Field of the Invention The present invention relates to a panel system for use on a superstructure of a marine vessel.

Background of the Invention Currently construction of the superstructure of a marine vessel occurs at a ship yard. Panelling is manufactured, assembled, welded in place and becomes a structural part of the superstructure. Finishing and other surface treatment of the panelling occurs in the ship yard once the panels have been welded in place. Surface treatment often occurs within a tented area and prevents other shipbuilding work from occurring while the area is tented-off. The surface treatment is a highly involved process and includes: applying filler to the surface of the panels to enable shaping of the panels and to fill voids and dents in the panels; sanding; and, painting. The sanding if very labour intensive with up to four workers using a common sanding board to sand back and shape the filler. The painting often comprises applying an acid wash followed by an etch primer to the bare panel before application of the filler. Once the filler has been applied and sanded, multiple coats of paint and/or other surface finishing coatings are applied. Scaffolding is required for the full duration of the surface treatment process.

Summary of the Invention

According to a first aspect of the present invention there is provided a prefabricated and pre-finished cosmetic panel for coupling to a superstructure of a marine vessel, the panel comprising:

a body of finished shape, the body having a first surface which faces seaward when the panel is coupled to the superstructure, the first surface being in a finished seaworthy state, and a coupling mechanism to facilitate coupling of the panel to the superstructure.

The body may be shaped such that a space is formed between the panel and the super structure when the panel is coupled to the super structure.

The coupling mechanism may comprise a first edge portion which lies behind a portion of the first surface when the panel is coupled to the super structure. The coupling mechanism may further comprise a second edge portion of the body spaced from the first edge portion and which lies behind the portion of the first surface when the panel is coupled to the super structure.

The first and second edge portions may be turned inwardly in a direction toward the upper edge portion.

The first and second edge portions may be are turned inwardly toward each other on a same side of the body. One or both of the first and second edge portions may be configured to enable a hook like coupling of the panel to the support structure.

The panel may be capable of elastically flexing to enable a snap fit coupling of the panel to the support structure.

A second aspect of the invention provides a marine vessel panel system comprising a plurality of panels according to the first aspect of the invention, wherein at least two of the panels are connected end to end. The system may comprise a plurality of end connectors capable of connecting ends of mutually adjacent panels together in a manner wherein the first surfaces of the mutually adjacent panels form a substantially continuous surface across the connected ends.

In one embodiment each end connector is configured to sit inside and bridge two mutually adjacent panels.

However in an alternate embodiment each end connector is capable of being attached at an end of a panel and provided with an inwardly directed portion wherein when two panels are juxtaposed end to end inwardly directed the portions of respective connectors face each other.

The system may comprise a mounting structure capable of attachment to the super structure and wherein the panels are configured to attach to the mounting structure to thereby couple the panels to the super structure.

The mounting structure may comprise a first portion to which each panel is coupled.

The mounting structure may further comprise a second portion vertically spaced from the first portion to which each panel is coupled.

The first edge portion of each panel may hook onto or extend about the first portion. The second edge portion may hook onto or about the second portion.

The mounting structure may comprise a plate lying in a substantially vertical plane and attached to the super structure. The mounting structure may further comprise an elongate member coupled to the super structure and located below an upper edge of the plate. The mounting structure may comprise a plurality of brackets coupled to the super structure and a plurality of elements, the elements being attachable to the brackets and configured to be received within a panel. Each element may have an edge that lies close to or abuts an inside surface of the panel, the inside surface being opposite to the first surface.

The brackets may be attached to the first portion of the mounting structure. The plurality of panels may comprise at least two panels of different shape or configuration.

The plurality of panels may comprise one or more non-straight panels. One of the non-straight panels may be a corner panel.

According to a third aspect of the invention there is provided a method of ship building comprising:

assembling, at a first site, a hull and super structure of a ship;

at a second site remote from the first site, pre-fabricating a plurality of pre finished panels according to the first aspect of the invention;

transporting the panels to the first site; and,

coupling the panels to the super structure. Coupling the panels to the super structure may comprise coupling each panel at at least two spaced apart locations to the super structure.

The method may comprise fitting a balustrade along at least a length of the ships structure using one or more fasteners and passing the fasteners through at least one of the panels for coupling with the super structure. The method may comprise connecting ends of mutually adjacent panels together.

The method may comprise fixing a mounting structure to the super structure and coupling the panels to the mounting structure to thereby couple the panels to the super structure.

Coupling the panels to the super structure may comprise locating a first edge portion of a panel about a first portion of the mounting structure and rotating the panel to locate a second opposite edge portion of the panel over or about a second vertically spaced portion of the mounting structure.

