GB2535511A

GB2535511A - A frame component and method of manufacture thereof

Info

Publication number: GB2535511A
Application number: GB1502808.7A
Authority: GB
Inventors: Duncan James; Mark Jones Daniel
Original assignee: Synseal Extrusions Ltd
Current assignee: Synseal Extrusions Ltd
Priority date: 2015-02-19
Filing date: 2015-02-19
Publication date: 2016-08-24
Anticipated expiration: 2035-02-19
Also published as: GB201502808D0; GB2535511B

Abstract

A frame component 13 includes a core member 15 located within an outer member 130, wherein a fire retardant material 16 is provided between at least part of the core and outer members. The outer member may include a cavity 100 in which the core member may be located. The frame may include a sheet material 17 which carries the fire retardant material on one surface and may be at least partially coated with an adhesive on the opposite side, to secure it to one of the core and outer members. The fire retardant material may be an intumescent. The core may be constructed of metal and the outer member may be constructed of plastics, such as PVCu. Also claimed is a method of manufacturing such a frame component.

Description

Title: A frame component and method of manufacture thereof

Description of Invention

This invention relates to frame components. More particularly, this invention relates to frame components for the construction of window or door frames, whereby the frame components include a fire retardant material.

Fire resisting doors intended for use in various markets and to suit various fire resistance time periods (as defined by applicable British Standards) have traditionally relied on thickness (i.e. bulk) of a door leaf to resist the passage of fire. A thick door leaf (of say 54mm) will take longer to burn through than a thinner door leaf of say 44mm. In addition, a door leaf or door frame of solid timber will take longer to burn through (due to the inherent bulk of the solid timber) than a door leaf or door frame of corresponding thickness formed from a composite material. A composite material means a mixture of materials such as wood, insulating foam and glass reinforced plastic (GRP).

In the UK there is a British Standard performance test for fire doors, namely BS476 part 22. Fire doors which meet this standard are rated by the number of minutes of protection deemed to be provided, commonly abbreviated by the prefix FD, followed by the number of minutes of fire protection, for example FD30 (for 30 minutes protection) or FD60 (for 60 minutes protection) and so forth.

In the UK natural wood or cellulosic fibre doors which rely on their bulk for fire resistance have for many years been manufactured to a thickness of 44mm so as to achieve a fire rating of 30 minutes, the base level for most UK fire door requirements.

It is possible to achieve a fire rating of 60 minutes by increasing the thickness of a door leaf to 54mm or greater and forming the door leaf and door frame from solid timber. However, the weight of a solid timber door leaf having a thickness of 54mm or greater is such that transportation and installation become impractical. Moreover, a solid timber door leaf is prone to weathering and, in particular, warping over time and it therefore may need replacing regularly.

Thus, there is an increasing demand for alternatives to a solid timber door leaf and door frame combination. Such alternatives include door frames formed from PVCu in combination with a door leaf formed from a composite material. Doors formed from composite materials are less prone to warping and are generally more resilient than most solid timber doors (this, of course, depends on the type of timber utilised in the solid timber door). There is an on-going challenge, however, to achieve British Standard fire rating approvals using such alternative materials.

It is possible to achieve a fire rating of 30 minutes for a PVCu door frame in combination with a 44mm door leaf formed from a composite material. This rating was achieved by incorporating intumescent seals between the door leaf and the PVCu door frame. However, at around 30 minutes or so the PVCu frame erodes to such an extent that gaps between the door frame and door leaf become so large that the intumescent seals no longer have the effect of preventing heat / fire transfer from one side of the frame to the other.

There is a commercial need for a lightweight and resilient fire resistant door (e.g. a PVCu door frame and composite door leaf combination) having a British Standards fire rating of 60 minutes or more.

It is an object of the present invention to seek to provide an improved fire resistant door (i.e. door frame and door leaf combination). It is a further object of the invention to seek to provide a lightweight and resilient fire resistant door that is able to achieve a fire rating of 60 minutes or more according to British Standard BS476 part 22.

In one aspect of the present invention we provide a frame component including a core member located within an outer member, wherein a fire retardant material is provided between at least a portion of the core member and the outer member.

