GB2616885A

GB2616885A - Fire-resistant under-frame packer body for a glazed frame assembly

Info

Publication number: GB2616885A
Application number: GB2204121.4A
Authority: GB
Inventors: Watts Allan
Original assignee: RAM EXTRUSION Ltd
Current assignee: RAM EXTRUSION Ltd
Priority date: 2022-03-24
Filing date: 2022-03-24
Publication date: 2023-09-27
Also published as: GB2616885A8; GB202204121D0

Abstract

The fire-resistant under-frame packer body 10 for a glazed frame assembly 100, to a fixed frame 110.under-frame packer body comprises a material in the form of a mix of a plastics material and an intumescent material. The under-frame packer body has a length of at least 300 millimetres and a width of at least 55 millimetres, to fit under the fixed frame of the glazed frame assembly. The packer may include a locator 12a that fits into a channel 12b in a frame part 110. Also claimed is a fixed frame with the packer. Also claimed is a glazed frame assembly with the fixed frame. Also claimed is a structure with the glazed frame assembly and a method of assembly a fixed frame where the method comprises providing the packer.

Description

FIRE-RESISTANT UNDER-FRAME PACKER BODY FOR A GLAZED FRAME ASSEMBLY

FIELD OF THE INVENTION

Embodiments of the present invention relate to a fire-resistant under-frame packer body. In particular, but not exclusively they relate to a glazed frame assembly having a load-bearing fire-resistant under-frame packer body beneath.

BACKGROUND TO THE INVENTION

It is increasingly common for glazed frame assemblies to be installed into a building to be supplied in the form of a pre-assembled unit or set comprising a 15 fixed frame and an opening frame, the opening frame being glazed and being pivotally or slidably supported by the fixed frame.

The fixed frame and/or opening frame are typically provided with a load-bearing under-frame timber packer fitted in the factory.

Although installation of a timber packer is relatively straightforward, there is a risk that the installed glazed frame assembly may not provide a sufficiently good level of fire protection. There is a risk that, in the event of a fire, temperatures may be reached at which the timber packer deforms and may even catch alight.

The result is that the glazed frame assembly may no longer be rigidly supported in position, and there is a risk that the glazed frame assembly may fall over or otherwise become unsealed. Clearly, should this occur, the glazed frame assembly 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.

In many countries, building regulations require glazed frame assemblies 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 glazed frame assembly 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.

BRIEF DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION

According to various, but not necessarily all examples of the disclosure there is provided an under-frame packer body comprising a material in the form of a mix of a plastics material and an intumescent material, wherein the under-frame packer body has a length of at least 300 millimetres and a width of at least 55 millimetres, to fit under a fixed frame of a glazed frame assembly.

According to various, but not necessarily all examples of the disclosure there is provided a fixed frame for a glazed frame assembly, the fixed frame comprising the under-frame packer body, secured to a lower frame section of the fixed frame.

According to various, but not necessarily all examples of the disclosure there is provided a glazed frame assembly comprising the fixed frame.

According to various, but not necessarily all examples of the disclosure there is provided a structure comprising the glazed frame assembly, wherein the under-frame packer body is in a single-layer configuration such that a bottom surface of the under-frame packer body is on a structural wall or structural floor of the structure, and a top surface of the same under-frame packer body is in contact with the fixed frame.

According to various, but not necessarily all examples of the disclosure there is provided a method of assembling a fixed frame of a glazed frame assembly, the method comprising: providing a fixed frame having frame sections including a lower frame section; providing an under-frame packer body comprising a material in the form of a mix of a plastics material and an intumescent material, wherein the body has a length of at least 300 millimetres and a width of at least 55 millimetres; cutting the length of the under-frame packer body to no less than a width of the lower frame section; and securing the cut length of the under-frame packer body to an underside of the lower frame section.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of various examples of embodiments of the present invention reference will now be made by way of example only to the accompanying drawings in which: FIG. 1 illustrates an under-frame packer body; and FIG. 2 illustrates a cross-section of an installed glazed frame assembly having the under-frame packer body.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION

FIGS. 1 and 2 illustrate an under-frame packer body 10 ("under-frame packer") for a glazed frame assembly 100.

