Fire panels and methods of assembly

Abstract

Described herein are fire panels configured to integrate together and which connect to a support structure such as a building frame in a manner that may allow for heat generated expansion of the fire panel or parts thereof. Methods of assembling the fire panel are also described. The fire panels and methods may provide a prefabricated consistent size of panel that may connect together strongly and which may address expansion under heat stress, particularly about connection points.

Description

[0001] FIRE PANELS AND METHODS OF ASSEMBLY

[0002] RELATED APPLICATIONS

[0003] This application derives priority from Australia patent application number 2024900058 filed on 10 January 2024 with WIPO DAS code EA20 incorporated herein by reference.

[0004] TECHNICAL FIELD

[0005] Described herein are fire panels and methods of assembly. More specifically, fire panels are described that are configured to integrate with other fire panels and which connect to a support structure in a manner that may allow for heat generated expansion of the fire panel or parts thereof and hence to protect the structure from fire or an explosion. Methods of assembling the fire panels are also described.

[0006] BACKGROUND ART

[0007] Fire walls and ceilings are common where segregation of areas is desired from a fire event. An aim of such fire walls and ceilings is to delay or even prevent fire egress across a space such as between rooms or dwellings and, in doing so, limit or prevent damage caused by a fire, or at least slow the spread of a fire. Fire walls and ceilings or insulated panels may also be used in cabinets or vaults used to house goods, for example hazardous substances.

[0008] Fire walls and ceilings typically comprise a fire retardant material, one example being a cementitious material. Manufacturers may use a variety of additives and components along with cement to form the wall and fire insulating barrier.

[0009] Fire walls and ceilings may be made in situ. Prefabrication of fire walls and ceilings may also be useful to speed installation on site.

[0010] Existing fire panels may be formed from a fire retardant material itself as a panel or by encasing this cementitious material in a structure such as steel.

[0011] These fire panels may be useful however, a weak point for such panels where failure may occur may be about a join between panels. One solution may be to produce ever larger single panels but there may be a practical limit to panel size, if only caused by limitations in what may be handled on site practically and maximum transport size requirements.

[0012] A further problem from fire panels may be caused by movement due to expansion of the fire panel in the event of a fire or explosion. As the fire panel heats up, sometimes to high extremes of temperature, the materials used to manufacture the fire panel will expand. Connection points between the fire panel and a support structure such as framing and connection points between fire panels (if present) will become stressed in the event of expansion and may become a point of failure of the connection and / or the fire panel itself.

[0013] It may be useful to provide a fire panel that may be pre-fabricated and which may address panel joint failure and / or panel expansion and connection stress and failure, or at least to provide the public with a choice.

[0014] Further aspects and advantages of the fire panels and methods of assembly will become apparent from the ensuing description that is given by way of example only.

[0015] SUMMARY

[0016] Described herein are fire panels configured to integrate together and which connect to a support structure such as a building frame in a manner that may allow for heat generated expansion of the fire panel or parts thereof. Methods of assembling the fire panel are also described. The fire panels and methods may provide a prefabricated consistent size of panel that may connect together strongly and which may address expansion under heat stress, particularly about connection points.

[0017] In a first aspect, there is provided a fire panel comprising: a fire retardant material; an enclosure that encloses the fire retardant material therein; and the fire panel having a shape comprising a generally planar front and rear face along with sides and ends; wherein one side or both sides of the fire panel comprise an overlapping member, the overlapping member or overlapping members configured to overlap and abut a surface or surfaces of a further overlapping member or overlapping members of a further fire panel.

[0018] In a second aspect, there is provided a method of assembling multiple fire panels on a support structure by: selecting a first fire panel substantially as described above; fitting the first fire panel to a support structure; and selecting a further fire panel substantially as described above; and fitting the further fire panel to the support structure, wherein, as the further fire panel is fitted, the sides of the first fire panel and the further fire panel are merged together so as to overlap and abut each other.

[0019] In a third aspect, there is provided a fire panel comprising: a fire retardant material; an enclosure that encloses the fire retardant material therein; the enclosure forming the panel shape, the panel shape comprising a generally planar front and rear face along with sides and ends, and wherein the fire panel further comprises an indirect connection assembly configured to connect the fire panel to a support structure, the indirect connection configured to allow movement of the fire panel relative to the support structure.

[0020] In a fourth aspect, there is provided a method of fitting a fire panel to a support structure by: selecting a fire panel substantially as described above; fitting the fire panel to a support structure by: connecting a fastener to the fire panel and a plate, fitting a part of the support structure between the plate and the fire panel, and tightening the fastener to form an indirect connection between the fire panel and the support structure; or connecting a part of the fire panel directly or indirectly to the support structure.

[0021] In a fifth aspect, there is provided a method of forming a fire panel comprising: selecting a fire panel comprising a base tray and top plate substantially as described above; filling the base tray with a fire retardant material; and fitting the top plate to the base tray.