The method may comprise snap fitting the panels onto the mounting structure. The method may comprise attaching a plurality of elements to the mounting structure, each element having an edge formed of a configuration

complimentary to a configuration of an interior surface of the panel, and fitting each panel over one or more of the elements. A fourth aspect of the invention provides a marine vessel comprising:

a hull;

a super structure supported on the hull; and,

a plurality of panels in accordance with the first aspect of the invention coupled to or supported by the super structure.

A first aspect of the invention provides a marine vessel comprising:

a hull;

a super structure supported on the hull; and,

a marine vessel panel system in accordance with the second aspect of the invention wherein panels of the panel system are coupled to supported by the super structure. Brief Description of the Drawings

In order to provide better understanding preferred 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 side elevation of a marine vessel with a panel system according to an embodiment of the present invention; Figure 2 is a plan view through the cross section AA of Figure 1 ;

Figure 3 is a cross sectional elevation of a panel system on a superstructure of a marine vessel according to an embodiment of the present invention; Figure 4 is an exploded cross sectional elevation of part of the panel system of Figure 3;

Figure 5 is a side elevation of part of the panel system of Figure 3; Figure 6 is a side elevation of a part of an alternative panel system of an embodiment of the present invention;

Figure 7 is a see-through perspective view of part of the panel system of Figure 3;

Figure 8 is a see-through perspective view of part of the panel system of Figure 3;

Figure 9 is a see-through perspective view of joined panels of the panel system of Figure 3;

Figure 10 is an exploded view of an alternative panel joining mechanism for part of the panel system of Figure 3;

Figure 11 is a cross sectional elevation of another embodiment of a panel system according to the present invention;

Figure 12 is a cross sectional elevation of another embodiment of a panel system according to the present invention;

Figure 13 is a cross sectional elevation of another embodiment of a panel system according to the present invention;

Figure 14 is a cross sectional elevation of another embodiment of a panel system according to the present invention; Figure 15 is a cross sectional elevation of another embodiment of a panel system according to the present invention;

Figure 16 is a cross sectional elevation of another embodiment of a panel system according to the present invention;

Figure 17 is an exploded view of a further embodiment of a panelling system in accordance with the present invention;

Figure 18 illustrates in part a method of building a ship utilising the panelling system shown in Figure 17;

Figure 19 illustrates a further stage in the method of building a ship utilising the panelling system; Figure 20 is an end view of a portion of a ship to which panels in accordance with embodiments of the present invention have been fitted; and, Figure 21 is a further perspective view from an alternate angle of the portion of the ship shown in Figure 20.

Detailed Description of Preferred Embodiments

In broad terms, embodiments of the present invention are manifested in the form of a cosmetic panel which can be coupled to a super structure of a marine vessel; a panelling system incorporating such panels; and a method of ship building utilising such panels and system. Each panel is pre-finished so that a seaward facing first surface is in a seaworthy condition. Thus when the panel is coupled to the super structure, no further surface finishing such as filling, sanding or painting is required, although sealant may be applied along abutting edges of adjacent panels. This enables the panels to be prefabricated at a location or site remote from a boat building site and subsequently attached to the super structure to form for example a bulwark. The panel comprises a coupling mechanism to facilitate the coupling of a panel to the super structure. In one embodiment the coupling mechanism is in the form of at least a first edge portion of the panel which lies to one side of a portion of the first surface when the panel is coupled to the super structure. In one embodiment a coupling mechanism comprises first and second opposite edge portions each of which lie to the same side of the portion of the first surface. The edge portions are turned inwardly toward each other. In this way, the edge portions in one embodiment can hook over or extend about the super structure or a mounting structure attached to the super structure. The panels may be shaped to form a space or void between the panel and the super structure when the panel is coupled to the super structure. Further, the panels may be configured or otherwise formed of the material which enables elastic flexing of the panels. This can enable a snap fit coupling of the panel to the support structure. The coupling mechanism may also comprise holes which are preformed in the panels and more particularly in the first and second edge portions to receive fasteners to couple the panels to the super structure. Alternately, the holes may be formed in the process of passing fasteners, for example self tapping screws through the panels and into the super structure. This panelling system comprises connectors in the form of infills which are configured to connect the ends of two mutually adjacent panels together to form a substantially

continuous surface across the connected ends.

