GB2559596A

GB2559596A - Packer element

Info

Publication number: GB2559596A
Application number: GB1702260.9A
Authority: GB
Inventors: Watts Allan
Original assignee: Craylon Ltd; RAM EXTRUSION Ltd
Current assignee: Craylon Ltd; RAM EXTRUSION Ltd
Priority date: 2017-02-10
Filing date: 2017-02-10
Publication date: 2018-08-15
Anticipated expiration: 2037-02-10
Also published as: GB201702260D0; GB2559596B

Abstract

The packer element 10 for use in securing a door unit 12 or window frame in position in an opening 14 formed in a building wall, the packer element 10 having a plastics material and an intumescent material. The packer may be extruded and include 32% PVC and 4% graphite based intumescent material by weight, and may also include a chalk filler, a plasticiser, a stabiliser, woodflour and acrylic. Also claimed is an assembly including a door or window frame located in an opening having at least one stack 10a of packers located between the frame and the opening. There may be several stacks at intervals with a fire resistant foam filling the remaining gaps. In the event of a fire the intumescent material will expand and may reduce the risk of the frame becoming insecurely located in the opening due to deformation of the plastic of the packers.

Description

(54) Title of the Invention: Packer element

Abstract Title: A packer element for a door frame having an intumescent material (57) The packer element 10 for use in securing a door unit 12 or window frame in position in an opening 14 formed in a building wall, the packer element 10 having a plastics material and an intumescent material. The packer may be extruded and include 32% PVC and 4% graphite based intumescent material by weight, and may also include a chalk filler, a plasticiser, a stabiliser, woodflour and acrylic. Also claimed is an assembly including a door or window frame located in an opening having at least one stack 10a of packers located between the frame and the opening. There may be several stacks at intervals with a fire resistant foam filling the remaining gaps. In the event of a fire the intumescent material will expand and may reduce the risk of the frame becoming insecurely located in the opening due to deformation of the plastic of the packers.

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PACKER ELEMENT

This invention relates to a packer element, and in particular to a packer element suitable for use in the installation of fire door units, windows or the like into a building.

It is increasingly common for fire doors to be installed into a building to be supplied in the form of a pre-assembled unit or set comprising a door frame and a door, the door being hinged to the frame. The frame and/or door are typically provided with intumescent material strips arranged to form a seal between the door and the frame in the event of a fire. Closer components may also be provided ensuring that, in use, the door will occupy a closed position, at rest.

During construction of a building, an opening into which the door unit is to be fitted is constructed. For ease of installation of the door unit, the opening is often constructed so as to be oversize compared to the dimensions of the door unit so as to ensure that the door unit can subsequently be received therein. During installation, packers are fitted between the door frame and the walls defining the opening so as to hold the door unit in an upright condition, and an expandable foam material is introduced between the frame and the walls.

Whilst installation of a door unit in this manner is relatively straightforward, there is a risk that the installed door unit may not provide a sufficiently good level of fire protection. By way of example, the packers typically used in securing the door unit in position are of a plastics material. There is a risk that, in the event of a fire, temperatures may be reached at which the material of the packers softens, degrades, shrinks or otherwise deforms. The softened packer material may then deform, with the result that the door unit may no longer be rigidly supported in position, and there is a risk that the door unit may fall over. Clearly, should this occur, the door unit will no longer provide fire protection. If this were to occur before evacuation of personnel from the building is completed, then those individuals remaining within the building may be put at risk. Clearly, this is undesirable.

In many countries, building regulations require fire doors or the like to provide protection to occupants of a building for a predetermined time period, for example for 30 minutes. It will be appreciated that in the circumstances set out above, whilst the door unit itself may be capable of providing the required duration of protection, the installation thereof may be such that the prescribed regulations are not complied with.

Using packers of an intumescent material instead of using plastics material packers may ensure that the door unit remains fixed in an upstanding condition, but carries the risk that swelling of the intumescent material in the event of a fire may cause deformation of the door frame which, in turn, may prevent normal operation of the door. If the door is prevented from fully closing, the level of fire protection provided by the door unit is impaired which, again, is undesirable and/or may result in a breach of fire regulations, and if the door were to become jammed in a closed position, escape from the building may be prevented.

It is an object of the invention to provide a packer element suitable for use in such applications and in which at least some of the disadvantages associated with known packers when used in such applications are overcome or are of reduced effect.

According to the present invention there is provided a packer element suitable for use in securing a door unit, window or the like in position, the packer element comprising a material in the form of a mix of a plastics material and an intumescent material.

By way of example, the intumescent material may comprise a graphite based intumescent material.

By forming the packer element from a material including an intumescent material and a plastics material, the packer element may be designed in such a manner that expansion thereof, in the event of a fire, is minimal, expansion of the intumescent material compensating for shrinkage, deformation or the like of the plastics material.