[0022] Advantages of the above fire panels and methods may include one or more of the following:

[0023] The fire panel design allows for pre-fabrication prior to site delivery therefore improving quality, reducing material waste, reducing disruptions of site operations and speeds up installation.

[0024] The way the fire panels connect together means that this potential weakness in fire protection is addressed and is either no longer a point of failure or is only a minor point of failure;

[0025] In addition, the way the fire panels may connect together means that the fire panels may be formed of a consistent size that may be optimised for transport and handling and not governed by the space to which the fire panels may be fitted.

[0026] The lack of use of fasteners about the fire panel joints may avoid risk of stress or heat conductivity through the fastener (if present).

[0027] The fire panel described placement and connection may increase in fire barrier protection. When the fire panel expands as it is heated, a join between the fire panels may abut more closely together as it expands. In addition, the fire panels may be free to slide and move relative to each other as well during expansion, thereby dissipating potential localised stresses. The fire panels may be connected to a supporting structure directly or indirectly. The way the connection is designed may allow the fire panel to expand relative to the connected support structure. This may avoid stress on connections used to connect the fire panel and the support structure. The support structure and the fire panel may, to some extent, slide and move relative to each other.

[0028] The fire panels described may be relocatable, hence not restricted in use to a specific site or location.

[0029] The fire panels provide full protection to the building structure, rather than integrating with it. This has the advantage that, after a fire event, the fire panels can be removed and replaced without disturbing the building structure.

[0030] BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Further aspects of the fire panels and methods will become apparent from the following description that is given by way of example only and with reference to the accompanying drawings in which:

[0032] Figure 1 illustrates a perspective view of a fire panel top plate and base tray;

[0033] Figure 2 illustrates a detail perspective view of an overlapping joint between two fire panels;

[0034] Figure 2A illustrates a section view of a direct fire panel to support structure connection;

[0035] Figure 3 illustrates a detail perspective view of an indirect connection assembly between a fire panel and a support structure;

[0036] Figure 4 illustrates a plan elevation of the bottom tray;

[0037] Figure 5 illustrates a plan elevation of the top plate;

[0038] Figure 6 illustrates a side elevation of the assembled bottom tray and top plate together about line 1 and 2 shown in Figure 4 and Figure 5;

[0039] Figure 7 illustrates a side cross-section elevation of the assembled bottom tray and top plate together about line 1 and 2 shown in Figure 4 and Figure 5;

[0040] Figure 8 illustrates a detail side cross-section elevation from item 3 of Figure 7 of the assembled bottom tray and top plate together;

[0041] Figure 9 illustrates a detail cross-section view of the fire panel connected indirectly to a support structure beam;

[0042] Figure 10 illustrates a perspective view of a wall comprising multiple fire panels from a first angle;

[0043] Figure 11 illustrates a perspective view of the wall above comprising multiple fire panels from a second angle;

[0044] Figure 12 illustrates the above wall in a plan elevation view;

[0045] Figure 13 illustrates a detail plan elevation view about area 4 indicated in Figure 12;

[0046] Figure 14 illustrates a side elevation view of the wall; Figure 15 illustrates a front elevation view of the wall;

[0047] Figure 16 illustrates a graph of average thermocouple temperature as measured during a fire panel trial;

[0048] Figure 17 illustrates a cross-section front elevation of an alternative overlapping fire panel configuration using a fire seal / sealant applied to the abutting surfaces and no fasteners used;

[0049] Figure 18 illustrates a cross-section front elevation of a further alternative overlapping fire panel configuration using a partial fire seal / sealant application to the abutting surfaces, no fasteners used and an interlinking element;

[0050] Figure 19 illustrates a cross-section front elevation of a further alternative overlapping fire panel configuration using overlapping members in a tongue and groove arrangement from each fire panel and where the overlapping members comprise a counter bore / hole and bolt that passes through the bore / hole and fire seal / sealant applied to either side of the joint about the counter bore / hole opening;

[0051] Figure 20 illustrates a cross-section front elevation of a further alternative overlapping fire panel configuration using overlapping members in a tongue and groove arrangement with a threaded hole that receives a fastener therein;

[0052] Figure 21 illustrates a cross-section front elevation of a yet further overlapping member fire panel configuration, in this Figure using 3 or 4mm steel plate to form the tray and top plate and intumescent mastic sealant between all of the abutting surfaces;

[0053] Figure 22 illustrates a cross-section front elevation of a yet further overlapping member fire panel configuration, in this Figure using 3 or 4mm steel plate to form the tray and top plate and intumescent graphite strip located between the abutting surfaces closest to the outer faces of the fire panel;

[0054] Figure 23 illustrates a cross-section front elevation of a yet further overlapping member fire panel configuration, in this Figure using the details as that of Figure 22 but with an elongated overlap (around 3 times longer than that shown in Figure 22); and

[0055] Figure 24 illustrates a cross-section front elevation of a yet further overlapping member fire panel configuration, in this Figure using a Z-shaped base tray and top plate instead of a U-shaped base tray and flat top plate described elsewhere herein.

