deform by buckling because of the occurring compressive
stresses which will be maximum in this area of the panel most
remote from the web portion. It has been found by tests that this
folding combined with the above-mentioned downward turning of the
entire flange portion generates a greater resistance to
disengagement of the adjoining ceiling panel from the locking
engagement in a fire, relative to the normal state, which manifests
itself in the fact that the integrity of the covering is maintained
for a relatively longer time.
[0015] When the ceiling panel is constructed with the angular
relationships defined in the claims, it has been found by tests
that particularly favourable conditions are achieved, as the angles
defined in claim 3 also facilitate assembly and disassembly of
panels to a certain extent, and as the relationship defined in
claim 9 gives the underside covering additional advantages in terms
of sealing. Also, the preferred embodiments provide a reduction in
the vibration-caused noise, which frequently occurs when ceiling
panels of the present general type are used onboard ships.
[0016] The invention also relates to an underside covering produced
by assembling a plurality of ceiling panels according to the
invention.
[0017] A preferred embodiment of the invention is shown in the
drawing, in which
[0018] FIG. 1 shows a cross-section through a panel,
[0019] FIG. 2 shows two panels according to the invention which are
connected in the engagement area, and
[0020] FIG. 3 illustrates the development in a fire where the joint
is deformed,
[0021] FIG. 4 shows the locking section in a deformed state in a
fire, and
[0022] FIG. 5 shows an expedient edge panel for the mounting of the
ceiling panels according to the invention.
[0023] FIG. 1 shows a cross-section through a ceiling panel 1
according to the invention. The ceiling panel 1 has a web portion 5
with an upper side which, in the mounted state of the ceiling
panel, faces an overlying ceiling, and a lower side which is
intended to face an underlying room. The web portion 5, which forms
the visible part of the ceiling panel in the room, is preferably
plane, but may optionally be provided with a modest curvature.
However, it will be appreciated that the web portion 5 defines an
imaginary main extent plane for the ceiling panel, viz. a plane
which is substantially parallel with the ceiling.
[0024] The ceiling panel 1 preferably has a rectangular basic form
with a longitudinal central area M, and the web portion 5 has
longitudinal edge sides 8, 9 and transverse edge sides. Flange
portions 20, 40 are arranged along each of the longitudinal edge
sides 8, 9 and extend in the entire length of the panel 1. The
shown ceiling panel is preferably made from a flat metallic plate
workpiece, and the flange portions 20, 40 are provided by bending
or similar working.
[0025] The flange portions 20, 40 comprise complementary engagement
areas by means of which two adjoining identical ceiling panels 1
may be interconnected. The engagement areas are generally
designated by the reference numerals 21 and 41 in FIG. 1 and thus
comprise respective panel parts which extend longitudinally of the
ceiling panel 1 in various mutual angles.
[0026] More particularly, the engagement areas 21, 41 are each
formed approximately with the shape of an S which is inclined
relative to a longitudinal plane H. The plane H extends
perpendicularly to the main extent plane of the ceiling panel 1,
and the angles defined below are calculated as measured relative to
a plane perpendicular to the main extent plane in parallel with the
plane H. As shown, the engagement area 41 consists of a first part
42 which extends upwards and away from the web portion 5 at an
angle .alpha. of preferably about 12.degree. relative to the plane
H. The part 42 merges via a bend into a second part 44 which
extends downwards back in the direction toward the web portion 5 at
an angle .theta. of preferably about 125.degree., and which, via a
bend or constriction 45, merges into a third part 46, which extends
upwards away from the central area M at an angle .beta. of likewise
about 12.degree.. Via a further bend the third part 46 merges into
a fourth part 48 which forms an angle .phi. of preferably about
79.degree. relative to the plane H. Before the fourth part 48
reaches an imaginary extension of the part 42, the fourth part 48,
via a bend, merges into a fifth part 50, which extends upwards away
from the web portion 5 at an angle .gamma. of about 12.degree.. It
will thus be appreciated that the first, third and fifth parts
extend substantially mutually in parallel with approximately the
same inclination relative to the plane H, which results in
well-controlled deformations in a fire. The fifth part 50 will be
called the "locking section" below.
[0027] It applies to the engagement area 21 that this is likewise
composed of a first part 22 which merges into a second part 24,
which in turn merges into a third part 26 with an end portion 28 to
form a nose 25, and that the overall course of these parts
approximately corresponds to the course of the corresponding parts
of the engagement area 41. However, it will preferably be so that
the angles of the parts relative to the plane H are selected such
that the angle x is greater than the angle x', and that the angle
y' is greater than the angle y, thereby providing a clamping force
upon assembly of two ceiling panels when the nose 25 is inserted
into the constriction 45. The mentioned end portion may optionally
be formed as a bend which merges into a rearwardly directed
extension 29 which imparts a certain rigidity to the part 26. It
will be appreciated from FIG. 1 that angles .alpha., .beta. and
.theta. corresponding to the angles .alpha., .beta. and .theta. in
the engagement area 41 may be provided in the engagement area 21 as
well.
