Field of the Invention

The present invention relates to fire protection devices and in particular to a fire resistant barrier.

The invention has been developed primarily for use as a door and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use.

Background

Fire doors are designed and installed in an attempt to protect lives and property from fire, smoke and heat by providing a barrier to withstand the fire, smoke and heat for a period of time. Fire doors are tested by approved Registered Testing Authorities to relevant national testing standards as defined in the Australian Building Code and the Australian Standards. Existing fire doors generally employ mixtures of Vermiculite, mineral fibres, clays and other inert materials in order to achieve superior high-temperature insulation for fireproofing purposes.

However, many materials used in the fire door construction are mined and are therefore subject to various supply problems. Furthermore, these deposits are few and far between, generally being found largely in South Africa, USA and China. As such, a fire door manufacturer must source raw material from various parts of the globe in the construction of fire doors, creating logistics problems.

As such, a need therefore exists for a fire resistant barrier comprising an alternative to existing materials so as to overcome or substantially ameliorate the above and other deficiencies, or to at least provide an alternative.

It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

Summary

The claimed invention seeks to provide a fire resistant barrier which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

According to one aspect, there is provided a fire resistant barrier comprising: at least one insulation layer comprising an engineered wood material; and at least one refractory layer adjacent the at least one insulation layer.

Advantageously, the use of an engineered wood material provides a cost effective alternative to Vermiculite. Engineered wood material is generally readily available in most countries around the world and is not prone to supply issues and price fluctuations. Importantly, engineered word products are manufactured from plantation renewable resources. Furthermore, the thermal properties of the engineered wood material and the refractory layer are sufficient to meet thermal rating standards as required under the testing standards, allowing for fire doors comprising this rating to be manufactured in faster and more cost effectively. Preferably, the at least one refractory layer is two refractory layers, and wherein the at least one insulation layer is disposed between the two refractory layers.

Preferably, the at least one insulation layer is two insulation layers, and wherein the at least one refractory layer is disposed between the two insulation layers.

Advantageously, the fire resistant barrier advantageously comprises thermal resistance and integrity protection from fire sources on either side of the fire resistant barrier. Furthermore, the duplication of layers compliments the thermal resistance and integrity rating of the fire resistant barrier.

Preferably, the engineered wood material has a thermal resistance R- value of greater than 0.44 m ² 'K/(W'in). Advantageously, the high thermal resistance reduces the thermal flux through the fire resistant barrier, thereby slowing the spread of fire.

Preferably, the engineered wood material is substantially moisture resistant.

Advantageously, the egress of water which may affect the thermal resistance of the engineered wood material is prevented. Preferably, the engineered wood material comprises medium density fiberboard.

Advantageously, medium density fiberboard is readily available as a cost effective and lightweight building product.

Preferably, the engineered wood material has a nominal density of between 600kg/m and 700kg/m ³ . Preferably, the refractory material is selected from the set of refractory materials comprising aluminium oxide, silicon oxide and magnesium oxide.

Advantageously, the above oxides exhibit superior characteristics as a refractory material.

Preferably, the fire resistant barrier further comprises at least one skin layer outwardly adjacent of the at least one refractory layer.

Advantageously, the at least one skin layer advantageously provide aesthetic and enhanced thermal resistance properties for the fire resistant barrier. Also, the at least one skin layer provides protection and securement for the at least one refractory layer.

Preferably, the fire resistant barrier further comprises at least one skin layer outwardly adjacent of the at least one insulation layer.

Preferably, the at least one skin layer is two skin layers.

Preferably, the at least one skin layer comprises plywood.

Preferably, the at least one skin layer comprises medium density fiberboard.

Preferably, the fire resistant barrier, further comprises an intumescent firestop portion. Advantageously, the intumescent firestop portion advantageously swells during heat exposure to obstruct one or more airgaps to prevent the spread of fire

Preferably, the intumescent firestop portion is adapted to produce hard char during heat exposure.

Preferably, the fire resistant barrier is substantially planar, and wherein the intumescent firestop portion defines at least one edge of the fire resistant barrier.

Advantageously, during heat exposure, the intumescent firestop portion will extend outwardly from the fire resistant barrier.

Preferably, the fire resistant barrier is shaped and sized for reception within a door frame thereby defining at least one gap therebetween in use, and wherein the intumescent firestop portion is adapted to at least partially fill the at least one gap during heat exposure.

Advantageously, during the event of a fire the intumescent firestop portion is adapted to at least partially fill the at least one gap so as to prevent the spread of fire.

Preferably, the fire resistant barrier is a door, and wherein the intumescent firestop portion is located at an upper edge of the door. Advantageously, as heat rises, the location of the intumescent firestop portion is most suited to prevent the spread of heat.

