WO2022117543A1

WO2022117543A1 - Fire-resistant structural panels

Info

Publication number: WO2022117543A1
Application number: PCT/EP2021/083508
Authority: WO
Inventors: Derek Ward
Original assignee: Intumescent Systems Ltd
Priority date: 2020-12-02
Filing date: 2021-11-30
Publication date: 2022-06-09
Also published as: GB2603273B; AU2021376718A1; GB202117243D0; GB2603273A; EP4256146A1

Abstract

A fire-resistant structural panel which includes an internal frame which borders a quantity of high density thermally insulating material and which comprises a plurality of elongate frame members each encased in a cloth material coated with a solution containing an intumescent material. The panel further comprises panel members which are dimensioned to match or substantially match the dimensions of the internal frame and which are secured one to each side of said internal frame. A coating of a solution containing an intumescent material is applied to all exposed surfaces of said fire-resistant structural panel.

Description

FIRE-RES ISTANT STRUCTURAL PANELS

Field of the Invention

This invention relates to fire-resistant structural panels for use in the construction industry .

The term " structural panels" includes wall , ceiling and floor panels for use , for example , in the construction of buildings including housing and industrial units . These items are merely indicative of the uses to which fire-resistant panels in accordance with the invention can be put .

In a further aspect , the invention relates to a building having internal and/or external walls and/or selected other structural members including floors and ceilings which are produced from fire-resistant panels in accordance with the invention .

Background to the Invention

Structural panels for use in the construction of both residential and commercial buildings are known . Such panels are used in the construction of internal and external walls , ceilings , rooves and floors of buildings and generally comprise a core of rigid foam insulating material sandwiched between and adhesively bonded or otherwise secured to inner and outer panels of , for example , plasterboard or wood .

These panels facilitate inter alia a fast-track building process for residential and commercial buildings with potential cost savings for reason that they are relatively lightweight and simple to erect ; in many cases , the use of such panels removes or limits the need for scaf folding and similar structures . However, currently available structural panels have limited ability to act as fire barriers , their resistance to the spread of smoke and fire being in many cases less than 10 minutes .

Examples of previously proposed panels are to be found in patent applications US 2009/ 0007513A1 and WO 86/ 00915A1 , and GB patent 1477658 .

The present invention sets out to provide structural panel s which have all the advantages of presently available structural panels and which additionally act as ef fective f ire breaks for periods in excess of one hour and, in many cases , for time periods in excess of four hours and more .

Additionally, fire resistant structural panels in accordance with the invention provide enhanced acoustic protection .

Statements of the Invention

In one aspect , the invention provides a f ire-resistant structural panel which includes an internal frame which borders a quantity of high density thermally insulating material and which comprises a plurality of elongate frame members each encased in a cloth material coated with a solution containing an intumescent material , said fire-resistant structural panel further comprising panel members which are dimensioned to match or substantially match the dimensions of the internal frame and which are secured one to each side of said internal frame , and a coating of a solution containing an intumescent material applied to all exposed surfaces of said f ire-resistant structural panel

Preferably, the high density thermally insulating material comprises one or more sheets of such material of thickness equal to the depth of said internal panel . The frame may include one or more additional elongate members which extend between one or more pairs of opposed elongate frame members .

The panel members may be adhered to the sheets of insulating material and/or the internal frame by an adhesive which includes an intumescent material .

More than one panel member may be secured to one or each side of the internal frame , each such panel member being secured to its neighbouring panel member by an adhesive which includes an intumescent material .

At least one side edge of each fire-resistant structural panel member may be recessed to receive a proj ecting side edge of an adj oining fire-resistant structural panel member .

Each elongate frame member preferably comprises a length of timber .

Each such length of timber is preferably rectangular in cross section .

Alternatively, each elongate frame member comprises a length of aluminium or other metallic material .

Again, each such length is preferably rectangular in cross section .

Alternatively, the frame may be constructed from a mix of elongate frame members of timber and a metallic material .

The cloth material preferably comprises aluminium pigment glass cloth of thickness of between 1 . 2mm and 1 . 4mm . A preferred cloth thickness is 1 . 3mm .

