WO2014053015A1 - A fire resistant building element - Google Patents

A fire resistant building element Download PDF

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Publication number
WO2014053015A1
WO2014053015A1 PCT/AU2013/001130 AU2013001130W WO2014053015A1 WO 2014053015 A1 WO2014053015 A1 WO 2014053015A1 AU 2013001130 W AU2013001130 W AU 2013001130W WO 2014053015 A1 WO2014053015 A1 WO 2014053015A1
Authority
WO
WIPO (PCT)
Prior art keywords
fire resistant
edging
core
building element
skin layers
Prior art date
Application number
PCT/AU2013/001130
Other languages
French (fr)
Inventor
Mark Winfield
Original Assignee
Paerls Miihome Ip Pty 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
Priority to AU2012904300 priority Critical
Priority to AU2012904300A priority patent/AU2012904300A0/en
Priority to AU2012904358 priority
Priority to AU2012904358A priority patent/AU2012904358A0/en
Application filed by Paerls Miihome Ip Pty Ltd filed Critical Paerls Miihome Ip Pty Ltd
Publication of WO2014053015A1 publication Critical patent/WO2014053015A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92Protection against other undesired influences or dangers
    • E04B1/94Protection against other undesired influences or dangers against fire
    • E04B1/941Building elements specially adapted therefor
    • E04B1/942Building elements specially adapted therefor slab-shaped
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building 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
    • E04C2/284Building 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
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2002/001Mechanical features of panels
    • E04C2002/004Panels with profiled edges, e.g. stepped, serrated

Abstract

A fire resistant building element which includes a core, fire resistant skin layers that extend adjacent opposing sides of the core; and fire resistant edging extending adjacent a single edge of the core between the skin layers.

Description

A FIRE RESISTANT BUILDING ELEMENT

TECHNICAL FIELD

[0001] The present invention relates to a fire resistant building element. The present invention has particular, although not exclusive application to building panels.

BACKGROUND

[0002] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

[0003] It is advantageous to construct buildings such as houses both quickly and using a minimum of materials with a view of reducing costs. Many modern buildings are constructed with prefabricated wall, floor, or roof panels that can be assembled together at the building site.

[0004] Some prefabricated wall panels may define openings such as doorways or windows. In practice, the support beam extending along the upper recesses defined in the serially arranged panels can act as a lintel to provide additional support to wall panel portions proximal to the openings.

[0005] Wall panels formed from lightweight material such as expanded polystyrene (EPS) are advantageously lightweight to facilitate handling during building construction and provide superior insulation and thermal benefits, although they undesirably have a poor fire rating whereby EPS begins to melt when temperatures exceed 120°C. Whilst panels formed from concrete are fire-resistant, they are undesirably heavy, have poor insulation properties, and are difficult to handle.

[0006] Embodiments of the present invention provide a lightweight fire-resistant building panel. SUMMARY OF THE INVENTION

[0007] According to one aspect of the present invention, there is provided a fire resistant building element, the building element including:

a core;

fire resistant skin layers extending adjacent opposing sides of the core; and fire resistant edging extending adjacent a single edge of the core between the skin layers.

[0008] Advantageously, the fire-resistant building element is typically lightweight owing to a lightweight core.

[0009] The edging may extend adjacent one or more edges of the element. The edging may form a complementary fit with the core. The complementary fit may be in the form of a dovetail joint. The edging may extend along a single edge of the core so that when adjacent elements are serially arranged, the core is surrounded by a pair of edgings and the skin layers. The edging may be in the form of an upright post.

[00010] The skin layers may define complementary joints to facilitate serial engagement of adjacent elements. Preferably, the joints overlap so that fasteners can be inserted though pairs of engaging joints to fasten the joints together. Each pair may include male and female joints at opposite ends of a skin layer. The edging may be provided between a pair of female joints of the panel.

[00011] Preferably, the elements are building panels such as wall panels. The core may include polystyrene material, preferably expanded polystyrene (EPS). The skin layers may include metal sheets, preferably integrally formed steel sheets.

[00012] The building element may further include one or more fire resistant shields extending adjacent respective skin layers. Each shield may include a magnesium oxide board or a ceramic or fibreboard, or a layer of material which is the same material as the edging.

[00013] The edging may include any one or more of: glass balls, gypsum, microfibers, resin polymers, wire reinforcing mesh, drying accelerators and pest resistant additives. [00014] The element may further define an edge recess in which wiring, pipes and other services can be provided.

[00015] According to another aspect of the present invention, there is provided a method for manufacturing a fire resistant building element , the element including a core and fire resistant skin layers extending adjacent opposing sides of the core, the method including the steps of:

providing fire resistant edging extending adjacent a single edge of the core between the skin layers.

