GB2150495A - Structural panel - Google Patents

Structural panel Download PDF

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Publication number
GB2150495A
GB2150495A GB08429547A GB8429547A GB2150495A GB 2150495 A GB2150495 A GB 2150495A GB 08429547 A GB08429547 A GB 08429547A GB 8429547 A GB8429547 A GB 8429547A GB 2150495 A GB2150495 A GB 2150495A
Authority
GB
United Kingdom
Prior art keywords
structural panel
cloth
structural
foam
resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB08429547A
Other versions
GB2150495B (en
GB8429547D0 (en
Inventor
Richard Dennis Curnow
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Bristol Composite Materials Engineering Ltd
Original Assignee
Bristol Composite Materials Engineering Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bristol Composite Materials Engineering Ltd filed Critical Bristol Composite Materials Engineering Ltd
Publication of GB8429547D0 publication Critical patent/GB8429547D0/en
Publication of GB2150495A publication Critical patent/GB2150495A/en
Application granted granted Critical
Publication of GB2150495B publication Critical patent/GB2150495B/en
Expired legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Landscapes

  • Laminated Bodies (AREA)
  • Building Environments (AREA)

Abstract

A structural panel having a core of a phenolic foam plastics material surrounded by a woven fibre cloth impregnated with a phenolic resin. In the case of large panels, internal stiffeners may be used to improve the structural rigidity. Also the panels may have an armour layer to give the panel bullet and fire resisting properties. The armour layer may be external or internal to the panel and may be for example an alumina or a ceramic tile.

Description

SPECIFICATION Structural panel The present invention relates to a structural panel and more particularly relates to fire resisting structural panels.
It is important that offshore structures such as drilling rigs etc have a high resistance to fire. The usual type of structures used in marine fields e.g.
boat hulls, are fabricated from composite materials e.g. resin/fibre glass which are not in general fire resisting.
The present invention relates to an improved structural panel which is lightweight, corrosion resistant, and has good fire resisting properties.
Thus according to the present invention there is provided a structural panel comprising a core of a phenolicfoam plastics material surrounded by a woven fibre cloth impregnated with a phenolic resin.
In the case of large panels, internal stiffeners may be used to improve the structural rigidity.
Also the panels may have an armour layer to give the panel bullet and fire resisting properties. The armour layer may be external to the panel and may be for example an alumina or a ceramic tile.
The woven fibre cloth is preferably fibre glass and is impregnated with a phenolic resin. Preferably a plurality of layers of woven fibre cloth and resin are laid up and placed togetherto form a laminate.
In the preferred use, a phenolic foam is used for the core and a phenolic resin is used with the woven fibre cloth so as to produce a structural panel which, under conditions of fire, has low smoke emission and reduced toxic combustion products in comparison to say structural panels produced from polyurethane foams and epoxy or polyester resins.
The woven fibre cloth is preferably made from woven glass fibre. A structural panel formed from the woven product tends to have greater strength and stiffness than a panel formed from the chopped fibre product and is useful for protective armour applications where high resistance to ballistic projectiles is required.
In insulation applications, it is preferred to incorporate a layer of mineral wool or a combination of a mineral wool or foam into the structural panel.
Structural panels according to the invention may be used in varying sizes for fire wall installations on oil rigs, fire doors for oil rigs, chemical plant, factories and any other situation requiring fire protection.
Some typical dimensions for a structural panel are a thickness of the order of 25-50 mm and a panel size of 1 metre by 2 metres.
The invention will now be described by way of example only and with reference to Figures 1 to 3 of the accompanying drawings, which show vertical cross sections of part of the structural panels.
In use a portion of glass cloth (Marglass M226 woven roving fabric) is impregnated with phenolic resin (J22005 - BP Chemicals) by dipping in a bath.
The solvents in the resin are then allowed to evaporate and the cloth is heated at 1 000C to obtain a tacky surface. The resin impregnated cloth is then cut to shape and the desired number of laminations are laid up and placed together. A similar shaped piece of phenolic foam ("Koolphen" Kooltherm Limited) is positioned against the laminates and a second layer of laminates are laid on top of the foam to produce a sandwich structure. The sandwich structure is then cured for about 60 minutes at 1 500C under 15 psi pressure. If necessary, stiffeners can be inserted into the foam and cloth during the process.
It is desirable to stagger the internal stiffners relative to each other so asto reduce heat transfer. Figure 1 shows a cross section through a structural panel 1 in which stiffeners 2 are incorporated.
If required, for instance an application where thermal insulation is required, outer skins 3 of resin cloth may be used to sandwich a central core of foam 5 with an intermediate layer of mineral wool 6 or mineral wool and foam between the foam 4 and skins 3. A cross section through a structural panel having this configuration is shown in Figure 2.
Figure 3 shows a cross section through a bullet and fire resisting panel comprising a central layer 7 of ceramic tiles or alumina surrounded by a core 8 of phenolic foam and having an outer layer 9 of glass rove cloth and phenolic resin.
1. A structural panel comprising a phenolic foam plastics material and a woven fibre cloth impregnated with a phenolic resin, the cloth surrounding the major part of the surface of the phenolic foam plastics material.
2. A structural panel according to claim 1 in which the woven fibre cloth is fibre glass.
3. A structural panel according to claim 1 or claim 2 in which a plurality of layers of the woven fibre cloth and resin are laid up and placed together to form a laminate.
3. A structural panel according to claim 1 or claim 2 in which a plurality of layers of the woven fibre cloth and resin are laid up and placed together to form a laminate.
4. A structural panel according to any of claims 1 to 3 comprising a layer of mineral wool or a combination of mineral wool and foam.
5. A structural panel according to any of the preceding claims having internal stiffners so as to increase the rigidity of the panel.
6. A structural panel according to claim 5 in which the internal stiffeners are in a staggered arrangement.
7. A structural panel according to any of the preceding claims having an internal or external layer of an armour.
8. A structural panel according to claim 7 in which the armour comprises alumina or ceramic titles.
9. A structural panel as hereinbefore described and with reference to Figures 1 to 3 of the accompanying drawings.
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (9)