During construction of a structure 1 for occupants, such as a building, openings 3 are formed in exterior or interior walls in which glazed frame assemblies can be installed.

A first example of a glazed frame assembly 100 is an elevated window as shown in FIG. 2, elevated above floor level by a structural wall 2 of the structure 1. The structural wall 2 can comprise a brick wall or a cladding frame, for example.

A second example of a glazed frame assembly 100 is a window arrangement that starts from floor level and is in contact with a structural floor of the structure 1. Some may be non-openable, and others may be openable to enable passage of occupants of the structure 1 therethrough.

The glazed frame assembly 100 may comprise one or more glass panes 126 in a single-glazing, double-glazing or triple-glazing configuration.

The glazed frame assembly 100 comprises a fixed frame 110 fitted to the opening 3 in the structure 1 and may comprise an opening frame 120 fitted to the fixed frame 110. The opening frame 120 is glazed and may be pivotally and/or slidably supported by the fixed frame 110. Alternatively, for non-opening use cases, the opening frame 120 may be omitted and the fixed frame 110 may be glazed.

The fixed frame 110 comprises a lower frame section 111 illustrated in FIG. 2. The lower frame section 111 may be approximately horizontal. If the fixed frame 110 is quadrilateral in shape, the fixed frame 110 may further comprise an upper frame section and lateral upstanding frame sections which may be perpendicular to the lower and upper frame sections.

During installation of the glazed frame assembly 100 into the opening 3 in the structure 1, the installer will add an under-frame packer 10 according to the invention, or the glazed frame assembly 100 may arrive at the construction site with the under-frame packer 10 preinstalled.

The under-frame packer 10 elevates the lower frame section 111 of the fixed frame 110 from the structure 1 According to the invention, the under-frame packer 10 comprises a material in the form of a mix of a plastics material and 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 under-frame packer 10 used to secure the glazed frame assembly 100 in position within the opening 3 in the structure 1 does not significantly alter. As a result, the glazed frame assembly 100 will remain firmly secured in position in the opening 3 of the structure 1 in the event of a fire. Furthermore, distortion of the glazed frame assembly 100 is avoided, and so the risk of the opening frame 120 thereof failing to operate properly is reduced. The degree of fire protection provided by such an arrangement is thus enhanced.

The under-frame packer 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 can be a PVC material or other extrudable 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 under-frame packer 10. More preferably, it may make up less than 25% by weight. Where graphite is used as the intumescent material, intumescent material may make up a value selected from the range approximately 10% to approximately 20% by weight of the material of the under-frame packer 10.

It has been found that a under-frame packer 10 using a quantity of graphite intumescent material in the regions of 10-20% by weight, results in an under-frame packer 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 under-frame packer 10 compensating for any shrinkage or movement of other materials in the under-frame packer 10 and so results in the glazed frame assembly 100 continuing to be maintained securely in an upright condition within the opening 3 of the structure 1. Furthermore, as the under-frame packer 10 does not significantly increase in dimensions, deformation of the glazed frame assembly 100, in the event of a fire, is avoided or restricted, and so the risk of the opening frame 120 failing to operate properly is avoided or reduced.

By contrast, the use of excessive or 100% intumescent material may result in net expansion of the under-frame packer 10 which could deform the glazed frame assembly 100.

The precise quantity of intumescent material in the mix can be chosen such that net expansion of the under-frame packer 10, in a fire test specified in British Standard BS476 Part 22: 1987, is less than 2% over at least 30 minutes. The minimal expansion is because the expansion of the intumescent material compensates for the shrinkage, deformation or the like of the plastics material.

As mentioned above, the material of the under-frame packer 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, 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.

The under-frame packer 10 may have a vicat softening point selected from the range 85 to 95 Celsius, based on the ISO 306 (B50) test.