Preferably, the fire resistant barrier further comprises a second intumescent firestop portion located at a lower edge of the door. Advantageously, the intumescent firestop portion is located to prevent the supply of air to a fire.

Preferably, the at least one refractory layer is adhered to the at least one insulation layer.

Preferably, the at least one refractory layer is fastened to the at least one insulation layer.

Preferably, each of the at least one insulation layer has a nominal thickness of about 9mm. Preferably, each of the at least one insulation layer has a nominal thickness of about 12mm.

Preferably, each of the at least one refractory layer has a nominal thickness of about 9mm.

Preferably, each of the at least one refractory layer has a nominal thickness of about 12mm.

Preferably, the plywood is 3 -ply plywood.

Preferably, the plywood is 6-ply plywood. Other aspects of the invention are also disclosed.

Brief Description of the Drawings

Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Fig. 1 shows a fire resistant barrier in accordance with a preferred embodiment of the present invention;

Fig. 2 shows the fire resistant barrier of Fig. 1 further comprising an intumescent firestop portion in accordance with another preferred embodiment of the present invention; and

Fig. 3 shows the fire resistant barrier of Fig. 1, wherein the fire resistant barrier is shaped and sized for reception within a door frame in accordance with another preferred embodiment of the present invention.

Detailed Description of Specific Embodiments

It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features. Fig. 1 shows a fire resistant barrier 100. The fire resistant barrier 100 comprises at least one insulation layer 105 comprising an engineered wood material and at least one refractory layer 110 adjacent the at least one insulation layer 105.

While the at least one refractory layer 110 may be provided on one side of the fire resistant barrier 100 only, for example for applications directed towards a known fire hazard, in one embodiment, the fire resistant barrier 100 comprises two refractory layers 1 10, the at least one insulation layer 105 being disposed between the two refractory layers 110. In this manner, the refractory layer 110 advantageously comprises thermal integrity protection from fire sources on either side of the fire resistant barrier 100. It should be noted that while the embodiments described in the figures show there being two refractory layers 110 in other embodiments more than two refractory layers 110 may be employed, depending on the application. Similarly, the more than two refractory layers 110 may surround one or more layers comprising engineered wood material for superior thermal resistance. In one embodiment, the fire resistant barrier 100 comprises a refractory layer 110 surrounded by insulation layers 105 on either side. In this manner, during a fire, the insulation layers 105 may be sacrificed by being burnt off, thereby absorbing thermal energy and protecting the refractory layer 110.

In a preferred embodiment, the engineered wood material has a thermal resistance R-value of greater than 0.44 m ^2» K/(W ^» in).

Furthermore, the engineered wood material is substantially moisture resistant so as to prevent the egress of water affecting the thermal resistance of the engineered wood material. In this manner, the at least one insulation layer 105 may be coated with a water impervious coating or treated with water phobic chemicals. The at least one insulation layer 105 is typically made from a non-asbestos material. In one embodiment, the engineered wood material comprises medium density fiberboard and preferably having a nominal density of between 600kg/m 3 and 700kg/m 3.

Turning now to the at least one refractory layer 110, the at least one refractory layer 110 comprises refractory material in one embodiment so as to be able to maintain integrity at high temperatures. The refractory material may be chosen from any suitable refractory material, however in a preferred embodiment, the refractory material is an oxide, such as aluminium oxide, silicon oxide and magnesium oxide.

In a preferred embodiment, the refractory material uses magnesium oxide (MgO), which may be manufactured from non-toxic Magnesium Oxide, Magnesium Chloride, Cellulose, Perlite and other fibrous reinforcement materials to create a homogenous insulator comprising no asbestos, carcinogens or formaldehyde.

Furthermore, the refractory material preferably has a thickness of between 2mm and 22mm, however in other embodiments other thicknesses may be selected depending on the application.

In a further preferred embodiment, the fire resistant barrier 100 further comprises at least one skin layer 115 outwardly adjacent of the at least one refractory layer 110. The at least one skin layer 115 may advantageously provide aesthetic and enhance thermal resistance properties for the fire resistant barrier 100. Also, the at least one skin layer 115 provides protection and securement for the at least one refractory layer 110.

Similarly, while the fire resistant barrier 100 may comprise one skin layer 115, in a preferred embodiment, the at least one skin layer 115 is two skin layers 115 as shown in Fig. 1. In this manner, the each of the two skin layers 115 are outwardly adjacent of a respective one of the two refractory layers 110. Similarly, in a preferred embodiment, the at least one skin layer 115 comprises medium density fiberboard. Further preferably, the at least one skin layer 115 has a thickness of between 2mm and 4mm, but may, depending on the application have differing thicknesses.