Referring to Figures 1 and 2, there is shown a marine vessel 10 which has a hull 12 and a superstructure 14 extending above the main deck. A potion of the hull 12 below a waterline 16 is not shown. The superstructure 14 has a funnel 18, deck house 20 and decks 22. The deck house 20 comprises wall panels 24, some of which may be opaque and some of which may be transparent so as to form windows. Each deck 22 has a deck floor 28, a bulwark 34, a hand rail 30 and end-capping comprising cosmetic panels 26. The bulwarks 34 may be or comprise cladding formed of cosmetic panels 26.

Panels 26 are prefabricated at a site remote from the site of construction or assembly of the hull 12 and super structure 14. Each panel 26 has a body 25 of a finished shaped, the body 25 having a first surface 27 which faces seaward when the panel is coupled to the super structure 14. The first surface 27 is in a finished seaworthy state so that when the panel 26 is coupled to the super structure 14, no further surface finishing such as sanding, filling or painting is required. Each panel 26 also comprises a coupling mechanism 29 to facilitate coupling of the panel 26 to super structure 14. Coupling mechanism 29 comprises a first edge portion 31 of the body which lies to one side of a portion of the first surface 27. The coupling mechanism 29 also comprises a second edge portion 33 of the body which lies to the same side of a portion of the first surface 27. That is, the first and second edge portions 31 and 33 lie on the same side of a portion of the first surface 27. Thus, when the panel 26 is coupled to super structure 14, the first and second edge portions 31 and 33 lie behind the portion of the first surface 27. The first and second edge portions 31 and 33 are turned inwardly toward each other on the same side of the surface 27.

As it is also apparent from Figures 3 and 4, panel 26 is shaped to form a space or void 48 between the panel 26 and super structure 14. Panel 26 may be made from various materials including aluminium, plastics materials, and composite materials and is pre-finished with a surface treatment, such as finished paintwork, a coating or brushed metal, so that when secured to the super structure no further finishing surface treatment is required. As described in greater detail below, in various embodiments, panels 26 may be capable of elastically flexing to enable a snap fit coupling of a panel 26 to super structure 14.

Referring to Figures 3 to 5, each deck 22 of the superstructure 14 comprises a deck structure comprising deck support beams 40 and stringers 44. The deck support beams 40 are typically arranged to extend substantially horizontally from a deck house portion of the superstructure 14 so as to preferably be spaced apart and substantially parallel to each other. Extending substantially horizontally between the deck support beams 40 are stringers 44. The stringers 44 are spaced apart and substantially parallel to each other, but extend perpendicular to the deck support beams 40. In one example the deck support beams 40 are inverted T-section' or 'l-section' beams. In one example the stringers 44 are 'L-section' beams.

In Figure 3 above and below the deck support beams 40 are wall panels 24 and 24' which form an external wall of the deck house 20. These panels 24 can be prefabricated and pre-finished. The panels 24 and 24' are fastened to a plate 68 which is in turn coupled to the deck support beams 40. The plate 68 is shown with vertically spaced, horizontally extending stringers 69. Typically the plate 68 is welded to the deck support beams 40. In an embodiment the panels 24 and 24' are glued to the framework of the deck house, which includes plate 68. In some embodiments the panels 24 and 24' are glued to mullions when the panels 24 or 24' are transparent. Furthermore fasteners such as bolts or rivets may be used.

A deck panel 50 is laid over the deck support beams 40 to form a deck surface. An outer end piece 58 is located between the deck panel 50 and a gutter. The gutter has a drain 54. A finishing piece 52 is located between the gutter and a bottom edge of an upper portion of the panel 26. A deck house end piece 60 is located between the deck panel 50 and wall panel 24. The wall panel 24 extends upwardly from the end piece 60. A ceiling panel 56 is fixed to the underside of the deck support beams 40 and extends from the vertical portion of the bracket 46 (or lower portion of the panel 26) to the wall panel 24'.

Coupled to the outer ends of the deck support beams 40 is a mounting structure 43 for the panels 26. The mounting structure comprises a first portion in the form of one or more plates 42 to which the panels 26 can be coupled. The plates 42 are typically rectangular and up-standing from a top surface of the deck support beams 40. Mutually adjacent plates 42 may be welded end to end to each other as well as to the deck support beams 40 so as to form a web extending along the length of the deck 22.

