IES69862B2 - A fire-retardant structural panel - Google Patents

Description

A FIRE-RETARDANT STRUCTURAL PANEL The present invention relates to a fire-retardant structural panel having male and female connectors at opposing lateral edges of the panel, the male connector comprising an inverted substantially V-shaped tongue culminating in a substantially open V-shaped tail and the female connector comprising a substantially U-shaped groove culminating in an inverted substantially U-shaped tail so that, in use, the tongue of the male connector of one fire retardant structural panel is located within the groove of the female connector of an adjacent fire retardant structural panel and the substantially open V-shaped tail of the male connector of one fire retardant structural panel is located about the inverted substantially U-shaped tail of the female connector of the adjacent fire retardant structural panel.

Preferably, the fire retardant structural panel comprises a fire retardant filler sandwiched between first and second facing panels, the terminal edges of which panels form inwardly extending pairs of male and female connectors housed in channels formed in the fire retardant filler so that, in use, the tongue of each male connector is located within the groove of a female connector of an adjacent fire retardant structural panel; the substantially open V-shaped tail of each male connector is located about the respective adjacent tails of the female connectors of the adjacent fire retardant structural panel; and a longitudinally extending mouth is formed between adjacent male and female connectors.

More preferably, a fire retardant sealant is provided between facing edges of the fire retardant fillers of adjacent fire retardant structural panels and in the mouth between adjacent male and female connectors.

Advantageously, the fire retardant filler comprises a slab of lamellar mineral wool fibre.

More advantageously, the fire retardant filler is fixed to the first and second facing panels by an adhesive comprising a single component moisture cure polyurethane.

An embodiment of the invention will now be described, with reference to the accompanying drawings, in which: Fig. 1 is an exploded sectional view of part of two fire retardant structural panels according to the present invent ion; Fig. 2 is a sectional view of part of two fire retardant structural panels according to the present invent ion; and Figs. 3-12 are sectional views of an apparatus for forming male and female connectors on a facing panel, for use in the fire retardant structural panel of Figs. 1 and 2.

Referring now to Figs. 1 and 2 of the accompanying drawings, there is illustrated a fire retardant structural panel according to the invention, generally indicated as 10.

The fire retardant structural panel 10 comprises a first facing panel 12 and a second facing panel 14, having a fire retardant filler 16 sandwiched therebetween.

The first and second facing panels 12,14 are each 5 formed from any suitable rigid fire retardant material, for example, steel sheeting. Such steel sheets may, preferably, be 0.55mm thick and, ideally, are coated with a non-scratch finish, for example, hard polyvinyl chlorine (PVC) coating.

The fire retardant filler 16 may be any suitable fire retardant material such as mineral (rock) wool fibres or the like. One such suitable fire retardant material is NEXUS+NXR lamella board supplied by Lamatherm Products Limited, of Forge Factory Estate, Maesteg, Mid Glamorgan, CF34 OAU, England.

This is a fibrous material laid down in layers in an oscillating manner; compressed; cut into lamellar strips, which are then laid down in a criss-cross orientation.

The fire retardant filler 16 is fixed to the first and second facing panels 12,14 using any suitable adhesive. The use of XP1672, a single component moisture cure polyurethane, from Chemique Adhesives and Sealants Limited, of Unit 21 Empire Close, off Brickyard Road, Aldridge, West Midlands WS9 8UR, England, is preferred.

Inwardly extending pairs of male connectors and female connectors, generally indicated as 18 and 20, respectively, are provided at the terminal laterally opposing sides of the first and second facing panels 12,14.

Each male connector comprises an inwardly inclined surface 22; an inverted substantially V-shaped tongue 24 having an outer limb 24a and an inner limb 24b; culminating in a substantially open V-shaped tail 26.

Each female connector 20 comprises an arcuate surface 28; a substantially U-shaped groove 30; culminating in an inverted substantially U-shaped tail 32.

Referring now in particular to Fig. 2 of the accompanying drawings, in use, each tongue 24 is located within the groove 30 of an adjacent fire retardant structural panel 10; the substantially open V-shaped tail 26 is located about the tail 32 of the adjacent fire retardant panel 10; and a longitudinally extending mouth 34 is formed between adjacent fire retardant structural panels 10, the mouth 34 being defined by the inwardly inclined surface 22 of the male connector 18 and the arcuate surface 28 of the adjacent female connector 20.

A fire retardant sealant 40 is provided between facing edges of the fire retardant fillers 16 of adjacent fire retardant structural panels 10 and in the mouth 34 between adjacent male and female connectors 18,20. The use of Flamex One intumescent sealant, which conforms to BS 476 Part 20 1987, is preferred.

Referring now to Figs. 3-12 of the accompanying drawings, there are illustrated stations 1-10 of an apparatus for forming the male and female connectors 18,20 respectively, at terminal laterally opposed sides of the facing panels 12,14.