The cloth material is preferably coated with an HWO1 or HWO2 intumescent-containing solution as supplied by Intumescent Systems Limited . The panel members are preferably secured to the internal frame by an adhesive which includes an intumescent material .

A preferred adhesive is SA20 hybrid high-temperature sealant adhesive as supplied by Intumescent Systems Limited .

Preferably, the high density thermally insulating material comprises rock-wall sheets of thickness of between 50mm and 70mm . A preferred sheet thickness is 60mm .

Preferred panel members comprise oriented strand boards ( OSB ) , medium density fibreboards (MDF) , plywood and particle boards .

The fire-resistant structural panel members may include on one side a sheet or sheets of cement board and on the other side a sheet or sheets of plaster board .

Preferably, adhesive including an intumescent material is applied to exposed surfaces of each sheet of compacted inert vitreous silicate mineral wool .

Each sheet of compacted high density thermally insulating material may comprise a single sheet dimensioned to cover substantially the entire surface of each panel member .

Alternatively, each sheet of compacted high dens ity thermally insulating material may comprise a plurality of edgewise abutting or overlapping smaller sheets or pieces of such material which together cover substantially the entire opposed surfaces of the panel members .

In both cases , the abutting edges of adj oining sheets of compacted high density insulating material inert may be covered by strips of tape , preferably tape which is coated with or includes a material which intumesces in the presence of excess heat and/or a fire .

In use , abutting edges of adj oining panel members are preferably covered with tape which preferably includes or is coated with a material which intumesces in the presence of fire or excess heat .

In a further aspect , the invention provides a building whose external and/or internal walls comprise fire-resistant structural panels each of which includes an internal frame comprising one or more sheets of high density thermally insulating material bordered by elongate frame members each encased in a cloth material coated with a solution containing an intumescent material , and panel members dimensioned to match or substantially match the dimensions of the internal frame and secured one to each side of said internal frame , and a coating of a solution containing an intumescent material applied to all exposed surfaces of said fire-resistant structural panel .

The ceilings and/or floors of the building may also comprise such fire-resistant structural panel .

Brief Description of the Drawings

The invention wil l now be described by way of example only with reference to the accompanying diagrammatic drawings , in which : -

Figure 1 is a plan view of a fire-resistant structural wall panel in accordance with the invention with one of its two facing panel members removed;

Figure 2 is a section taken along line A-A of Figure 1 but with both facing panel members in place ;

Figure 3 is a perspective view to an enlarged scale of one corner of a fire-resistant structural ceiling panel of the same construction as the wall panel illustrated in Figure l illustrated in Figure 1 ; and Figure 4 is an isometric view from above of fire-resistant structural panels assembled to define external and internal walls of a building under construction .

Detailed Description of the Invention

The fire-resistant structural wall panel 10 illustrated in Figures 1 and 2 of the accompanying drawings comprises a pair of external panel members 12 , 14 ( only one of which is shown in Figure 1 ) secured one to each side of an internal frame constructed from elongate frame members 16 .

It is to be understood that the panel illustrated in Figures 1 and 2 could equally well act as a floor or ceiling panel depending on its orientation and/or location .

Typically, each external panel member 12 , 14 comprises a fire board or an assembly of fire boards coated on its external surface with a coating which includes an intumescent material . In a preferred arrangement , each surface of each panel member is coated with such a coating .

As will be explained below, each panel member may comprise a single sheet of a suitable material , or a plurality of such sheets adhered together by means o f an adhesive which preferably contains a substance which intumesces in the presence of extreme heat .

In one example , the panel members comprise fire boards such as "S INIAT GTEC" fire boards ("S INIAT" is a registered trademark of ETEX NV) , Gypsum plasterboard, fire-line plasterboard, cement board and OS board .

The frame members 16 are typically lengths of timber of rectangular cross section covered with sheets 18 of fabric or other material such as glass cloth coated with a solution which intumesces in the presence of excessive heat . The sheets are typically adhered to the timber frame members 16 with an adhesive which preferably contains a substance which intumesces in the presence of excessive heat .

