A FIRE RETARDING PANEL

Field of the Invention

This invention relates to a fire retarding panel and in particular to a panel for forming or making a fire wall.

Summary of the Invention

According to the invention, there is provided a fire retarding panel including: first and second layers which are formed from a fire retarding material; and a separator layer formed from a material that inhibits the passage of fluid therethrough, the separator layer being arranged to separate the first and second layers.

The first and second layers may be formed from any suitable flame retarding sheet material which includes:

gypsum (calcium sulfate dehydrate),

Pratliperl™ (also known as Pratley Perlite or aluminum silicate) or any suitable material having similar fire retarding properties, sawdust or any suitable fibrous or cellulose material, and

Borax™ or any suitable borate.

The above materials may be present in a weight ratio of 76,8 : 10,2 : 12,8 : 0,2.

The first and second layers may be of any suitable thickness. Typically, the thicknesses of the first and second layers vary between 15 mm and 175 mm, the thickness preferably being in the order of 25 mm.

The separator layer may be formed from any suitable fluid impervious synthetic plastics or metallic material. Typically, the separator layer is formed from aluminum, preferably in a foil form. The thickness of the separator layer may be varied as desired and is preferably in the region of between 260-300 microns.

The panel may be of any conventional geometric shape. The panel is preferably substantially rectangular, the dimensions being varied as desired. Typically, the length, width and thickness of a rectangular panel may be in the regions of 0,8 to 1 ,5 m, 2,5 to 4 m and 25 to 100 mm, respectively.

According to a further aspect of the invention, there is provided a method of making a fire retarding panel, the method including the steps of.- pouring or introducing a flame retarding material into a mould to form a first layer; overlaying the first layer with a fluid impervious separator layer; pouring or introducing further flame retarding material into the mould to form a second layer which overlays the separator layer; allowing the first and second layers to cure or set; and demoulding the panel once the first and second layers have set or cured.

The first and second layers and separator layers may be formed from the materials used or applied in the first-mentioned aspect above. It is to be appreciated, that the mould may be configured to form a panel having the shape and dimensions as described in the first mentioned aspect.

Detailed Description of the Invention

The invention will now be described by way of the following non-limiting example with reference to the following drawings.

In the drawings:-

Figure 1 shows a three dimensional view of a panel in accordance with the invention;

Figures 2, 4, and 6 show cross sectional views of three panels that were used during tests to establish their fire-retarding properties;

Figures 3, 5, and 7 show graphic representations of the test results of the panels in Figures 2,4, and 6 respectively; and

Figure 8 shows a table summarizing the test results of the panels of Figures 2,4, and 6 as well as other panels tested.

Referring now to the drawings, reference numeral 10 generally designates a fire retarding panel in accordance with the invention.

The panel 10 includes first and second layers 12 and 14 which are formed from a flame retarding material and a separator layer 16 which is formed from a material which inhibits the passage of fluid therethrough, the separator layer 16 being arranged to separate the first and second layers 12 and 14.

The first and second layers 12 and 14 are formed from any suitable flame retarding material which includes:

gypsum,

PralipeM ™, sawdust or any suitable fibrous or cellular material, and

Borax™.

The above materials are present in a weight ratio of 76,8 : 10,2 : 12,8 : 0,2.

More particularly, the composition comprises 60 kg gypsum, 8 kg Praliperi ™, 10 kg sawdust, and 15O g Borax™.

The first and second layers 12 and 14 are each about 25 mm thick. It is to be appreciated, that this thickness is variable in accordance with the intended use of the panel 10.

The separator layer 16 is formed from heavy duty aluminum foil. The thickness of the separator layer 16 is preferably in the region of between 260 - 300 microns.

The panel 10 can be manufactured in any desired geometric shape. The panel 10 is preferably substantially rectangular form, the dimensions being varied as desired. Typically, the length, width and thickness of a rectangular panel 10 are in the region of 1.2 m, 3 m and 50 mm respectively.

Manufacture of the panel 10 generally includes the steps of:- pouring or introducing the flame retarding material into a mould (not shown) to form a first layer 12; overlaying the first layer 12 with the fluid impervious separator layer 16; pouring or introducing further flame retarding material into the mould to form the second layer 14 which overlays the separator layer 16; allowing the first and second layers 12 and 14 to cure or set at ambient temperature; and demoulding the panel 10 once the first and second layers have set or cured.

In operation, a plurality of panels 10 are connected to each of other end on end using any suitable adhesive to form a firewall for use in the partitioning or division of space to form separate rooms or offices. Alternatively, the panels 10 are connected end on end using any suitable framework (not shown) intended for

such purpose. The applicant believes that the panel 10 in accordance with the invention will provide a solution to that experienced in the 9/11 attack in the USA in that the firewalls inhibit the conduction of heat therethrough thereby to facilitate the localization of a fire to a room or office bounded by the firewalls. It is of course to be appreciated that the panels 10 could be used for ceiling panels or any purpose where a fire needs to be localized or isolated from the rest of a building, structure or specific region.

Referring now to Figures 2 to 7:

The panel 10 shown in Figure 2 is a panel 10 as would typically be used as a door or wall panel. It is desired that, if a fire is burning on one side of the panel, the opposite side of the panel does not reach a temperature of more than 160° C.

A furnace was created on one side of the panel 10 and the temperature of the furnace over time is shown as the upper line in Figure 3. The lower line in Figure 3 shows the temperature of the side of the panel 10 not exposed to the furnace over time.

The panel 10 in Figure 4 is a panel 10 as would typically be used in the construction of a safe.

The panel 10 in Figure 6 only includes one layer of fire retarding material 12 and was conducted as a comparative test. This test shows that the panels 10 of Figures 2 and 4 displayed superior fire retarding properties as the temperature of the side of the panel 10 not exposed to the furnace only rose to 28° C and 79° C respectively after a time of 240 min had passed.

In Figure 8, Panels 1 , 3, and 5 refer to the panels of Figures 2, 4, and 6 respectively.

The invention is not limited to the precise constructional details as herein described and/or with reference to the accompanying drawings. For example, a plurality of separator layers may be arranged to span a plurality of layers formed from the flame retarding material.