Support Element for Supporting a Window Frame

Abstract

A strip-shaped support element for supporting a window frame comprises an intumescent material such as expandable graphite or sodium and/or potassium silicate. In particular, the support element comprises intumescent material on at least one surface, optionally on all surfaces, in a thickness of at least 0.25 mm.

Claims

1. A strip-shaped support element for supporting a window frame, the strip-shaped support element having a first side surface extending in a longitudinal direction and configured to rest against a wall, and a second side surface extending in the longitudinal direction, wherein the second side surface is substantially perpendicular to the first side surface and is configured to support the window frame, wherein the support element is made of a load-bearing material, wherein the support element comprises intumescent material on at least a surface thereof in a thickness of at least 0.25 mm, which material is selected from the group consisting of: (a) expandable graphite in an amount of 5-70%, and (b) sodium and/or potassium silicate in an amount of 10-30%.

2. The strip-shaped support element according to claim 1, wherein the support element also comprises rigid foam, selected from the group comprising rigid polyurethane foam.

3. The strip-shaped support element according to claim 1, wherein at least one layer parallel to the second side surface of the support element comprises intumescent material.

4. The strip-shaped support element according to claim 1, wherein the support element comprises intumescent material on at least one surface which is a third side surface extending in the longitudinal direction, wherein the third side surface is adjacent to the second side surface on a side opposite the first side surface.

5. The strip-shaped support element according to claim 1, wherein the support element comprises a layered structure with at least one outer layer with intumescent material and at least one layer without intumescent material.

6. The strip-shaped support element according to claim 5, wherein the outer layer with intumescent material is fastened to the layer without intumescent material by adhesion or by screws.

7. The strip-shaped support element according to claim 5, wherein the support element comprises intumescent material in a thickness of between 0.25 mm and 10 mm, and wherein the intumescent material is expandable graphite in an amount of 20-70%.

8. The strip-shaped support element according to claim 1, wherein the support element comprises intumescent material in a thickness of at least 10 mm, and wherein the intumescent material is expandable graphite in an amount of 5-20%.

9. The strip-shaped support element according to claim 1, wherein the support element comprises intumescent material throughout, and wherein the intumescent material is expandable graphite in an amount of 5-20%.

10. The strip-shaped support element according to claim 9, wherein the support element comprises rigid polyurethane foam with 5-10% expandable graphite, obtainable by pressing a starting material, in that expandable graphite flakes in a polyurethane and/or polyisocyanate matrix are pressed in a pressing direction P, wherein the pressing direction P is perpendicular to the second surface of the support element.

11. The strip-shaped support element according to claim 1, wherein the support element comprises intumescent material in a thickness of at least 10 mm, and wherein the intumescent material is sodium and/or potassium silicate in an amount of 10-30%.

12. A building section comprising: a wall; at least one strip-shaped support element having a first side surface extending in a longitudinal direction and configured to rest against a wall, and a second side surface extending in the longitudinal direction, wherein the second side surface is substantially perpendicular to the first side surface and is configured to support the window frame, wherein the support element is made of a load-bearing material, wherein the support element comprises intumescent material on at least a surface thereof in a thickness of at least 0.25 mm, which material is selected from the group consisting of: (a) expandable graphite in an amount of 5-70%, and (b) sodium and/or potassium silicate in an amount of 10-30%; wherein the support element is arranged laterally from the wall, and wherein the support element is fastened to the wall by means of at least one fastening element, wherein the first side surface of the support element rests against the wall; and a window frame, which is supported at least partially on the second surface of the support element.

13. The building section according to claim 12, wherein the building section comprises a plurality of the support elements, wherein: (a) support elements butt directly against each other horizontally, so that the at least one surface comprising intumescent material forms a horizontal fire control barrier without interruption; and/or (b) a fire-retardant layer is introduced horizontally between the support elements, wherein the fire-retardant layer is selected from the group comprising mineral wool.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0059] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawings) will be provided by the Office upon request and payment of the necessary fee.