[0056] DETAILED DESCRIPTION

[0057] As noted above, described herein are fire panels configured to integrate together and which connect to a support structure such as a building frame in a manner that may allow for heat generated expansion of the fire panel or parts thereof. Methods of assembling the fire panel are also described. The fire panels and methods may provide a prefabricated consistent size of panel that may connect together strongly and which may address expansion under heat stress, particularly about connection points.

[0058] For the purposes of this specification, the term 'about' or 'approximately' or 'substantially' and grammatical variations thereof mean a quantity, level, degree, value, number, frequency, percentage, dimension, size, amount, weight or length that varies by as much as 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1% to a reference quantity, level, degree, value, number, frequency, percentage, dimension, size, amount, weight or length.

[0059] The term 'comprise' and grammatical variations thereof shall have an inclusive meaning - i.e. that it will be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components or elements.

[0060] The term 'fire panel' and grammatical variations thereof is used to refer to a panel that may be used on a wall, a ceiling or a floor space. Reference to one or the other should not be seen as limiting.

[0061] A Fire Panel with an Over Lapping Member

[0062] In a first aspect, there is provided a fire panel comprising: a fire retardant material; an enclosure that encloses the fire retardant material therein; and the fire panel having a shape comprising a generally planar front and rear face along with sides and ends; wherein one side or both sides of the fire panel comprise an overlapping member, the overlapping member or overlapping members configured to overlap and abut a surface or surfaces of a further overlapping member or overlapping members of a further fire panel.

[0063] Sides and Ends

[0064] As noted above, the panel shape comprises sides and ends and the sides may comprise an overlapping member.

[0065] The terms 'sides' and 'ends' and grammatical variations thereof are used herein interchangeably but for ease of writing, the overlapping member is written to be on a side or sides of the fire panel. As should be appreciated, the overlapping member (or members) could be on a sides or ends of a panel and reference to one or the other should not be seen as limiting.

[0066] Fire Retardant Material

[0067] As noted, the fire panel may comprise a fire retardant material. Materials of this nature may be cement like or cementitious and include cement along with other materials that together form a fire retardant or fire insulating material.

[0068] The fire retardant material may be formed in to blocks or panel shapes alone but may lack hardness and durability hence the desire to enclose this material within an enclosure made of a different structural material, at least in a prefabricated panel context.

[0069] Many different fire retardant and insulating materials exist and it is envisaged that almost any of these materials may be used to form the fire panels described.

[0070] Note that the fire retardant material used may meet, on its own, fire standards for a fire wall or barrier as may be published and prescribed for applications such as fire walls in buildings or fire and explosion walls for cabinets and vaults. This standard may extend to 240 minutes of fire protection without fire panel degradation and loss of integrity leading to a fire spreading beyond the fire panel.

[0071] Fire Panel and Enclosure Shape and Form

[0072] As noted above, the fire panel comprises an enclosure that encloses the fire retardant material therein. The enclosure may form the panel shape. The panel shape may comprise a generally planar front and rear face along with opposing sides and ends.

[0073] In one example, each fire panel may have a length of up to 5.5m although shorter lengths may also be used as well. This length may be a practical limit set by the length of a container or truck bed used to transport such panels to a site for installation. Theoretically, longer length fire panels may be produced but, 5.5m long provides a compromise between length and transport ease.

[0074] Each fire panel may have a width about each end of around 1150mm. Again, higher or lower widths may be possible however, this width again present a compromise between width and manufacturing and installation ease.

[0075] The enclosure may comprise a base tray and a top plate that connect together to define a volume inside that the fire retardant material is added to.

[0076] The base tray and the top plate may have a geometry that complements and fits together and which defines an interior volume between the base tray and the top plate.

[0077] In one embodiment, the base tray may have a generally planar form with sides and ends extending generally orthogonal to the generally planar form; wherein the sides of the base tray are shaped to form the overlapping members; and the top plate has a generally flat planar shape. This may give the base tray a U-shaped cross-section shape.

[0078] In an alternative embodiment, the base tray and the top plate both have a Z-shaped cross-section shape, the Z-shaped cross-section shape of the base tray and the top plate being configured to complement and fit together.

[0079] Other shapes and forms may also be used and reference to the above configurations should not be seen as limiting. Spacer Members

[0080] Optionally, the base tray and top plate may be held apart via spacer members. Spacer members may provide structural support between the base tray and top plate. Spacer members may take the form of rods or cylindrical tubes with a longitudinal axis extending from one planar face to the opposing planar face of the fire panel corresponding to the base tray and top plate. The spacer members may be located on or about the overlapping member or side(s) of the fire panel.