The intrinsic material properties of the under-frame packer 10 may be selected so that the under-frame packer 10 functions as a load-bearing body for transferring and spreading a weight load of the glazed frame assembly 100 to the underlying structure 1, with minimal deformation. The weight load may be significant when considering the cantilevering effect of a hinged opening frame 120, and wind loading.

For example, the under-frame packer 10 may have a Shore "A" hardness of 15 between 80 and 95 and/or may have a density between 1.3 and 1.6 sg The geometry of the under-frame packer 10 is selected to spread the weight of the glazed frame assembly 100 to the underlying structure 1.

The under-frame packer 10 may have a top surface shaped for continuous contact with the underside of the frame assembly. At least some of the top surface may be substantially planar. The whole top surface may be substantially planar if the below-described locator 12A is not present. The under-frame packer 10 may have a planar bottom surface opposite the top surface. The planar parts of the top and bottom surfaces may be parallel. The top and bottom surfaces may be joined by perpendicular side walls and end walls that collectively define a constant thickness of the under-frame packer 10. The width of the under-frame packer 10 may be constant. The under-frame packer 10 may comprise a rectangular cross-section.

The under-frame packer 10 may be supplied in a long length to an installer or window manufacturer, so that the under-frame packer 10 can be cut down to match the width of a window opening 3 or the width of the glazed frame assembly 100. For the purpose of this disclosure, the width of a window opening 3 which can be approximated as the width of the glazed frame assembly 100 although in practice the window opening 3 may be slightly wider than the width of the glazed frame assembly 100, to assist installation. The relevant width of the glazed frame assembly 100 can be characterised as the width of the lower frame section 111 of the fixed frame 110. In another implementation, the length of the under-frame packer 10 matches the slightly larger width of the window opening 3, so the ends of the under-frame packer 10 slightly overhang the ends of the lower frame section 111.

Cutting down a long under-frame packer 10 to a required length is better than joining short under-frame packers end to end because the small gaps left could create a week spot for fire ingress When fitted to the glazed frame assembly 100, the under-frame packer 10 has a cut length (L) selected from the range 300 millimetres to 4000 millimetres, depending on the width of the part of the glazed frame assembly 100 to which it is fitted.

Standard window widths in the United Kingdom range from 488 millimetres to 1770 millimetres. Therefore, the cut and fitted length (L) may be from the range approximately 450 millimetres to approximately 1850 millimetres.

Specific examples of cut and fitted lengths (L) of the under-frame packer 10 include, for example, 488 millimetres, 630 millimetres, 915 millimetres, 1200 millimetres, and 1770 millimetres, each plus or minus 50 millimetres.

During construction of the glazed frame assembly 100, the pre-cut length (L) of 30 the under-frame packer 10 may be equal to or greater than 1770 millimetres, to maximise compatibility with different window widths. For ease of transport, the pre-cut length (L) may be no greater than 4000 millimetres or no greater than 10 metres The width (W) of the under-frame packer 10 is selected to enable the under-frame packer 10 to be fitted under a fixed frame 110 of a glazed frame assembly 100 in a stable load-bearing manner.

The width (W) depends on the depth of the opening 3 in the structure 1 and the depth of the glazed frame assembly 100. The width should be sufficient that it is not necessary to place two under-frame packers alongside each other.

The under-frame packer 10 may be supplied in different widths (VV) for different installations.

The width (W) may be selected from the range approximately 55 millimetres to approximately 200 millimetres Widths less than 55 millimetres may be unstable during fitting and a potential weak point for fire ingress. In a specific example, a lower limit width is approximately 80 millimetres.

In a specific example, the upper limit width is a value greater than 110 millimetres such as approximately 120 millimetres. Widths greater than 120 millimetres may be wider than the depth of the opening 3/glazed frame assembly 100, but could be used in bespoke installations.