[0060] FIG. 1 shows cross-sectional views of a first embodiment of a support element according to the invention, wherein the lower diagram represents an insulating part during the pivoting procedure;

[0061] FIG. 2 shows a schematic, cross-sectional view of a building section, which shows a support element according to FIG. 1 in the installed state;

[0062] FIGS. 3a-3h show views of alternative support elements according to the invention;

[0063] FIGS. 4a and 4b show, from the side (above, in the figure), embodiments of support elements according to the invention with homogeneously distributed expandable graphite exposed to flames for 30 minutes;

[0064] FIGS. 5a, 5b, and 5c show the results of the flame-exposure experiments with embodiments of support elements according to the invention with homogeneously distributed expandable graphite with an expanded graphite layer on the flame-exposed side;

[0065] FIG. 5d shows the layout of the flame-exposure experiments, wherein the arrows indicate the direction of the flames in the various experiments; and

[0066] FIGS. 6a and 6b show the different ways in which insulating layers are formed during the expansion of the graphite from a support element according to the invention as a function of the orientation of the pressing direction.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

[0067] FIG. 1 shows a first embodiment of the support element according to the invention for supporting a window frame. The cross section of the support element 2 has the shape of an angle. An insulating part 4 with a rectangular cross section can be connected to the support element 2. The insulating part 4 can also have a different shape, however, or it can be omitted entirely.

[0068] The support element 2 extends primarily in a longitudinal direction. The length of a support element 2 in the longitudinal direction can be freely selected and is preferably between 10 and 150 cm. The support element 2 can be a one-piece unit, or it can consist of two pieces bonded permanently to each other. In the embodiment shown, the support element 2 has an L-shaped cross section. The shape of the support element 2 can also be rectangular or comprise a beveled surface. The support element 2 is made of a load-bearing material, which is adapted to bearing the load of the window fame without itself undergoing deformation.

[0069] It is preferred that the material of the support element 2 have a compressive stress at 10% compression according to DIN EN 826 in the range from 2 to 15 MPa, especially in the range from 4 to 8 MPa. The bulk density of the material should be in the range from 100 to 1,200 kg/m.sup.3, preferably between 350 and 800 kg/m.sup.3. The thermal conductivity of the rigid foam material should be in the range from 0.05 to 0.2 W/mK, preferably in the range from 0.06 to 0.15 W/mK. The material is dimensionally stable and compressively stable under the load of the window.

[0070] The support element 2 comprises a first side surface 6 extending in the longitudinal direction, which serves to rest against a wall 8 (FIG. 2). The first side surface 6 is part of a first web 10 of the support element 2. The support element 2 also comprises a second longitudinally extending side surface 12, which is substantially perpendicular to the first side surface 6 and which serves to support a window frame 34 (FIG. 2). In the exemplary embodiment shown here, the second side surface 12 is part of a second web 16 of the support element 2, which is connected to the first web 10 and projects at an angle from the first web 10. In the example shown here, the angle is 90. The first side surface 6 and the second side surface 12 meet along one edge and also intersect at the same angle as the two webs 10, 16, i.e., therefore at 90 in this case. The second side surface 12 and the third side surface 45 also meet along an edge and intersect at an angle of 90 in the preferred embodiment illustrated.

[0071] In the first web 10, one or preferably several through-holes 18 can be provided, which allow the passage of one or more fastening elements 20 (FIG. 2) such as screws. Each through-hole 18 therefore passes through the first web 10 of the support element 2 from an inner side surface 22, which is opposite the first side surface 6, to the first side surface 6. As can be derived from FIG. 2, each fastening element 20 serves to fasten the support element 2 to the wall 8.

[0072] It is also possible not to provide any through-holes 18 in the first web 10 of the support element in advance. Instead, the through-holes are introduced into the support element 2 by the installer only after it has arrived at the installation site.

[0073] The insulating part 4 is arranged in the area of the inner side surface 22 of the first web 10 of the support element 2. It is preferably made of foam or mineral wool, especially preferably of hard flexible foam. Such foams are usually self-supporting but cannot bear any load. Examples of materials of this type include polystyrene, Styrodur, Styropor, Styrofoam, or Neopur, with bulk densities of <100 kg/m.sup.3, preferably <50 kg/m.sup.3, which are known as thermal insulation materials. The compressive strength of such insulating materials is preferably at most 50% of the compressive strength of the load-bearing rigid foam used for the support element 2, usually less than 20% of that strength.