Preferably, the outer member includes, in cross section, a cavity defined by a first part arranged, in use, adjacent to an edge of a windowpane or a door leaf; a second part opposite to the first part; and third and fourth parts extending between the first and second parts and spaced from one another.

Preferably, the core member is located or is locatable within the cavity.

Preferably, the fire retardant material is provided between at least a portion of the core member and at least a portion of an inner surface of one or both of the third and fourth parts of the outer member. For instance, the fire retardant material may be provided between at least a portion of the core member and at least a portion (e.g. substantially all) of the inner surface of one or both of the third and fourth parts of the outer member.

In some embodiments, fire retardant material may additionally be provided between at least a portion of the core member and at least a portion of an inner surface of one or both of the first and second parts of the outer member.

In some embodiments, the fire retardant material may be provided between the core member and the inner surface of the first, third and fourth parts of the outer member. The inventors have discovered that the fire retardancy of frame components according to these particular embodiments of the invention is vast improved over the prior art.

The frame component may utilise a sheet material.

Preferably, the sheet material carries the fire retardant material on one surface thereof. The opposite surface of the sheet material to the surface carrying the fire retardant material may be at least partially coated with an adhesive, such that the sheet material can be secured or is securable to one of the core member and the outer member.

Preferably, the fire retardant material is an intumescent.

Preferably, the core member is of a metal construction. In embodiments, the 15 core member may be formed of aluminium or steel.

Preferably, the outer member is of a plastics construction, e.g. extruded PVCu.

In a second aspect the invention relates to a frame for a door leaf or a 20 windowpane including a frame component according to any one of the above embodiments.

In a third aspect the invention relates to the combination of a door leaf and a frame according to the second aspect, wherein the door leaf has a thickness of 25 from about 35mm to about 54mm.

In some embodiments the door leaf may be a composite door leaf.

In a fourth aspect the invention relates to the combination of a door leaf and a 30 frame according to the second aspect, wherein the door leaf is a composite door leaf.

In some embodiments the door leaf may have a thickness of from about 35mm to about 54mm.

In a further aspect the invention relates to a method of manufacturing a frame component including the steps of: * obtaining a core member; * covering at least a portion of the core member with a fire retardant material; * obtaining an outer member; and * locating the covered core member within the outer member, such that the fire retardant material is provided between said at least a portion of the core member and the outer member.

The step of covering at least a portion of the core member with a fire retardant material may include: * obtaining a sheet material having a surface carrying the fire retardant material and a surface opposite thereto at least partially coated in adhesive and, preferably, a release liner to protect the adhesive; * removing the release liner (if present) from the sheet material to expose the adhesive; and * securing the sheet material to said at least a portion of the core member.

The frame component obtainable from the method of manufacture may include any one or more of the optional features of the previous aspects of the invention. For instance, the fire retardant material may be an intumescent. The core member may be of metal construction. The outer member may be of plastics construction.

Embodiments of the various aspects of the invention will now be described by way of example only, with reference to the accompanying drawings, of which: Figure 1 shows a front view of a door frame embodying the invention; Figure 2 is a partial cross-section along line A-A in Figure 1; Figure 3 is a cross-section along line B-B in Figure 1; Figure 4 is a cross-section along line C-C in Figure 1; and Figure 5 shows a front view of a door and window frame embodying the invention.

Referring to figure 1 there is shown a door frame 1 and a door leaf 2. The door frame 1 includes first and second frame components 11, 12. The first and second frame components 11, 12 are upstanding and connected at their respective upper ends by a third frame component 13 and at their lower ends by a fourth frame component 14. The door leaf 2 is mounted to the door frame 1 by hinges 3a, 3b. The door leaf 2 may include a handle 4.

