GB2362897A

GB2362897A - A panel and a method

Info

Publication number: GB2362897A
Application number: GB0109353A
Authority: GB
Inventors: Matthew Smyth
Original assignee: SMYTH PLASTICS Ltd
Current assignee: SMYTH PLASTICS Ltd
Priority date: 2000-04-17
Filing date: 2001-04-17
Publication date: 2001-12-05
Also published as: GB0109353D0; GB0009325D0

Abstract

A panel (10) and a method of providing a fire resistant panel (10) are described. The panel (10) has a core (d), and at least one outer face (a, b) which is spaced apart from the core (d) by a spacing means (c) such that fluid can pass through the space. The spacing means (c) is preferably a fabric (c) in which a plurality of threads (5) are arranged substantially perpendicular to the plane of the outer face (a, b) and the sides of the core (d). In the event of fire, the panel (10) resists the passage of heat through the panel (10) due to the presence of the core (d), and also permits heat to spread throughout the gap such that the temperature load generated by the fire is spread over a wider area.

Description

2362897 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 is 16 17 18 19 20 21 22 "Panel

and a Method" The present invention relates to a panel and a method, and more particularly to a fire resistant insulating sandwich panel and a method of providing for a fire resistant insulating sandwich panel.

Conventionally, sandwich panels are used in the construction industry for partitioning, flooring, ceiling, in-fill and cladding, and other uses. Such sandwich panels are normally composed of two skins of material bonded directly to a core. The skins can be formed from a wide variety of materials including steel and plastics, of which there are numerous types, and which provide a hardwearing, protective surface. Cores are generally formed from glass wool or foam, or such similar insulating materials with the objective of minimising heat loss. Such panels are installed in a range of applications due to their lightweight, and consequent ease of handling, low maintenance, high strength, good insulation properties and generally good appearance. End users 2 1 3 4 6 7 8 9 11 12 13 14 16 17 18 19 21 22 23 24 25 26 27 28 29 of such sandwich panels include the construction industry and mass transit industry (rail, road, sea and air) where lower weight provides the resulting advantage that such mass transit vehicles can carry more passengers, cargo and also results in a lower fuel consumption and higher speed.

However, most of these sandwich panels have a disadvantage in that they have a relatively low resistance to fire and consequently high emissions of smoke and toxic fumes which, according to UK Government (Home Office) figures, may result in more fatalities than caused by actual burning of victims.

Fires often start at one point and, due to the heat build up at this point caused in part by the resistance to heat conduction through the panel due to the foam core, the fire actually prepares the adjacent area for ignition, and hence the fire spreads in this manner.

The present invention addresses this problem.

According to a first aspect of the present invention there is provided a panel comprising a core, and at least one outer face which is spaced apart from the core by a spacing means such that fluid can pass therethrough.

According to a second aspect of the present invention 31 there is provided a method of providing a fire 3 1 2 3 4 6 7 8 9 10 11 12 13 14 is 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 resistant panel, the method comprising spacing an outer face apart from a core by use of a spacing means, such that fluid can pass through a gap between the outer face and the core.

Preferably, there are two outer faces provided, typically, one outer face on two sides of the core.

Typically, the core comprises a substantially planar body having a thickness, and the two sides are the relatively large area surfaces of the body.

Preferably, the spacing means comprises a fabric in which a plurality of threads are arranged substantially perpendicular to the plane of the outer face and the sides of the core.

The outer surface of the outer face may have a paint, preferably a fire resistant paint, furnished thereon.

Preferably, the apparatus is arranged such that fluid, which is typically air, can flow through a void arranged between the threads, and defined between the outer surface of the core and the inner surface of the outer face.

Typically, the thickness of the core may range from 5 mm to 80 mm and the thickness of the outer surface may range from 3 mm to 22 mm. Preferably, the core, the spacing means and the outer face(s) are formed from fire resistant materials.

4 1 2 3 4 5 6 7 8 9 10 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Typically, the core is formed from a relatively high strength structural material, and is preferably a phenolic (preferably resin based) syntactic foam. Typically, the spacing means is a three dimensional fabric and is preferably reinforced with phenolic resin. Typically, the outer face(s) is/are a laminate material and is preferably a glass reinforced phenolic material.

Preferably, the panel is arranged such that it substantially fire safe and is also preferably relatively light weight. The panel is typically a thermal insulating panel, and may in the event of fire, resist the passage of heat through the panel due to the high strength phenolic resin based syntactic foam core, but will also preferably permit heat to spread throughout the air voids created by the three dimensional phenolic resin reinforced fabrics skins, thus typically spreading the temperature load over a wider area rather than confining the higher temperatures to the fire source. Typically, the thermal insulation values of the panel are substantial, and preferably sound transmissions through the panel are substantially reduced.

is Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawing, in which:- Fig. 1 is a perspective view of a sandwich panel in accordance with the present invention.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 is 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Fig. 1 shows a sandwich panel generally designated at 10 and which is in accordance with the present invention.

The sandwich panel 10 comprises a core (d), which is preferably a phenolic resin based syntactic foam (d) The core-(d) preferably has the features of being a high strength structural core (d).

