Fire-resistant building panels

Abstract

The fire-resistant structural building panel which comprises an internal rectangular frame which bordering high density thermally insulating material 10. The frame comprises horizontal frame members 1

Description

Field of the invention 5 This invention relates to fire-resistant panels for use in the construction of buildings. More especially the invention concerns fire-resistant structural 10 panels which in use define sections of external walls for use in the construction of housing and industrial units. Background to the Invention 15 Structural panels for use in the construction of both residential and commercial buildings are commonplace. Such panels generally include a core of rigid foam insulating 20 material sandwiched between and adhesively bonded or otherwise secured to inner and outer panels of, for example, plasterboard or wood. Structural panels facilitate inter alia a fast-track building 25 process for residential and commercial buildings with potential cost savings for reason that they are relatively lightweight and simple to erect. However, currently available structural panels have limited 30 ability to act as fire barriers, their resistance to the spread of smoke and fire being in many cases less than ten minutes. 23 05 25 Our UK Patent 2603273B discloses a fire-resistant structural panel for residential and commercial buildings having enhanced resistance to the spread of smoke and fire and the present invention concerns fire resistant structural panels having 5 improved features to those disclosed in this earlier patent. More particularly, the present invention sets out to provide fire resistant building panels which in use define sections of external walls of residential and industrial buildings and which 10 in use define sections of external walls of a building and which have all the advantages of presently available structural panels and which additionally act as effective firebreaks for periods in excess of four hours. 15 Additionally, fire resistant structural panels in accordance with the invention provide enhanced acoustic protection. Statements of the Invention 20 In a preferred aspect, the invention provides a fire-resistant structural building panel which, in use, defines a part of an external wall of a building and which comprises a rectangular frame which borders a quantity of high density thermally 25 insulating material and includes upper and lower generally horizontal frame members each coated on at least one side with a solution including an intumescent material and each connected to generally vertical side frame members also coated on at least one side with a solution which contains an intumescent material 30 and which includes an internal open-ended channel or conduit which extends downwardly from the upper generally horizontal frame member and is dimensioned to receive cabling connectable to a source of electricity; said building panel further comprising a plurality of equally dimensioned sheet members each 23 05 25 coated on at least one side with a solution which includes an intumescent material and each adhered to its neighbouring sheet or sheet members, each sheet member being secured to said frame members and dimensioned to match the dimensions of the 5 rectangular frame along the horizontal sides and one generally vertical side of the frame but to extend beyond the other vertical side of the frame to define a channel open to receive an additional vertical frame member of width and depth substantially equal to the width and depth respectively of the 10 channel, the arrangement being such that, if damaged, one or each outermost sheet member can be removed from the panel and replaced by a fresh sheet member without significant damage to the surface of the underlying panel. 15 Preferably, each sheet member of said panel is coated on at least one side with a solution including an intumescent material. A preferred intumescent containing solution is HW01 as supplied 20 by the Applicant. Typically, the thickness of the panel members is between 10 and 14mm, preferably 12.5mm. 25 Each of the other sheets of the panel preferably comprises plasterboard of thickness between 10mm and 14mm, preferably 12.5mm. The total thickness of the panel is preferably between 120mm and 140mm, preferably 132mm. 30 An additional side frame member may be provided for attachment to said one vertical side frame member for selective location within said channel. 23 05 25 Brief description of the Drawings The invention will now be described by way of example only with reference to the accompanying drawings in which :-5 Figure 1 is a side view of a fire-resistant building panel in accordance with the invention with one external facing sheet removed to show internal features of the panel; 10 Figure 2 is an end view from above of the panel shown in Figure 1; Figure 3 is an end view of adjoining end portions of panels in accordance with the invention which together form sections of 15 an internal wall of a building; Figure 4 illustrates adjoining end portions of panels in accordance with the invention which together define a corner section of a building; and 20 Figure 5 is a side view in section of a central part of a panel in accordance with the invention. 25 Detailed Description of the Invention The structural fire-resistant building panel illustrated in the drawings is intended for use in new and existing buildings to define, in concert with other identical or similar panels, the 30 external walls of rooms and spaces within such buildings. The illustrated building panel comprises a rectangular timber frame 10 which borders sheets 12 of a high density thermally insulating material such as that known as rock-wall 23 05 25 insulation. Typically, the thickness of the insulating material is between 40 and 60mm (preferably 40mm) . The frame 10 comprises upper and lower horizontal elongate timber side members 14a, 14b each coated with a solution which includes an intumescent 5 material, and vertical elongate timber side frame members 16a, 16b also coated with a solution which contains an intumescent material. A suitable coating is the intumescent coating HW01 supplied by 10 the Applicant. Typically, the overall dimension of the frame is 1220mm by 2440mm. 15 As will be seen from Figure 2, the front and rear sides of the panel are covered by panel sheets 18a, 18b each secured to the frame 10 by any conventional means. In use, the panel sheet 18a is positioned on the external face of the panel and the sheet 18b on the internal face of the panel. 20 As will be seen more clearly from Figure 2, the side frame member 16a is spaced inwardly from the adjacent side edges of the panel sheets 18a, 18b to define an open sided channel 20 whose length is equal to the length of an additional side member 22 (see 25 Figure 4) and whose cross section is marginally greater than that of the side member 22 to assist insertion of the side member 22 into the channel 20 when required. As illustrated in Figure 3 of the drawings, the side member 22, 30 in use, is attached to the exposed side surface of the frame member 16b to define a lengthwise extending extension which, when required, defines a close fit within the channel 20 of an adjoining panel. In this way the panels can readily be joined one to each other to define an external wall of a building. Screws 24 are provided to secure the side member 22 within the channel 20. 5 As will be seen from Figure 4, also be positioned within the channel 20 when securing rectangular reinforced corner the additional side member 22 can open side of a panel to close the adjoining panels to define a of a room or space. 10 Turning now to Figure 5 of the drawings, the internal panel sheet 18b comprises an inner lining comprising an OSB panel 26, sheets 28 of plasterboard and a sheet 30 of cement board positioned between the plasterboard sheets 28. 23 05 25 15 Each external panel sheet 18a comprises an inner OSB panel 26, an intermediate lining 32 of silicon cloth and an outer cover sheet of cement board 34. The panel 26 and cover sheet 28 are secured one to another by a suitable adhesive which preferably includes an intumescent material. 20 As will be seen from Figure 1, the panel 10 includes an internal open-ended channel 11 which extends downwardly from the upper end of the frame 10. This channel is dimensional to receive cabling connected to a source of electricity. 25 The panel illustrated is essentially for use in ground floors of buildings. For floors above ground level, the channel will extend over the entire height of the panel. 30 The intumescent content of the panels to act as fire hours, a period of time extinguish a fire. Once the described building panels enables breaks for periods in excess of four normally sufficient to locate and a fire has been extinguished, the LO CXI exposed sheets of any fire affected panels can be readily removed and replaced with fresh cover sheets. It will be appreciated that the foregoing is merely exemplary 5 of fire-resistant panels in accordance with the invention and that modifications can readily be made thereto without departing from the true scope of the invention as set out in the appended claims . 10 23 05 25