Figure 2 shows a cross sectional view of the door frame 1 and door leaf 2. The door leaf 2 may be a composite door leaf. In the illustrated embodiment the door leaf 2 includes a first section 21 and a second section 22. As will be appreciated from figures 2 to 4 the first section 21 extends around the periphery of the door leaf 2 and provides a structural framework therefor. The first section 21 is typically formed of a cellulosic fibre or wood. In some embodiments the first section 21 is formed of a solid timber. In alternative embodiments, the first section 21 may include a mixture of cellulosic fibres or wood. In some embodiments, the first section 21 may be formed from a number of discrete sections that are fixed or joined together.

The second section 22 may be formed of insulating foam. In some embodiments, the second section 22 may include phenolic insulating foam.

In embodiments, the first section 21 and second section 22 may be sandwiched between a pair of panels 24a, 24b, such as glass reinforced plastics (GRP) panels.

In embodiments, the door leaf 2 may have a thickness of from about 35mm to about 54mm, such as from about 35mm to about 50mm or from about 30mm to about 54mm. In some embodiments, the door leaf 2 may have a thickness of 44mm. For instance, the first and second sections 21, 22 may have a thickness of 40mm and the panels 24a, 24b may each have a thickness of 2mm.

In some embodiments, the door leaf 2 may have one or more fielded areas (not shown) in order to provide a contemporary visual appearance. It is to be appreciated that the thickness of the door leaf 2 at the or each fielded area may differ from the remainder thereof.

Figure 2 also shows a cross sectional view of the third and fourth frame components 13, 14. The third frame component 13 may include a core member 15 located within an outer member 130. In embodiments, the outer member 130 may include a cavity 100 defined by a first part 131 arranged adjacent to the door leaf 2, a second part 132 opposite to the first part 131, and third and fourth parts 133, 134 extending between the first and second parts 131, 132 and spaced from one another.

Intumescent seals 60a, 60b may be incorporated between the door leaf 2 and the third frame component 13, as per the prior art. One or more additional intumescent seals 60c may be incorporated between the third frame component 13 and the edge of an opening in a structure.

The outer member 130 is preferably of a plastics construction, e.g. extruded PVCu. As will be appreciated from the figures the outer member 130, and particularly the third and fourth parts 133, 134, may include discrete cavities 101a, 101b, 101c, 101d to provide for improved insulation across the third frame component 13.

The core member 15 may be located or is locatable within the cavity 100 of the outer member 130. In some embodiments the core member 15 is of a metal construction such that it provides structural reinforcement to the outer member 130. In embodiments, the core member 15 may be formed of aluminium or steel.

In the illustrated embodiment the core member 15 is a sheet of metal that has been formed into an elongate part having a rectangular cross section. This is advantageous because the resultant core member 15 is relatively lightweight whilst also able to provide the requisite reinforcement to the outer member 130. It is to be appreciated that the core member 15 may take other forms.

For instance, the core member 15 need not have a rectangular cross section. Instead, a cross section of the core member 15 may correspond to the shape of any polygon, or it may even correspond to a circle or an ellipse. Moreover, the core member 15 need not be hollow as illustrated. In some embodiments the core member 15 may be a solid (or a substantially solid) elongate part.

In accordance with the invention a fire retardant material 16 is provided between at least a portion of the core member 15 and the outer member 130. In some embodiments the fire retardant material 16 is provided between at least a portion of the core member 15 and at least a portion of an inner surface of one or both of the third and fourth parts 133, 134 of the outer member 130. In other embodiments, fire retardant material 16 may additionally be provided between at least a portion of the core member 15 and at least a portion of one or both of an inner surface of the first and second parts 131, 132 of the outer member 130.

By locating the fire retardant material 16 between the core member 15 and the outer member 130 it has been possible to achieve a fire rating in excess of 60 minutes according to British Standard BS476 part 22. This fire rating was achieved using a 44mm composite door in combination with a PVCu frame reinforced by a steel core member 15. Indeed, following rigorous testing the inventors have discovered that the most effective arrangement is to locate the fire retardant material 16 between the core member 15 and the inner surfaces of the first, third and fourth parts 131, 133, 134 of the outer member 130, as illustrated.

In embodiments, the fire retardant material 16 is an intumescent. This is advantageous because when exposed to heat the intumescent material swells and is retained by the cavity between the core member 15 and the outer member 130. When it reaches a critical temperature the intumescent begins to produce a char, which char is a poor conductor of heat. The result is that heat transfer across the frame component 13 is arrested.

