Beam

Abstract

The beam comprises: an internal strut 102a; and a pair of boards 104 arranged substantially parallel with one another and connected by the internal strut to form a hollow beam. The pair of boards comprises fire-retardant or fire-resistant composite materials. Also defined is a method of forming a hollow beam for interior decoration. The method comprises: coupling each strut of a plurality of struts to a surface of each sheet of a pair of sheets so as to dispose the plurality of struts between the pair of sheets to form a hollow panel. The struts are arranged such that longitudinal axes of the struts are substantially parallel; and cutting the hollow panel in a direction substantially parallel to the longitudinal axis of each strut of the plurality of struts to provides at least one hollow beam.

Description

Field of the Invention The present invention relates to fire-rated construction materials and methods of forming the same. In particular, the present invention related to fire-rated beams for interior decoration. Background of the Invention There is a need for lightweight and fire-rated construction materials to replace timber for non-structural uses such as interior decoration. Existing solutions comprise metal-based products, however these products do not have the same visual appeal as timber and are not preferred by most consumers. Alternative timber products may be considerably heavier and require additional cost in labour and materials to transport and install. Objects and aspects of the present claimed invention seek to alleviate at least these problems with the prior art. Summary of the Invention At its most general, the present invention provides a stable, lightweight and fire-rated beam for use in construction and decoration. By using fire-resistant and / or fire-retardant materials, a superior fire rating of the beam is achieved. By using composite materials, the beam is stable to a range of environmental conditions, e.g., temperature and humidity, and will not warp or twist which may be unattractive and functionally detrimental. By providing a pair of boards, or ‘skins’ separated by struts interspersed with voids such that the beam is hollow, the beam is lightweight and low density yet sturdy. By providing a lightweight beam, support structure or work required to support the beam may be minimal, reducing cost and time of installation. According to a first aspect of the invention, there is provided a hollow, fire-rated beam for interior decoration, the beam comprising: an internal strut; and a pair of boards arranged substantially parallel with one another and connected by the internal strut to form a hollow beam; wherein the pair of boards comprises fire-retardant or fire-resistant composite materials. In some embodiments, the internal strut comprises fire-retardant or fire-resistant composite materials. Fire-resistant materials may be materials that are non-combustible. Such materials may not burn if exposed to fire. Fire-retardant materials may be combustible materials that are treated with a fire-retardant substance. Such a fire-retardant substance may be applied to combustible materials to delay combustion if exposed to fire. Fire-retardant substances may decelerate or inhibit the spread of fire through combustible materials and / or reduce the intensity of a fire through combustible materials. Fire-rated materials may comprise fire-resistant and / or fire-retardant materials. A fire-rated beam may not fail structurally under predetermined conditions, such as a specified heat intensity and exposure time. A fire-rated beam may exhibit a rate of heat transfer through the beam under predetermined conditions, such as a specified heat intensity and exposure time, that falls below a predetermined safe threshold. The fire-rated beam of the present invention may meet EuroClass B in testing and receive a classification of EN13501. The beam may comprise a decorative coating arranged on outer surfaces of the pair of boards. In this way, the composite board may be an attractive decoration option. The decorative coating may be arranged on all outer surfaces of the beam. Accordingly, no bare faces of the beam may be visible and the aesthetic advantage of the beam may be maximised. Further, an interior of the beam may be protected by the coating. Alternatively, the decorative coating may be arranged on some outer surfaces of the beam. In some embodiments, the decorative coating may be arranged on one outer surfaces of the beam. For example, a decorative coating may be arranged on an outer surface of one of the pair of boards of a beam, while no decorative coatings are arranged on all other surfaces of the beam. Decorative coating may be applied to outer surfaces of the pair of boards before assembly with the strut. The decorative coating may be one selected from the group: veneer; laminate; lacquer. The decorative coating may be any suitable coating, e.g., oil, wax oil, varnish or paint. The decorative coating may be a fire-rated laminate. The decorative coating may be a polyvinyl chloride or acrylonitrile butadiene styrene edging. The decorative coating may be relatively thin compared with the boards and so use of a fire-rated decorative coating may not be necessary. The decorative coating may be bonded to the pair of boards using an adhesive. In this way, no fixing mechanism may be visible on the exterior of the beam. The internal strut and the pair of boards may be bonded using an adhesive. In this way, a strength of the bond between the struts and boards may be uniform along the beam. Further, assembly of the beam may be cost-effective and no excess weight is added to the beam. The adhesive may comprise a fire-resistant two-part epoxy. In