GB2600951A - Structural insulated panels - Google Patents

Structural insulated panels Download PDF

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Publication number
GB2600951A
GB2600951A GB2017840.6A GB202017840A GB2600951A GB 2600951 A GB2600951 A GB 2600951A GB 202017840 A GB202017840 A GB 202017840A GB 2600951 A GB2600951 A GB 2600951A
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GB
United Kingdom
Prior art keywords
panel
mineral wool
sheet
silicate mineral
fire
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
GB2017840.6A
Other versions
GB2600951B (en
GB202017840D0 (en
Inventor
Alfred Ward Derek
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.)
Intumescent Systems Ltd
Original Assignee
Intumescent Systems 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 Intumescent Systems Ltd filed Critical Intumescent Systems Ltd
Priority to GB2017840.6A priority Critical patent/GB2600951B/en
Publication of GB202017840D0 publication Critical patent/GB202017840D0/en
Publication of GB2600951A publication Critical patent/GB2600951A/en
Application granted granted Critical
Publication of GB2600951B publication Critical patent/GB2600951B/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • E04C2/296—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 composed of insulating material and non-metallic or unspecified sheet-material
    • 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
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/243—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 one at least of the material being insulating
    • 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
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
    • E04C2/526—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits with adaptations not otherwise provided for, for connecting, transport; for making impervious or hermetic, e.g. sealings
    • E04C2/528—Impervious or hermetic panels not otherwise provided for

Abstract

A fire-resistant insulated panel is disclosed comprising a sheet 16 of compacted inert vitreous silicate mineral wool sandwiched between and adhered to rigid orientated strand boards (OSB) 18 by an intumescent adhesive. Elongate batons 22 (fig.4) may be located around two or more sides of the OSB. One or more of the edges of the panel are covered by strips, sheets, or discrete pieces of graphite cloth. The mineral wool sheet 16 may be between 55 and 65mm thick. The adhesive may be applied to the exposed surface of the mineral wool sheet. A single mineral wool sheet may cover the entire surface of the OSB or there may be a plurality of smaller sheets abutting edgewise. Also disclosed is a building with walls comprising a panel with a compacted inert vitreous silicate mineral wool sandwiched between and adhered to rigid boards by an intumescent adhesive, and a method of making said panel.