[0074] The insulating part 4 is pivotably connected to an outer edge area of the first web 10 of the support element 2. It could also be pivotably connected to an outer edge area of the second web 16 of the support element 2. At the top of FIG. 1, the insulating part 4 can be seen in its insulating position, in which the insulating part 4 covers at least most of the inner side surface 22 of the first web 10 of the support element 2; in the present case, it covers that surface completely. In this position, the insulating part 4 rests preferably against both the first web 10 and the second web 16 of the support element 2. It is especially preferred that the support element 2 and the insulating part 4 fit together in such a way that they form a rectangular cross section. The combination of the support element 2 and insulating part 4 is preferably also transported in this insulating position.

[0075] The lower part of FIG. 1 shows the insulating part 4 as it is being pivoted; it is on its way into a working position, in which it exposes at least most of the inner side surface 22 of the first web 10 of the support element 2. In this working position of the insulating part 4, the fastening elements 20 can be introduced into the through-holes 18 without hindrance. If no through-holes 18 are present in the support element 2, the installer has free access to the first web 10 of the support element 2 when the insulating part 4 is in this working position and can produce the through-holes 18 there before he introduces the fastening elements 20 through the through-holes 18 and into the wall 8. The pivot angle between the working position and the insulating position of the insulating part 4 is usually between 60 and 120, but there are no limitations. The pivotable connection between the insulating part 4 and the support element 2 is preferably achieved by a flexible adhesive strip 24, which is adhered both to the insulating part 4 and to the support element 2. In the embodiment shown in FIG. 1, the adhesive strip 24 is configured as a flat, straight covering over the butt joint between the support element 2 and the insulating part 4. Many other arrangements of the adhesive strip 24, however, can also be envisioned.

[0076] The skilled person can also conceive of many other possible ways of realizing the pivoting connection between the insulating part 4 and the support element 2 besides the adhesive strip 24. For example, the insulating part 4 and the support element 2 could be connected to each other by a different type of element such as an elastic element; a small area of the insulating part 4 could also be laminated directly to the support element 2; or some other mechanical pivoting connection could be realized between the insulating part 4 and the support element 2.

[0077] In the embodiment shown in FIG. 1, furthermore, a second adhesive strip 26 is provided, which connects the edge area of the second web 16 of the support element 2 to the insulating part 4. This adhesive strip 26 should be easily detachable at least from the support element 2, because it must be removed from the support element 2 before the insulating part 4 can be pivoted into the working position (FIG. 1, below). The adhesive strip 26 is preferably reusable, so that, after the support element 2 has been fastened to the wall 8 and the insulating part 4 has been pivoted back into the insulating position, it can be reattached to the support element 2. Instead of the second adhesive strip 26, the detachable connection between the insulating part 4 and the second web 16 of the support element 2 can also be realized in some other way.

[0078] If the pivotable connection is created between the second web 16 of the support element 2 and the insulating part 4, then logically the detachable adhesive connection between the insulating part 4 and support element 2 will be between the insulating part 4 and the first web 10 of the support element 2.

[0079] In principle, however, the pivotable connection between the insulating part 4 and the support element 2 can also be the only connection between these two components. The insulating part 4 should then remain in the insulating position without any external influence; for example, as a result of an appropriate selection of the size and shape of the support element 2 and of the insulating part 4, the insulating part can wedge itself detachably between the inner side of the support element 2 perpendicular to the inner side surface 22 and the pivoting connection.

[0080] The insulating part 4 can also be configured in such a way that the surface of the insulating part 4 arranged adjacent to the inner side surface 22 of the support element 2 leaves enough free space to accommodate the portions of the fastening elements 20 which may be projecting from the inner side surface 22 (not shown in the drawing).