The mounting structure 43 also comprises a second portion in the form of one or more elongated members 46 coupled to the super structure 14. The members 46 extend parallel to and are co-terminus with the plates 42. The members 46 are typically a T-section or L-section: with one portion 47 extending horizontally and being coupled by fasteners 66 to at least two deck support beams 40; and, another portion 49 extending vertically. The vertical portion 49 is positioned outside of the deck support beams 40 (relative to the deck house 20). As is most evident from Figure 4 upper edges of the plates 42 and members 46 are both vertically and horizontally displaced relative to each other. A panel 26 is coupled to super structure 14 by fastening first edge portion 31 to plate 42. The fastening is affected by bolts 64 which pass through holes in plate 42 as well as holes 70 formed in first edge portion 31. In this particular embodiment, the bolts 64 further pass through: spacers 61 and 62 which extend parallel to each other on opposite sides of the first edge portion 31 ; and, holes formed in a barrier or balustrade 32. This also fastens balustrade 32 to super structure 14. In this embodiment a hand rail 30 extends along an upper edge of balustrade 32. Although of no significance to the present invention, the balustrade 32 may for example be in the form of a rectangular plate of metal, glass, plastics material or composite material. When panel 26 is coupled to plate 42 first edge portion 32 is sandwiched initially between the two spacers 61 and 62, then sandwiched between the plate 42 and barrier 32. It will also be seen that the first edge portion 31 hooks over or extends about the plate 42. Panel 26 is further coupled to super structure 14 by fastening second edge portion 33 to an elongate member 46. This is achieved by use of fasteners such as a plurality of bolts or tek screws 63 (only one shown) that pass through or form a hole 72 in second edge portion 33 and extend into elongate member 46. In an alternate arrangement, clips may be used in place of the fasteners 63. In a further variation the second edge portion 33 may be extended and turned to form a hook like member that hooks over an upper edge of elongate member 46.

In the illustrated embodiment, it will also be seen that the first and second edge portions 31 and 33 are horizontally and vertically displaced relative to each other in a manner commensurate with the relative horizontal and vertical displacement of upper edges or portions of plate 42 and elongate member 46.

A panelling system to enable for example the construction of bulwark 34 along a portion of super structure 14 comprises a plurality of panels 26 which are attached end to end. Panels 26 may be made of various shapes, sizes and configurations. For example with reference to Figures 1 and 2 the panels 26 in the panelling system may comprise a first set of straight panels 26a having an identical cross sectional shape and each being formed to a standard length, and a second set of one or more non-straight (i.e. curved) panels 26b, 26c configured to extend about a corner or a change in direction of bulwark 34. Panels 26b form concave corners while panels 26c form convex corners. The corners may be smooth or sharp as desired. These curved shapes can eliminate, or at least reduce, fairing required to make the surface smooth.

Some curved panels may comprise two or more changes in direction along the length of the body, such that the length is, for example S-shaped or Z-shaped.

In the panelling system, the mutually adjacent ends of panels 24 are coupled so that their respective first (i.e. seaward facing) surfaces 27 are substantially continuous. To this end, the panelling system comprises a plurality of end connectors or infills 80 which are arranged to connect ends of mutually adjacent panels 24 together so that the first surfaces of the panels 24 form a

substantially continuous surface across the connected ends. Figures 7 to 9 illustrate a first form of infill 80 used to couple the ends of two adjacent panels 26 together. Infill 80 is configured to sit inside and bridge or span across two mutually adjacent panels 26. The infill 80 is fastened to panels 26 using the same fasteners that fasten the panels to the plate 42. The infill 80 may have seals for preventing ingress of liquid. Holes 70' in first edge portion 31 of the plate 42 and spacer 61 align with holes 70 to receive fasteners (not shown) that pass through an upper part of infill 80 and couple first edge portion 33 to the plate 42. Holes 72' in vertical part 49 of member 46 align with holes 72 to receive fasteners that pass through the infill and couple the second edge portion 33 to member 46.

Figure 10 shows an alternative form of connector or infill provided as a complementary set of infills 9OA and 9OB for fastening panels end to end. In this embodiment each infill 9OA and 9OB sits inside or lines an end portion of the inside wall of each panel 26. Each infill 9OA and 9OB has an inwardly directed portion in the form of a flange 96. The respective flanges 96 are abutted and fastened together with fasteners, such as bolts, rivets or screws through holes 92 and 94, respectively. This embodiment can assist in replacing a panel 26 if necessary. Figures 11 , 12 and 13 show different shaped panels 26, where each of the shapes can be pre-fabricated to be of the desired shape. When installed the panels can repeat end to end to form a visibly continuous profiled shape as desired. The height of the panel 26 can be varied as desired according to the particular job. In some cases higher panels can be used to form cladding of the bulwark 34 as shown in Figures 15 and 16. The bulwark 34 is generally formed at a bow region of each deck 22 of the vessel and is higher than the edge capping on the sides and stern regions of the deck 22. Here the plate 42 extends upwardly enough to provide a middle fastening place of the panel 26, which fastens to the bottom of barrier 32 and an upper fastening place which fastens the plate 42 to the panel 26 and an intermediate part of the barrier 32.