Preferably, the quantity of intumescent material present within the packer element is such that expansion thereof, in use, is small, for example is less than 2%.

The intumescent material preferably makes up less than 50% by weight of the material of the packer element. More preferably, it may make up less than 25% by weight. More preferably still, the intumescent material makes up less than 10% by weight of the material. Conveniently, the intumescent material makes up 2 - 7% by weight of the material, preferably forming approximately 4% by weight of the material.

The plastics material is preferably a PVC material.

The material of the packer element may further comprise other materials, for example chalk, serving as fillers and/or to aid moulding or extrusion of the material to a desired shape.

The packer element is conveniently of extruded form. A coloured line or other marking is preferably formed on the packer element to provide an indication to an installer of the thickness of the packer element. A range of packer elements of different thicknesses, provided with differently coloured lines or markings, is preferably provided.

The invention further relates to an assembly comprising a door frame, window frame or the like located within an opening, and at least one stack of packer elements located between the frame and the opening, wherein at least one of the packer elements takes the form set out hereinbefore. The frame conveniently forms part of a preassembled door unit. Preferably each packer element takes the form set out hereinbefore. A space between the frame and the opening is preferably filled with a foam material.

The invention will further be described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a diagrammatic view illustrating a door unit, in use, installed using packer elements in accordance with embodiments of the invention; and

Figure 2 is a view illustrating a packer element of the type used in the installation shown in Figure

1.

Referring to the accompanying drawings, a packer element 10 in accordance with an embodiment of the invention is illustrated, a series of packer elements 10 being used, as shown in Figure 1, in securing a door unit 12 in position in an opening 14 formed in a building. Whilst described in relation to the installation of a door unit in an opening, it will be appreciated that the invention is not restricted in this regard and may be employed in the installation of, for example, window frames or the like.

As shown in Figure 1, during the construction of a building, openings 14 are formed or left in locations in which a door unit 12 is to be installed. The openings 14 are typically formed in such a manner as to be oversized compared to the nominal dimensions of the door unit 14 for ease of subsequent installation of the door unit 12. If they are not formed to be oversized, then there is a risk that when the door unit 12 is to be installed, the door unit 12 may actually be slightly larger than the opening 14, in which case either modifications will need to be made to the door unit 12 or a new door unit 12 will need to be obtained to fit the opening 14. The installation delays arising through needing to take such action is undesirable. Rather than run the risk of incurring such delays, it is preferred to form the opening to be oversized, and to fill a gap remaining between the door unit 12 and the opening 14.

In order to secure the door unit 12 within the opening 14, packer elements 10 are inserted between the door frame 16 of the door unit 12 and the opening 14. A number of packer elements 10 may be stacked together to form a stack 10a of thickness substantially matching the size of the gap between the door frame 16 and the opening 14, the stack of packer elements 10 then being forced between the door frame 16 and the opening 14 to secure the door unit 12 in an upright condition within the opening 14. The door unit 12 is thus firmly secured within the opening 14. Using too greater thickness stack of packer elements 10 is to be avoided so as to avoid distortion of the door frame 16 which could otherwise prevent closure of a door 18 of the door unit 12.

Stacks 10a of packer elements 10 are inserted at intervals around the door frame 16.

After installation of the packer elements 10, the remainder of the space between the door unit 12 and the opening 14 is filled with a suitable fire resistant foam material 20.

As mentioned hereinbefore, the packer elements 10 typically used in securing door units 12 in position are of plastics material form. Whilst in some applications this may be acceptable, where used in securing a fire door in position there is a risk that in the event of a fire the temperature may rise to a point at which the packer elements 10 melt or soften with the result that the door unit 12 may no longer be firmly secured within the opening 14. The door unit 12 may, in such circumstances, move to a position in which it no longer closes the opening 14, and so the degree of fire protection provided by the door unit 12 may be unacceptably impaired.

In accordance with the invention, rather than using packer elements 10 of a plastics material, the packer elements 10 are manufactured from a material incorporating a quantity of an intumescent material. The quantity of intumescent material present is selected, relative to the likely expansion thereof in the event of a fire, such that the overall dimensions of the stack 10a of packer elements 10 used to secure the door unit 12 in position within the opening 14 does not significantly alter. As a result, the door unit 12 will remain firmly secured in position in the opening 14 in the event of a fire. Furthermore, distortion of the frame 16 of the door unit 12 is avoided, and so the risk of the door 18 thereof failing to operate properly is reduced. The degree of fire protection provided by such an arrangement is thus enhanced.

The packer element 10 shown in the accompanying drawings is manufactured by extrusion from a material comprising a mix of a suitable plastics material and a suitable intumescent material. One form of intumescent material that is particularly convenient to use is graphite as this material is of relatively low cost compared to other intumescent materials, can readily be mixed with a plastics material, and the resulting formulation is suitable for use in an extrusion process. However, the invention is not restricted in this regard and other production processes may be used and other materials may be used.