As shown in Fig. 1, a three-dimensional fabric (c) which is preferably a phenolic resin reinforced three dimensional fabric (c), is applied to both large area faces of the core (d), such that the strands of the threedimensional fabric (c) project outwardly from the large area faces of the core (d). The three dimensional fabric (c) is preferably secured to the core (d) by any suitable means, such as a bonding agent e.g. adhesive. An outer skin (b) is secured to the outer surface of each respective three dimensional fabric (c), where the outer skin (b) is preferably a glass reinforced phenolic laminate (b), and this is preferably bonded to the outer surface of the three dimensional fabric (c) by any suitable means such as a bonding agent e.g. adhesive.

Preferably, the outer surface of the each respective glass reinforced phenolic laminate (b) is sealed with paint (a), which is preferably a fire resistant paint, or a variety of fire resistant paints, which may be designed to provide a cosmetic benefit without 6 1 2 3 4 6 7 8 9 11 12 13 14 is 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 detracting from the fire performance of the panel. It should be noted that both the core (d) and the three dimensional fabric (c) can be produced in a variety of thicknesses, specifications and density according to the needs of the end user, and in the examples shown in Fig. 1, the thickness range of the three dimensional fabric (c) is maybe from 3mm to 22mm, and the thickness range of the core (d) may be from Smm to 8Omm.

Accordingly, the three dimensional fabric (c) provides an air gap between the network of individual fibres 5, and hence air can flow through the three dimensional fabric (c), that is through the area bounded by the inner surface of each respective glass reinforced phenolic laminate (b) and the respective outer surface of the core (d).

Accordingly, the sandwich panel 10 as a whole has the advantage that phenolic resin based products are difficult to ignite, and during combustion, emit relatively small amounts of smoke and toxic fumes thereby rendering them safe in accidental fires. In addition, the three dimensional fabric (c) provides the benefit that heat from the fire source will travel through the air void, and dissipate over a large area instead of localising at one point and thus minimising the risk of immediate fire spread. A test exists in the marine industry, this being ISO 9705, which illustrates this problem and it is 7 1 believed that the sandwich panel 10 will pass the requirements of this test.

2 3 4 5 Additional advantages in the sandwich panel 10 are that the panel 10 exhibits increased thermal insulation properties due to the presence of the two air gaps created by the three dimensional fabric (c), in addition to the "U" or thermal conductivity value of the core (d) in the form of the phenolic syntactic foam (d). Additionally, the acoustic insulation properties of the sandwich panel 10 are excellent due to the presence of the air gaps provided by the three-dimensional fabrics (c) and the composition of the core (d).

6 7 8 9 10 11 12 13 14 is 16 17 18 Modifications and improvements may be made to the embodiment without departing from the scope of the invention.

8 1 2 3 4 6 7 8 9 10 11 12 13 14 is 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Claims

CLAIMS:

1. A panel comprising a core, and at least one outer face which is spaced apart from the core by a spacing means such that fluid can pass therethrough.

2. A panel according to claim 1, wherein there are two outer faces provided, one outer face being provided on each side of the core.

3. A panel according to claim 2, wherein the core comprises a substantially planar body having a thickness, and the two sides are the relatively large area surfaces of the body.

4. A panel according to either of claims 2 or 3, wherein the spacing means comprises a fabric in which a plurality of threads are arranged substantially perpendicular to the plane of the outer face and the sides of the core.

5. A panel according to any of claims 2 to 4, wherein the outer surface of the outer face comprises a fire resistant paint furnished thereon.

6. A panel according to either of claims 4 or 5 when dependent on claim 4, wherein the apparatus is arranged such that air can flow through a void arranged between the threads, and defined between the outer surface of the core and the inner surface of the outer face.

9 2 3 4 6

7 8 9 11 12 13 14 is 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 7. A panel according to claim 3, or to any of claims 4 to 6 when dependent on claim 3, wherein the thickness of the core is in the range from 5 mm to 80 mm and the thickness of the outer surface is in the range from 3 mm to 22 mm.

8. A panel according to any of claims 2 to 7, wherein the core, the spacing means and the outer faces are formed from fire resistant materials.

9. A panel according to any preceding claim, wherein the core is formed from a relatively high strength structural material.

10. A panel according to any preceding claim, wherein the core is formed from a resin based phenolic syntactic foam.

11. A panel according to claim 4 or to any of claims 5 to 10 when dependent on claim 4, wherein the spacing means is a three dimensional fabric reinforced with phenolic resin.

12. A panel according to any preceding claim, wherein the outer faces are a laminate material.

13.

A panel according to any preceding claim, wherein the outer face is formed from a glass reinforced phenolic material.

14. A method of providing a fire resistant panel, the method comprising spacing an outer face apart from a core by use of a spacing means, such that fluid can pass through a gap between the outer face and the core.

4 6 7 8 9 10 11 12 13 14 is 16 17 18 19 20 21 22

15. A method according to claim 14, wherein the panel formed by the method is a thermal insulating panel.

16. A panel according to either of claims 14 or 15, wherein in the event of fire, the panel resists the passage of heat through the panel due to the presence of the core, and also permits heat to spread throughout the gap such that the temperature load generated by the fire is spread over a wider area.

17. A panel substantially as hereinbefore described with reference to the accompanying drawings.

18. A method substantially as hereinbefore described with reference to the accompanying drawings.