GB2176745A - Fire resistant structural panel - Google Patents

Fire resistant structural panel Download PDF

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Publication number
GB2176745A
GB2176745A GB08615125A GB8615125A GB2176745A GB 2176745 A GB2176745 A GB 2176745A GB 08615125 A GB08615125 A GB 08615125A GB 8615125 A GB8615125 A GB 8615125A GB 2176745 A GB2176745 A GB 2176745A
Authority
GB
United Kingdom
Prior art keywords
grph
layer
resin
ceramic blanket
blanket
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
GB08615125A
Other versions
GB2176745B (en
GB8615125D0 (en
Inventor
Norman Frank Dewey
Alan Hall
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.)
Dewey Waters & Co
Original Assignee
Dewey Waters & Co
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 Dewey Waters & Co filed Critical Dewey Waters & Co
Publication of GB8615125D0 publication Critical patent/GB8615125D0/en
Publication of GB2176745A publication Critical patent/GB2176745A/en
Application granted granted Critical
Publication of GB2176745B publication Critical patent/GB2176745B/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
    • 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
    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • E04B1/941—Building elements specially adapted therefor
    • E04B1/942—Building elements specially adapted therefor slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • 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
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/02—Ceramics
    • 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

Abstract

A structural panel 10 comprises a fire-resistant ceramic blanket 18, a phenolic resin foam layer 14 and one or more layers 12, 16 of glass fibre reinforced phenolic (grph) resin. The ceramic blanket 18 is secured to one of the grph resin layers by direct adhesion to an adjacent grph layer 16, or is held in place by a metal mesh 20 and securing connectors 24. A further grph resin layer 22 may be provided on the side of the ceramic blanket remote from the foam layer 14. The structural panels are joined together by means of flanges 30, covered by a capping strip 36 which comprises a ceramic blanket layer 44 and at least one layer 40 of grph resin. <IMAGE>