Various layer configurations may be used depending on the application. According to preferred embodiments, the fire resistant barrier 100 may be configured for residential purposes wherein the fire resistant barrier 100 has a nominal thickness of about 37mm and commercial purposes wherein the fire resistant barrier 100 has a nominal thickness of about 47mm.

Specifically, a first residential configuration embodiment comprises 3 layers, having a first 12mm thick insulation layer, a second 12 mm refractory layer and a third 12mm insulation layer, providing the fire resistant barrier 100 with a nominal thickness of 37mm. Furthermore, a second residential configuration embodiment comprises 5 layers, having a first 3 -ply plywood layer, a second 9mm thick insulation layer, a third 12 mm refractory layer, a fourth 9mm insulation layer and a fifth 3 -ply plywood layer.

Further, a first commercial configuration embodiment comprises 3 layers, having a first 18mm thick insulation layer, a second 12 mm refractory layer and a third 18mm insulation layer, providing the fire resistant barrier 100 with a nominal thickness of 47mm.

Yet further, a second commercial configuration embodiment comprises 5 layers, having a first 6-ply plywood layer, a second 12mm thick insulation layer, a third 12 mm refractory layer, a fourth 12mm insulation layer and a fifth 6-ply plywood layer. Turning now to Fig. 2, there is shown the fire resistant barrier 100 further comprising an intumescent firestop portion 120. As is shown in the figure, the intumescent firestop portion 120 may be located within a recess at the edge of the fire resistant barrier 100. The intumescent firestop portion 120 advantageously swells during heat exposure to obstruct one or more airgaps to prevent the spread of fire. In one embodiment, the intumescent firestop portion comprises rockwool preferably coated with an intumescent. So as to be adapted for the applications described below, the intumescent firestop portion 120 may be provided with an outer ridged skin, such as by coating or located within a suitable container.

In a preferred embodiment, the intumescent firestop portion 120 is adapted to produce hard char during heat exposure.

In one embodiment, as is shown in Fig. 2, the fire resistant barrier 100 is substantially planar, and wherein the intumescent firestop portion 120 defines at least one edge of the fire resistant barrier 100. In this manner, during heat exposure, the intumescent firestop portion 120 will extend outwardly from the fire resistant barrier 100. Turning now to Fig. 3, there is shown the fire resistant barrier 100 wherein the fire resistant barrier 100 is shaped and sized for reception within a door frame 205. As is shown in Fig. 3 a, the fire resistant barrier 100 defines at least one gap 210 between the fire resistant barrier 100 and the door frame 205. As such, in use, during the event of a fire, as is shown in Fig. 3b, the intumescent firestop portion 120 is adapted to at least partially fill the at least one gap 210 so as to prevent the spread of fire. The intumescent firestop portion 120 is configured such that once expended, the intumescent firestop portion 120 does not exert so much pressure on the door frame such that the door cannot be opened. In one embodiment, the fire resistant barrier 100 may be shaped and configured as a door, and wherein the intumescent firestop portion 120 is located at an upper edge of the door. In other embodiments other intumescent firestop portions 120 may be located at lateral edges of the door depending on the application. For example, in one embodiment, there are provided 3 intumescent firestop portions 120, preferably located on upper and lateral edges of the fire resistant barrier 100. In one particular embodiment, the lateral edges of the fire resistant barrier 100 are provided with wooden strips.

Note that the fire resistant barrier 100 need not only be suited for doorways, and may in alternative embodiments be used in applications such as for windows, ducting, exhausts and the like.

The at least one refractory layer 110 may be adhered to the at least one insulation layer 105 by a suitable adhesive. Preferably, the adhesive comprises a polyurethane based adhesive which may be a moisture-curing, 100% solid, solvent-free, waterproof polyurethane adhesive.

In an alternative embodiment, the at least one refractory layer 110 is fastened to the at least one insulation layer 105 using fasteners such as screws nails and the like. In a yet further embodiment, the fire resistant barrier 100 is provided with an edgewise located strip, the strip comprising inwardly facing walls so as to sandwich the layers and the at least one insulation layer together.

Interpretation

Embodiments:

Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description of Specific Embodiments are hereby expressly incorporated into this Detailed Description of Specific Embodiments, with each claim standing on its own as a separate embodiment of this invention.

Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

Different Instances of Objects

As used herein, unless otherwise specified the use of the ordinal adjectives "first", "second", "third", etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Specific Details

In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

Terminology

In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "forward", "rearward", "radially", "peripherally", "upwardly", "downwardly", and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

Comprising and Including

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

Scope of Invention

Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Industrial Applicability

It is apparent from the above, that the arrangements described are applicable to the fire protection industries.