**WARNING** start of CLMS field may overlap end of DESC **. SPECIFICATION Structural panel The present invention relates to a structural panel and more particularly relates to fire resisting structural panels. It is important that offshore structures such as drilling rigs etc have a high resistance to fire. The usual type of structures used in marine fields e.g. boat hulls, are fabricated from composite materials e.g. resin/fibre glass which are not in general fire resisting. The present invention relates to an improved structural panel which is lightweight, corrosion resistant, and has good fire resisting properties. Thus according to the present invention there is provided a structural panel comprising a core of a phenolicfoam plastics material surrounded by a woven fibre cloth impregnated with a phenolic resin. In the case of large panels, internal stiffeners may be used to improve the structural rigidity. Also the panels may have an armour layer to give the panel bullet and fire resisting properties. The armour layer may be external to the panel and may be for example an alumina or a ceramic tile. The woven fibre cloth is preferably fibre glass and is impregnated with a phenolic resin. Preferably a plurality of layers of woven fibre cloth and resin are laid up and placed togetherto form a laminate. In the preferred use, a phenolic foam is used for the core and a phenolic resin is used with the woven fibre cloth so as to produce a structural panel which, under conditions of fire, has low smoke emission and reduced toxic combustion products in comparison to say structural panels produced from polyurethane foams and epoxy or polyester resins. The woven fibre cloth is preferably made from woven glass fibre. A structural panel formed from the woven product tends to have greater strength and stiffness than a panel formed from the chopped fibre product and is useful for protective armour applications where high resistance to ballistic projectiles is required. In insulation applications, it is preferred to incorporate a layer of mineral wool or a combination of a mineral wool or foam into the structural panel. Structural panels according to the invention may be used in varying sizes for fire wall installations on oil rigs, fire doors for oil rigs, chemical plant, factories and any other situation requiring fire protection. Some typical dimensions for a structural panel are a thickness of the order of 25-50 mm and a panel size of 1 metre by 2 metres. The invention will now be described by way of example only and with reference to Figures 1 to 3 of the accompanying drawings, which show vertical cross sections of part of the structural panels. In use a portion of glass cloth (Marglass M226 woven roving fabric) is impregnated with phenolic resin (J22005 - BP Chemicals) by dipping in a bath. The solvents in the resin are then allowed to evaporate and the cloth is heated at 1 000C to obtain a tacky surface. The resin impregnated cloth is then cut to shape and the desired number of laminations are laid up and placed together. A similar shaped piece of phenolic foam ("Koolphen" Kooltherm Limited) is positioned against the laminates and a second layer of laminates are laid on top of the foam to produce a sandwich structure. The sandwich structure is then cured for about 60 minutes at 1 500C under 15 psi pressure. If necessary, stiffeners can be inserted into the foam and cloth during the process. It is desirable to stagger the internal stiffners relative to each other so asto reduce heat transfer. Figure 1 shows a cross section through a structural panel 1 in which stiffeners 2 are incorporated. If required, for instance an application where thermal insulation is required, outer skins 3 of resin cloth may be used to sandwich a central core of foam 5 with an intermediate layer of mineral wool 6 or mineral wool and foam between the foam 4 and skins 3. A cross section through a structural panel having this configuration is shown in Figure 2. Figure 3 shows a cross section through a bullet and fire resisting panel comprising a central layer 7 of ceramic tiles or alumina surrounded by a core 8 of phenolic foam and having an outer layer 9 of glass rove cloth and phenolic resin. CLAIMS
1. A structural panel comprising a phenolic foam plastics material and a woven fibre cloth impregnated with a phenolic resin, the cloth surrounding the major part of the surface of the phenolic foam plastics material.
2. A structural panel according to claim 1 in which the woven fibre cloth is fibre glass.
3. A structural panel according to claim 1 or claim 2 in which a plurality of layers of the woven fibre cloth and resin are laid up and placed together to form a laminate.
3. A structural panel according to claim 1 or claim 2 in which a plurality of layers of the woven fibre cloth and resin are laid up and placed together to form a laminate.
4. A structural panel according to any of claims 1 to 3 comprising a layer of mineral wool or a combination of mineral wool and foam.
5. A structural panel according to any of the preceding claims having internal stiffners so as to increase the rigidity of the panel.
6. A structural panel according to claim 5 in which the internal stiffeners are in a staggered arrangement.
7. A structural panel according to any of the preceding claims having an internal or external layer of an armour.
8. A structural panel according to claim 7 in which the armour comprises alumina or ceramic titles.
9. A structural panel as hereinbefore described and with reference to Figures 1 to 3 of the accompanying drawings.
GB08429547A 1983-11-25 1984-11-22 Structural panel Expired GB2150495B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB8331491 1983-11-25