this way, the adhesive may contribute to the superior fire rating of the beam. The strut and / or the pair of boards may be formed from fire-retardant engineered wood. In this way, the strut and boards may be stable and slow the progress of fire through the beam. The strut and / or the pair of boards may be formed from fire-retardant medium-density fibreboard, in this way, the material of the strut and boards may be uniform to resist warping or twisting. The strut and / or the pair of boards may be formed from fibre-reinforced gypsum. Fibre-reinforced gypsum is generally considered to be fire-resistant. According to a second aspect of the invention, there is provided a method of forming a hollow beam for interior decoration, the method comprising: coupling each strut of a plurality of struts to a surface of each sheet of a pair of sheets so as to dispose the plurality of struts between the pair of sheets to form a hollow panel; wherein the struts are arranged such that longitudinal axes of the struts are substantially parallel; and cutting the hollow panel in a direction substantially parallel to the longitudinal axis of each strut of the plurality of struts to provide at least one hollow beam. The struts and the sheets may be formed of fire-retardant or fire-resistant composite materials. Cutting the hollow panel may comprise making at least three cuts in the hollow panel to provide four hollow beams. In this way, a plurality of beams may be produced from one panel. Cutting the hollow panel may comprise making a cut through a strut. In this case, both cut ends may comprise part of a strut so the resulting beams may have closed ends. This may allow a decorative coating to be applied to the cut end which may be visually appealing. Each strut may be separated from any adjacent strut by a void, wherein a width of the void may be larger than a width of the strut. In this way, the panel and resulting beams may be lightweight and low density. Cutting the hollow panel may comprise making a cut through a void. This may allow a cut to be made more easily as less material is being cut. The plurality of struts may comprise at least seven struts. In this way, when the panel is divided into four beams by three cuts, each beam may comprise a number of struts between 1 and 2. The beams may have an average of 1.75 struts each. This may ensure strength and rigidity of the lightweight beams. In other embodiments, there may be more than seven struts, or fewer than seven struts. Accordingly, when a panel is divided into beams, each beam may comprise a number of struts selected to tune a strength and rigidity of the beam for the beam’s intended purpose. A panel may be divided into any suitable number and configuration of beams in any suitable manner. As an example, a 300 mm wide beam may comprise three struts arranged at a first end, a middle and a second end. Three struts may provide reinforcement to the beam and inhibit a bowing of the boards of the beam in a centre of the width of the beam. The method may further comprise bonding a decorative coating to an outer surface of each sheet of the pair of sheets. This may take place before the panel is cut into beams. In this way, the beam may be adapted for use in a variety of settings. The beam may be decorated according to customer desire or protected according to environmental requirements. For example, a wood veneer may be applied to make the panel appear like wood. Additionally or alternatively, a lacquer may be applied to protect the panel from water ingress. Lacquers may also be used to provide beams in different colours to provide different aesthetic options to the customer. The method may further comprise bonding a decorative coating to an outer surface of each sheet of the hollow beam. The method may further comprise bonding the decorative coating to surfaces of the hollow beam so that all outer surfaces of the beam comprise the decorative coating. This may take place after the panel is cut into beams. In this way all surfaces of the beam may be decorated and / or protected. Brief Description of the Drawings Embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings, in which: Figure 1 depicts a schematic cross-section view of a hollow, fire-rated beam according to an embodiment of the first aspect of the invention; and Figure 2 depicts a schematic cross-section view of a hollow panel according to an embodiment of the second aspect of the invention. Detailed Description With reference to Figure 1, there is provided a schematic cross-section view of a hollow, fire-rated beam 100 for interior decoration. The beam 100 comprises: internal struts 102a, 102b; and a pair of boards 104 arranged substantially parallel with one another and connected by the internal struts 102a, 102b to form a hollow beam; wherein the pair of boards 104 comprises fire-retardant or fire-resistant composite materials. In the embodiment of Fig. 1, the internal struts 102a, 102b also comprise fire-retardant or fire-resistant composite materials. The struts 102a, 102b are separated by a void 106. A first strut 102a is disposed at an end of the pair of boards 104 such that the strut 102a is arranged flush with the end of each board of the pair of boards 104. A second strut 102b is disposed between opposite ends of each board of the pair of boards 104. The second strut 102b is not near an edge of the pair of boards 104. As such, the struts 102a, 102b are arranged asymmetrically with respect to the pair of boards 104. In some embodiments, a groove, or rebate, may be machined into a strut that is disposed at an edge of a pair of boards. Further, the beam 100 comprises a decorative coating 108 arranged on outer surfaces of the pair of boards 104. The decorative