[0081] Threaded Insert

[0082] Optionally, the fire panel may further comprise at least one threaded insert. The threaded insert(s) may be configured to receive and retain a fastener therein. The fastener may connect the fire panel to a support structure described further below. The threaded insert(s) may be located at the end or the ends of the fire panel. Each end may have multiple threaded inserts. The threaded insert(s) may have an internal thread configured to threadingly connect to a threaded fastener therein.

[0083] This method of connection using threaded inserts and fasteners may not be essential and other methods of connection may be used.

[0084] Overlapping Member(s)

[0085] As noted above, one panel shape side or both panel shape sides comprise an overlapping member configured to overlap and abut a further overlapping member from a further fire panel side.

[0086] The overlapping member or overlapping members of the fire panel when overlapping and abutting a further overlapping member or overlapping members of a further fire panel may form a lap joint or, a tongue and groove connection.

[0087] The overlapping member(s) may further comprise at least one interlinking element. For example, male teeth and female openings that interlink between a part of the overlapping members.

[0088] This overlap between the fire panels was found by the inventors to be very effective at preventing fire egress and damage about joins between fire panels. Traditionally, fire panels are merely abutted about the sides together, or overlapped in their entirety. This method of joining fire panels together does achieve some degree of fire egress but not to an extent that may be desired.

[0089] The overlapping member configuration may comprise in one example an L-shape cross-section with one part of the side of the fire panel protruding beyond the other part to form the L-shape. The further panel may then mate with this lap joint in an overlapping manner to form a lap joint. Other shape crosssections may also be used as noted above and demonstrated further in the Examples below.

[0090] In one example, each fire panel may have a fixed front and rear planar face and the overlapping member on side of the fire panel differs in plane to the opposing side. Multiple fire panels may then fit side to side to form a wall or ceiling of multiple fire panels.

[0091] Alternatively, the fire panels may have a common shape and common sized overlapping members. In this case, each fire panel may be juxtaposed or alternated from front to rear planar face so as to alternate the overlapping members of each fire panel.

[0092] No fasteners may be used between the overlapping members to connect together a fire panel to a further fire panel. This may be useful to increase the speed of construction. The overlapping members in this embodiment may simply abut one another once fitted together in a lap joint arrangement.

[0093] In an alternative embodiment, fasteners may be used to connect the overlapping members of the fire panel and the further fire panel. Fasteners such as screws or bolts may be used about the overlapping members of each fire panel to assist with connection of the fire panels together. In these embodiments, the overlapping members may have a bore / hole and / or thread therein configured to receive a fastener therein.

[0094] The overlapping members of the fire panel and the further fire panel may not be constrained in movement or, may be only partly constrained in movement relative to each other so that the fire panel and the further fire panel move independently due to expansion caused by heating of the fire panel or the further fire panel. The fire panel and the further fire panel may move independently via sliding movement. This lack of constraint in movement may be achieved by not using a fastener about the overlapping members or, for example, by using an oversize hole relative to a fastener diameter and in doing so, providing room for the fastener to move within the hole.

[0095] As noted above, other forms of lap joint may be used. For example, on one fire panel side, two overlapping members may extend about and abut one opposing tongue member in a male / female lap joint fitting. Reference to a single overlapping member on each fire panel side that abuts the other should not be seen as limiting.

[0096] In one example, the overlapping member(s) may have a width sufficient that, the outwardly extending overlapping members of each fire panel when fitted together may result in a uniform overall wall width. The joints between fire panels may sit generally flush so as to form a flush wall face made up of multiple fire panels.

[0097] The geometry of the overlapping member(s) may be varied to suit fabrication needs and fire insulation needs. For example, the length of overlap extending from a side of a fire panel may be shortened or lengthened to increase the surface area of the internal abutting faces of the overlapping members of opposing fire panels. Longer internal abutting faces may be more insulating but also harder to fabricate hence, an optimum geometry is envisaged for desired outcomes and ease of fabrication.

[0098] Fire Seal / Sealant

[0099] As noted above, the overlapping member of one fire panel is configured to abut the overlapping member of a further fire panel. The surfaces of the overlapping members may abut directly. Fire seal or sealant may be located between the abutting surfaces.

[0100] More specifically, fire seal or fire sealant may be located between the surfaces of the overlapping members of the fire panel and the further fire panel when the overlapping members of the fire panel and the further fire panel overlap and abut together.

[0101] Fire seal / sealant may be applied along part of the abutting surfaces. Fire seal / sealant may be applied about an outer face of the fire panels e.g. to plug an opening.

[0102] Fire seal / sealant may be applied partly into the joint formed by the abutting surfaces.

[0103] Fire seal / sealant may be applied along the length of the abutting surfaces of the overlapping members.

[0104] Example fire seal / sealants may be wet fire sealant and / or dry intumescent strip. The fire sealant may be intumescent mastic sealant. The dry intumescent strip may be an intumescent graphite strip. Other fire seals / sealants may also be used.

[0105] The fire seal / sealant may be applied post connection of the fire panels. The fire seal / sealant may be applied prior to connection of the fire panels.