Publications (3)

Publication Number Publication Date
GB8429547D0 GB8429547D0 (en) 1985-01-03
GB2150495A true GB2150495A (en) 1985-07-03
GB2150495B GB2150495B (en) 1987-04-08

Family

ID=10552336

Family Applications (1)

Application Number Title Priority Date Filing Date
GB08429547A Expired GB2150495B (en) 1983-11-25 1984-11-22 Structural panel

Country Status (4)

Country Link
CA (1) CA1229463A (en)
GB (1) GB2150495B (en)
NL (1) NL8403563A (en)
NO (1) NO162980C (en)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2176745A (en) * 1985-06-20 1987-01-07 Dewey Waters & Co Fire resistant structural panel
GB2182607A (en) * 1985-09-19 1987-05-20 Geoffrey Crompton Building components
WO1999007961A1 (en) * 1997-08-11 1999-02-18 John Bartholomew Lee A building panel and method of forming same
WO2002066758A1 (en) * 2001-02-21 2002-08-29 Sika Schweiz Ag Prefabricated construction element for buildings
GB2408016A (en) * 2003-11-14 2005-05-18 Intelligent Engineering Structural sandwich member
WO2008135724A2 (en) * 2007-05-02 2008-11-13 Alderley Materials Limited Thermal insulating structures

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110511531B (en) * 2019-09-18 2022-05-17 营口象圆新材料工程技术有限公司 Phenolic foam composite board and preparation method thereof

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2176745A (en) * 1985-06-20 1987-01-07 Dewey Waters & Co Fire resistant structural panel
GB2182607A (en) * 1985-09-19 1987-05-20 Geoffrey Crompton Building components
GB2182607B (en) * 1985-09-19 1990-05-09 Geoffrey Crompton Fire-resistant components
WO1999007961A1 (en) * 1997-08-11 1999-02-18 John Bartholomew Lee A building panel and method of forming same
US6295786B1 (en) 1997-08-11 2001-10-02 John Bartholomew Lee Building panel and method of forming same
WO2002066758A1 (en) * 2001-02-21 2002-08-29 Sika Schweiz Ag Prefabricated construction element for buildings
GB2408016A (en) * 2003-11-14 2005-05-18 Intelligent Engineering Structural sandwich member
WO2008135724A2 (en) * 2007-05-02 2008-11-13 Alderley Materials Limited Thermal insulating structures
WO2008135724A3 (en) * 2007-05-02 2009-04-02 Alderley Materials Ltd Thermal insulating structures
GB2463813A (en) * 2007-05-02 2010-03-31 Advanced Insulation Plc Thermal insulating structures
GB2463813B (en) * 2007-05-02 2012-01-04 Advanced Insulation Plc Thermal insulating structures
US9067382B2 (en) 2007-05-02 2015-06-30 Advanced Insulation Plc Thermal insulating structures

Also Published As

Publication number Publication date
CA1229463A (en) 1987-11-24
NO162980B (en) 1989-12-04
GB2150495B (en) 1987-04-08
GB8429547D0 (en) 1985-01-03
NO844671L (en) 1985-05-28
NL8403563A (en) 1985-06-17
NO162980C (en) 1990-03-14

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Legal Events

Date Code Title Description
732 Registration of transactions, instruments or events in the register (sect. 32/1977)
PCNP Patent ceased through non-payment of renewal fee

Effective date: 19921122