Without being bound to any particular theory it is believed that this improved fire retardancy is a consequence of providing the intumescent between the core member 15 and the outer member 130. Providing the intumescent in this location means that as the intumescent begins to swell when exposed to heat it is retained within the gap between the core member 15 and the outer member 130 and thus continues to be effective at retarding fire / heat for longer. Locating the intumescent between the core member 15 and the outer member 130 has been found to be more effective at retarding fire / heat than the intumescent seals that are routinely incorporated between the door frame 1 and door leaf 2.

A sheet material 17 may be utilised. In embodiments, the sheet material 17 may carry the fire retardant material 16 (e.g. intumescent) on one surface thereof. In embodiments, the opposite surface to the surface carrying the fire retardant material 16 may be provided with an adhesive and, preferably, a release layer for protecting the adhesive.

In alternative embodiments, a fire retardant foam (such as an intumescent 5 foam) may be located between the core member 15 and the outer member 130.

In the illustrated embodiment the fourth frame component 14 does not embody the present invention. Instead, the fourth frame component 14 is a conventional PVCu extrusion. In some embodiments, however, the fourth frame component 14 may be replaced by a frame component embodying the present invention, such as the third frame component 13.

Figures 3 and 4 show cross sectional views of the second and the first frame components 12, 11, respectively.

The second and first frame components 12, 11 are essentially identical to the third frame component 13. For completeness, and referring to figure 3, the second frame component 12 may include a core member 15 located within an outer member 120. In embodiments, the outer member 120 may include a cavity 100 defined by a first part 121 arranged adjacent to the door leaf 2, a second part 122 opposite to the first part 121, and third and fourth parts 123, 124 extending between the first and second parts 121, 122 and spaced from one another.

The outer member 120 is preferably of a plastics construction, e.g. PVCu.

The core member 15 may be located within the cavity 100 of the outer member 120. A fire retardant material 16 may be located between the core member 15 and the first, third and fourth parts 121, 123, 124 of the outer member 120.

Referring now to figure 4, the first frame component 11 may include a core member 15 located within an outer member 110. In embodiments, the outer member 110 may include a cavity 100 defined by a first part 111 arranged adjacent to the door leaf 2, a second part 112 opposite to the first part 111, and third and fourth parts 113, 114 extending between the first and second parts 111, 112 and spaced from one another.

The outer member 110 is preferably of a plastics construction, e.g. PVCu.

The core member 15 may be located within the cavity 100 of the outer member 110. A fire retardant material 16 may be located between the core member 15 and the first, third and fourth parts 111, 113, 114 of the outer member 110.

A method of manufacturing the frame components 11-13 will now be described with reference to the figures. The method may include obtaining a core member 15 and covering at least a portion thereof with a fire retardant material 16. In some embodiments, the method may include utilising a sheet material 17. The sheet material 17 may carry the fire retardant material 16 (e.g. intumescent) on one surface thereof. The opposite surface of the sheet material 17 to the surface carrying the fire retardant material 16 may be provided with an adhesive and, preferably, a release layer for protecting the adhesive. In some embodiments, the method may include removing the release liner (if present) from the sheet material 17 to expose an adhesive and securing the sheet material 17 (and hence the fire retardant material 16) to at least a portion of the core member 15. The method may also include the step of obtaining an outer member 110, 120, 130 (which may be of plastics, e.g. PVCu construction) and locating the covered (or at least partially covered) core member 15 within a cavity 100 of the outer member 110, 120, 130, such that the fire retardant material 16 is provided between a portion of the core member 15 and the outer member 110, 120, 130.

The frame components 11-13 may be subsequently joined together with the 5 fourth frame component 14 to provide the door frame 1.

Referring now to figure 5, there is shown an alternative embodiment of the invention to that illustrated in figures 1 to 4. For ease of the description components of the embodiment shown in figure 5 are denoted by the same numbers used to describe the components of the embodiment shown in figures 1 to 4 but with the addition of a prime (').

