Panel for a firewall

Field of the Invention

[0001] The present invention relates to firewalls and panel joint reinforcements for a firewall.

Background to the Invention

[0002] Firewalls function to prevent the spread of fire from one side of the firewall to the other side thereof. The firewall functions to prevent the collapse of an adjoining building or part of a building and the resulting impacts inevitably caused by such a collapse. Firewalls must meet certain standards regarding official regulations in terms of its fire resistance, for example pursuant to the National Building Code of Finland, Part E1 . One such test set forth in the Building Standards is EN 1363-2: 1999. To meet this test firewalls are predominantly constructed in concrete, necessitating heavy-duty foundations and not enabling a displacement of firewalls, for example upon alteration of use or expansion of the building. EP 2 218 841 B1 presents a relatively light-structured firewall solution, meeting official regulations. A double layered firewall is provided characterized in that the body components forming the panel is fitted with a corrugated steel sheet structure, which covers essentially completely an opening established in the middle of the body component and which extends partially to within vertical profiles connecting horizontal top and bottom profiles. On either side of the corrugated sheet, fire-resistant elements are mounted. These fire resistant elements comprise a core portion of mineral wool and metal places affixed to both of the core portion’s main surfaces. While this panel meets at least the classification of EIM-60 of the National Building Code of Finland, there is a need for a panel which is relatively lighter than the firewall solution proposed in EP 2 218 841 B1.

[0003] A sandwich panel is an assembly consisting of a lightweight core adhered between two relatively thin, strong facing sheets, typically metal, plywood or other lightweight material. A typical sandwich panel is described in EP2 657 426 A2.The core typically comprises polystyrene foam, rigid urethane foam, injected urethane foam or other semi-rigid types. The core may also comprise glass wool fibre, stone wool fibre and the like. Sandwich panels have profiled joints which engage with adjacent panels on assembly as indicated in Figure 1 .

[0004] The sandwich panel 100 has a tongue 102 or male projecting part formed on one longitudinal edge of the panel (for example the upper end in a horizontal arrangement of a plurality of panels) and a groove 101 constructed in the opposing longitudinal end of the panel (for example the lower end in a horizontal arrangement of the plurality of panels). On assembly the tongue 102 of one panel engages with the groove of an adjacent panel along the length of the panel. An example panel may have dimensions for example of 1200mm along a vertical edge and 4000mm along its length.

[0005] In normal fagade configurations additional strengthening of joints and the interaction of the panels and the cooperating joints provide sufficient mechanical resistance. However firewalls increase the need for additional mechanical strength or resistance. Increasing mechanical strength or resistance is achieved by stitching or mounting the firewall panels to the underlying support structure via mechanical fixings such as stitching screws. Stitching screws are inserted through the joint formed by engaged tongue and groves in adjacent panels. These stitching screws mount the sandwich panel to an underlying mounting frame for mounting the fire wall on the relevant structure. These stitching screws reinforce the joint and provide a certain level of mechanical stability. Whilst the facing sheets of the sandwich panel are relatively strong, the steel thickness in such a panel is generally limited to about 0.7 to 0.8mm. This alone does not provide sufficient mechanical strength where the mechanical demands, such as those which result in a fire, are high and accordingly.

[0006] It is therefore desirable to provide an improved firewall assembly which maintains the lightweight aspect of the sandwich panel but which provides an increased mechanical resilience and which preferably meets at least the classification of EIM 120.

Summary of the Invention

[0007] In one aspect, the present invention provides a sandwich panel for a firewall, the sandwich panel comprising an insulating core sandwiched between a first shell element and a second shell element, each shell element comprising a tongue at one end of the panel and a groove at the opposing end of the panel, the tongue configured to co-operate with a groove of a first adjacent sandwich panel to form a first joint and the groove configured to cooperate with a tongue of a second adjacent sandwich panel to form a second joint, and wherein the sandwich panel further comprises: a first reinforcing member engaged with the tongue and a second reinforcing member engaged with the groove at the opposing end of the panel wherein the first and second reinforcing members provide reinforcement of the first and second joints respectively.

[0008] The structure of the sandwich panel provides for a single layer firewall with increased mechanical performance.