The male connector 18 is progressively formed at the right hand stations (as illustrated in Figs. 3-12), by feeding the terminal edge of the facing panel 12 or 14 between a series of pairs of rollers 36. In Figs. 3-8 and 11 and 12, the pairs of rollers 36 rotate about an axis parallel to the plane of the facing panel 12 or 14 and, in Figs. 9 and 10, the pairs of rollers 36 rotate about an axis perpendicular to the plane of the facing panel 12 or 14. At stations 1 and 2 (Figs. 3 and 4), the inclined surface 22 is formed. The outer limb 24a of the tongue 24 is formed at stations 3 and 4 (Figs. 5 and 6) ,- the inner limb 24b is formed at stations 5-8 (Figs. 7-10); and the tail 26 is formed at station 8 (Fig. 10). Stations 9 and 10 (Figs. 11 and 12) serve to confirm that the orientation and geometry of the male connector 18 is within the desired specification.

The female connector 20 is simultaneously progressively formed by feeding the other terminal edge of the facing panel 12 or 14 between a series of pairs of rollers 38 (left hand stations as illustrated in Figs. 3-12). In Figs. 3-6 and 10-12, the pairs of rollers 38 rotate about an axis parallel to the plane of the facing panel 12 or 14 and, in Figs. 7-9, the pairs of rollers 38 rotate about an axis perpendicular to the plane of the facing panel 12 or 14. The arcuate surface 28 is formed at stations 1-6 (Figs. 3-8) and, at this time, the groove and tail of the female connector 20 are also being formed. By station 7 (Fig. 9), the substantially U-shaped groove 30 and tail 32 have been formed. Stations 8-10 (Figs. 10-12) serve to confirm that the orientation and geometry of the female connector 20 meet the desired specification.

Fire retardant structural panels 10 according to the invention are then formed in the following manner.

Two table units or gig boards are provided, each with heater tape installed thereon, connected to transformers and operated by a 220 V electrical supply, the heater tapes being heat controlled by thermostats. Each table unit is covered with 4mm aluminium sheeting, in order to uniformly distribute heat for adhesive-cure. The aluminium sheeting is sprayed with a paint finish, in order to protect the PVC lamination on the surface of the facing panel 12 or 14 from marking. The gig bars of the desired thickness of fire retardant structural panel 10 are then placed on a first table unit. In this connection, the normally desired thickness of structural panel 10 would be 100mm or 150mm.

The facing panel 12, having pre-formed male and female connectors 18,20, is then placed on the first table unit, with the PVC lamination face down. A glue applicator then applies the adhesive in bead form onto the upper surface of the facing panel 12. The adhesive applicator is driven by a geared drive rack and pinion system, which runs at a uniform speed so that the adhesive is laid down evenly at 300g/m2. The adhesive applicator also generates a water mist. The fire retardant filler 16 is then positioned on the first facing panel 12 and the adhesive applicator applies a second layer of water mist and adhesive onto the upper surface of the fire retardant filler 16.

The second facing panel 14, with pre-formed male and female connectors 18,20, is then placed on the fire retardant filler 16, with the PVC coating face up. The second table unit is then placed over the panel assembly, which is then subjected to pressure at 5-10psi at a temperature of 20-35°C for 10 minutes, or until the adhesive has cured.

The fire retardant structural panels 10 according to the present invention may be used as ceiling and/or wall panels. It will be appreciated that the provision of facing panels 12,14 and of interconnecting adjacent male and female connectors 18,20 provide structural rigidity.

In addition, the provision of interconnecting male and female connectors 18,20 provides effective fire retardant properties.

Claims (5)

CLAIMS:

1. A fire retardant structural panel having male and female connectors at opposing lateral edges of the panel, the male connector comprising an inverted substantially V-shaped tongue culminating in a substantially open V-shaped tail and the female connector comprising a substantially U-shaped groove culminating in an inverted substantially U-shaped tail so that, in use, the tongue of the male connector of one fire retardant structural panel is located within the groove of the female connector of an adjacent fire retardant structural panel; and the substantially open V-shaped tail of the male connector of one fire retardant structural panel is located about the inverted substantially U-shaped tail of the female connector of the adjacent fire retardant structural panel.

2. A fire retardant structural panel according to claim 1, in which a fire retardant filler is sandwiched between first and second facing panels, the terminal edges of said panels forming inwardly extending pairs of male and female connectors housed in channels formed in the fire retardant filler so that, in use, the tongue of each male connector is located within the groove of a female connector of the adjacent fire retardant structural panel; the substantially open V-shaped tail of each male connector is located about the respective adjacent inverted substantially U-shaped tails of the female connectors of the adjacent fire retardant structural panel; and a longitudinally extending mouth is formed between adjacent male and female connectors.

3. A fire retardant structural panel according to claim 2, in which a fire retardant sealant is provided between facing edges of the fire retardant fillers of adjacent fire retardant structural panels and in the 5 mouth between adjacent male and female connectors.

4. A fire retardant structural panel according to claim 2 or 3, in which the fire retardant filler comprises a slab of lamellar mineral wool fibre.

5. A fire retardant structural panel according to any one of claims 2-4, in which the fire retardant filler is fixed to the first and second facing panels by an adhesive comprising a single component moisture cure 15 polyurethane.