PRE-FABRICATED CEILING ASSEMBLY AND METHOD OF FORMING

Abstract

A prefabricated ceiling panel and method of forming the same is provided. The panel comprises various built-in features including cable trays, lighting elements, and other features. The panel further comprises a layered structure comprising a plurality of layers to increase the fire resistance, insulation, and/or structural features of the panel.

Claims

1. A prefabricated ceiling panel assembly comprising: a plurality of layers comprising a first woven glass layer, a fire retardant layer, and a second woven glass layer, and a surface layer; wherein at least one of the plurality of layers is manufactured from a single sheet of material that is shaped to span an entire ceiling area of a modular structure ceiling space; wherein the at least one of the plurality of layers comprises at least one pre-cut opening; and wherein at least the fire retardant layer comprises a flame-retardant material comprising a resistance to fire and smoke generation.

2. The prefabricated ceiling panel assembly of claim 1, wherein the flame-retardant material comprises ASTM E84 polypropylene tri polymer honeycomb.

3. The prefabricated ceiling panel assembly of claim 1, wherein the at least one pre-cut opening is provided to accommodate at least one of an electrical component, fan element or a lighting element, and a ducting element.

4. The prefabricated ceiling panel assembly of claim 1, wherein at least one of the first and second woven glass layer comprises as an 1808 woven glass layer.

5. The prefabricated ceiling panel assembly of claim 1, wherein the surface layer comprises a veil for aesthetic and/or acoustic purposes.

6. The prefabricated ceiling panel assembly of claim 1, wherein the prefabricated ceiling panel comprises an upper surface and a lower surface, and wherein the lower surface is operable to be provided proximal an interior volume of a modular building structure.

7. The prefabricated ceiling panel assembly of claim 6, wherein the surface layer is provided on the lower surface of the prefabricated ceiling panel.

8. A prefabricated ceiling panel assembly comprising: a plurality of layers comprising an upper layer, a fire retardant layer, a woven glass layer, and a lower layer; at least one of the plurality of layers being manufactured from a single sheet of material this is shaped to span an entire ceiling area of a modular structure ceiling space; at least one of the plurality of layers secured to at least one other layer by an adhesive; wherein at least one of the plurality of layers comprises at least one pre-cut opening; and wherein at least the fire retardant layer comprises a flame-retardant material comprising a resistance to fire and smoke generation.

9. The prefabricated ceiling panel of claim 8, wherein the upper layer comprises a woven glass layer.

10. The prefabricated ceiling panel of claim 8, wherein the lower layer comprises a surface layer.

11. The prefabricated ceiling panel of claim 8, wherein the fire retardant layer and the woven glass layer are provided between the upper layer and the lower layer.

12. The prefabricated ceiling panel of claim 8, wherein each of the plurality of layers are secured to an adjacent layer by an adhesive.

13. A modular building structure comprising: a plurality of substantially vertical sidewalls at least partially defining an interior volume of the modular building structure; a prefabricated ceiling panel assembly comprising an upper layer, a fire retardant layer, a woven glass layer, a lower layer, and a plurality of reinforcing members; at least one of the plurality of layers of the ceiling panel assembly being manufactured from a single sheet of material this is shaped to span an entire ceiling area of a modular structure ceiling space; at least one of the plurality of layers of the ceiling panel assembly comprising at least one pre-cut opening; and the fire retardant layer comprising a flame-retardant material comprising a resistance to fire and smoke generation; and wherein at least the lower layer of the prefabricated ceiling panel assembly is secured to an upper portion of at least one of the plurality of substantially vertical sidewalls.

14. The modular building structure of claim 13, further comprising a lighting element provided within the at least one pre-cut opening.

15. The modular building structure of claim 13, wherein at least one of the plurality of layers is secured to at least one other layer by an adhesive.

16. The modular building structure of claim 13, further comprising plumbing features provided within the modular building structure.

17. The modular building structure of claim 13, wherein the upper layer comprises a woven glass layer.

18. The prefabricated ceiling panel of claim 13, wherein the lower layer comprises a surface layer.

19. The prefabricated ceiling panel of claim 13, wherein the lower layer defines an upper limit of the interior volume of the modular building structure.

20. The prefabricated ceiling panel of claim 13, wherein the surface layer comprises a veil for aesthetic and/or acoustic purposes.

Description

DESCRIPTION OF THE FIGURES

[0016] FIG. 1 is a top perspective view of a pre-fabricated ceiling structure and a building unit according to one embodiment of the present disclosure.

[0017] FIG. 2 is a top perspective view of a pre-fabricated ceiling structure and a building unit according to one embodiment of the present disclosure.

[0018] FIG. 3 is an exploded, cross-sectional elevation view of components or layers for forming a ceiling structure according to one embodiment of the present disclosure.