[00016] The step of providing may involve pouring the edging as a slurry. The method may involve the step of waiting for the slurry to set which advantageously impedes delamination of the skin layers. Prior to the step of providing, the method may further include the step of removing a margin of the core in which the edging is to be provided. The removed margin and provided edging may form a dovetail joint.

[00017] The method may involve the steps of complementarily engaging adjacent elements and fastening the engaged elements together with intrusive fasteners.

BRIEF DESCRIPTION OF THE DRAWINGS

[000 8] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[00019] Figure 1a is a close-up plan view of a pair of building panels about edge joints in accordance with an embodiment of the present invention; and

[00020] Figure 1 b is a zoomed-out plan view of the building panels of Figure 1a. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[00021] According to an embodiment of the present invention, there is provided a pair of interlocking fire-resistant building wall panels 10a, 10b as shown in Figure 1 which together form part of a panel wall. Each wall panel 10 includes an expanded polystyrene (EPS) core 12. A pair of fire-resistant steel-sheet skin layers 14a, 14b extends adjacent opposing side faces of the core 12. Fire-resistant vertical edging 16 extends adjacent the core 12 between the skin layers 14a, 14b. Advantageously, the wall panel 10 is typically lightweight owing to its lightweight core 2 which facilitates handling during building construction. Further, each panel 10 is resistant to the adverse effects of fire including burning (e.g. being non-flammable) or heat (e.g. being an insulator or reflector). A detailed description of the panels 10 is provided below.

[00022] The edging 16 extends adjacent a female edge of each panel 10 which defines a pair of female skin joints 18a, 18b. The edging 16 forms a complementary fit with the core 12 in the form of a dovetail joint 20. As can best be seen in Figure 1b, the edging 16 forms a post extending along a single upright edge of the core 12 so that when adjacent panels 10a, 10b are serially interlocked, the core 12 is surrounded and protected by a pair of edgings 16 and the pair of skin layers 14a, 14b.

[00023] The skin layers 14 define complementary male joints 22a, 22b and female joints 18a, 8b at opposite skin ends to facilitate serial engagement of adjacent panels 10. The joints 18, 22 overlap so that screws can be inserted though pairs of engaging joints 18a, 22a to fasten the joints 18a, 22a together.

[00024] Each panel 10 further includes one or more (and preferably two) fire resistant shields 24 extending adjacent respective skin layers 14. Each shield 24 includes a magnesium oxide board or a ceramic or fibreboard, or a layer of material which is the same or similar material as the edging 16. The edging 16 includes any one or more of: glass balls, gypsum, microfibers, resin polymers, wire reinforcing mesh, drying accelerators and pest resistant additives.

[00025] The panel 10 further defines an edge service recess 26 along the male edge in which wiring and pipes and other services can be provided.

[00026] A method for manufacturing a panel 10 is now briefly described.

[00027] Initially, the core 12 is formed. Opposite margins of the core 12 are removed by cutting or routing to define the dovetail joint 20 for receiving the edging 16, and the service recess 26 for receiving wires and pipes. [00028] The fire resistant skin layers 14a, 14b are bent to form the joints 18, 22 and are bonded to opposing sides of the core 12.

[00029] A fire-resistant slurry is poured into the dovetail joint 20 and sets to form the edging 16. Bonding between the edging 16 and skin layers 14a, 14b owing to the setting slurry impedes delamination of the skin layers 14a, 14b from the core 12. The female joints 18a, 18b are set firm, whereas the male joints 22a,22b have some compliance to facilitate insertion during engagement.

[00030] Adjacent panels 10a, 10b are complementarity engaged together and fastened together with the screws.

[00031] As can best be seen in Figure 1b, the fire resistant edging 16 acts insitu as a structural post 16 within a panel wall at regular intervals along the length of the wall. The structural post 16 remains intact and continues to support axial and lateral building loads under extreme temperatures and for long periods such as in an intense fire event. As previously mentioned, the structural post 16 further prevents the delamination of the panel face skin layers 14a, 14b by way of their secure attachment to the post 16 under the same extreme temperatures. Therefore, after an intense fire event, the cores 12 may melt but the structural performance of the building is not compromised due to the integration of the fire-resistant edging 16 (cast insitu post).

[00032] The preferred embodiment was described in relation to building wall panels. The present invention is also applicable to floor panels, roof panels, panel beams and lintels, stairs and landings and other types of building elements.

[00033] The preferred embodiment was described in relation to building wall panels. The present invention is also applicable to floor panels, roof panels, panel beams and lintels, stairs and landings, and other types of building elements.

