Patent GB-1407770-A (GB)
Title: Building panel
IPC: B28B1/16
Filed: 1973-12-06
Abstract: 1407770 Building panels E S B INC 6 Dec 1973 [8 Jan 1973] 56641/73 Heading E1B [Also in Divisions B2 and B5] A fire-resistant sound-absorbent laminated building panel comprises a fire-resistant core sheet 10 Fig I having numerous voids throughout its structure and a groove 12 extending along each edge, a plurality of binder strips 20 Figs 2, 3, 4 extending one along each edge of the core sheet, each strip being wider than the thickness of the core sheet and having an inwardly projecting ridge 22 interlocked in the groove of the core sheet along which the strip extends, the binder strips being attached at their ends e.g. by members 33 to form a binder frame surrounding the core sheet, a first non- combustible Portland cement mortar layer selfadhered to one face of the core sheet and to portions of the binder frame projecting beyond this one face, the outer face of the first mortar layer being flush with the edges of the binder strips projecting beyond the one face of core sheet, and a second non-combustible Pertland cement layer self-adhered to the other face of the core sheet and to the portions of binder frame projecting beyond this other face, the outer face of the second mortar layer being flush with the edges of the binder strips projecting beyond the other face of the core sheet. The panel may be made by grooving and bevelling the edges of the core sheet, placing the binder strips along the edges of the core sheet with their ridges interlocked in the grooves, attaching the binder strips to each other at their ends to form the binder frame, placing the resultant assembly in a horizontal position, pouring a layer of Portland cement mortar on the upper face of the core sheet, making the layer of mortar flush with the adjacent edge of the binder frame and allowing it to set, turning the resultant assembly and applying a second layer of mortar by an identical method. The core sheet may be a foam material or a multiple fibre or granule-based structure, a preferred sheet being made from long wool fibres chemically treated against organic growths which have coated with a Portland cement slurry and bonded under pressure. The edge binder strips may be of plastics material e.g. polypropylene or metal e.g. aluminium or steel, tongues 26, 28 and serrations 24 being optionally provided theron, the tongues 26, 28 in the embodiment shown defining a locking slot 30. The Portland cement mortar is preferably a hydraulic cement modified to provide rapid setting e.g. by using a finely ground material, by the addition of a chemical accelerator e.g. a calcium salt, phosphoric acid or a salt thereof or an amine or by the addition of an organic latex e.g. an acrylic latex, a natural rubber latex, a styrene-butadiene polymer, neoprene, polyvinyl chloride, polyvinyl acetate, a mixture of polyvinyl alcohol and an acrylic resin, polyvinylidene chloride or a bis-phenol- A epoxy resin emulsion. A panel according to the invention may be decorated by bonding a sheet of decorative material e.g. a fire-resistant wallpaper, a fabric or a textured plastics material thereto. For external use, one of the mortar layers may be imprinted prior to setting e.g. by a roller to provide a threedimensional decorative pattern simulating shingles or ship-lap boarding. Alternatively, stone particles may be applied to a mortar layer prior to setting.