[0106] A Method of Assembling Over Lapping Member Fire Panels

[0107] In a second aspect, there is provided a method of assembling multiple fire panels on a support structure by: selecting a first fire panel substantially as described above; fitting the first fire panel to a support structure; and selecting a further fire panel substantially as described above; and fitting the further fire panel to the support structure, wherein, as the further fire panel is fitted, the sides of the first fire panel and the further fire panel are merged together so as to overlap and abut each other.

[0108] In the above method the overlapping member configuration described elsewhere is formed by fitting together the different overlapping members of the sides of each fire panel as the fire panels are installed.

[0109] A Fire Panel with an Indirect Support Structure Connection

[0110] In a third aspect, there is provided a fire panel comprising: a fire retardant material; an enclosure that encloses the fire retardant material therein; the enclosure forming the panel shape, the panel shape comprising a generally planar front and rear face along with sides and ends, and wherein the fire panel further comprises an indirect connection assembly configured to connect the fire panel to a support structure, the indirect connection configured to allow movement of the fire panel relative to the support structure.

[0111] Indirect Connection Assembly

[0112] As noted, the fire panel and a support structure may be connected together indirectly. In this context, the term 'indirect' refers to the fact that the fire panel and support structure are not directly connected together and instead are connected via a third separate member, the connection assembly. Indirect connection may also be termed 'independent connection' herein.

[0113] Sliding movement

[0114] Due to the indirect connection described, the fire panels may not be constrained in movement about the planar face of the fire panel relative to the support structure. As a result, the fire panel may move independently in the plane of the fire panel planar face relative to the support structure in the event of expansion due to heating of the fire panel, such as, during a fire or explosion. Independent movement may be sliding movement.

[0115] Indirect Assembly

[0116] The indirect connection assembly may in one example comprise a fastener connected to the fire panel and connected to a plate. The plate may extend from the fastener to define a space between the fire panel and the plate. On connection of the indirect connection assembly, a part of the support structure may be sandwiched between the plate and the fire panel by the fastener to form the indirect connection.

[0117] The fastener may extend orthogonally from the fire panel planar face. The fastener may have a shaft that fits through an opening in the plate and which receives a nut or holding part thereon to connect the plate to the fastener.

[0118] A spacer member such as a washer or further plate may be located between the fire panel planar face and the plate to create a gap between the fire panel and the plate. The spacer member may also be threaded on the fastener shaft. The spacer member depth may equate to a desired gap between the fire panel planar face and the plate. This gap may be governed in part by a depth of the support structure to which the fire panel and plate sandwich over. Support Structure

[0119] The support structure may be a frame work such as a building frame work. The frame work may comprise steel beams with flanges e.g. a 'T 'or T cross-section beam, or parallel flange channel. Where the plate is used, the fire panel may sandwich a flange, or part of a flange, from the beam.

[0120] The support structure may instead be framing or other substrates as may be used to form a support structure for walls, ceilings, floors, cabinets, vaults and so on.

[0121] A Method of Fitting a Fire Panel to a Support Structure

[0122] In a fourth aspect, there is provided a method of fitting a fire panel to a support structure by: selecting a fire panel substantially as described above; fitting the fire panel to a support structure by: connecting a fastener to the fire panel and a plate, fitting a part of the support structure between the plate and the fire panel, and tightening the fastener to form an indirect connection between the fire panel and the support structure; or connecting a part of the fire panel directly or indirectly to the support structure.

[0123] A Method of Forming a Fire Panel

[0124] In a fifth aspect, there is provided a method of forming a fire panel comprising: selecting a fire panel comprising a base tray and top plate substantially as described above; filling the base tray with a fire retardant material; and fitting the top plate to the base tray.

[0125] Advantages

[0126] Advantages of the above fire panels and methods may include one or more of the following:

[0127] The fire panel design allows for pre-fabrication prior to site delivery therefore improving quality, reducing material waste, reducing disruptions of site operations and speeds up installation.

[0128] The way the fire panels connect together means that this potential weakness in fire protection is addressed and is either no longer a point of failure or is only a minor point of failure;

[0129] In addition, the way the fire panels may connect together means that the fire panels may be formed of a consistent size that may be optimised for transport and handling and not governed by the space to which the fire panels may be fitted. The lack of use of fasteners about the fire panel joints may avoid risk of stress or heat conductivity through the fastener (if present).

[0130] The fire panel described placement and connection may increase in fire barrier protection. When the fire panel expands as it is heated, a join between the fire panels may abut more closely together as it expands. In addition, the fire panels may be free to slide and move relative to each other as well during expansion, thereby dissipating potential localised stresses. The fire panels may be connected to a supporting structure directly or indirectly. The way the connection is designed may allow the fire panel to expand relative to the connected support structure. This may avoid stress on connections used to connect the fire panel and the support structure. The support structure and the fire panel may, to some extent, slide and move relative to each other.