[00034] In one embodiment, the edging 16 extends adjacent top, bottom and at least one upright edge of the rectangular core 12 between the skin layers 14a,14b so that the core 12 is completely encapsulated by fire-resistant material when two adjacent panels 10a, 10b are serially connected. [00035] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect.

Claims

The claims defining the invention are as follows:
1. A fire resistant building element, the building element including:
a core;
fire resistant skin layers extending adjacent opposing sides of the core; and fire resistant edging extending adjacent a single edge of the core between the skin layers.
2. A fire resistant building element as claimed in claim 1 , wherein the edging extends along a single edge of the core such that when adjacent elements are serially arranged, the core is surrounded by a pair of edgings and the skin layers.
3. A fire resistant building element as claimed in claim 1 , defining an edge recess in which wiring, pipes and other services can be provided.
4. A fire resistant building element as claimed in claim 1 , further including one or more fire resistant shields extending adjacent respective skin layers.
5. A fire resistant building element as claimed in claim 4, wherein each shield includes a magnesium oxide board, a ceramic, a fibreboard, or a layer of material which is the same material as the edging.
6. A fire resistant building element as claimed in claim 1 , wherein the edging extends adjacent one or more edges of the element.
7. A fire resistant building element as claimed in claim 1 , wherein the edging forms a complementary fit with the core.
8. A fire resistant building element as claimed in claim 7, wherein the
complementary fit is in the form of a dovetail joint.
9. A fire resistant building element as claimed in claim 1 , wherein the edging is in the form of an upright post.
10. A fire resistant building element as claimed in claim 1 , wherein the skin layers define complementary joints to facilitate serial joining of adjacent elements.
11. A fire resistant building element as claimed in claim 10, wherein the joints overlap so that fasteners can be inserted though pairs of engaging joints to fasten the joints together.
12. A fire resistant building element as claimed in claim 10, wherein each pair includes male and female joints at opposite ends of a skin layer.
13. A fire resistant building element as claimed in claim 1 , wherein the edging is provided between a pair of female joints of the panel.
14. A fire resistant building element as claimed in claim 1 , wherein: the core includes polystyrene material; the skin layers include metal sheets; and the edging includes any one or more of: glass balls, gypsum, microfibers, resin polymers, wire reinforcing mesh, drying accelerators and pest resistant additives.
15. A method for manufacturing a fire resistant building element , the element including a core and fire resistant skin layers extending adjacent opposing sides of the core, the method including the steps of:
providing fire resistant edging extending adjacent a single edge of the core between the skin layers.
16. A method as claimed in claim 15, wherein the step of providing involves pouring the edging as a slurry in contact with the skin layers such that the slurry sets to advantageously impede delamination of the skin layers.
17. A method as claimed in claim 15 wherein, prior to the step of providing, the method further includes the step of removing an edging margin of the core in which the edging is to be provided and/or ajservices margin of the core in which wiring, pipes and other services can be provided. 8. A method as claimed in claim 17 wherein the removed edging margin and provided edging form a dovetail joint.
19. A method as claimed in claim 15, further involving the step of complementarily engaging adjacent elements together and fastening the engaged elements together with intrusive fasteners.
20. A method as claimed in claim 15, further involving the step of complementarily engaging adjacent elements together such that the core is surrounded by a pair of edgings and the skin layers.
PCT/AU2013/001130 2012-10-02 2013-10-02 A fire resistant building element WO2014053015A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
AU2012904300 2012-10-02
AU2012904300A AU2012904300A0 (en) 2012-10-02 A Fire Resistant Building Element
AU2012904358 2012-10-05
AU2012904358A AU2012904358A0 (en) 2012-10-05 A Fire Resistant Building Element

Publications (1)

Publication Number Publication Date
WO2014053015A1 true WO2014053015A1 (en) 2014-04-10

Family

ID=50434323

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2013/001130 WO2014053015A1 (en) 2012-10-02 2013-10-02 A fire resistant building element

Country Status (1)

Country Link
WO (1) WO2014053015A1 (en)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20090132246A (en) * 2008-06-20 2009-12-30 (주)케이에스텍 Fire stop panel and cap
US20120040135A1 (en) * 2008-12-04 2012-02-16 Jon Micheal Werthen Sandwich Panel, Support Member for Use in a Sandwich Panel and Aircraft Provided with Such a Sandwich Panel

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20090132246A (en) * 2008-06-20 2009-12-30 (주)케이에스텍 Fire stop panel and cap
US20120040135A1 (en) * 2008-12-04 2012-02-16 Jon Micheal Werthen Sandwich Panel, Support Member for Use in a Sandwich Panel and Aircraft Provided with Such a Sandwich Panel

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