Claims

1. A fire-resistant building panel which, in use, defines a 5 part of an external wall of a building and which comprisesa rectangular frame which borders a quantity of high density thermally insulating material and includes upper and lower generally horizontal frame members each coated on at least one side with a solution including an 10 intumescent material and each connected to generallyvertical side frame members also coated on at least one side with a solution which contains an intumescent material and which includes an internal open-ended channel or conduit which extends downwardly from the upper generally 15 horizontal frame member and is dimensioned to receivecabling connectable to a source of electricity; said building panel further comprising a plurality of equally dimensioned sheet members each coated on at least one side with a solution which includes an intumescent material and20 each adhered to its neighbouring sheet or sheet members,each sheet member being secured to said frame members and dimensioned to match the dimensions of the rectangular frame along the horizontal sides and one generally vertical side of the frame but to extend beyond the other vertical25 side of the frame to define a channel open to receive anadditional vertical frame member of width and depth substantially equal to the width and depth respectively of the channel, the arrangement being such that, if damaged, one or each outermost sheet member can be removed from the30 panel and replaced by a fresh sheet member withoutsignificant damage to the surface of the underlying panel.

2. A building panel as claimed in claim 1 wherein each external panel member comprises at least three equally dimensioned23 05 25sheets each coated on at least one side with a solution including an intumescent material.

3. A building panel as claimed in claim 1 or claim 2 wherein 5 each external panel member preferably comprises an innersheet of oriented strand board (OSB) and two sheets of plasterboard.

4. A building panel as claimed in any one of the preceding 10 claims wherein the thickness of sheets is between 10 and14mm.

5. A building panel as claimed in claim 1 wherein said internal open-ended channel extends along the full height of the 15 panel.

6. A building panel as claimed in any one of the proceeding claims wherein an additional side frame member is provided for attachment to one said vertical side frame member for 20 selective location within said channel.

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