Fire resistant rigid foam construction panel

Abstract

A fire resistant rigid foam construction panel, includes a rigid foam insulation core. The rigid foam insulation core has an inside face, an outside face, a top edge, a bottom edge, a first end and a second end. At least one fire rated facing sheet is secured by adhesive to the inside face of the core. At least one fire rated facing sheet secured by adhesive to the outside face of the core. Fire rated cover strips are positioned at all joints, such that all of the inside face and all of the outside face of the core are covered by fire rated materials.

1 . A fire resistant rigid foam construction panel, comprising: 
 a rigid foam insulation core having an inside face, an outside face, a top edge, a bottom edge, a first end and a second end;    at least one fire rated facing sheet secured by adhesive to the inside face of the core;    at least one fire rated facing sheet secured by adhesive to the outside face of the core; and    fire rated cover strips positioned at all joints, such that all of the inside face and all of the outside face are covered by fire rated materials.    
   
   
       2 . The fire rated rigid foam construction panel as defined in  claim 1 , wherein a fire rated end plate covers each of the first end and the second end of the core.  
   
   
       3 . The fire rated rigid foam construction panel as defined in  claim 1 , wherein a fire rated top plate covers the top edge of the core.  
   
   
       4 . The fire rated rigid foam construction panel as defined in  claim 1 , wherein a fire rated bottom plate covers the bottom edge of the core.  
   
   
       5 . The fire rated rigid foam construction panel as defined in  claim 1 , wherein each facing sheet is made from a cementious material.  
   
   
       6 . The fire rated rigid foam construction panel as defined in  claim 5 , wherein the cementious material is fibre reinforced.  
   
   
       7 . The fire rated rigid foam construction panel as defined in  claim 1 , wherein there is more than one facing sheet covering each of the inside face and the outside face, the facing sheets being in end to end relation with the fire rated cover strips between the facing sheets being a fire rated abutting cover strip secured by adhesive to the core, the abutting cover strip comprising a body defining a first shoulder adapted to engage an edge of a first facing sheet, a second shoulder parallel and opposed to the first shoulder, the second shoulder being adapted to engage an edge of a second facing sheet, a first wing projecting beyond the first shoulder and adapted to underlie the first facing sheet when it is engaged with the first shoulder, and a second wing projecting beyond the second shoulder and adapted to underlie the second facing sheet when it is engaged with the second shoulder.  
   
   
       8 . The fire rated rigid foam construction panel as defined in  claim 2 , the end plate having an outer face, an inner face, a first peripheral side edge and a second peripheral side edge, a first backing plate being spaced from the first peripheral side edge and extending perpendicularly from the inner face of the end plate, a first shoulder being provided on the inner face of the end plate between the first peripheral side edge and the first backing plate, the first shoulder being adapted to engage an edge of one of the facing sheets, a second backing plate being spaced from the second peripheral side edge and extending perpendicularly from the inner face of the end plate, a second shoulder being provided on the inner face of the end plate between the second peripheral side edge and the second backing plate, the second shoulder being adapted to engage an edge of one of the facing sheets.  
   
   
       9 . The fire rated rigid foam construction panel as defined in  claim 3 , the top plate having an outer face, an inner face, a first peripheral side edge and a second peripheral side edge, a first backing plate being spaced from the first peripheral side edge and extending perpendicularly from the inner face of the top plate, a first shoulder being provided on the inner face of the top plate between the first peripheral side edge and the first backing plate, the first shoulder being adapted to engage an edge of one of the facing sheets, a second backing plate being spaced from the second peripheral side edge and extending perpendicularly from the inner face of the top plate, a second shoulder being provided on the inner face of the top plate between the second peripheral side edge and the second backing plate, the second shoulder being adapted to engage an edge of one of the facing sheets.  
   
   
       10 . The fire rated rigid foam construction panel as defined in  claim 4 , the bottom plate having an outer face, an inner face, a first peripheral side edge and a second peripheral side edge, a first backing plate being spaced from the first peripheral side edge and extending perpendicularly from the inner face of the bottom plate, a first shoulder being provided on the inner face of the bottom plate between the first peripheral side edge and the first backing plate, the first shoulder being adapted to engage an edge of one of the facing sheets, a second backing plate being spaced from the second peripheral side edge and extending perpendicularly from the inner face of the bottom plate, a second shoulder being provided on the inner face of the bottom plate between the second peripheral side edge and the second backing plate, the second shoulder being adapted to engage an edge of one of the facing sheets.  
   
   
       11 . The fire rated rigid foam construction panel as defined in  claim 1 , wherein the inside face includes an inside corner having two facing sheets in perpendicular relation, the fire rated cover strip being an inside corner cover strip secured by adhesive to the core, the inside corner cover strip comprising a body defining a first shoulder adapted to engage an edge of a first facing sheet, a second shoulder parallel and perpendicular to the first shoulder, the second shoulder being adapted to engage an edge of a second facing sheet, a first wing projecting beyond the first shoulder and adapted to underlie the first facing sheet when it is engaged with the first shoulder, and a second wing projecting beyond the second shoulder perpendicular to the first wing and adapted to underlie the second facing sheet when it is engaged with the second shoulder.  
   
   
       12 . The fire rated rigid foam construction panel as defined in  claim 1 , wherein the outside face includes an outside corner having two facing sheets in perpendicular relation, the fire rated cover strip being an outside corner cover strip secured by adhesive to the core, the outside corner cover strip comprising a body defining a first shoulder adapted to engage an edge of a first facing sheet, a second shoulder parallel and perpendicular to the first shoulder, the second shoulder being adapted to engage an edge of a second facing sheet, a first wing projecting beyond the first shoulder and adapted to underlie the first facing sheet when it is engaged with the first shoulder, and a second wing projecting beyond the second shoulder perpendicular to the first wing and adapted to underlie the second facing sheet when it is engaged with the second shoulder.  
   
   
       13 . The fire rated rigid foam construction panel as defined in  claim 7 , wherein the abutting cover strip has a recessed topographical profile positioned between the first shoulder and the second shoulder.  
   
   
       14 . The fire rated rigid foam construction panel as defined in  claim 13 , wherein the recessed topographical profile is selected from one of a rectangular channel, an arcuate channel, a “V” channel.  
   
   
       15 . The fire rated rigid foam construction panel as defined in  claim 7 , wherein the abutting cover strip has a raised topographical profile positioned between the first shoulder and the second shoulder.  
   
   
       16 . The fire rated rigid foam construction panel as defined in  claim 15 , wherein the raised topographical profile is an arcuate ridge.  
   
   
       17 . The fire rated rigid foam construction panel as defined in  claim 8 , wherein a fastener retaining backing material is positioned along the inner face of the end plate.  
   
   
       18 . The fire rated rigid foam construction panel as defined in  claim 9 , wherein a fastener retaining backing material is positioned along the inner face of the top plate.  
   
   
       19 . The fire rated rigid foam construction panel as defined in  claim 10 , wherein a fastener retaining backing material is positioned along the inner face of the bottom plate.