[0131] The fire panels described may be relocatable, hence not restricted in use to a specific site or location.

[0132] The fire panels provide full protection to the building structure, rather than integrating with it. This has the advantage that, after a fire event, the fire panels can be removed and replaced without disturbing the building structure.

[0133] The embodiments described above may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features.

[0134] Further, where specific integers are mentioned herein which have known equivalents in the art to which the embodiments relate, such known equivalents are deemed to be incorporated herein as if individually set forth.

[0135] WORKING EXAMPLES

[0136] The above described fire panels and methods are now described by reference to specific examples and the following item numbering:

[0137] 1 Fire panel

[0138] 2 Base tray

[0139] 3 Top plate

[0140] 4 End wall

[0141] 5 Side wall

[0142] 6 Enclosure Interior volume

[0143] 7 Rebate / Overlapping members 8 Panel planar front

[0144] 9 Panel planar rear

[0145] 10 Panel sides

[0146] 11 Panel ends

[0147] 12 Rebate abutting surfaces

[0148] 13 Movement direction of the overlapping members

[0149] 15 Openings in top plate

[0150] 16 Interlocking elements, 16A female element, 16B male element

[0151] 17 Fire seal / sealant

[0152] 18 Through bolt / fastener

[0153] 19 Bore / hole

[0154] 20 Spacer members

[0155] 30 Threaded insert

[0156] 40 Indirect connection assembly

[0157] 41 Fastener

[0158] 42 Fastener shaft

[0159] 43 Plate

[0160] 44 Plate lip

[0161] 45 Space between plate and fire panel

[0162] 46 Nut

[0163] 47 Spacer member

[0164] 48 Connection movement

[0165] 50 Fire retardant mixture

[0166] 60 Exterior cladding

[0167] 70 Cladding framing

[0168] 100 Support structure

[0169] EXAMPLE 1

[0170] In this example, a fire panel 1 is described with reference to Figures 1-9. As shown in Figures 1-9, a fire panel 1 is illustrated. The fire panel 1 comprises a base tray 2 and a top plate 3 that connect together to define an enclosure or interior volume 6. The interior volume 6 encloses a fire retardant material 50. The base tray 2 and top plate 3 together form the panel 1 shape, the panel 1 shape comprising a generally planar front and rear face 8, 9 along with sides 10 and ends 11. The base tray 2 / fire panel 1 sides 10 comprise an overlapping member (also termed a rebate herein) 7 that is configured to overlap and abut a further overlapping member 7 from a further fire panel 1 side 10.

[0171] As shown, the base tray 2 has a generally planar form with side walls 5 and end walls 4 extending generally orthogonal to the generally planar form of the base tray 2. The base tray 2 side walls 5 are shaped to form the rebate or overlapping members described 7.

[0172] The top plate 3 has a generally flat planar shape with a relatively thin depth.

[0173] The base tray 2 and top plate 3 are held apart via spacer members 20 located on the rebate 7. The spacer members 20 may be cylindrical tubes as shown with a longitudinal axis extending from one planar face to the opposing planar face of the fire panel 1 corresponding to the base tray 2 and top plate 3. Not shown for clarity is the use of additional spacer members throughout holding the top plate 3 from the base tray 2. These may be located about the internal sides of the planar face regions 8, 9 of the base tray 2 and top plate 3. In this example, the spacer members 20 may be 5-10mm rods spaced at 250- 500mm centres.

[0174] The fire panel 1 has threaded inserts 30 that are threaded and receive and retain a fastener 41 therein. The fastener 41 may connect the fire panel 1 to a support structure 100 described further below. The bushes 30 are located the end or the ends 11 of the fire panel 1.

[0175] The overlapping member 7 configuration or lap joint may comprise an L-shape cross-section best seen in Figure 2 with one part of the side 10 of the fire panel 1 protruding beyond the other part to form the L- shape. A further panel 1 may then mate with this lap joint 7 in an overlapping manner. There may be no fasteners or connections between the lap joints 7 and the fire panels 1 and the fire panel 1 overlapping members 7 may be free to move to some extent relative to each other as shown in arrow direction 13. Alternatively, fasteners or connections may be used (see Figure 2A). In this case, the connection may be but configured so that the fasteners or connections may move to some extent, movement enabled by use of an oversize opening through which the fastener is connected.

[0176] The lap joint 7 described is formed by fitting together the different overlapping members 7 on the sides 10 of each fire panel 1 as the fire panels 1 are installed on a support structure 100.

[0177] The fire panel 1 further may comprise an indirect connection assembly 40 configured to connect the fire panel 1 to the support structure 100. Indirect connection allows for movement of the fire panel 1 relative to the support structure 100 as shown in arrow direction 48. As best seen in Figure 3, the indirect connection 40 may be formed via a fastener 41 connected to the fire panel 1 and connected to a plate 43. The plate 43 may extend to form a lip 44 from the fastener 41 to define a space 45 between the fire panel 1 and plate 43. On connection of the indirect connection assembly 40, a part of the support structure 100 e.g. part of an I beam, is sandwiched between the plate 43 and the fire panel 1 by the fastener 41 to form the indirect connection.