Description

STRUCTURAL INSULATED PANELS
Field of the Invention
This invention relates to structural insulated panels. More 5 especially, the invention relates to structural Insulated panels having enhanced fire resistance properties for use in the construction industry. The term "panels" includes wall, ceiling and floor panels and slabs for use, for example, in the construction of buildings such as housing and industrial units. 10 These items are merely indicative of the uses to which insulated panels in accordance with the invention can be put.
In a further aspect, the invention relates to a building whose internal and/or external walls and selected other structural members are produced from structural insulated panel boards in 15 accordance with the invention.
In a still further aspect, the invention relates to a method of producing the aforementioned structural insulated panels.
Background to the Invention
Structural insulated 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, roofs 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, oriented strand board (referred to below as OSD board).
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 and, in many cases, remove or limit the need for scaffolding and similar structures.
However, currently available insulated panels produced from OSP board have limited ability to act as a fire barrier, their 5 resistance to the spread of smoke and fire being in many cases less than 10 minutes.
The present invention sets out to provide a structural insulated panel which has all of the advantages of presently available OSD boards and which additionally acts as an effective fire break for periods in excess of one hour and in many cases for time periods in excess of four hours and more.
Additionally, structural insulated panels in accordance with the invention provide enhanced acoustic protection.
Statements of the Invention
In one aspect, the invention provides a fire resistant insulated panel which comprises a sheet of compacted inert vitreous silicate mineral wool sandwiched between and adhered on one or each side to a rigid oriented strand board by means of an adhesive which intumesces in the presence of fire or excessive heat.
Preferably, the adhesive is applied to each exposed surface of the sheet of compacted inert vitreous silicate mineral wool.
The sheet of compacted inert vitreous silicate mineral wool may comprise a single sheet dimensioned to cover substantially the entire surface of each rigid oriented strand board.
The sheet of compacted inert vitreous silicate mineral wool may comprise a plurality of edgewise abutting smaller sheets of 30 compacted inert vitreous silicate mineral wool which, in use, together cover substantially the entire opposed surfaces of the rigid oriented strand board.
Abutting edges of adjoining sheets of compacted inert vitreous silicate mineral wool may be covered by strips of tape which 5 intumesces in the presence of high temperatures.
Elongate batons may be located around two or more sides of one of the two rigid boards to provide support the other board.
Alternatively, the sheet of compacted inert vitreous silicate mineral wool may comprise a plurality of edgewise abutting smaller sheets of compacted inert vitreous silicate mineral wool which together cover substantially the entire opposed surfaces of the oriented strand boards.
In both cases, the abutting edges of adjoining sheets of compacted inert vitreous silicate mineral wool are preferably 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 adjoining panel boards are preferably covered with tape which preferably includes or is coated with a 20 material which intumesces in the presence of fire or excess heat.
In a preferred embodiment, the core of mineral wool lamellae is adhered to one or each panel by means of an adhesive sealant whose composition includes discrete quantities of trimethoxy(vinyl)silane, propylamine, ethylenediamine, benzene propanoic acid, hydroxyphenyl) propionyl, pentamethyl methyl, dioctyltin oxide and tetraethylorthosilicate.
A preferred adhesive sealant is of a composition which includes discrete quantities of trimethoxy(vinyl)silane, 3- (trimethoxysily1) propylamine; N-(3-(trimexhoxysily1) propyl)ethylenediamine; benzene propanic acid, 3.5-bis(1,1- dimethylethyl)-4-hydroxy-C7-9-branched alkyl esters; alpha-3-(3-(2H-benzotriazol-2-y1)-5-tec-buty1-4-hydroxyphenyl) propionyl-omega-hydroxypoly(oxy-ethlylen), alpha-3-(2H-benzotriazol-2-y1)-5-tert-buty1-4-hydroxyphenyl) propionyl-omega-3(3-(2H-benzo-triazol-2-y1)-5-tert-buty1-4-hydroxyphenyl) propionyloxypoly(oxyethylene); Bis(1.2.2.6.6-pentamethy1-4-piperidyl)sebacate; methyl(1.2.2.6.6.pentamethy1-4-piperidinyl)sebacate; dioctyltin oxide; and tetraethylorthlosilicate.
Such an adhesive sealant is disclosed in the Applicant's co-pending patent application G32015385.4.
The batons may be secured in place using the same adhesive sealant.
The panel boards may, for example, comprise OSD board, 15 plasterboard or plywood.
One or more exposed edges of a fireproofed insulated panel in accordance with this invention and/or one or more joints between adjoining fireproofed insulated panels may be covered and/or sealed with strips, sheets or discrete pieces of graphite cloth.
The batons may be similarly covered.
The thickness of an inert vitreous silicate mineral wool lamellae sheet in accordance with this invention is preferably between 55 and 65mm, typically 60m.
In a further aspect, the invention provides a building whose internal and/or external walls comprise fireproofed insulated panels each of which comprises a rigid sheet of compacted inert vitreous silicate mineral wool sandwiched between and adhered on each side to a rigid panel by an adherent which includes a material which intumesces in the presence of fire and/or excessive heat.
S
In a still further embodiment, the invention provides a method of producing a fire resistant insulated panel which comprises the steps of adhering a sheet of compacted inert silicate mineral wool to a first panel framed on at least two opposite sides by batons of substantially the same thickness as that of the sheet of compacted inert silicate mineral wool, applying adherent including a material which intumesces in the presence of fire or excessive heat over the exposed surface of the sheet of compacted inert silicate mineral wool, and locating a second panel over the exposed surface of the sheet of compacted inert silicate mineral wool with the sides of the panel supported by the batons, each baton being previously coated or covered with an intumescent containing material.
Brief Description of the Drawings