[0081] FIG. 2 sketches the installation situation of a support element 2 according to the invention, wherein the orientation of the support element 2 represents the situation in which the element is installed below the window opening. On the other three sides of the window opening, the support element 2 must be rotated as appropriate. In addition to the wall 8, to which the support element 2 is fastened by means of the fastening elements 20, the illustrated building section 28 usually also comprises an outer wall 30, which is usually made of a thermally insulating material. This outer wall is rear-vented, and the support element 2 is arranged in the intermediate space 32 between the main wall 8 and the outer wall 30. The outer wall 30 is usually connected to the main wall 8 by struts, projections, or pins. The window frame 34 is usually arranged adjacent to the intermediate space 32 and is supported on the second side surface 12 of the support element 2. Sealing elements 36 made of PUR foam, for example, can also be inserted between the window frame 34 and the support element 2. Sealing elements 38 made of PUR foam, for example, can also be arranged between the window frame 34 and a projecting part of the outer wall 30, i.e., a part which projects beyond the height of the support element 2.

[0082] The strip-shaped support elements are usually arranged around the entire window opening. It is also possible to install one or more support elements only underneath the window opening, because here is where most of the weight of the window is supported.

[0083] In cases where the window frame 34 is surrounded on all sides by support elements, the one or more support elements on the bottom of the window opening are usually connected to the wall 8 by screws or the like. At this point, but especially on the other sides of the window opening, it is possible under certain circumstances that an adhesive bond between the support element 2 and the wall 8 can also be sufficient. The adhesive bond can also be advantageous when fastening is achieved by means of the fastening elements 20. The adhesive can preferably serve simultaneously as a diffusion barrier as well.

[0084] The length of a support element usually corresponds exactly to the corresponding length or width of the window opening. Nevertheless, it is also possible to arrange several support elements in a row along each side of the window opening. The individual support elements are usually mitered and either butt up against each other or are preferably attached to each other, especially by means of an adhesive.

[0085] FIGS. 3a-3h show additional alternatives of the support elements according to the invention.

[0086] The support element 2 in FIG. 3a corresponds to the support element of FIG. 1 with the difference that there is no insulating part here. It is provided intumescent material continuously throughout. An insulating part is also absent from the other embodiments described below, but it could just as well be present in each of them.

[0087] The support element 2 of FIG. 3b corresponds to the support element of FIG. 3a with the difference that it does not have an L-shaped cross section; it has instead a wedge shape, with a bevel on a side facing away from the first side surface 6. The form of the bevel can be varied in any way desired. It is also conceivable that the support element 2 could have a rectangular cross section.

[0088] The support element 2 in FIG. 3c corresponds to the support element of FIG. 3a with the difference that not the entire support element is provided with intumescent material but rather only a layer 47 with intumescent material is provided on the second side surface 12. The rest of the layer 46 has no intumescent material. It preferred in this case that the layer 47 be at least 10 mm thick. If the intumescent material is expandable graphite, it is preferred that this make up 5-20% of the layer 47. In this embodiment, it is guaranteed that there will an especially pronounced upward expansion of the intumescent material in the direction toward the window frame in the event of a fire.

[0089] The support element 2 of FIG. 3d corresponds to the support element of FIG. 3c with the difference that the layer 47 with intumescent material is arranged on the third side surface 45, i.e., the side facing away from the first side surface 6. Otherwise, the same parameters as those described for FIG. 3c apply to the layer 47 here also. In this embodiment, it is guaranteed that there will be an especially pronounced expansion of the intumescent material toward the side (toward the right in the figure) in the direction toward the outer wall.

[0090] The support element 2 of FIG. 3e corresponds to the support element of FIG. 3c with the difference that an additional layer 47 with intumescent material is arranged on the side facing away from the second side surface 12.

[0091] The support element 2 of FIG. 3f corresponds to the support element of FIG. 3c with the difference that the layer 47 with intumescent material is thinner; it preferably has a thickness of between 0.25 mm and 10 mm, more preferably between 0.5 mm and 5 mm, even more preferably between 1 mm and 3 mm. If the intumescent material is expandable graphite, it preferably makes up 20-70%, more preferably 30-60% of the layer 47.

[0092] The strip-shaped layer 47 with intumescent material in FIG. 3f is fabric-like, film-like, or paper-like. The layer 47 in the original state is preferably in the form of a roll of material, which is unwound and adhered to the layer 46. In the embodiment according to FIG. 3f, it is guaranteed that, in the event of a fire, there will be an especially pronounced upward expansion of the intumescent material in the direction toward the window frame.

