FIRE RESISTANT GLAZING UNIT

Abstract

Fire resistant glazing units, processes for the manufacture of such fire resistant glazing units, the use of fire resistant glazing units in construction, and constructions comprising such glazing units. A fire resistant glazing unit may include two panes of glass which are arranged together with a seal to enclose a fire-resistant interlayer. The seal is adapted to breach in the event of a fire causing increased pressure between the panes, releasing pressure before it can build up and cause a pane to break in an unfavourable manner.

Claims

1. A glazing unit, comprising: a first pane and a second pane, which may be the same or different; a fire resistant interlayer between the first pane and the second pane; and a seal which, together with the first pane and the second pane, encloses the fire-resistant interlayer, wherein the seal is configured to breach in an event of increased pressure between the first pane and the second pane.

2. The glazing unit of claim 1, wherein the seal comprises a polysulphide polymer.

3. The glazing unit of claim 1, wherein the seal is characterised by a Shore A hardness of about <45.

4. The glazing unit of claim 3, wherein the seal is characterised by a Shore A hardness of about 10-about 30.

5. The glazing unit of claim 4, wherein the seal is characterised by a Shore A hardness of about 25.

6. The glazing unit of claim 1, wherein the seal is characterised by a maximum tensile elongation of about about <70%.

7. The glazing unit of claim 1, wherein the seal is characterised by a loss of thermal stability at about 150 C.-about 250 C.

8. The glazing unit of claim 1, wherein the seal is characterised by a tensile strength of about 0.3 MPa-about 0.6 MPa.

9. The glazing unit of claim 1, wherein the seal is characterised by a weight loss of about 5%-about 50% as measured at 250 C.

10. The glazing unit of claim 1, wherein the seal comprises a section comprising a thermoplastic polymer or a thermosetting polymer.

11. The glazing unit of claim 1, further comprising a second seal enclosing the first seal, wherein the second seal is configured to breach in an event of increased pressure between the first pane and the second pane.

12. The glazing unit of claim 1, further comprising a spacer.

13. The glazing unit of claim 12, wherein the spacer comprises acrylonitrile butadiene styrene, nylon, polytetrafluoroethylene, polypropylene, polyethylene, high density polyethylene, polyurethane, silicone, polyester, stainless steel, titanium or epoxy resin; or is a thermoplastic or thermosetting plastic spacer.

14. The glazing unit of claim 1, wherein the first pane and the second pane comprise toughened glass or laminated glass.

15. The glazing unit of claim 1, wherein the fire-resistant interlayer comprises a potassium silicate gel.

16. The glazing unit of claim 1, wherein the fire-resistant interlayer comprises an organic hydrogel.

17. The glazing unit of claim 1, further comprising a second seal enclosing the seal, the second seal comprising a polysulphide polymer characterised by: a Shore A hardness of about 10 to about 45, a maximum tensile elongation of about 5%-about 70%, a loss of thermal stability at about 150 C.-about 250 C., a tensile strength of about <0.6 MPa, and/or a weight loss of about 5%-about 50% as measured at 250 C., wherein: the first pane and the second pane both comprise toughened glass or toughened laminated glass, the fire resistant interlayer comprises an organic hydrogel or a potassium silicate gel between the first pane and the second pane, and the seal consists essentially of a thermoplastic spacer.

18. The glazing unit of claim 1, further comprising a second seal enclosing the seal, the second seal comprising a polysulphide polymer characterised by a Shore A hardness of about 10 to about 45, a maximum tensile elongation of about 5%-about 70%, a loss of thermal stability at about 150 C.-about 250 C., a tensile strength of about <0.6 MPa, and/or a weight loss of about 5%-about 50% as measured at 250 C., wherein: the first pane and the second pane both comprise toughened glass or toughened laminated glass, the fire resistant interlayer comprises an organic hydrogel or a potassium silicate gel between the first pane and the second pane, and the seal consists essentially of acrylonitrile butadiene styrene which is sealingly connected to the first pane and the second pane using butyl polymer.

19. A process for the manufacture of a glazing unit, the process comprising: (a) providing a first and a second pane; (b) partially assembling the glazing unit by spacing apart the first pane and the second pane and holding them in position with a seal which, in a completed glazing unit, is configured to breach in the event of increased pressure between the first pane and the second pane, the seal comprising an opening and together with the first pane and the second pane define an internal space; (c) delivering a fire-resistant material into the internal space through the opening in the seal; and (d) closing the opening in the seal to enclose the fire-resistant interlayer.