Figure 5 shows a door frame 1' and a door leaf 2'. The door frame 1' includes first and second frame components 11', 12'. The first and second frame components 11', 12' are upstanding and connected at their respective upper ends by a third frame component 13' and at their lower ends by a fourth frame component 14'. The door leaf 2' is mounted to the door frame 1' by hinges 3a', 3b'. The door leaf 2' may include a handle 4'. The door frame 1' also includes windowpanes 20, 30, 40 which are held by additional frame components 50-55. Frame components 50-55 embody the inventive features of the first frame component 11, 11' and need not be described in further detail. It is simply to be understood that the frame components according to the present invention may be utilised to manufacture either window or door frames.

In short, due to the location of the fire retardant material within the frame components of the present invention, it has been possible to manufacture a fire door (which is formed of a 44mm composite door leaf and a PVCu door frame) that is able to achieve a fire rating of 60 minutes or more according to British Standard BS476 part 22. It is anticipated that this fire rating will also be achievable using composite doors having a thickness of as little as 35mm, due to the fire retardant nature of the frame components. In addition to achieving a fire rating of 60 minutes or more, these doors are lightweight (because they are not formed solely from solid timber) and weatherproof.

When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claims

Claims 1. A frame component including a core member located within an outer member, wherein a fire retardant material is provided between at least a 5 portion of the core member and the outer member.
2. A frame component according to claim 1, wherein the outer member includes, in cross section, a cavity defined by a first part arranged, in use, adjacent to an edge of a windowpane or a door leaf; a second part opposite to the first part; and third and fourth parts extending between the first and second parts and spaced from one another.
3. A frame component according to claim 2, wherein the core member is located or is locatable within the cavity.
4. A frame component according to claim 2 or claim 3, wherein the fire retardant material is provided between at least a portion of the core member and at least a portion of an inner surface of one or both of the third and fourth parts of the outer member.
5. A frame component according to claim 4, wherein the fire retardant material is additionally provided between at least a portion of the core member and at least a portion of an inner surface of one or both of the first and second parts of the outer member.
6. A frame component according to any preceding claim including a sheet material, wherein the sheet material carries the fire retardant material on one surface thereof.
7. A frame component according to claim 6, wherein the opposite surface of the sheet material to the surface carrying the fire retardant material is at least partially coated with an adhesive, such that the sheet material can be secured or is securable to one of the core member and the outer member
8. A frame component according to any preceding claim, wherein the fire retardant material is an intumescent.
9. A frame component according to any preceding claim, wherein the core member is of a metal construction.
10. A frame component according to any preceding claim, wherein the outer member is of a plastics construction, e.g. PVCu.
11. A frame for a door leaf or a windowpane, including a frame component according to any one of the preceding claims.
12. In combination, a door leaf and a frame according to claim 11, wherein the door leaf has a thickness of from about 35mm to about 54mm.
13. A combination according to claim 12, wherein the door leaf is a composite door leaf.
14. In combination, a door leaf and a frame according to claim 11, wherein the door leaf is a composite door leaf.
15. A combination according to claim 14, wherein the door leaf has a thickness of from about 35mm to about 54mm.
16. A method of manufacturing a frame component including the steps of: * obtaining a core member; * covering at least a portion of the core member with a fire retardant material; * obtaining an outer member; and * locating the covered core member within the outer member, such that the fire retardant material is provided between said at least a portion of the core member and the outer member.
17. A method of manufacturing a frame component according to claim 16, wherein the step of covering at least a portion of the core member with a fire retardant material includes: * obtaining a sheet material having a surface carrying the fire retardant material and a surface opposite thereto at least partially coated in adhesive and, preferably, a release liner to protect the adhesive; * removing the release liner (if present) from the sheet material to expose the adhesive; and * securing the sheet material to said at least a portion of the core member.
18. A frame component substantially as hereinbefore described with reference to and as shown in the accompanying drawings.
19. A method of manufacturing a frame component substantially as hereinbefore described.
20. Any novel feature or novel combination of features described herein and/or shown in the accompanying drawings.