Description

SPECIFICATION Fire resistant structural panel This invention relates to structural panels for buildings, cladding and the like, and is particularly directed to fire-resistant panels.
It is becoming more common to construct cladding, housings or small buildings from glass fibre reinforced resin panels. However, there is a problem with such materials in relation to their fire resistance, since all organic resins will burn or decompose at temperatures much lower than metals, cementitious or other more refractory materials used in building. The present invention seeks to provide a structural panel, made principally from glass fibre reinforced resin, but having improved fire-resistant properties.
According to the present invention there is provided a structural panel which comprises a fire-resistant ceramic blanket and, on one side of the ceramic blanket, a phenolic resin foam layer and one or more layers of glass fibre reinforced phenolic (grph) resin, the ceramic blanket being secured to a said grph resin layer.
Optionally, a further grph resin layer is provided on the side of the ceramic blanket remote from the foam layer. Preferably, the foam layer is sandwiched between two grph resin layers, thus providing a layer of grph resin adjacent the ceramic blanket.
The ceramic blanket may either be secured directly to said adjacent grph resin layer by adhesion, or else a layer of metal mesh may be provided on the side of the ceramic blanket remote from the foam layer and secured through the blanket to a said grph layer.
Where the ceramic blanket is adhered to an adjacent grph layer, this is preferably achieved by contacting the blanket with the phenolic resin before the resin cures. Where the ceramic blanket is secured by a metal mesh, this securement is preferably provided by means of metal securing elements, such as studs, bolts or the like, arranged at suitable intervals, secured at one end thereof to a said grph resin layer.
A panel having this structure will have improved fire resisting properties with respect to a fire on the side of the panel adjacent the ceramic blanket. Even if the fire melts or decomposes any grph layer on that side, the ceramic blanket will remain in place and will resist the transmission of destructive heat through to the foam layer, which in turn will resist the transmission of heat to the remote grph layer. Although metal studs may be used to secure the metal mesh layer, these have been found in practice not to transmit sufficient heat as to cause the structure to fail prematurely.
Two ceramic blankets may be provided on either side of the phenolic resin foam layer, each being secured either by a layer of metal mesh to the other side of the panel or by adjacent grph layers. A panel of this form will thus resist fire from either side of the panel.
The grph layer remote from the metal mesh may be of a composition, or be coated with a composition, which changes its app'earance (e.g. colour) in response to a marked increase in temperature. Thus, if a fire is present on the other side of the panel, the heat transmitted through the metal connecting studs may cause a local change in appearance of the grph layer remote from the fire, and thereby give an indication to the outside world that there is a fire. Indeed, a series of connecting studs may be arranged so as to convey a readable message when such change in appearance takes place, indicating that there is a fire and alerting any viewer to the need to call the fire brigade.
The panels are preferably provided with flanges around their edges, by means of which the panels are interconnected.
These edge connections could provide a weak point for fire resistance, and in response to this the present invention further provides a structure made from such panels in which the edge joints are capped on the side adjacent the ceramic blanket by capping strips which incorporate a ceramic blanket layer and one or more grph resin layers. A metal mesh layer may be provided between the ceramic blanket and a said grph layer. The capping strips are suitably secured by connectors passing through the strips and the adjacent structural panels to the side of the foam layer remote from the ceramic blanket.
In order that the invention may be more clearly understood, two embodiments will now be described with reference to the accompanying drawings, wherein: Fig. 1 shows a cross-section through part of a structure incorporating ceramic panels according to one embodiment of the present invention; and Fig. 2 shows a cross-section through part of a structure incorporating ceramic panels according to a second embodiment of the present invention.
Referring to Fig. 1; a structural panel 10 comprises an outer layer 12 of grph, a layer 14 of phenolic resin foam, optionally a layer 16 of grph on the side of the foam remote from the outer layer 12, a ceramic blanket 18, a steel wire mesh 20, and optionally an inner grph layer 22. A series of connectors 24 in the form of stainless steel nuts and bolts extend at intervals through the panel, each bolt having a large head 26 which is secured to the outer grph layer 12, either by moulding it into the layer or by locating it on the surface of the layer 12 remote from the foam layer 14.Adjacent the nuts 27 are washers 28 large enough not to pass through the mesh of the wire layer 20 in the event that the adja cent grph layer 22 disintegrates in a fire. (The nuts and bolts are arranged this way round for convenience and appearance; it being intended that the layer 12 will be the one on the outside of the building, and hence should have the more pleasing appearance. However, the bolts could be reversed, if desired.) The heads 26 of the bolts could alternatively be secured to the grph layer 16.
The panels 10 are adapted for interconnection by means of inwardly directed flanges 30, the flanges of adjacent panels abutting each other, with a suitable sealing material 32 in between, and secured by for example nuts and bolts 34. These joints are internally capped by means of separate capping strips 36. The capping strip has the general form of a channel with outturned flanges 38 at its mouth, and comprises an inner grph layer 40, a wire mesh layer 42, and an outer ceramic blanket layer 44 (the terms "inner" and "outer" being used in the same sense as for the panel 10). An additional grph layer (not shown) may be provided on the side of the ceramic blanket layer remote from the grph layer 40, if desired. The capping strips are secured in place by means of the connecting studs 24 (nuts and bolts) nearest the edges of the panels 10, the bolts passing through the flanges 38.
A structure made from such panels is intended to resist a fire which occurs on the side adjacent the grph layers 22: i.e. inside the building. Assuming that the fire is sufficiently hot so as to destroy the inner grph layers 22,40; the connecting studs 24 will retain in place the wire mesh layers 20,42, and hence the ceramic blanket layers 18,44. There will thus remain a highly fire-resistant material on the inside of the structure. The ceramic blanket layer 18 and the foam layer 14 resist the transmission of heat to the outside of the building, and thus retain the structural integrity for the longest possible time.However, the metal studs 24 transmit heat at a greater rate, albeit insufficient to cause their detachment from the outer grph layers 12, but by means of heat-induced colour changes in the grph layer 12, or in a paint or other coating applied to the outside of that layer, an external visible indication of the fire can be given, which does not rely on the operation of electrical or other special devices. The inner grph layer 22 is optional, but provides a surface finish to that side of the panel.
Fig. 2 shows an embodiment of the invention that does not contain the wire mesh 20,42. During construction, the ceramic blanket 18 is laid on the grph layer 16 before the grph layer 10 is cured. This results in fibres of the ceramic blanket 18 becoming embedded in the grph layer 16, the latter being provided with ample resin for this purpose.
The grph layer 16 can thus support the ceramic blanket 18 and so make the wire mesh 20 redundant, so that most of the connectors 24 can be omitted from the structural panel 10 as their main function was to retain the wire mesh 20. However, some connectors 24 may still be required to secure the capping strips 36.
The capping strip 36, as shown in Fig. 2 comprises a grph layer 46 which supports the ceramic blanket 44 in place of a wire mesh layer. This is performed in the same manner as the layers in the structural panel 10. However, a capping strip similar in construction to that of Fig. 1 could be employed instead, if desired.