20. Use of a glazing unit in construction, the glazing unit comprising: a first pane and a second pane, which may be the same or different; a fire resistant interlayer between the first pane and the second pane; and a seal which, together with the first pane and the second pane, encloses the fire-resistant interlayer, wherein the seal is configured to breach in an event of increased pressure between the first pane and the second pane.

Description

DRAWINGS

[0349] FIG. 1 is a cross section of a glazing unit of configuration A.

[0350] FIG. 2 is a cross section of a glazing unit of configuration B.

[0351] FIG. 3 is a cross section of a glazing unit of configuration C.

[0352] FIG. 4 is a cross section of the Configuration of Examples 13-16.

[0353] FIG. 5 is a cross section of the Configuration of Example 17.

[0354] FIG. 6 shows the result of testing a glazing unit with a polysulphide polymer seal characterised by a Shore A hardness of 25 (Example 2) according to EN 1364-1.

DESCRIPTION

[0355] Example glazing units can have a number of possible basic configurations, which are illustrated in FIGS. 1 to 3.

[0356] Configuration A

[0357] Glazing unit configuration A is depicted cross-sectionally in FIG. 1. The glazing unit has two parallel opposed rectangular panes 1 separated at their peripheries by a primary seal comprising spacer 2. Spacer 2 is sealingly connected to the panes it separates with an adhesive (not labelled). The primary seal formed from spacer 2 and its adhesive encloses an internal space 4 along with the two opposed panes 1. Each pane 1 has a thickness of about 5 mm. Spacer 2 is about 5 mm high (i.e. extends inward from the perimeter of the pane by about 5 mm) and consists of a single continuous elongate piece of material bent into a substantially rectangular shape following the perimeter of pane 1. A fire-resistant interlayer fills the internal space 4 enclosed by the primary seal. Both the fire-resistant interlayer and the primary seal are enclosed by a secondary seal 3. The secondary seal 3 is substantially the same height as spacer 2.

[0358] Configuration B

[0359] Glazing unit configuration B is depicted cross-sectionally in FIG. 2. The configuration is similar to configuration A but triple glazed, with three panes of toughened glass 1 defining two internal spaces 4 both enclosing fire-resistant interlayers.

[0360] Configuration C

[0361] Glazing unit configuration C is depicted cross-sectionally in FIG. 3. This is an alternative_triple glazing unit building on the structure of Configuration A with a further pane 5, which together with spacer 6 and secondary seal 7 defines an additional internal space (not labelled) parallel to internal space/fire resistant interlayer 4. The additional internal space may be evacuated to form an insulating fire-resistant glazing unit.

[0362] The following examples are for illustration only and should not be taken to limit the scope of the invention.