[0028] FIG. 2 shows two identical ceiling panels 1, 1' arranged
side by side and assembled by the insertion of the engagement area
21' into the engagement area 41, i.e. by the insertion of the nose
25 into the constriction 45. As mentioned, the engagement areas 21
and 41 are preferably, but not necessarily shaped such that this
insertion establishes a clamping of the engagement area 21', one of
the engagement areas being deformed elastically during the
insertion. As will appear, the insertion areas are moreover shaped
so as to provide suspension of the ceiling panel 1' from the
ceiling panel 1, thereby allowing vertical forces from e.g. the own
weight of the panels to be transferred across the joint.
[0029] In the use of the ceiling panel for covering a ceiling a
plurality of the ceiling panels 1 are mounted side by side at a
desired distance below the ceiling, as shown in FIG. 2. Before the
mounting, a supporting structure in the form of e.g. supporting
strips secured to the walls is arranged at a suitable height. The
supporting structure is adapted to support and retain the
transverse edge sides of the ceiling panels 1, as each ceiling
panel thus extends as a self-supporting unit between two supporting
strips, as well as preferably also the longitudinal edge sides of
the outermost ceiling panels of the underside covering. For use as
an underside covering in e.g. cabins on board ships, the ceiling
panels will typically have a length of about 3 meters,
corresponding to the distance between two of the walls of the
cabin, a width of about 0.3 meter and a height of the engagement
area 21 of about 23 mm and of the engagement area 41 of about 25
mm. The ceiling panels are mounted singly side by side, with the
nose 25 of a new ceiling panel being inserted into the constriction
45. It will moreover be seen from FIG. 2 that the individual
ceiling panels may easily be disassembled from each other by
applying an upwardly directed pressure along the left edge side 8
of the ceiling panel, thereby pressing the end portion 28 clear of
the part 48 so that the nose 25 may be moved out of the
constriction 45. By turning the ceiling panel it may then be moved
clear of the adjoining ceiling panels and be removed.
[0030] In order to comply with the present and expected future
regulations as regards restriction of the damage caused by a fire,
it is necessary to construct the underside covering so that it is
tight and thereby prevents passage of flames and smoke from the
underlying room, and so that collapse of the ceiling panels is
prevented for as long a time as possible at the elevated
temperatures in the room. It has been found by fire tests that the
present invention provides an extension of the time it takes before
there is a real risk of collapse of the underside covering.
[0031] When an underside covering composed of a plurality of
self-supporting ceiling panels according to the invention suspended
as described above is affected by a fire, the underside covering
will typically assume a shape as a single-or double-curved face
because of the linear expansion of the material. FIG. 3 shows
somewhat exaggerated and schematically how the flange portion 40,
as well as the flange portion 20 (not shown) with which the flange
portion 40 is connected, is deformed in the course of a fire, and
it will be seen how the inclination of the flange portions and the
special S-shape of the engagement areas give rise to a downwardly
directed turning of the entire joint during a fire load, and that
this inclination increases gradually. It will be appreciated that
during this deformation a stronger clamping force is simultaneously
generated in the joint, which thereby becomes more tight. During
this deformation stability failure typically occurs in the part of
the cross-section of the ceiling panel in which the greatest
compressive stresses occur, i.e. particularly in the locking
section 50, which will consequently try to assume a bulging shape
with regular creases in the longitudinal direction of the ceiling
profile, as shown in FIG. 4. It has been found that this
deformation provides an increased resistance to a release of the
engagement between the flange portions 20 and 40 and thereby
against separation of the joint.
[0032] The stated structure of the flange portions, for one thing,
provides an increased resistance against separation forces in the
joint between the panels in a fire and thereby against loss of
integrity of the covering and thereby collapse of the covering,
and, for another, an increased risk of the required tightness
against flames and flue gases being lost.
[0033] FIG. 5 shows an edge panel for use in connection with the
mounting of ceiling panels according to the invention to form the
underside covering. The edge profile is preferably shaped as a
half-ceiling panel according to the invention, as the edge profile
just comprises one S for connecting the edge profile with the
adjoining ceiling panel, it being possible for the opposite
longitudinal edge of the edge panel to be provided with a bend so
that the longitudinal edge may be connected in a particularly
expedient manner with the locking strip which extends from the
supporting structure.
* * * * *