[0093] The support element 2 of FIG. 3g corresponds to the support element of FIG. 3f with the difference that the layer 47 with intumescent material is arranged on the third side surface 45, i.e., the side surface facing away from the first side surface 6. Otherwise, the same parameters as those described for FIG. 3f apply to the layer 47 also. In this embodiment, it is guaranteed that, in the event of a fire, there will be an especially pronounced expansion of the intumescent material toward the side (toward the right in the figure) in the direction of the outer wall.

[0094] The support element 2 of FIG. 3h corresponds to the support element of FIG. 3f with the difference that the layer 47 with intumescent material covers only part of the second side surface 12.

[0095] The layer 47 of the embodiment of FIG. 3d can also be combined with the layers 47 of the embodiment of FIG. 3c or 3e. The thin layer 47 of the embodiment of FIG. 3g can also be combined with the thin layer 47 of the embodiment of FIG. 3f or 3h. In addition, various thin layers 47 with various thicknesses of the layer 47 can be combined. For example, the thin layer 47 of FIG. 3g can be combined with the thick layer 47 of FIG. 3c.

[0096] In principle, all of the side surfaces or any desired selection of side surfaces can be completely or partially covered by a layer 47 with intumescent material.

[0097] The geometries of the support element 2 described on the basis of FIG. 3b can also be used in all of these embodiments.

[0098] In all of the previously described variants, one or more layers 47 can also extend over only a part of the associated side surface.

PRODUCTION EXAMPLES

Example 1A: Support Element with Waterglass

[0099] Inert sodium or potassium silicate (10-20%) is mixed to form a homogeneous mass with the base material, e.g., a rigid PUR foam or a rigid PUR/PIR foam, and optionally with one or more additives such as a curing agent. The mixture is pressed in a mold and cured by heat. Panels can be cut and processed into strip-shaped support elements.

Example 1B: Support Element with Expandable Graphite

[0100] Rigid PUR and/or PIR foam which originates from production residues and/or recycled material, e.g., old insulating panels, and which has been ground to a maximum particle size of approximately 5 mm, preferably of approximately 1 mm, is mixed with 5-10%, preferably 7.5%, of expandable graphite (average particle size, approximately 1 mm) and binder material, e.g., in liquid form, in a ratio of 1:5, calculated on the basis of the weight of the ground rigid foam. The mixture is introduced into a panel mold and treated by heat and pressure in a pressing direction P perpendicular to the surface of the panels, so that a rigid foam material with a bulk density of approximately 550 kg/m.sup.3 is obtained. The thickness of the panels is preferably 2-7 cm.

[0101] Alternatively, comminuted rigid foam pieces, expandable graphite flakes, and binder material can be introduced layer by layer in alternation (e.g., by interspersing) and then pressed.

[0102] Cured panels resulting from the pressing operation are cut into strip-shaped parts, and L-shaped support elements 2 according to FIG. 3a are produced by bonding a wider and a narrower element together, wherein, for both elements, the pressing direction P is preferably perpendicular to the second surface 12, which is intended to rest against the window frame 24 (see FIG. 1). The bonding is achieved by the use of an adhesive and/or by mechanical fastening with nails, screws, or metal clamps.

Example 1C: Support Element with an Expandable Graphite-Containing Layer

[0103] In the alternative embodiment shown in FIG. 3c, the upper layer 47 of the produced panel (i.e., a surface perpendicular to the pressing direction P) has a thickness of at least 10 mm, preferably of 15 mm, and has been combined with expandable graphite, wherein the remainder of the support element has not been combined with expandable graphite.

[0104] The strip-shaped support elements are produced as described in Example 1B.

Fire Tests

[0105] According to the test criteria of DIN 1366-5, support elements 2 of rigid PUR/PIR foam with expandable graphite, produced according to Example 1B with a thickness of 30 mm or 50 mm, were exposed to flames at 180 C. (see test layout in FIG. 5d), during which procedure the increase in temperature was measured on the opposite side after 5, 15, and 25 minutes in comparison to corresponding rigid foam without expandable graphite.