TABLE-US-00001 TABLE 1 Examples Fire Example Resistant No. Configuration Panes Primary Seal Secondary Seal Interlayer 1 A Toughened Acrylobutadiene Polysulphide Organic glass polymer spacer polymer hydrogel bound to pane characterised by a with butyl Shore A hardness polymer of 25 adhesive 2 A Toughened Acrylobutadiene Polysulphide Potassium glass polymer spacer polymer silicate gel bound to pane characterised by a with butyl Shore A hardness polymer of 25 adhesive 3 A Toughened Thermoplastic Polysulphide Organic glass spacer.sup.1 polymer hydrogel characterised by a Shore A hardness of 25 4 A Toughened Thermoplastic Polysulphide Potassium glass spacer polymer silicate gel characterised by a Shore A hardness of 25 5 A Toughened Thermoplastic Polysulphide Potassium glass spacer polymer silicate gel characterised by a Shore A hardness of 40, a Young's Modulus of 0.4 MPa, and a tensile elongation of 58.3% 6 B Toughened Acrylonitrile Polysulphide Organic glass butadiene polymer hydrogel styrene characterised polymer by a Shore A spacer bound hardness of 25 to pane with butyl polymer adhesive 7 B Toughened Acrylonitrile Polysulphide Potassium glass butadiene polymer silicate gel styrene characterised polymer by a Shore A spacer bound hardness of 25 to pane with butyl polymer adhesive 8 B Toughened Thermoplastic Polysulphide Organic glass spacer polymer hydrogel characterised by a Shore A hardness of 25 9 B Toughened Thermoplastic Polysulphide Potassium glass spacer polymer silicate gel characterised by a Shore A hardness of 25 10 C Toughened Acrylonitrile Polysulphide Organic glass butadiene polymer hydrogel styrene characterised polymer by a Shore A spacer bound hardness of 25 to pane with butyl polymer adhesive 11 C Toughened Acrylonitrile Polysulphide Potassium glass butadiene polymer silicate gel styrene characterised polymer by a Shore A spacer bound hardness of 25 to pane with butyl polymer adhesive 12 C Toughened Thermoplastic Polysulphide Organic glass spacer polymer hydrogel characterised by a Shore A hardness of 25 13 C Toughened Thermoplastic Polysulphide Potassium glass spacer polymer silicate gel characterised by a Shore A hardness of 25 14 A One pane of Acrylonitrile Polysulphide Organic toughened butadiene polymer hydrogel glass and one styrene characterised pane of polymer by a Shore A laminated spacer bound hardness of 25 glass to pane with comprising a butyl polymer layer of adhesive polyvinyl butyral foil.sup.2 15 A One pane of Acrylonitrile Polysulphide Potassium toughened butadiene polymer silicate gel glass and one styrene characterised pane of polymer by a Shore A laminated spacer bound hardness of 25 glass to pane with comprising a butyl polymer layer of adhesive polyvinyl butyral foil.sup.2 16 A One pane of Thermoplastic Polysulphide Organic toughened spacer polymer hydrogel glass and one characterised pane of by a Shore A laminated hardness of 25 glass comprising a layer of polyvinyl butyral foil 17 A One pane of Thermoplastic Polysulphide Potassium toughened spacer polymer silicate gel glass and one characterised pane of by a Shore A laminated hardness of 25 glass comprising a layer of polyvinyl butyral foil 18 A Laminated Acrylonitrile Polysulphide Organic glass butadiene polymer hydrogel comprising a styrene characterised layer of polymer by a Shore A polyvinyl spacer bound hardness of 25 butyral foil.sup.3 to pane with butyl polymer adhesive 19 A One pane of Acrylonitrile Polysulphide Potassium toughened butadiene polymer silicate gel glass and one styrene characterised pane of polymer by a Shore A laminated spacer bound hardness of 25 glass to pane with comprising a butyl polymer layer of adhesive polyvinyl butyral foil 20 A One pane of Thermoplastic Polysulphide Organic toughened spacer polymer hydrogel glass and one characterised pane of by a Shore A laminated hardness of 25 glass comprising a layer of polyvinyl butyral foil 21 A One pane of Thermoplastic Polysulphide Organic toughened spacer polymer hydrogel glass and one characterised pane of by a Shore A toughened hardness of 25 glass comprising a layer of polyvinyl butyral foil approximately at its centre 22 A Toughened Thermoplastic Polysulphide Potassium glass spacer polymer silicate gel characterised by a Shore A hardness of 45 comprising a section of nylon polymer 23 A Toughened Thermoplastic Polysulphide Potassium glass spacer polymer silicate gel characterised by a Shore A hardness of 45 comprising a section of nylon polymer 24 A Toughened Thermoplastic Polysulphide Potassium glass spacer polymer silicate gel characterised by a Shore A hardness of 45 scored to remove a v- shaped notch of material 25 A Toughened Thermoplastic Polysulphide Potassium glass spacer polymer silicate gel characterised by a Shore A hardness of 45 comprising four corner shims embedded at the corners of the seal Reference A Toughened Thermoplastic Silicone Potassium Example 1 glass spacer polymer (DOW silicate gel (Does not CORNING embody the 3362 insulating invention) glass sealant) of Shore A hardness 41 Reference A Toughened Thermoplastic Polysulphide Potassium Example 2 glass spacer polymer silicate gel (Does not characterised embody the by a Shore A invention) hardness of 45 .sup.1Binds to panes to form a primary seal without the need for a separate adhesive. .sup.2See FIG. 4 .sup.3See FIG. 5

[0363] General Experimental Details

[0364] Polysulphide polymers with the properties described in this specification can be obtained commercially (for example IGK 311 or IGK 330 from Isolierglasklebstoffe GmbH, Frankfurt, Germany) or prepared according to methods described in Lee, T. Properties and Applications of Elastomeric Polysulfides; RAPRA Review Reports; Smithers RAPRA (Shrewsbury, United Kingdom); 1 Jan. 1999 (http://www.smithersrapra.com/publications/books/browse-by-category/review reports/properties-applications-elastomeric-polysulfides). For example, it is possible to prepare the polysulphide polymers described herein which have a Shore A hardness of <45 by obtaining IGK 330 and increasing the amount of the plasticiser component beyond that recommended by the supplier when preparing the polymer.