[0009] The first shell element and the second shell element may be formed from metal or metal alloy. Examples may be steel, copper, aluminium or the like. The thickness of the shell element may be in the range of 0.4mm to 0.9mm. This provides a self- supporting metal faced sandwich panel.

[0010] The first reinforcing member may comprise a metal plate, optionally a steel plate, or other metal or metal alloy plate.

[0011] The sandwich panel according to any previous claim wherein the second reinforcing member may comprise a metal plate, optionally a steel plate or other metal or metal alloy.

[0012] The first reinforcing member may have a first portion for engaging with the tongue and a second portion which extends a distance beyond the tongue extending into the groove of a cooperating tongue. The reinforcing member may have a U shaped, J shaped, hook shaped, T shapes, Z shaped or S shaped cross-section.

[0013] A plurality of first reinforcing members may be engaged with the tongue along the longitudinal length of the sandwich panel.

[0014] The second reinforcing member may be a planar element.

[0015] The second reinforcing member may have dimensions of approximately 20mm x 2 mm.

[0016] The groove may extend along the length of the sandwich panel and wherein the second reinforcing member extends along the length of the groove.

[0017] The second reinforcing member may comprise one or more reinforcing members.

[0018] The tongue may extend along the length of the sandwich panel and further comprising a third reinforcing member said third reinforcing member engaged with the tongue at the opposing longitudinal ends of the tongue. The third reinforcing member provides additional mechanical resilience for a firewall. The third reinforcing member may replace at least a portion of the first reinforcing member at the opposing longitudinal ends of the tongue. The planar element may be a metal plate. The third reinforcing member may have an approximate width of 50mm, height of 124mm and thickness of 2mm.

[0019] A further embodiment of the invention includes a joint assembly for a firewall comprising at least two sandwich panels each sandwich panel comprising an insulating core sandwiched between a first shell element and a second shell element, each shell element comprising a tongue at one end of the panel and a groove at the opposing end of the panel, the joint assembly comprising: a first reinforcing member engaged with the tongue of the first of the at least two sandwich panels; a second reinforcing member engaged with the groove of the second of the at least two sandwich panels, and a fixing means for stitching the firewall to a support structure, the fixing means arranged to engage the first member and the second reinforcing member, the tongue of the first of the at least two sandwich panels and the groove of the second of the at least two sandwich panels and the support structure said wherein the first and second members and the fixing means reinforce a joint formed by the co-operable engagement of the tongue of a first of the at least two sandwich panels with the groove of a second of the at least two sandwich panels.

[0020] The fixing means may comprise a screw, bolt or other mechanical fixing.

[0021] A plurality of fixing means may be installed along the joint. The plurality of fixing means may be equidistant along the joint.

[0022] The first reinforcing member may comprise a metal plate, optionally a steel plate.

[0023] The second reinforcing member may comprise a metal plate, optionally a steel plate.

[0024] The first reinforcing member may have a first portion for engaging with the tongue of the first sandwich panel and a second portion which extends a distance beyond the tongue extending into the groove of the cooperating second sandwich panel.

[0025] The first reinforcing member may have a U shaped, J shaped, hook shaped, T shapes, Z shaped or S shaped cross-section.

[0026] The distance which the second portion extends beyond the tongue may be approximately 6mm.

[0027] A plurality of first reinforcing members may be engaged with the tongue along the longitudinal length of the sandwich panel.

[0028] The second reinforcing member may be a planar element.

[0029] The second reinforcing member may have dimensions of approximately 20mm x 2 mm.

[0030] The groove extends along the length of the sandwich panel and wherein the second reinforcing member extends along the length of the groove.

[0031] The second reinforcing member may comprise one or more reinforcing members.

[0032] The tongue may extend along the length of the sandwich panel and may further comprise a third reinforcing member said third reinforcing member engaged with the tongue at the opposing longitudinal ends of the joint.

[0033] The joint assembly may further comprise a plurality of fixings for engaging with the third reinforcing member.

[0034] The joint assembly may further comprise a support plate inserted between the plurality of fixings and the joint adjacent the third reinforcing member.

[0035] The planar element may comprise a metal plate.