The sheets 18 typically comprise aluminium glass cloth of thickness between 1 . 1mm and 1 . 5mm ( typically 1 . 3mm) and weight between 50g/m2 and 70g/m2 ( typically 60g/m2 ) coated with an intumescent solution, ( typically Applicant ' s HW01 coating material ) .

In an alternative arrangement the frame members 16 comprise lengths of metal such as steel . Such frame members are treated in the same way as described above with reference to frame members 16 .

Located within the assembly of frame members 16 are sheets 20 of compacted high density inert vitreous silicate mineral wool , these sheets being sandwiched between and adhered to the adj oining faces of one or each o f the two rigid panel members 12 by an adhesive which preferably includes a material which intumesces in the presence of excessive heat .

As mentioned previously, a suitable adhesive comprises the Applicant ' s SA20 intumescent containing adhesive which includes measured quantities of an intumescent material .

Typically, the thickness of each mineral wool sheet 20 is between 40mm and 70mm, this depending on the thickness of the frame members 16 .

Typically, the density of each mineral wool sheet is between 120 and 180kg/m3 .

In addition to providing ef fective fire protection, the mineral wool sheets provide ef fective insulation against heat loss . The adhesive is l iberally applied to each side of the sheets 20 of compacted inert vitreous silicate mineral wool and/or the exposed surfaces of the frame members 16 .

As shown in Figures 1 and 2 , one side edge of the illustrated panel 10 is recessed along its full length to create a channel 22 to receive the lengthwise extending protruding side edge of an adj oining frame member 16 of a neighbouring panel to provide a tight bonding between adj oining panels . For end panels , the respective frame member 16 extends to the periphery of the frame member .

The sides of the channels 22 are preferably coated with an adhesive including a content of intumescent material .

The abutting edges of adj oining panels 10 are covered with adhesive tape including or coated with an intumescent material .

As will be seen from Figure 3 , openings 24 are selectively formed in the panels 10 to receive building members such as columns , beams and the like .

As will be seen from Figure 2 , each panel 12 , 14 comprises a plurality of individual sheets adhered together to define a single panel .

Typically, the panels 12 comprise up to four individual panel sheets which typically comprise sheets of OSB , fire-line plasterboard, gypsum plasterboard and cement board adhered one to another using an adhesive , preferably an adhesive which includes a material which intumesces in the event of excessive heat .

Typically, the panels 14 comprise individual panel sheets of OSB and cement board adhered one to the other using an adhesive , preferably an adhesive which intumesces in the event of excessive heat . Once constructed, all exposed surfaced are coated with a solution or paint which includes a material which intumesces in the event of a fire or excessive heat .

Thus , the coated panels 12 , 14 and frame members 16 ensure that a fire-resistant char is produced on all exposed surfaces of the panel and frame members 12 , 14 in the event of fire or excessive heat . This char has been found to remain in place and to resist the passage of f lames for periods of time well in excess of 60 minutes , more likely periods in excess of four hours .

Once a fire has been fully extinguished, the outermost charred sheet of the panel can readily be removed and replaced with a fresh panel sheet coated on all exposed surfaces with a solution or paint which includes a material which intumesces in the event of excessive heat . Panel sheets behind the outermost charred sheet were found to be undamaged and well able to receive a fresh outer panel sheet . Connections for electric sockets and the like were al so found to be undamaged and able to be reused once the appropriate connections had been made .

In some cases , it was found that the panel sheet exposed after removal of the charred sheet could itsel f be employed as the fresh uncharred face of the panel sheet .

When subj ected to a fire test , panels in accordance with the invention continued to provide an ef fective fire break for periods in excess of four hours .

An assembly of panels to form internal and external structural fireproofed insulated internal walls 12 , 14 respectively of a mock-up building is shown in Figure 4 .

As will be seen from this Figure , openings 24 for doorways , windows , support beams and the like are simply cut into the panels as and where required . Such panelled structures are intended to replace conventional brick built external and internal walls of buildings thereby reducing building costs and erection times .