[0365] Silicone polymers with the properties described in this specification can be obtained commercially or prepared by methods described in The use of Silicone Sealants in Dual-Sealed Insulating Glass Units, Insulating Glass Technical Manual, Dow Corning America. 2013 (https://www.dowcorning.com/content/publishedlit/62-1492-01.pdf).

[0366] Polyurethane polymers with the properties described in this specification can be obtained commercially (e.g. IGK 130 from Isolierglasklebstoffe GmbH, Frankfurt, Germany) and modified according to methods known in the art.

[0367] Butyl polymers with the properties described in this specification can be obtained commercially (e.g. Euroseal from Thermoseal, Wigan, United Kingdom).

[0368] Other materials referred to in the specification are readily available commercially or can be prepared by the skilled person with a common general knowledge of fire resistant glazing units.

[0369] A Zwick Roell 3115 Durometer was used for measuring Shore A Hardness values at 22 C. Each test material was placed on a flat surface and the durometer was brought into contact with its surface. The durometer was then pressed against the material's surface. After indentation had occurred, the final reading was taken. The test was repeated 3 times and an average value was adopted.

[0370] A Zwick Roell Z030 tensile tester was used for measuring the maximum tensile elongation. Measurements were carried out at 22 C. Each material was prepared from a mold 2 mm60 mm10 mm and presented to the equipment such that a gauge length of approximately 20 mm was obtained. The material was then clamped on to the tester before zeroing the normal force. The material was then subjected to tension using a separation speed of 50 mm/min. The increase in the material's pre-registered gauge length was measured and expressed as a percentage of its original gauge length.

[0371] A TA Instruments AR G2 rheometer was used for determining loss of thermal stability in the test materials, using an oscillation procedure. The rheometer was fitted with an environmental testing chamber (ETC). An ETC bottom fixture and a 25 mm ETC parallel steel plate were used. The sample was prepared having a diameter of 25 mm. After placing the sample between the rheometer plates, the gap was closed until a 1N normal force was achieved. Controlled heating was then commenced between 25 C. and 225 C. using a 20 C./min gradient. A frequency value of 1 Hz and strain value of 3e-3% were used during the measurement. Changes in the storage and loss moduli were then monitored and plotted against temperature.

[0372] A thermogravimetric analysis approach was used when determining the loss of thermal stability in the materials. Weight loss in the test materials was monitored as a function of heating temperature. A TA Instruments TGA 5500 tester was used for the measurements. Approximately 5 mg of each test material was used. Weight loss was monitored in an air atmosphere using a heating rate of 20 C./min, for heating between 25 C. and 800 C.

[0373] A Zwick Roell Z030 tester was used for recording tensile strength. Measurements were obtained at 22 C. Samples of the material were prepared into dog-bone-shape having a neck of dimensions 2 mm2 mm, using a press. Thus, samples were obtained having desirable shoulders for gripping. The sample was then mounted on to the tensile tester such that the gauge length was 20 mm and was subjected to controlled tension, using a gap speed of 50 mm/min. The tensile force was recorded as a function of gauge length (deformation). Stress/strain curves were then plotted after normalising the data with respect to the material's dimensions.

[0374] Testing Protocols

Fire TestReference Example 1

[0375] A 570 mm2200 mm glazing unit in 5/3/5 [glass (mm)/interlayer (mm)/glass (mm)] arrangement was prepared having a potassium silicate gel interlayer and using silicone polymer (DOW CORNING 3362 insulating glass sealant) of Shore A hardness 41 and a tensile strength of 1.03 MPa as the secondary seal. The sample was fire tested in a steel frame according to EN 1364-1. The unit was observed to balloon and fire side pane broke in an unfavourable manner.

Fire TestReference Example 2

[0376] A 570 mm2200 mm glazing unit in 5/3/5 [glass (mm)/interlayer (mm)/glass (mm)] arrangement was prepared having a potassium silicate gel interlayer and using a polysulphide polymer of Shore A hardness 45, a tensile strength of 1.2 MPa, and a weight loss of 3.2% at 250 C. as the secondary seal. The sample was fire tested in a steel frame according to EN 1364-1. The unit was observed to balloon and the fire side pane broke in an unfavourable manner.