[0106] On the side facing away from the flames, the temperatures were measured directly on the material after 5, 15, and 25 minutes for experimental applications on a ceiling (Tables 1-4) and a wall (Tables 5-6). The measured temperature increases (in degrees Kelvin; starting temperature, 23 C.) are reproduced in the following tables (Tables 1, 3, 5: measurement on surface of the elements; Tables 2, 4, 6: measurement at the butt joint).

Ceiling

[0107]

TABLE-US-00001 TABLE 1 30 mm, surface. test site material without expandable graphite material with expandable graphite 3.29 4.03 4.10 4.14 3.01 3.07 3.08 3.14 5 min 1 0 1 0 1 1 1 7 15 min 15 23 26 2 22 21 24 29 25 min 52 52 52 20 43 43 48 53

TABLE-US-00002 TABLE 2 30 mm, butt joint. no graphite with graphite test site 3.32 4.07 3.04 3.11 5 min 4 2 2 10 15 min 30 32 17 35 25 min 117 158 45 56

TABLE-US-00003 TABLE 3 50 mm, surface. test site material without expandable graphite material with expandable graphite 4.11 4.17 4.18 4.24 3.15 3.21 3.22 3.28 5 min 0 0 0 0 0 0 3 3 15 min 1 3 2 2 2 3 4 4 25 min 11 11 17 11 9 9 12 12

TABLE-US-00004 TABLE 4 50 mm, butt joint. no graphite with graphite test site 4.14 4.21 3.18 3.25 5 min 1 2 0 3 15 min 2 4 3 4 25 min 20 18 12 12

Wall:

[0108]

TABLE-US-00005 TABLE 5 30 mm, surface. test site material without expandable graphite material with expandable graphite 1.15 1.21 1.22 1.28 1.29 7.07 7.08 7.14 5 min 8 0 5 1 8 1 8 5 15 min 19 22 30 20 33 25 30 30 25 min 57 50 52 49 57 44 49 50

TABLE-US-00006 TABLE 6 30 mm, butt joint. no graphite with graphite test site 1.18 1.25 1.32 7.11 5 min 2 1 2 3 15 min 30 22 30 25 25 min 80 67 50 45

[0109] Through the use of expandable graphite in the support elements 2 used both on ceilings and walls, the increase in temperature, especially at the butt joints, is considerably reduced. Thus, in the case of the rigid foam on the ceiling without expandable graphite, the temperature in the joint increased by, on average, 137.5 C. after 25 minutes; in the case of material with expandable graphite, it increased by only 50.5 C. on average. On the wall, the temperature of the rigid foam without expandable graphite increased in the joint by 73.5 C. on average; and in the case of the material with expandable graphite, it increased by only 47.5 C. on average. The increase in temperature, especially at the joints, was therefore significantly reduced by the use of support elements with expandable graphite.

[0110] FIGS. 4a and 4b show support elements with homogeneously distributed expandable graphite with an original thickness of 3 cm after exposure to flame on one side for 30 minutes (at the top in the figure). A graphite layer approximately 8 cm thick developed from 1 cm of material used.

[0111] FIGS. 5a-5c show top views of the flame-exposed side of support elements with homogeneously distributed expandable graphite with an expanded graphite layer on the flame-exposed side. In FIGS. 5a-5c, the arrows indicate the butt joints between adjacent components. FIG. 5d shows the layout of the flame exposure experiment. In FIG. 5d, the arrows indicate the direction of the flames in the various experiments. Depending on the arrangement (compare FIG. 5d, schematic diagram in the cross-sectional plane), the expanded graphite layer projects clearly beyond the plane of the concrete elements between the support elements, whereas the element, prior to exposure to flame, is on the same level with them (see especially FIG. 5b).

[0112] On the left, FIG. 6a shows part of a 30-mm-thick support element partially sawn through after 30 minutes of exposure to flame; the pressing direction P, indicated by the arrow, extends horizontally. The expansion in the direction of the pressing direction P is approximately twice as great (about 8 cm) as the expansion on the side perpendicular to the pressing direction, here the flame-exposed side on the right (approximately 4 cm). FIG. 6b shows the test piece after rotation by 90. It was thus determined that the expansion of the intumescent material on a surface perpendicular to the pressing direction P leads to greater expansion in the event of a fire than on a surface parallel to the pressing direction P.