[0178] The fastener 41 has a shaft 42 that fits through an opening in the plate 43 and this receives a nut 46 to connect the plate 43 to the fastener 41. A spacer member 47 is located between the fire panel 1 planar face and the plate 43 to create a gap between the fire panel 1 and the plate 43. The spacer member 47 is also threaded on the fastener 41 shaft 42. The spacer member 47 depth may equate to a desired gap between the fire panel 1 planar face and the plate 43. This gap may be governed in part by a depth of the support structure 100 to which the fire panel 1 and plate 43 lip 44 sandwich over.

[0179] The indirect connection 40 may be assembled by fitting a fire panel 1 to a support structure 100 by connecting the fastener 41 to the fire panel 1 and the plate 43, fitting a part of the support structure 100 between the plate 43 lip 44 and the fire panel 1, and tightening the fastener 41 or nut 46 on the fastener 41 to form an indirect connection between the fire panel 1 and support structure 100.

[0180] EXAMPLE 2

[0181] In this example, a fire panel 1 as used in a wall is described with reference to Figures 10-15.

[0182] As shown in Figure 10-15, the wall comprises, on one side the above described fire panels 1 joined via the lap joints 7 described to form a wider planar wall surface. As shown, the outer face of the fire panel 1 wall may be generally flat the joints only partly visible. The fire panels 1 are connected indirectly as noted above to I-beams which form the main support structure 100. The wall shown also comprises cladding framing 70 ('tophat girts' in this example) and external cladding 60 in the form of Coloursteel™ aluminium cladding.

[0183] The wall illustrated in Figures 10-15 was used as a test rig in a trial to determine the fire rating of the fire panels 1 when linked together and connected to a support structure 100. In the trial, even after 240 minutes of simulated fire burning from a furnace, the wall manufactured from the fire panels 1 showed no sign of damage and no sign of fire egress or spread. The trial outperformed many other designs of fire wall. No buckling or change in external fire wall shape or structure was noted despite expansion having occurred due to the heat from the fire.

[0184] EXAMPLE 3

[0185] In this example a trial of a ceiling manufactured using fire panels was completed.

[0186] In this example, the test structure comprised three 100mm thick fire panels, the fire panels having L- shaped overlapping members that were installed to abut each other. Fire sealant was fitted to the abutting surface opening post installation flush with the panel surfaces. Two beams were attached to the shorter edges of the panels to support the fire panels on the frame. The fire panels were left unconstrained at the other edges. Roofing purlins and roofing cladding was fixed to the beams supporting (above) the fire panels.

[0187] The fire panels were tested in a furnace. The temperature of the non-furnace side of the fire panel wall was measured over time to test the insulation properties of the fire panels.

[0188] The furnace temperature was raised over a time period of 240 minutes, initially quickly to approximately 600°C and then more gradually to a peak of 1200°C.

[0189] As shown in Figure 16, the average temperature on the insulated side of the fire panel wall gradually rose as anticipated from an ambient temperature of 17°C to approximately 120°C after 240minutes.

[0190] Other observations made were that the wall and fire panels maintained structural integrity, insulation, protection of structural members above the membrane after 247 minutes of the trial. The fire resistance level (FRL) was - / 240 / 240.

[0191] EXAMPLE 4

[0192] As noted elsewhere in this specification, the geometry of the overlapping members may vary. This example describes some alternatives with reference to Figures 17 to 24.

[0193] Figure 17 illustrates a cross-section front elevation of an overlapping member 7 fire panel 1 configuration using the lap joint approach described above. In this Figure, a fire seal / sealant 17 is applied to the abutting surfaces 12 of the overlapping members 7. No fasteners are used.

[0194] Figure 18 illustrates a cross-section front elevation of an overlapping member 7 fire panel 1 configuration using a partial fire seal / sealant 17 application to the abutting surfaces 12, no fasteners used and an interlinking element 16. The interlinking element 16 may comprise as shown an extension or male portion 16 B from one overlapping member 7 that interlinks with an opening or female portion 16A of a further overlapping member 7. The fire seal / sealant 17 in this example is only located about the faces 8 of the fire panel 1 and only slightly into the joint itself between the abutting surfaces 12.

[0195] Figure 19 illustrates a cross-section front elevation of an overlapping member 7 fire panel 1 configuration using overlapping members 7 in a tongue and groove arrangement from each fire panel 1 and where the overlapping members 7 comprise a counter bore / hole 19 and bolt 18 that passes through the bore / hole 19. Fire seal / sealant 17 is applied as a plug to either side of the joint about the counter bore / hole 19 opening and which covers the bolt 18 therein.