The thickness (T) of the under-frame packer 10 is selected to enable the under-frame packer 10 to be fitted as a single layer rather than as a stack. A single layer is more suitable for load-bearing applications. A single layer also provides a substrate to which parts can be affixed such as a bracket, sill or flashing.

The under-frame packer 10 may be supplied in different thicknesses (T) for different purposes.

The thickness (T) may be at least approximately 10 millimetres. The thickness 5 (T) may be selected from the range approximately 10 millimetres to approximately 20 millimetres.

In example implementations, the under-frame packer 10 may be supplied in continuous lengths to suit window width, in widths ranging from approximately millimetres to approximately 115-120 millimetres, and thicknesses ranging from approximately 12 millimetres to approximately 20 millimetres.

The method by which the under-frame packer 10 is fitted to the bottom of the fixed frame 110 is now described. Figure 2 only illustrates a single type of fixed frame 110 and is not representative of all of the types of fixed frame 110 that the under-frame packer 10 can be used for.

The under-frame packer 10 is secured to an underside of the lower frame 20 section 111 of the fixed frame 110. The under-frame packer 10 may bear at least some of the weight of the glazed frame assembly 100.

the under-frame packer 10 is in a single-layer configuration such that a bottom surface of the under-frame packer 10 is on the structural wall 2 or structural floor of the structure 1, and the top surface of the same under-frame packer 10 is against the bottom of the lower frame section 111 of the fixed frame 110.

Widthwise, one side wall of the under-frame packer 10 may be to the interior side of the structure 1/lower frame section 111 and the opposite side wall of the 30 same under-frame packer 10 may be to the exterior side of the structure 1/lower frame section 111 To assist in initial positioning of the under-frame packer 10, the under-frame packer 10 can comprise a locator 12A configured to control a positioning of the under-frame packer 10 relative to the fixed frame 110.

The locator 12A may be configured to form part of a plug-socket connection between the under-frame packer 10 and the fixed frame 110. The bottom of the lower frame section 111 can comprise a corresponding locator engaging portion 12B to which the locator 12A of the under-frame packer 10 is engaged.

The illustrated locator 12A on the under-frame packer 10 is a plug and the locator engaging portion 12B on the lower frame section 111 is a socket. Alternatively, the locator 12A can be a socket and the locator engaging portion 12B can be a plug.

The locator 12A may comprise a protrusion in the length direction. The locator 12A may be a protrusion formed in the top surface. The locator engaging portion 12B may comprise a channel in the length direction. The locator 12A may extend continuously along the whole uncut length of the under-frame packer 10, as a result of being formed by extrusion.

The under-frame packer 10 can be pushed towards the lower frame section 111 such that the locator 12A engages with the locator engaging portion 12B. Alternatively, the under-frame packer 10 can be slid laterally into the lower frame section 111 if the locator 12A is an interference fit with the locator engaging portion 12B.

Some lower frame sections can lack a locator engaging portion 12B, so for those implementations a locator 12A may be omitted.

Once the under-frame packer 10 has been positioned against the bottom of the lower frame section 111, the under-frame packer 10 may be affixed to the bottom of the lower frame section 111.

FIG. 2 shows the under-frame packer 10 being secured to the lower frame section 111 by mechanical fixings 150. The mechanical fixings 150 can comprise screws, for example.

The illustrated lower frame section 111 is a composite lower frame section 111, also referred to as a hybrid section. The composite lower frame section 111 comprises frame section portions (profiles) made of different materials. The illustrated lower frame section 111 of the fixed frame 110 comprises a first frame section portion 112 of a first material and a second frame section portion 114 of a second material. The first frame section portion 112 may comprise a timber profile. The second frame section portion 114 can comprise a moulded plastics profile. The undersides of the first and second frame section portions 112, 114 may be generally planar with each other and alongside each other. The first frame section portion 112 may comprise the locator engaging portion 12B as a channel in its underside.

Alternatively, the first frame section portion 112 may be below the level of the second frame section portion 114. The under-frame packer 10 may connect to the first frame section portion 112 but not the second frame section portion 114.