Following construction, the outer faces of the external walls may be clad with, for example , hanging tiles for aesthetic and/or weathering purposes .

Fire tests conducted on a house whose external and internal walls , floors and ceilings were constructed in accordance with this invention demonstrated that a fire occurring in a room or other location of the house was retained within that room or location, it being prevented by the described coated panels from moving to adj oining rooms or locations for periods in excess of four hours .

Indeed, when the fire was finally extinguished after such a period, the fire damage was found to be confined to the room of the initial source of the fire .

The test also demonstrated that confinement of the fire within its initial location would enable persons resident in the building to move to a fire- free part of the building before safely leaving the building .

Following the fire test , the outer panel sheets of the panels within the room were removed and replaced, and the damaged electrical connections reconnected leaving the room, and the house , ready for occupancy .

It will be appreciated that the foregoing is merely exemplary of panel boards in accordance with the invention and that modi fications can readily be made thereto without departing from the true scope of the invention as expressed in the appended claims .

Claims

1 . A fire-resistant structural panel which is characterised in that it includes an internal frame ( 10 ) which borders a quantity of high density thermally insulating material ( 20 ) and which comprises a plurality of elongate frame members ( 16 ) each encased in a cloth material ( 18 ) coated with a solution containing an intumescent material , said fire-resistant structural panel further comprising panel members ( 12 , 14 ) which are dimensioned to match or substantially match the dimensions of the internal frame and which are secured one to each side of said internal frame , and a coating of a solution containing an intumescent material applied to all exposed surfaces of said fire-resistant structural panel .

2 . A panel as claimed in claim 1 characterised in that the high density thermally insulating material comprises one or more sheets of such material of thickness equal to the depth of said internal panel .

3 . A panel as claimed in claim 1 or claim 2 wherein the frame includes one or more additional elongate members which extend between one or more pairs of opposed elongate frame members .

4 . A panel as claimed any one of the preceding claims wherein the panel members are adhered to the sheets of insulating material and/or the internal frame by an adhesive which includes an intumescent material . A panel member as claimed in any one of the preceding claims wherein more than one panel member is secured to one or each side of the internal frame , each such panel member being secured to its neighbouring panel member by an adhesive which includes an intumescent material . A panel member as claimed in any one of the preceding claims wherein at least one side edge of each fire-resistant structural panel member is recessed to receive a proj ecting side edge of an adj oining fire-resistant structural panel member . A panel as claimed in any one of the preceding claims wherein each elongate frame member comprises a length of timber . A panel as claimed in claim 7 wherein each length of timber is rectangular in cross section . A panel as claimed in any one of the preceding claims wherein the cloth material comprises aluminium pigment glass cloth of thickness of between 1 . 2mm and 1 . 4mm . A panel as claimed in claim 9 wherein the cloth material is coated with an intumescent-containing solution . A panel as claimed in any one of the preceding claims wherein the panel members are secured to the internal frame by an adhesive which includes an intumescent material . A panel as claimed in any one of the preceding claims wherein the high density thermally insulating material comprises rock-wall sheets of thickness of between 50mm and 70mm . A panel as claimed in any one of the preceding claims wherein each sheet of compacted high density thermally insulating material comprises a plurality of edgewise abutting or overlapping smaller sheets or pieces of such material which together cover substantially the entire opposed surfaces of the panel members . A building whose external and/or internal walls comprise fire-resistant structural panels each of which includes an internal frame ( 10 ) comprising one or more sheets ( 20 ) of high density thermally insulating material bordered by a elongate frame members ( 16 ) each encased in a cloth material ( 18 ) coated with a solution containing an intumescent material , and panel members ( 12 , 14 ) dimensioned to match or substantially match the dimensions of the internal frame ( 10 ) and secured one to each side of said internal frame , and a coating of a solution containing an intumescent material applied to all exposed surfaces of said fire-resistant structural panel . A building as claimed in claim 14 wherein the ceilings and/or floors of the building also comprise said fire resistant structural panels .