[0196] Figure 20 illustrates a cross-section front elevation of an overlapping member 7 fire panel 1 configuration using overlapping members 7 in a tongue and groove arrangement with a threaded hole 19 that receives a fastener 18 therein. In this case, each side of the panel 1 comprises two overlapping members 7. Figure 21 illustrates a cross-section front elevation of an overlapping member 7 fire panel 1 using 3mm or 4mm steel plate to form the base tray 2 and top plate 3 and with intumescent mastic sealant 17 between all of the abutting surfaces 12.

[0197] Figure 22 illustrates a cross-section front elevation of an overlapping member 7 fire panel 1 configuration using an intumescent graphite strip 17 located between the abutting surfaces 12 closest to the outer faces 8 of the fire panel 1.

[0198] Figure 23 illustrates a cross-section front elevation of an overlapping member 7 fire panel 1 configuration, using the details as that of Figure 22 but with an elongated overlap (around 3 times longer than that shown in Figure 22). This shows how the dimensions and geometry of the overlapping members 7 may be altered to suit desired fire insulative properties.

[0199] Figure 24 illustrates a cross-section front elevation of an alternative fire panel configuration. In this Figure the base tray 2 and top plate 3 are adjusted in form. The base tray 2 has a Z-shaped cross-section instead of a U-shape cross-section and the top plate 3 has a complementary Z-shaped cross-section instead of a flat shape described elsewhere herein. The resulting Z-shape base tray 2 and top plate 3 may then be connected together to form the panel shape.

[0200] Aspects of the fire panels and methods have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope of the claims herein.

Claims

WHAT IS CLAIMED IS:

1. A fire panel comprising: a fire retardant material; an enclosure that encloses the fire retardant material therein; and the fire panel having a shape comprising a generally planar front and rear face along with sides and ends; wherein one side or both sides of the fire panel comprise an overlapping member, the overlapping member or overlapping members configured to overlap and abut a surface or surfaces of a further overlapping member or overlapping members of a further fire panel.

2. The fire panel as claimed in claim 1 wherein the enclosure comprises a base tray and a top plate that connect together to define a volume inside that the fire retardant material is added to.

3. The fire panel as claimed in claim 2 wherein the base tray and the top plate have a geometry that complements and fits together and which defines an interior volume between the base tray and the top plate.

4. The fire panel as claimed in claim 2 wherein: the base tray has a generally planar form with sides and ends extending generally orthogonal to the generally planar form; wherein the sides of the base tray are shaped to form the overlapping members; and the top plate has a generally flat planar shape.

5. The fire panel as claimed in claim 2 wherein the base tray and the top plate both have a Z-shaped cross-section shape, the Z-shaped cross-section shape of the base tray and the top plate being configured to complement and fit together.

6. The fire panel as claimed in claim 1 wherein the overlapping member or overlapping members of the fire panel when overlapping and abutting a further overlapping member or overlapping members of a further fire panel form a a lap joint or, a tongue and groove connection.

7. The fire panel as claimed in claim 1 wherein the overlapping members further comprise at least one interlinking element.

8. The fire panel as claimed in claim 1 wherein no fasteners are used between the overlapping members to connect together a fire panel to a further fire panel.

9. The fire panel as claimed in claim 1 wherein fasteners are used to connect the overlapping members of the fire panel and the further fire panel.

10. The fire panel as claimed in claim 1 wherein the overlapping members have a hole and / or thread therein configured to receive a fastener therein.

11. The fire panel as claimed in claim 1 wherein the overlapping members of the fire panel and the further fire panel are not constrained in movement or, are only partly constrained in movement relative to each other so that the fire panel and the further fire panel move independently due toexpansion caused by heating of the fire panel or the further fire panel.

12. The fire panel as claimed in claim 11 wherein the fire panel and the further fire panel move independently via sliding movement.

13. The fire panel as claimed in claim 1 wherein fire seal or fire sealant is located between the surfaces of the overlapping members of the fire panel and the further fire panel when the overlapping members of the fire panel and the further fire panel overlap and abut together.

14. A method of assembling multiple fire panels on a support structure by: selecting a first fire panel as claimed in claim 1; fitting the first fire panel to a support structure; and selecting a further fire panel as claimed in claim 1; and fitting the further fire panel to the support structure, wherein, as the further fire panel is fitted, the sides of the first fire panel and the further fire panel are merged together so as to overlap and abut each other.

15. A method of fitting a fire panel to a support structure by: selecting a fire panel as claimed in claim 1; fitting the fire panel to a support structure by: connecting a fastener to the fire panel and a plate, fitting a part of the support structure between the plate and the fire panel, and tightening the fastener to form an indirect connection between the fire panel and the support structure; or connecting a part of the fire panel directly or indirectly to the support structure.

16. A method of forming a fire panel comprising: selecting a fire panel comprising a base tray and top plate as claimed in claim 2; filling the base tray with a fire retardant material; and fitting the top plate to the base tray.

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