coating 108 is arranged on three sides of the beam 100. An open end 110 of the beam 100 is not covered by the decorative coating 108. The open end 110 of the beam 100 may provide a void used during installation of the beam 100. In some embodiments, the open end 110 of the beam 100 may be covered by a decorative coating. The decorative coating 108 and the struts 102a, 102b are bonded to the pair of boards 104 using a fire-resistant two-part epoxy. In some embodiments, a liquid phenol-resorcinol adhesive may be used to bond the struts to the boards. The struts 102a, 102b and the pair of boards 104 may be formed from fire-retardant medium-density fibreboard. In other embodiments, the boards 104 are formed of glass fibre reinforced gypsum and the struts 102a, 102b are formed of wood fibre reinforced gypsum. Accordingly, Figure 1 illustrates a stable, lightweight and fire-rated hollow beam which is avoids warping in response to temperature and humidity changes in normal use. With reference to Figure 2, there is provided a schematic cross-section view of a hollow panel 200 from which hollow beams for interior decoration, such as hollow beam 100, may be formed. The panel 200 comprises a plurality of struts 202 disposed between a pair of sheets 204. Longitudinal axes of each strut 202 are substantially parallel. Voids 212 separate adjacent struts 202 of the panel 200. The voids 212 are wider than the struts 202. In fact, the voids 212 may be twice as wide as the struts 202. In other embodiments, any suitable number of struts and voids and any suitable relative sizes of the struts and voids may be used. During assembly of the struts on the boards, spacers may be used to separate adjacent struts so that a desired size of void is maintained. The spacers may preferably be removed after the struts are secured. An example spacer may measure between 20 mm and 30 mm to provide a void of a similar size between adjacent struts of a beam. In use, to form a hollow beam from the hollow panel 200, the hollow panel is cut in a direction substantially parallel to the longitudinal axis of the struts 202. Cut lines 206, 208, 210 illustrate where cuts are made to form beams from the panel 200. Any suitable tool or machine may be used to cut the panel 200 to forms beams. Computer numerical control (CNC) machines such as a CNC beam saw or CNC router may be used. Alternatively, a hand saw, circular saw, panel saw, or vertical panel saw may be used. In Figure 2, three cuts are used to provide four beams from the panel 200 comprising seven struts 202. Cut lines 206 and 210 pass through the sheets 204 and voids 212. Cut line 208 passes through the sheets 204 and a strut 202. Cut lines 206, 208 and 210 cut the panel into four beam each having an open end, like open end 110 of beam 100, and a closed end, like the opposite end of beam 100 which is closed by strut 102a. Accordingly, each beam cut from the panel 200 may be substantially identical. A central strut may have an increased width compared with other struts so that, when cut in half, each half remains comparable in strength to the other struts. In other embodiments, any suitable number and configuration of beams may be cut from any suitable panel. The struts 202 and sheets 204 may comprise fire-retardant or fire-resistant composite materials. For example, the struts 202 and the sheets 204 may be formed from fire-retardant medium density fibreboard. In another example, the struts 202 and the sheets 204 may be formed of fibre reinforced gypsum. Any suitable combination of materials may be used. The panel further comprises a decorative coating 214 arranged on outer surfaces of the sheets 204. In Figure 2, the decorative coating 214 is not arranged along short sides of the panel 200 to obscure the struts 202. In some embodiments, a decorative coating is arranged along short sides of each beam after being cut from the panel. Further embodiments within the scope of the present invention may be envisaged that have not been described above, for example, the hollow, fire-rated beam may be used for external decoration, as a component of an item of furniture, e.g., a bed frame, or for any suitable other purpose. The hollow, fire-rated beam may achieve its superior fire rating in any suitable manner. The hollow, fire-rated beam and panel may comprise any number of struts and voids. For example, each beam may comprise two struts extending along a full length of the pair of boards. Alternatively, each beam may comprise four struts, each strut extending only partially along each board of the pair of boards. The hollow, fire-rated beam and panel may be decorated with any suitable decorative coating. The components of the hollow, fire-rated beam and panel may be coupled together in any suitable manner. For example, the struts may be connected to the boards or sheets using fasteners such as screws. Prior to cutting the panel into beams, a longitudinal axis of each panel may not be parallel with longitudinal axes of the struts. When a panel is cut into beams, a non-straight cut line may be used. For example, the beams may be cut from the panel so as to comprise a curved or waved edge. The waves may be regular, e.g., sinusoidal, or irregular, e.g., free formed. In this way, unique decorative beams may be provided from a regular panel. To provide a stable, lightweight and fire-rated hollow beam, an innovative design is required. The present invention utilises fire-resistant and fire-retardant materials in an efficient and effective arrangement to provide a superior construction material. The invention is not limited to the specific examples or structures illustrated, a greater number of components than are illustrated in the figures could be used, for example.