[0036] The third reinforcing member has an approximate width of 50mm, height of 124mm and thickness of 2mm. [0037] In a further embodiment there comprises a firewall comprising a plurality of sandwich panels each sandwich panel comprising an insulating core sandwiched between a first shell element and a second shell element, each shell element comprising a tongue at one end of the panel and a groove at the opposing end of the panel, the tongue configured to engage with a groove of an adjacent panel of the plurality of sandwich panels and the groove configured to engage with a tongue of a second adjacent panel of the plurality of sandwich panels, the co-operable engagement of the tongues and grooves forming a plurality of joints; and wherein the firewall further comprises

a plurality of first reinforcing members engaged with the tongue of each of the plurality of sandwich panels;

a plurality of second reinforcing members engaged with the groove of each of the plurality of sandwich panels; and

fixing means for stitching the plurality of joints, the fixing means arranged to engage each first reinforcing member and each second reinforcing member with the corresponding joints of the plurality of joints said wherein the first and second members and the fixing means reinforce the corresponding joint.

[0038] The firewall may further comprise a plurality of third reinforcing members, wherein each third reinforcing member may be arranged for engagement with each of the plurality of joints at opposing longitudinal ends of the joint.

[0039] The firewall may further comprise a plurality of fixings for fixing the third reinforcing member to the panel adjacent to the joint.

[0040] The firewall may further comprise a plurality of support plates engaged between the plurality of fixings and the joint.

[0041] The third reinforcing element may comprise a planar element.

[0042] The third reinforcing member may have an approximate width of 50mm, height of 124mm and thickness of 2mm.

Brief Description of the Drawings

[0043] Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings in which:

[0044] Figure 1 is a cross section of a panel joint between two sandwich panels

[0045] Figure 2 is a cross section of a modified panel joint having reinforcements in accordance with the present invention.

[0046] Figure 3 is a vertical cross section of a horizontal panel joint at the longitudinal end of the panel joint in accordance with the present invention [0047] Figure 4 is a further vertical cross sectional view of a horizontal panel joint at the longitudinal end of the panel joint in accordance with the present invention

[0048] Figure 5 is a partial view of two sandwich panels of the present invention in a firewall configuration.

Detailed Description of the Drawings

[0049] Sandwich panels as described above and in particular sandwich panels for use in firewalls must achieve additional mechanical resilience. To date it has not been possible to achieve the desired additional mechanical resilience with single panel fire walls. The sandwich panel 100 comprises an insulating core sandwiched between a first shell element 103 and a second shell element 103. The shell elements can be formed from a metal or a metal alloy, for example, steel, copper, aluminium or the like. The insulating core may be polystyrene foam, rigid urethane foam, injected urethane foam, or other semi-rigid insulating types. Additionally the core may be glass wool fibre, stone wool fibre or other stone wool core. At one end of the panel each shell element comprises a male tongue or protrusion 102. At the opposing end of the panel there is a female indentation or groove 103. The tongue of one panel cooperates with a groove of an adjacent panel to form a joint 105. The tongue and the groove extend along the length of the panel. When the tongue and the groove are cooperating it will be appreciated that the joint extends along the length of the panels. In normal installation these joints are horizontal joints, however the tongue and groove arrangement may be equally used on vertical joints.

[0050] Sandwich panels as described and shown in Figure 1 are generally referred to as self-supporting metal faced panels. The metal may be steel, copper or aluminium. In one configuration steel is used as the shell material. The shell thickness is generally in the range of 0.4 mm to 0.9mm and in one configuration the shell thickness is 0.6mm

[0051] Sandwich panels such as that described above are often used in a standard fagade or internal wall and may meet El 60, 90, 120 and 240 classification, however where additional mechanical resilience is required (EIM classification) stitching screws or other fixings are employed to stitch the joint to the underlying support structure. However to maintain a light weight structure, steel thicknesses in sandwich panels is limited. To increase the joint strength and to withstand mechanical impacts after a fire of two hours, additional reinforcing elements 107 and 108 are employed to reinforce the joints 105. Testing of such resilience in one configuration employs an impact of 200kg in shuttle after 144 minutes. The configuration as described herein passed said testing. These additional reinforcing elements or members strengthen the sandwich panel firewall by transferring the loads from the point of impact, through the joints and to the underlying constructional support frame.