The invention will now be described by way of example only with reference to the accompanying diagrammatic drawings, in which:-Figure 1 is an isometric view from above of a plurality of structural wall panel boards assembled to define external and 20 internal walls of a building under construction; and Figures 2 to 4 illustrate stages during manufacture of a panel board in accordance with the invention.
Detailed Description of the Invention
An assembly of panels to form internal and external structural fireproofed insulated internal walls 10, 12 respectively of a mock-up building is shown in Figure 1.
As will be seen from this Figure, openings 14 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.
Various stages in the construction of a panel in accordance with the invention are illustrated in Figures 2 to 4.
As will be seen from Figures 2 and 3, the illustrated panel comprises a rigid sheet 16 of compacted inert vitreous silicate mineral wool sandwiched between and adhered to a pair of rigid oriented strand (OSD) boards 18 of substantially the same dimensions as those of the sheet 16. The adherent comprises an adhesive which intumesces in the presence of fire or excessive heat, the adhesive being liberally applied to each side of the sheet 16.
As will be seen from Figure 4, the boards 18 are supported along at least two opposite sides by elongate batons 20, these batons being produced from wood or other suitable material and covered by cloth material 22 coated or including an intumescent material.
The number of batons will depend on the intended location of the panel. For example, a panel intended to be located between two adjoining panels may include batons 20 along only its uppermost and lowermost edges, adhesive tape including or coated with an intumescent material being employed to cover the abutting edges of adjoining panels. End panels, on the other hand, may include a baton 20 extending along three or all exposed edge or edges of the panel.
The rigid sheet 16 is adhered to one of the boards 18 by means of an adhesive sealant whose composition includes discrete quantities of trimethoxy(vinyl)silane, propylamine, ethylenediamine, benzene propanoic acid, hydroxyphenyl) 5 propionyl, pentamethyl methyl, dioctyltin oxide and tetraethylorthosilicate.
As already mentioned, such an adhesive is disclosed in the Applicant's co-pending patent application G32015385.4.
Adhesive sealant is then applied to one side of the second board 10 18 and to the exposed surfaces of the batons 20. The second board then positioned onto the covered batons 20 to cover the previously exposed surface of the first board.
Openings 24 are formed in selected panels to accommodate beams, window frames, door frames and the like.
As will be seen from Figure 3, exposed side edges of the board 16 are covered with strips 26 which include or are coated with an intumescent material.
The size and shape of individual panels may vary widely depending on their intended purpose.
When subjected to a fire test, panels in accordance with the invention continued to provide an effective fire break for periods in excess of four hours.
Two specific examples of the construction and assembly of structural fireproofed insulated panel boards in accordance with 25 the invention will now be described.
Example 1
In this example, 1200mm x 600mm x 60mm thick rigid rectangular sheets 16 of compacted inert vitreous silicate mineral wool as supplied, for example, by Rockwall(,) were cut to size and coated with an ablative coating before being adhered by means of Applicant's 5A20 adhesive sealant to one side of one of a pair of 11mm thick rectangular OSB boards 18. Where necessary, the sheets 16 were suitably shaped and dimensioned to ensure that the entire face of the board was covered. Edges between adjoining pieces or sheets were covered with adhesive intumescent tape.
As mentioned, the composition of this adhesive/ sealant includes discrete quantities of trimethoxy(vinyl)silane, propylamine, ethylenediamine, benzene propanic acid, hydroxyphenyl)propionyl, pentamethyl methyl, dioctyltin oxide and tetraethylorthosilicate.
Batons 20 had previously been adhered along three of the four side edges of the board using Applicant's SA20, the 15 corresponding sides of the sheet 16 abutting against these batons.
The exposed fourth side of the sheet 16 was then covered with a suitably dimensioned strip of intumescent coated foam material 26, this extending to the respective side edge of the board.
At this stage the adhered sheets extended over substantially the entire surface of one side of the selected board 18 other than the board surface covered by the batons 22.
The joints between the neighbouring edges of individual sheets 16 and sheet pieces were then covered with strips of adhesive tape including or coated with a material which intumesces in the presence of excess heat caused, for example, in the event of a fire.
Applicant's SA20 adhesive was then applied to the exposed surface of the completed adhered sheet 16 and a second OSB board 30 18 of the same dimensions as those of the first board was placed over the coated surface of the first board and the batons 20 to complete the panel.
Panels in accordance with the invention can subsequently be cut and shaped in the same way as existing building materials to define, for example, openings 24 such as that illustrated in the drawings for receiving and supporting beams, and window and door frames. Exposed edges of cut panels are covered with strips of cloth 22 or other material coated or including a material which intumesces in the presence of fire or excessive heat.
When subjected to a fire test, the panel continued to provide an effective fire break for a period in excess of four hours.
Example 2
This second example concerns the production of an internal wall 15 panel for residential or other buildings.
In this example, the production process described above was followed with the exception that the second board comprised a sheet of plaster board. As for the external wall panel of Example 1, when subjected to a fire test, the internal panel 20 continued to provide an effective fire break for a period in excess of four hours.
In use the internal panel boards are assembled as shown for example in the appended drawings. It will be noted that openings are formed in panels where appropriate to accommodate beams and 25 other building structures.
It will be appreciated that the foregoing is merely exemplary of panel boards in accordance with the invention and that modifications can readily be made thereto without departing from the true scope of the invention as expressed in the appended claims.