The plastics material is preferably a PVC material, and conveniently includes suitable plasticisers, fillers and stabilisers. The intumescent material preferably makes up less than 50% by weight of the material of the packer element. More preferably, it may make up less than 25% by weight. Where graphite is used as the intumescent material, it preferably makes up less than 10% by weight of the material. For example, it may constitute 2 - 7% by weight of the material, preferably forming approximately 4% by weight of the material.

It has been found that a packer element 10 using a quantity of graphite intumescent material in the regions of 2-7% by weight, and preferably in the region of 4% by weight, results in the formation of a stack 10a of packer elements 10 that, in use, does not undergo a significant change of dimensions in the event of a fire, the expansion of the intumescent material within the material of the packer elements 10 compensating for any shrinkage or movement of other materials in the packer elements 10 and so results in the door unit 12 continuing to be maintained securely in an upright condition within the opening 14. Furthermore, as the stack 10a of packer elements 10 does not significantly increase in dimensions, deformation of the door frame IS, in the event of a fire, is avoided or restricted, and so the risk of the door 18 failing to operate properly is avoided or reduced.

It should be noted that, in use, the packer elements 10 within a stack 10a thereof may expand by different degrees. By way of example, some of the packer elements 10 may thermally shield others thereof, or parts of others thereof, with the result that not all of the intumescent material within the packer elements 10 of a stack 10a may be fully 'activated' under fire conditions.

As mentioned above, the material of the packer element 10 conveniently includes a filler, for example in the form of chalk. This may make up, for example, 30-50% by weight of the material, and preferably makes up around 40% by weight thereof. It may also contain a plasticiser making up, for example, 10-20% by weight of the material, conveniently forming approximately 16% by weight thereof. The material may also include a stabiliser making up approximately 5% by weight, woodflour making up approximately 2% by weight and acrylic making up approximately 1% by weight of the material. The remainder is of a suitable plastics material such as PVC, the PVC making up, for example, 25-40% by weight of the material, preferably making up approximately 32% by weight thereof.

Preferably, packer elements 10 in a range of thicknesses may be produced. By way of example, they may be formed in thicknesses of 1mm, 3mm and 5mm. However, these are merely examples and other thicknesses may be produced. In order to aid identification of the thickness of a packer element 10, the packer elements 10 are preferably formed with a coloured line 22 therein, the different thicknesses of packer element 10 being formed with differently coloured lines 22.

Whilst a specific embodiment of the invention is described hereinbefore, it will be appreciated that the invention is not restricted to the specific arrangement described and illustrated, but rather extends to any arrangement falling within the scope of the appended claims. As noted hereinbefore, the packer element may be used in other applications, for example in securing window frames or the like in position.

Claims

CLAIMS:

1. A packer element comprising a material in the form of a mix of a plastics material and an intumescent material.

2. An element according to Claim 1, wherein the intumescent material comprises a graphite based intumescent material.

3. An element according to Claim 1 or Claim 2, wherein the quantity of intumescent material 10 in the material of the packer element is chosen such that expansion of a stack of packer elements, in the event of a fire, is minimal, expansion of the intumescent material compensating for shrinkage, deformation or the like of the plastics material.

4. An element according to Claim 3, wherein the quantity of intumescent material present 15 within the packer element is such that expansion thereof, in use, is less than 2%.

5. An element according to any of the preceding claims, wherein the intumescent material makes up less than 50% by weight of the material of the packer element.

20

6. An element according to Claim 5, wherein the intumescent material makes up less than

25% by weight of the material of the packer element.

7. An element according to Claim 6, wherein the intumescent material makes up less than 10% by weight of the material of the packer element.

8. An element according to Claim 7, wherein the intumescent material makes up 2-7% by weight of the material of the packer element.

9. An element according to Claim 8, wherein the intumescent material makes up around 4% by weight of the material of the packer element.

5

10. An element according to any of the preceding claims, wherein the plastics material is a PVC material.

11. An element according to any of the preceding claims, wherein the material of the packer element further comprises other materials serving as fillers and/or to aid moulding or extrusion of

10 the material to a desired shape.

12. An element according to any of the preceding claims and of extruded form.

13. An element according to any of the preceding claims and provided with a coloured line or 15 other marking to provide an indication to an installer of the thickness of the packer element.

14. An assembly comprising a door frame, window frame or the like located within an opening, and at least one stack of packer elements located between the frame and the opening, wherein at least one of the packer elements comprises a packer element according to any of the preceding

20 claims.

15. An assembly according to Claim 14, wherein the frame forms part of a preassembled door unit.

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