[0052] Two reinforcing members are employed with each joint. A first reinforcing member 108 engaged with the tongue of the sandwich panel. A second reinforcing member 107 engages with the groove of the sandwich panel. The first and second reinforcing members 108 and 107 may be pre-installed in the factory or may be installed on site at the point of assembly of the firewall. The first and second reinforcing members may be a metal or metal alloy plate, such as a steel plate.

[0053] The tongue of the sandwich panel can be formed by an overlap or fold in the shell element forming. The first reinforcing member 108 can be configured to hook or otherwise engage this overlap in the tongue 102 of the sandwich panel. In one configuration the first reinforcing member has a J shaped cross section where the hook on the J engages with the tongue and the upright of the J extends beyond the tongue into the groove 101 of the adjacent panel. In one configuration, but not restricted as such the extension beyond the tongue towards the groove is 6mm. While not shown the first reinforcing member can be a planar element, an S shaped element, a T shaped element, a Z shaped element, a U shaped element or the like.

[0054] Along the length of the tongue a single reinforcing member 108 can be used. Alternatively a plurality of separate reinforcing members can be inserted along the longitudinal length of the tongue at the joint. In a configuration the J shaped members can be for example 20 x 12mm, having a thickness of 1.5mm and a length of 235mm. The J shaped members can abut each other along the length of the tongue or can be separated at a distance from one another.

[0055] The second reinforcing element 107 as shown in figure 2 is a planar element. In one configuration the second reinforcing element comprises a steel plate of 20x2mm and extends along the full length of the panel/groove. The second reinforcing element can be a single piece or a plurality of pieces, for example two pieces inserted from either end of the panel and joined.

[0056] Stitching screws 106 provide additional mechanical strength. The stitching screws engage the second reinforcing member 107, the groove, the cooperating tongue and the first reinforcing member 108. The combination of the first and second reinforcing members with the joint formed by the cooperating tongue and groove and the stitching screws or fixings provide the additional mechanical strength required to achieve the higher mechanical performance required. Stitching screws can be for example fastener type, SFS SX 14/20-S16-5 5x48. These stitching screws lock the metal sheets together. Stitching screws can be positioned at any interval along the length of the joint. In one configuration a distance of 120mm between adjacent stitching screws is implemented however it will be appreciated that it is not restricted as such.

[0057] As shown in figure 3, at the opposing longitudinal ends of the tongue, i.e. at the ends of each panel additional joint support is provided. At the panel ends, support plates 109 are connected through to the support system. Where multiple panels are arranged in a fire wall these additional joint support plates are provided at corners of the panel. To further reinforce the ends of the panels an additional reinforcing member 1 1 1 is inserted into or formed as the male tongue and inserted between the shell element of the panel and the core material. This third reinforcing element can be a planar element, and can be a metal plate or alternative profile. In one configuration the third reinforcing element or member has an approximate width of 50mm, height of 124mm and thickness of 2mm. This embodiment is not restricted as such and the element may extend along the full height of the panel or any portion thereof as shown in Figure 4. This third reinforcing element can be referred to as a joint support steel plate. A plurality of fixings 1 10 are provided for connecting the third reinforcing member/joint support steel plate, the second reinforcing member 107 in the female joint and the support plate 109. The fixings engage the steel plate 109, the second reinforcing member 107 and the third reinforcing member at the joint. Additional fixings or fasteners engage the support plate 109 and the third reinforcing member extending away from the joint 105Fasteners of the type TDBL T-8, 6x16 may be used however it will be appreciated that other fasteners may provide similar engagement functionality. The joint support plates 1 1 1 can be placed in every panel corner at the longitudinal ends of the panel as shown in Figure 5.

[0058] Figure 5 shows an end of the panel with joint support plates 109 and fixings and the reinforced joint with the stitching screws 106. The combination of the first and second reinforcing members and the stitching screws provide a reinforced panel for a firewall which exceeds performance previously possible with single layer fire walls. Combined with the joint support as described in figures 3 and 4, a further performance is achieved and the mechanical and fire resistance of the panel further improved.

[0059] The words“comprises/comprising” and the words“having/including” when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0060] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.