DETAILED DESCRIPTION

[0019] The following is a listing of components according to various embodiments of the present disclosure, and as shown in the drawings:

[0020] 2 Ceiling Assembly

[0021] 4 Main Ceiling Panel

[0022] 6 Conduit

[0023] 8 Lifting Element

[0024] 10 Reinforcing Members

[0025] 12 Prefabricated Building Unit

[0026] 14 Apertures

[0027] 20a, 20b Finishing Mat

[0028] 22a, 22b Structural Mat

[0029] 24 Fire Resistant Layer

[0030] 26 Fire Resistant Veil

[0031] FIG. 1 is a top perspective view of a pre-fabricated ceiling assembly 2 comprising a main ceiling panel 4, at least one electrical conduit 6, at least one lighting or fan assembly 8, a plurality of reinforcing members 10, and related adhesives and installation fixtures and hardware. In certain embodiments, the main ceiling panel 4 comprises a mono-formed composite ceiling with a prefinished texture including, for example, a polyester surface veil impregnated with unsaturated resin solution.

[0032] In various embodiments, a main ceiling panel is provided and comprises a plurality of layers. In one embodiment, the layers comprise a fiberglass or woven glass layer, such as an 1808 woven roving glass layer; a fire-retardant layer, such as an ASTM E84 polypropylene tripolymer honeycomb layer; an additional glass layer, such as an 1808 woven virgin glass layer; and a surface layer, such as a veil for aesthetic and/or acoustic purposes.

[0033] As shown in FIG. 1, the main ceiling panel 4 comprises a plurality of reinforcing members 10, such as steel studs, to provide structural support to the panel 4 and related components and accessories. The number and type of reinforcing members 10 may be varied based on the size, shape, thickness, structure, etc. of an associated ceiling panel 4. The ceiling panel 4 is preferably shaped, cut, or sized to fit a prefabricated building unit 12. The prefabricated building unit 12 may comprise any number and type of building units including, but not limited to, modular prefabricated bathroom units.

[0034] FIG. 2 is a partially exploded perspective view of a pre-fabricated ceiling assembly 2 comprising a main ceiling panel 4. As shown, the main ceiling panel 4 comprises a plurality of pre-formed cut-outs or apertures 14 to accommodate lighting and ducting features, for example.

[0035] FIG. 3 is an exploded, cross-sectional elevation view of components or layers for forming a ceiling structure according to one embodiment of the present disclosure. As shown, a ceiling panel or portion of a ceiling panel in accordance with one embodiment of the present disclosure comprises a first finishing mat 20a as a lower or base layer of the panel or structure. A first structural fiberglass mat 22a is provided above the first finishing mat 20a. A fire resistant layer 24 is provided as an interior layer, the fire resistant layer preferably comprising a honey-comb core layer with at least some fire resistant properties or treatment. The fire resistant layer 24 is provided between the first structural fiberglass mat 22a and a second structural fiberglass mat 22b. As shown, a fire resistant veil 26 is provided vertically above the second structural fiberglass mat 22b. A second finishing mat 20b is provided as an upper layer of the ceiling panel.

[0036] In various embodiments, including but not limited to the embodiment provided in FIG. 3, the layers are preferably laminated, joined or formed using a linear pultrusion impregnation system with unsaturated polyester resin solution at a temperature range of approximately 250-500 degrees Fahrenheit, and preferably approximately 325 degrees Fahrenheit. The pultrusion process of the present disclosure comprises a process wherein at least some of the layers provided in FIG. 3, for example, are bonded under heat and pressure. U.S. Patent Application Publication No. 2001/0048175 to Edwards et al., which is hereby incorporated by reference in its entirety, discloses a process for in-line forming of pultrusion composites. Processes and features of Edwards et al. may be employed in embodiments of the present disclosure. The present disclosure contemplated methods of forming a ceiling panel using pultrusion processes as opposed to convention wet molding of layers. U.S. Pat. No. 8,182,643 to Fanucci et al., which is hereby incorporated by reference in its entirety, provides a process for fabricating structure including a pultrusion process. Such features and methods are contemplated for use in combination with embodiments of the present disclosure. Pultrusion processes contemplated for use in forming ceiling structures according to various embodiments of the present disclosure have provided unforeseen and novel advantages over known construction and formation methods. For example, the use of an in-line pultrusion process in forming ceiling structures of the present disclosure have been shown to reduce or avoid the occurrence of swelling or bulging of the ceiling structure during and after formation. The application of heat and pressure to the various layers shown and described herein provides distinct advantages over known devices and methods. In certain embodiments, the bonding process is accomplished with the addition of a fire-resistant resin and finishing the product with a fire-resistant bonding coat.