Claims

1. A hollow, fire-rated beam for interior decoration, the beam comprising:an internal strut; anda pair of boards arranged substantially parallel with one another and connected by the internal strut to form a hollow beam;wherein the pair of boards comprises fire-retardant or fire-resistant composite materials.

2. The hollow, fire-rated beam according to claim 1, wherein the internal strut comprises fire-retardant or fire-resistant composite materials.

3. The hollow, fire-rated beam according to claim 1 or claim 2, wherein the beam comprises a decorative coating arranged on outer surfaces of the pair of boards.

4. The hollow, fire-rated beam according to claim 3, wherein the decorative coating is arranged on all outer surfaces of the beam.

5. The hollow, fire-rated beam according to claim 3 or claim 4, wherein the decorative coating is one selected from the group: veneer; laminate; lacquer.

6. The hollow, fire-rated beam according to any one of claims 3 to 5, wherein the decorative coating is bonded to the pair of boards using an adhesive.

7. The hollow, fire-rated beam according to any preceding claim, wherein the internal strut and the pair of boards are bonded using an adhesive.

8. The hollow, fire-rated beam according to claim 6 or claim 7, wherein the adhesive comprises a fire-resistant two-part epoxy.

9. The hollow, fire-rated beam according to any preceding claim, wherein the strut and / or the pair of boards are formed from fire-retardant engineered wood.

10. The hollow, fire-rated beam according to claim 9, wherein the strut and / or the pair of boards are formed from fire-retardant medium-density fibreboard.

11. The hollow, fire-rated beam according to any preceding claim, wherein the strut and / or the pair of boards are formed from fibre-reinforced gypsum.

12. A method of forming a hollow beam for interior decoration, the method comprising: coupling each strut of a plurality of struts to a surface of each sheet of a pair of sheets so as to dispose the plurality of struts between the pair of sheets to form a hollow panel;wherein the struts are arranged such that longitudinal axes of the struts are substantially parallel; andcutting the hollow panel in a direction substantially parallel to the longitudinal axis of each strut of the plurality of struts to provide at least one hollow beam.

13. The method of forming a hollow beam for interior decoration according to claim 12, wherein the struts and / or the sheets are formed of fire-retardant or fire-resistant composite materials.

14. The method of forming a hollow beam for interior decoration according to claim 12 or 13, wherein cutting the hollow panel comprises making at least three cuts in the hollow panel to provide four hollow beams.

15. The method of forming a hollow beam for interior decoration according to any one of claims 12 to 14, wherein cutting the hollow panel comprises making a cut through a strut.

16. The method of forming a hollow beam for interior decoration according to any one of claims 12 to 15, wherein each strut is separated from any adjacent strut by a void, wherein a width of the void may be larger than a width of the strut.

17. The method of forming a hollow beam for interior decoration according to claim 16, wherein cutting the hollow panel comprises making a cut through a void.

18. The method of forming a hollow beam for interior decoration according to any one of claims 12 to 17, wherein the plurality of struts comprises at least seven struts.

19. The method of forming a hollow beam for interior decoration according to any one of claims 12 to 18, further comprising bonding a decorative coating to an outer surface of the hollow beam.

20. The method of forming a hollow beam for interior decoration according to claim 19, further comprising bonding the decorative coating to surfaces of the hollow beam so that all outer surfaces of the beam comprise the decorative coating.11

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