As shown in Figures 6 and 14, panel 26 can be placed atop a panel 26A to form a higher bulwark panel. The panel 26A is fastened to member 46A in a similar manner to panel 26 fastening to bracket 46. Member 46A is fastened to the top portion of the plate 42 (and the top of panel 26). Again the plate 42 extends upwardly more to fasten the plate 42 to the upper portion of the panel 26 and the bottom of the barrier 32, as well as the plate 42 to the upper portion of the panel 26A and the intermediate part of the barrier 32.

Figures 17 - 21 illustrate a further embodiment of panels and panelling system. In these Figures, the same references numbers are used to denote the same or similar features of the panels and panelling system illustrated in figures 1 - 16. Figures 17 - 21 illustrate a plurality of panels 26 having a first surface 27 and first and second edge portions 31 and 33. In this embodiment the first edge portion 31 lies closer to surface 27 than second edge portion 33. However the most significant difference in the panelling system in Figures 17 - 21 is the modified form of the mounting structure 43. In this embodiment, the mounting structure 43 comprises plate 42 and elongate member 46 as in the initial embodiment, but in addition incorporates a plurality of brackets 100a and 100b (hereinafter referred to in general as "brackets 100") and elements 102a and 102b (hereinafter referred to in general as "elements 102"). The brackets 100 are fastened by mechanical fasteners 104 at spaced apart locations to plate 42, and extend in a generally vertical plane. As shown most clearly in Figure 17, the brackets 100a are provided with a pair of parallel spaced apart flanges 106 whereas brackets 100b are formed with only a single flange 106. Brackets 100a are positioned to coincide with and span ends of two adjacent panels 26. The brackets 100b are disposed into lie intermediate opposite ends of a panel 26. Elements 102a are of the same general shape and configuration as elements 102b differing only in that elements 102a are of greater thickness. This greater thickness is to enable the elements 102a to span the edges, and sit inside, of two adjacent panels 24. A length 108 of element 102a sits between flanges 106 of bracket 100a and is held in place by mechanical fasteners that pass between the flanges 106 and through holes 110 formed in the length 108. Elements

102b are coupled to corresponding brackets 100b by mechanical fasteners that extend through the flange 106 of the bracket 100b and holes 110 formed in the elements 102b. As is most evident from Figures 20 and 21 , the elements 102 are provided with an edge 112 shaped and configured in a manner complimentary to an interior shape of panel 26. In this way, edge 112 lies close to or abuts an inside surface of a panel 26 when the panel 26 is coupled with the super structure 14.

Brackets 102 are provided with a depending foot 114 having an edge 116 which abuts elongate member 46 when the elements 102 are attached to their corresponding brackets 100. Each element 102 is also provided with a finger 118 which extends over an upper edge of plate 42. In order to couple panels 26 to super structure 14 the mounting structure 43 comprising the plate 42 and elongate member 46 is attached to a deck 22. Next, brackets 100 are attached to the plates 42 and subsequently the elements 102 are attached to the brackets 100. Each panels 26 is now fitted over a number of elements 102 by holding the panel 26 in an inclined position relative to its fixed position, hooking first edge portion 31 over plate 42 and fingers 118 then rotating the panel 24 to fit second edge portion 33 about or over element 46 and foot 114 of elements 102. This is shown sequentially in Figures 19 and 20.

Barriers 32 may then be attached to the super structure 14 in a similar manner as described herein above in relation to the first embodiment with bolts 64 passing through first edge portion 31. As shown in Figure 21 , element 102a is partially received within one panel 26 with half of the thickness of element 102a extending from the end of that panel. When a further panel 26 is fitted to the super structure on a left hand side of panel 24, an end of the further panel will receive the protruding portion of element 102a. Thus the elements 102a also act as infills or connectors between ends of adjacent panels 26. If desired sealant may be applied between ends of adjacent panels 24. Irrespective of whether or not sealant is applied, it would also be apparent that the panels 26 are connected or coupled by the elements 102a in a manner so that the first surfaces 27 of mutually adjacent panels 26 form a substantially continuous surface across the connected ends of the panels.

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The panel system can be modular with multiples of prefabricated pre-finished panels able to be prepared out of sequence with the normal construction of the superstructure. At a convenient time with they can be secured to the superstructure so as to be in a substantially finished state.

Modifications and variations as would be obvious to a skilled person are intended to fall within the scope of the present invention.