Field of the invention

The present invention relates to fire-resisting panels. It particularly relates to panels which are suitable for lining the deckheads and bulkheads of vehicle/cargo decks, machinery spaces, aircraft hangers, accommodation spaces, equipment spaces, storage spaces and dangerous/hazardous goods spaces of aluminium, steel and composite ships. Background of the invention

It is known to use fire-resisting composite panels which are a composite a support panel and a combustible, intumescing (expanding), and relatively thin layer of insulation to provide thermal resistance. On exposure to heat, the intumescing material expands, retarding heat transfer. The expansion of the intumescing material on adjacent panels also operates to seal gaps between those panels.

This intumescing insulation is combustible because it includes latex binder, which is essential for keeping the insulation together in its dormant state (prior to the application of heat). This insulation is not rated as "non-combustible'' when tested to ISO (International Organization for Standardization) standard 1182 (Reaction to Fire Tests for Products - Non-Combustibility Test). Failure to meet that non- combustibility test limits the range of sea-going vessels in which it may be used.

Summary of the Invention

In contrast, in one aspect, the present invention provides a fire-resisting panel which comprises:

a relatively thin support structure; with

a relatively thick, non-intumescing, insulation layer adhered to it. It is preferred that the support structure comprises a support panel which is faced on each side with a fibre reinforced plastic sheet.

It is preferred that the support structure comprises a honeycomb core. It is preferred that the honeycomb core is aluminium.

It is preferred that the insulation layer comprises inorganic insulation materials with a binder. It is also preferred that the binder is organic.

It is preferred that the insulation layer is in the range of 20mm to 30mm thick. It is particularly preferred that the insulation layer is approximately 25mm thick.

It is preferred that the fire-resisting panel has been formed by a process in which the insulation layer is adhered to the support structure by applying the insulation layer to an uncured fibre reinforced plastic sheet and then curing the composite panel with heat and under pressure.

It is preferred that a layer of metal foil is adhered to the face of the support structure remote from the insulation layer.

It is preferred that the insulation layer has a low-flame spread barrier adhered to it.

In another aspect, the present invention provides fire-resisting cover strip comprising a channel containing non-intumescing insulation material.

Brief description of the drawings

For a better understanding of the invention, and to show how it may be carried into effect, embodiments of it are shown, by way of non-limiting example only, in the accompanying drawings. In the drawings:

figure 1 is an orthographic projection illustrating a portion of a panel according to a preferred embodiment of the present invention;

figure 2 is a cross-sectional view of the panel of figure 1 ;

figure 3 is an orthographic projection, partially cut away, illustrating aspects of the manufacture of the panel of figure 1 ; and

figure 4 is a cross-sectional view, illustrating aspects of the use of the panel of figure 1. Description of preferred embodiments of the invention

As is most clearly shown in figure 3 a panel 1 according to a preferred

embodiment of the invention comprises a relatively thin support structure 5 with a relatively thick insulation layer 6 adhered to it. The support structure 5 comprises a support panel 2 which is an aluminium honeycomb core which is faced on one side with a fibre reinforced plastic sheet 3 and on the other side with another fibre reinforced plastic sheet 4. The support panel 2 is approximately, but not limited to, 10mm thick. The thickness of the support panels is chosen depending on the level of stiffness/strength required.

The insulation layer 6 comprises inorganic insulation materials with an organic binder. A preferred material for the insulation layer 6 is an alkaline earth silicate paper comprising soluble fibre, periite and organic binder and having a nominal density of about 88kg/m ³ . A suitable material is the "Unifrax FyreWrap Marine Board" product of Unifrax Corporation, of Niagara Falls, NY, USA. The thickness of the insulation layer 6 is approximately, but not limited to, 25mm. The thickness of the insulation layer 6 is chosen, depending on the level of fire resistance required. The insulation layer 6 is adhered to the support structure 5 by applying the insulation panel to the uncured fibre reinforced plastic sheet 4, and then curing the composite panel 1 with heat and under pressure.

It is preferred that a layer of metal foil (which is not illustrated in the drawings) is adhered to the reverse side of the support structure 5. The insulation layer 6 is typically protected by a barrier 7 which has low-flame spread characteristics. This barrier 7 can either be adhered by an additional layer of adhesive, applied between the insulation layer 6 and the barrier. Alternatively, the barrier 7 may have a pre-existing layer of adhesive, in which case it is directly applied to the insulation layer 6. The composite panefs 1 are typically sized so that they are installed in a panel grid of 2400mm x 1200mm (8 feet x 4 feet) centres. 2400mm x 1200mm has been chosen as it is a standard commercial size for wood and metal sheet. Ships are typically constructed with 1200mm frames, so panels that are sized 2400mm x 1200mm will generally line up with these frames. A is illustrated in figure 4, gaps between adjacent panels 1 are sealed by using cover strips 10. Each cover strip 10 comprises a longitudinally-extending channel 8 which has a broad "U-shaped" cross-section, the cross-section being filled with insulating material 9. The insulating material 9 is preferably of the same composition as is the insulation layer 6. Cover strips 10 are manufactured from metal, typically stainless steel of 0.4 to 0.55mm thickness. Strips of steel are roll formed to create a profile which stiffens the section of steel, and has a section for receipt of insulation. The cover strip 0 is typically manufactured in two different lengths, "long" typically 2305mm end to end, and "short" typically 1110mm end to end. Insulation is installed into the cover strips, which is typically 12 to 36mm thick.

Cover strips are installed beiow the corresponding mounting channel 2, and cover the edge of one composite panel 1, the exposed section of channel 12, and the edge of the adjacent composite panel 1. The cover strips are fixed into place typically with machine screws 1 , which are inserted through hole/s in the cover strips and screwed into the threaded insert in the channel. Each cover strip 10 is held in place by a series of bolts or other fasteners 11 which attach to mounting framework 12 and which hold the cover strip in place. The machine screws 11 operate to compress the insulation 9 against the panel 1 to create a fire seal.

While the present invention has been described with reference to a few specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications may occur to those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims.

A reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that the referenced prior art forms part of the common general knowledge, in Australia or elsewhere.

Throughout this specification, the words "comprise", "comprised", "comprising" and "comprises" are to be taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

In the claims, each dependent claim is to be read as being within the scope of its parent claim or claims, in the sense that a dependent claim is not to be interpreted as infringed unless its parent claims are also infringed.