The load path from the second frame section portion 114 may pass through the first frame section portion 112 to the under-frame packer 10.

The top surface of the under-frame packer 10 is beneath the or each frame section portion 112, 114.

The under-frame packer 10 may be secured to at least one of the frame section portions 112, 114, and optionally to both frame section portions. In the illustrated example, one or more mechanical fixings 150 secure the under-frame packer 10 to the first frame section portion 112 of the first material, and one or more further mechanical fixings 150 secure the under-frame packer 10 to the second frame section portion 114 of the second material.

In some examples, the top surface of the under-frame packer 10 is secured to the lower frame section 111 of the fixed frame 110 by an adhesive such as a hot melt glue. This can be in addition to, or instead of mechanical fixings 150.

The mechanical fixings 150 can comprise screws such as wood screws. The screws may be self-tapping or may be drilled into pre-drilled holes in the under-frame packer 10.

It would be appreciated that the number and type of materials of the lower frame section 111 may be different from those described above (timber profile and/or moulded plastics profile and/or metal profile). In further implementations, the lower frame section 111 is non-composite and may be of a single material.

The illustrated opening frame 120, which the under-frame packer 10 is not attached to, is a composite frame comprising a frame section portion 122 of a first material and another frame section portion 124 of another material. For example, the frame section portion 122 may comprise a moulded plastics profile. The frame section portion 124 may comprise a metal profile such as aluminium or steel. The frame section portion 124 may be visible from an exterior of the structure 1.

It would be appreciated that the number and type of materials of the opening frame 120 may be different from those described above (timber profile and/or moulded plastics profile and/or metal profile). In further implementations, the opening frame 120 is non-composite and may be of a single material.

In FIG. 2, a part of the glazed frame assembly 100 is affixed directly to the exterior-facing side wall of the under-frame packer 10. The illustrated part is an exterior sill 130 configured to form a building-exterior sill of the glazed frame assembly 100. Alternatively, the part can be flashing (weatherproofing membrane).

The exterior sill 130 is affixed to the under-frame packer 10 via a mechanical fixing such as a screw. The thickness (T) of the under-frame packer 10 is sufficient to receive a screw of at least five millimetres in diameter.

In FIG. 2, another part of the glazed frame assembly 100 is affixed directly to the interior-facing side wall of the under-frame packer 10. The illustrated part is an interior sill 140 configured to form a building-interior sill of the glazed frame assembly 100. It is possible that parts can be fitted to the under-frame packer 10 as shown in FIG. 2, but not in all implementations.

The interior sill 140 is affixed to the under-frame packer 10 via adhesive. Whether sills are screwed directly to the packer depends on the implementation.

According to an aspect of the invention, there is provided a method of assembling a fixed frame 110 of a glazed frame assembly 100.

The method comprises providing the fixed frame 110 of the glazed frame assembly 100. The fixed frame 110 has frame sections including a lower frame section 111.

The method further comprises providing an under-frame packer 10 of the type described in this disclosure.

The method further comprises cutting the length of the under-frame packer 10 to a width of the lower frame section 111, which is approximately the width of the opening 3 in the structure 1 to which the glazed frame assembly 100 is to be fitted.

The method further comprises securing the cut length of the under-frame packer 10 to an underside of the lower frame section 111. An optional locator 12A may assist with initial positioning. The securing may be achieved via mechanical fixings 150 and/or adhesive.

Although embodiments of the present invention have been described in the preceding paragraphs with reference to various examples, it should be appreciated that modifications to the examples given can be made without departing from the scope of the invention as claimed.

Features described in the preceding description may be used in combinations other than the combinations explicitly described.

Although functions have been described with reference to certain features, those functions may be performable by other features whether described or not.

Although features have been described with reference to certain embodiments, those features may also be present in other embodiments whether described or not.