Claims (14)

  1. CLAIMS1. A fire resistant insulated panel which comprises a sheet of compacted inert vitreous silicate mineral wool sandwiched between and adhered on one or each side to a rigid oriented strand board by an adhesive which intumesces in the presence of fire or excessive heat.
  2. 2. A panel as claimed in claim 1 wherein the adhesive is applied to each exposed surface of the sheet of compacted inert vitreous silicate mineral wool
  3. 3. A panel as claimed in any one of the preceding claims wherein the sheet of compacted inert vitreous silicate mineral wool comprises a single sheet dimensioned to cover substantially the entire surface of each rigid oriented strand board.
  4. 4. A panel as claimed in claim 1 and claim 2 wherein the rigid sheet of compacted inert vitreous silicate mineral wool comprises a plurality of edgewise abutting smaller sheets of compacted inert vitreous silicate mineral wool which in use, together cover substantially the entire opposed surfaces of the boards.
  5. S. A panel as claimed in any one of the preceding claims wherein abutting edges of adjoining sheets of compacted inert vitreous silicate mineral wool are covered by strips of tape which intumesce in the presence of fire and/or high temperatures.
  6. 6. A panel as claimed in any one of the preceding claims wherein elongate batons are located around two or more sides of one of the rigid boards to provide support for the other rigid board.
  7. 7. A panel as claimed in any one of the preceding claims wherein abutting edges of adjoining sheets of compacted inert vitreous silicate mineral wool are covered by strips of tape which include or are coated with a material which intumesces in the presence of fire or high temperatures.
  8. 8. A panel as claimed in any one of the preceding claims wherein the sheet of mineral wool lamellae is adhered to the external boards of rigid material by means of an adhesive sealant whose composition includes discrete quantities of trimethoxy(vinyl)silane, propylamine, ethylenediamine, benzene propanoic acid, hydroxyphenyl) propionyl, pentamethyl methyl, dioctyltin oxide and tetraethylorthosilicate.
  9. 9. A panel as claimed in claim 7 wherein the adhesive has a composition which includes discrete quantities of trimethoxy(vinyl)silane, 3-(trimethoxysily1) propylamine; N-(3-(trimethoxysily1) propyl)ethylenediamine; benzene propanic acid, 3.5-his(1,1-dimethylethyl)-4-hydroxy-C7-9- branched alkyl esters; alpha-3-(3-(2H-benzotrlazol-2-y1)- 5-tert-buty1-4-hydroxyphenyl)proplonyl-omega- hydroxypoly(oxy-ethlylen), alpha-3-(2H-benzotriazol-2- y1)-5-tert-buty1-4-hydroxyphenyl)propionyl-omega-3(3- (2Hbenzo-trlazol-2-y1)-5-tert-buty1-4-hydroxyphenyl)propionyloxypoly (oxyethylene); Bis(1.2.2.6.6-pentamethy1-4-piperidyl)sebacate; methyl(1.2.2.6.6.pentamethy1-4-piperidinyl)sebacate; dioctyltin oxide; and tetfaethylorthlosilicate.
  10. 10. A panel as claimed in any one of the preceding claims wherein one or more edges of the panel and/or one or more joints between adjoining panels are covered by strips, sheets or discrete pieces of graphite cloth.
  11. 11. A panel as claimed in any one of the preceding claims wherein the thickness of the inert vitreous silicate mineral wool lamellae slab is between 55 and 65mm,
  12. 12. A panel as claimed in claim 9 wherein the thickness is 6 Omra
  13. 13. A building whose internal and/or external walls are produced from fire resistant insulated panels each of which comprises a sheet of compacted inert vitreous silicate mineral wool sandwiched between and adhered on each side to a rigid board by an adhesive which includes or comprises a material which intumesces in the presence of fire or excessive heat.
  14. 14. A method of producing a fire resistant insulated panel which comprises the steps of applying a co=ing of an adhesive which comprises or includes a substance which intumesces in the presence of fire and/or excessive heat to one side of a sheet of compacted inert silicate mineral wool, adhering said sheet of compacted inert mineral wool to one side of a first board framed on at least two opposite sides by batons of substantially the same thickness as that of the sheet of compacted inert silicate mineral wool, applying a coating of an adhesive which comprises or includes said substance which intumesce in the presence of fire or excessive heat to the other side of the sheet of compacted inert silicate mineral wool, and locating a second board over said other side of the sheet of compacted inert silicate mineral wood with the sides of the second board supported by the batons, each baton being covered or coated with a substance or material which intumesces in the presence of fire or excessive heat.
GB2017840.6A 2020-11-12 2020-11-12 Structural insulated panels Active GB2600951B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
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Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB2017840.6A GB2600951B (en) 2020-11-12 2020-11-12 Structural insulated panels

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GB202017840D0 GB202017840D0 (en) 2020-12-30
GB2600951A true GB2600951A (en) 2022-05-18
GB2600951B GB2600951B (en) 2023-09-06

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1477658A (en) * 1974-10-08 1977-06-22 Ici Ltd Laminates
WO1986000915A1 (en) * 1984-07-26 1986-02-13 Dixon International Limited Adhesive or cement
US20090007513A1 (en) * 2007-02-27 2009-01-08 International Resin S.A. Fire resistant and intumescent laminate, useful as a vapor barrier in wood and steel constructions

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1477658A (en) * 1974-10-08 1977-06-22 Ici Ltd Laminates
WO1986000915A1 (en) * 1984-07-26 1986-02-13 Dixon International Limited Adhesive or cement
US20090007513A1 (en) * 2007-02-27 2009-01-08 International Resin S.A. Fire resistant and intumescent laminate, useful as a vapor barrier in wood and steel constructions

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Publication number Publication date
GB2600951B (en) 2023-09-06
GB202017840D0 (en) 2020-12-30

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