Claims (16)

1. A structural panel comprising a fire-resistant ceramic blanket and, on one side of the ceramic blanket, a phenolic resin foam layer and one or more layers of glass fibre reinforced phenolic (grph) resin, the ceramic blanket being secured to a said grph resin layer.
2. A structural panel according to claim 1 which also comprises a further grph resin layer on the side of the ceramic blanket remote from the foam layer.
3. A structural panel according to claim 1 or claim 2 wherein the foam layer is sandwiched between two grph resin layers, thus providing a layer of grph resin adjacent the ceramic blanket.
4. A structural panel according to claim 3 wherein the ceramic blanket is secured directly to said adjacent grph resin layer by adhesion.
5. A structural panel according to claim 4 wherein the blanket is secured to said adjacent grph layer by contacting the blanket with the resin before the resin cures, whereby fibres of the blanket are embedded in the resin.
6. A structural panel according to any one of claims 1 to 3 wherein a metal mesh is provided on the side of the ceramic blanket remote from the foam layer and secured through the ceramic blanket to a grph resin layer.
7. A structural panel according to claim 6 wherein the metal mesh is secured by means of securing elements, arranged at suitable intervals.
8. A structural panel according to any one of the preceding claims wherein a ceramic blanket is provided on either side of the foam layer, each being secured to a grph resin layer.
9. A structural panel according to any one of the preceding claims wherein the panel is provided with flanges around the edge, by means of which the panel may be connected to adjacent panels.
10. A structural panel substantially as herein described with reference to the drawings.
11. A structure incorporating a plurality of structural panels according to any one of the preceding claims, the panels being joined edge to edge.
12. A structure according to claim 11 which further comprises a capping strip over the joint, the strip incorporating a ceramic blanket layer and one or more grph resin layers.
13. A structure according to claim 12 wherein the ceramic blanket in the capping strip is supported by a grph resin layer on the side of the ceramic blanket proximal to the joint.
14. A structure according to claim 12 wherein the ceramic blanket in the capping strip is supported by a wire mesh layer on the side remote from the joint.
15. A structure according to any one of claims 12 to 14 wherein the capping strip is secured to the structural panels by connectors passing through the strip and the ceramic blankets of the adjacent structural panels to grph layers of the panels.
16. A structure substantially as described with reference to the drawings.
GB08615125A 1985-06-20 1986-06-20 Fire resistant structural panel Expired GB2176745B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB858515652A GB8515652D0 (en) 1985-06-20 1985-06-20 Fire resistant structural panel

Publications (3)

Publication Number Publication Date
GB8615125D0 GB8615125D0 (en) 1986-07-23
GB2176745A true GB2176745A (en) 1987-01-07
GB2176745B GB2176745B (en) 1988-12-21

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Family Applications (2)

Application Number Title Priority Date Filing Date
GB858515652A Pending GB8515652D0 (en) 1985-06-20 1985-06-20 Fire resistant structural panel
GB08615125A Expired GB2176745B (en) 1985-06-20 1986-06-20 Fire resistant structural panel

Family Applications Before (1)

Application Number Title Priority Date Filing Date
GB858515652A Pending GB8515652D0 (en) 1985-06-20 1985-06-20 Fire resistant structural panel

Country Status (1)

Country Link
GB (2) GB8515652D0 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2207449A (en) * 1987-07-31 1989-02-01 Am & S Europ Flame proof joints in plasterboard cladding
GB2499295A (en) * 2011-12-15 2013-08-14 Envirup Ltd Insulation panel with profiled ends for abutment with adjacent panel

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2150495A (en) * 1983-11-25 1985-07-03 Bristol Composite Mat Structural panel

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2150495A (en) * 1983-11-25 1985-07-03 Bristol Composite Mat Structural panel

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2207449A (en) * 1987-07-31 1989-02-01 Am & S Europ Flame proof joints in plasterboard cladding
GB2499295A (en) * 2011-12-15 2013-08-14 Envirup Ltd Insulation panel with profiled ends for abutment with adjacent panel
GB2499295B (en) * 2011-12-15 2015-02-11 Envirup Ltd Insulation panel and methods

Also Published As

Publication number Publication date
GB8515652D0 (en) 1985-07-24
GB2176745B (en) 1988-12-21
GB8615125D0 (en) 1986-07-23

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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