Whilst endeavoring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

I/we claim:

Claims

CLAIMS1. An under-frame packer body comprising a material in the form of a mix of a plastics material and an intumescent material, wherein the under-frame packer body has a length of at least 300 millimetres and a width of at least 55 millimetres, to fit under a fixed frame of a glazed frame assembly.
2. The under-frame packer body of claim 1, wherein the length of the under-frame packer body is at least one metre.
3. The under-frame packer body of claim 1 or 2, wherein the width of the under-frame packer body is greater than 110 millimetres
4. The under-frame packer body of any preceding claim, wherein the under-frame packer body has a thickness of at least 10 millimetres.
5. The under-frame packer body of any preceding claim, comprising a locator configured to control a positioning of the under-frame packer body relative to the fixed frame.
6. The under-frame packer body of claim 5, wherein the locator is configured to form part of a plug-socket connection between the under-frame packer body and the fixed frame.
7. The under-frame packer body of claim 1, wherein the intumescent material comprises a graphite based intumescent material.
8. The under-frame packer body of any preceding claim, wherein the quantity of intumescent material in the mix is chosen such that expansion of the packer body, in a fire test specified in British Standard B5476 Part 22: 1987, is less than 2% over at least 30 minutes, expansion of the intumescent material compensating for shrinkage, deformation or the like of the plastics material.
9. The under-frame packer body of any preceding claim, wherein the intumescent material makes up less than 50% by weight of the material of the packer body.
10. The under-frame packer body of claim 9, wherein the intumescent material makes up less than 25% by weight of the material of the packer body.
11. The under-frame packer body of claim 10, wherein the intumescent material makes up a value selected from the range approximately 10% to approximately 20% by weight of the material of the packer body.
12. The under-frame packer body of any preceding claim, wherein the plastics material is a PVC material.
13. The under-frame packer body of any preceding claim, wherein the material of the packer body further comprises other materials serving as fillers and/or to aid moulding or extrusion of the material to a desired shape.
14. The under-frame packer body of any of the preceding claims and of extruded form.
15. The under-frame packer body of any preceding claim, wherein the under-frame packer body is a load-bearing body for transferring a load of the fixed frame to an underlying structure.
16. A fixed frame for a glazed frame assembly, the fixed frame comprising the under-frame packer body of any preceding claim, secured to a lower frame section of the fixed frame.
17. The fixed frame of claim 16, wherein the lower frame section comprises a locator engaging portion engaged with the locator of the under-frame packer body as defined in claim 5 or 6.
18. The fixed frame of claim 16 or 17, wherein the under-frame packer body is secured to the lower frame section of the fixed frame by mechanical fixings and/or by adhesive.
19. The fixed frame of claim 16, 17 or 18, wherein the under-frame packer body is secured to a timber frame section portion of the lower frame section and/or is secured to a metal frame section portion of the lower frame section and/or is secured to a moulded plastic frame section portion of the lower frame section.
20. A glazed frame assembly comprising the fixed frame of any one of claims 16 to 19.
21. The glazed frame assembly of claim 20, comprising an opening frame supported by the fixed frame.
22. The glazed frame assembly of claim 20 or 21, comprising a first sill or flashing secured to a first side of the under-frame packer body.
23. The glazed frame assembly of claim 22, comprising a second sill secured to a second opposite side of the under-frame packer body.
24. A structure comprising the glazed frame assembly of any one of claims to 23, wherein the under-frame packer body is in a single-layer configuration such that a bottom surface of the under-frame packer body is on a structural wall or structural floor of the structure, and a top surface of the same under-frame packer body is in contact with the fixed frame.
25. A method of assembling a fixed frame of a glazed frame assembly, the method comprising: providing a fixed frame having frame sections including a lower frame section; providing an under-frame packer body comprising a material in the form of a mix of a plastics material and an intumescent material, wherein the body has a length of at least 300 millimetres and a width of at least 55 millimetres; cutting the length of the under-frame packer body to no less than a width of the lower frame section; and securing the cut length of the under-frame packer body to an underside of the lower frame section.