Fire TestExample 4

[0377] A 570 mm2200 mm glazing unit in 5/3/5 [glass (mm)/interlayer (mm)/glass (mm)] arrangement was prepared having a potassium silicate gel interlayer and a polysulphide polymer of Shore A hardness 25, and a weight loss of 9.3% at 250 C., as the secondary seal. The sample was fire tested in a steel frame according to EN1364-1. The unit was observed to balloon and subsequently steam release was observed. The fire side pane then broke in a favourable manner because of thermal shock.

Partial Fire TestExample 4

[0378] A 570 mm2200 mm glazing unit in 5/3/5 [glass (mm)/interlayer (mm)/glass (mm)] arrangement having a potassium gel silicate interlayer was prepared using a polysulphide polymer of Shore A hardness 25 and a weight loss of 9.3% at 250 C., as the secondary seal. The sample was fire tested in a steel frame according to EN1364-1. The unit was observed to balloon and subsequently steam release was observed. The test was stopped prior to breakage of the fire side pane in order to assess the structure of the unit. Subsequent examination revealed several bursts in the seal where steam had vented. FIG. 6 shows a picture taken of the unit following the test. A seal burst can be seen at point A, while the surrounding pane B can be seen to be intact. The thermoplastic spacer C (i.e. the primary seal) and secondary seal residue at A can be seen to have been pushed outwards by pressure build-up between the first and second panes, this pressure eventually causing the seal to breach.

Fire TestExample 5

[0379] A 570 mm2200 mm glazing unit in 5/3/5 [glass (mm)/interlayer (mm)/glass (mm)] arrangement was prepared having a potassium silicate gel interlayer and a polysulphide polymer of Shore A hardness 40, a Young's Modulus of 0.4 MPa, and a tensile elongation of 58.3% as the secondary seal. The sample was fire tested in a steel frame according to EN 1364-1. The unit was observed to balloon and subsequently steam release was observed. The fire side pane then broke in a favourable manner because of thermal shock.

Fire TestExample 22

[0380] A 570 mm2200 mm glazing unit in 5/3/5 [glass (mm)/interlayer (mm)/glass (mm)] arrangement was prepared having a potassium silicate gel interlayer and a polysulphide polymer of Shore A hardness 45 as the secondary seal. A part of the secondary seal was removed and in its place was embedded a nylon plastic piece of 3 mm5 mm20 mm. The sample was fire tested in a steel frame according to EN 1364-1. The unit was observed to balloon and subsequently steam release was observed from the position of the nylon plastic piece. The fire side pane then broke in a favourable manner because of thermal shock.

Fire TestExample 23

[0381] A 570 mm2200 mm glazing unit in 5/3/5 [glass (mm)/interlayer (mm)/glass (mm)] arrangement was prepared having a potassium silicate gel interlayer and a polysulphide polymer of Shore A hardness 50 as the secondary seal. A part of the secondary seal was removed and in its place was embedded a piece of butyl polymer of 3 mm5 mm20 mm (butyl melting point 170 C.). The sample was fire tested in a steel frame according to EN 1364-1. The unit was observed to balloon and subsequently steam release was observed from the position of the butyl polymer insert. The fire side pane then broke favourably in a non-explosive manner because of thermal shock.

Fire TestExample 24

[0382] A 570 mm2200 mm glazing unit in 5/3/5 (glass (mm)/interlayer (mm)/glass (mm)) composition having a potassium silicate gel interlayer was prepared using a polysulphide polymer of Shore A hardness 45 as the secondary seal. In this example, the secondary seal was scored to remove a v-shaped notch of sealant extending from the outer edge of the seal towards the centre of the glazing unit by about 30% of the seal width. The sample was fire tested in a steel frame according to EN 1364-1. Steam release was observed and ballooning was minimal. The fire side pane then broke favourably in a non-explosive manner because of thermal shock.

Fire TestExample 25

[0383] A 570 mm2200 mm glazing unit in 5/3/5 [glass (mm)/interlayer (mm)/glass (mm)] arrangement was prepared having a potassium silicate gel interlayer and a polysulphide polymer of Shore A hardness 45 as the secondary seal. Four corner shims were embedded into the secondary seal at the corners of the unit. The sample was fire tested in a steel frame according to EN 1364-1. The unit was observed to balloon and subsequently steam release was observed. The fire side pane then broke favourably in a non-explosive manner because of thermal shock.