FIRE-RESISTANT GLAZING

Abstract

A fire resistant glazing is provided that seeks to avoid the issue of air gaps forming between a glazing and a frame into which the glazing is placed, a method of manufacturing the fire resistant glazing and the use of same. The fire-resistant glazing includes an intumescent edge mass located at least partially between the first sheet of glazing material and the second sheet of glazing material and which is suitable for, and may be installed within, a glazing frame.

Claims

1.-25. (canceled)

26. A fire-resistant glazing comprising: at least a first sheet of glazing material comprising a first major face, a second major face and at least one edge face; and at least a second sheet of glazing material comprising a first major face, a second major face and at least one edge face, wherein the first sheet of glazing material and the second sheet of glazing material are arranged in a spaced-apart face-to-face arrangement with the first major faces of the first and second sheet of glazing material facing each other to form a cavity, and wherein the edge faces of the first and second sheets of glazing material are substantially aligned to form a glazing edge; an intumescent layer located in the cavity between the first sheet of glazing material and the second sheet of glazing material; and wherein the fire-resistant glazing further comprises an intumescent edge mass, and wherein the intumescent edge mass is located at least partially between the first sheet of glazing material and the second sheet of glazing material.

27. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass is entirely located between the first sheet of glazing material and the second sheet of glazing material.

28. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass protrudes beyond the glazing edge.

29. A fire-resistant glazing according to claim 28, wherein one or more edge faces on one or more sheets of glazing material is/are provided with the intumescent edge mass.

30. A fire-resistant glazing according to claim 29, wherein one or more second major faces of the sheets of glazing material is/are provided with the intumescent edge mass.

31. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass is in direct contact with the first major surface of the first and/or second sheets of glazing material.

32. A fire-resistant glazing according to claim 26 wherein the intumescent edge mass is substantially continuous on at least one glazing edge.

33. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass is further provided with a protection layer.

34. A fire-resistant glazing according to claim 26, further comprising a secondary sealant located between the first sheet of glazing material and the second sheet of glazing material, and wherein the secondary sealant includes at least one groove parallel to the glazing edge in which the intumescent edge mass is at least partially located.

35. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass comprises a water-resistant intumescent material, preferably exfoliated graphite.

36. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass comprises a paste, putty, mastic or caulk.

37. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass is not applied as a solid strip or tape.

38. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass has a minimum reaction temperature of between 90? C. and 220? C., more preferably, the intumescent edge mass has a minimum reaction temperature of between 120? C. to 175? C.

39. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass has a foaming pressure of at least 0.7 N/mm.sup.2, and/or wherein the intumescent edge mass has an expansion ratio of from 3 to 30, and/or wherein the intumescent edge mass has a density of from 800 kg/m.sup.3 to 1900 kg/m.sup.3.

40. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass has a three-dimensional direction of action.

41. A fire-resistant glazing according to claim 26, wherein the intumescent edge mass is non-continuous upon at least one glazing edge.

42. A fire-resistant glazing according to claim 41, wherein an area where the intumescent edge mass is not present is proximate to a glazing corner and/or not proximate to a glazing hinge.

43. A method of manufacturing a fire-resistant glazing comprising the steps of: (i) providing a semi-finished fire-resistant glazing comprising: at least a first sheet of glazing material comprising a first major face, a second major face and at least one edge face; and at least a second sheet of glazing material comprising a first major face, a second major face and at least one edge face, wherein the first sheet of glazing material and the second sheet of glazing material are arranged in a spaced-apart face-to-face arrangement with the first major faces of the first and second sheet of glazing material facing each other to form a cavity, and wherein the edge faces of the first and second sheets of glazing material are substantially aligned to form a glazing edge; and an intumescent layer located in the cavity between the first sheet of glazing material and the second sheet of glazing material; and (ii) applying an intumescent edge mass at least partially between the first sheet of glazing material and the second sheet of glazing material.

44. A method according to claim 43, wherein the semi-finished fire-resistant glazing comprises a secondary sealant and wherein, prior to the step of applying the intumescent edge mass, a portion of the secondary sealant is removed to form a groove that is substantially parallel to the glazing edge.

45. A method according to claim 43, wherein a removable protective layer is applied to the intumescent edge mass after application of the intumescent edge mass.

Description

[0092] Embodiments of the present invention will now be described by way of example only with reference to the following accompanying drawings, in which:

[0093] FIG. 1 illustrates a schematic cross-sectional view of a conventional fire-resistant glazing;

[0094] FIG. 2 illustrates a schematic cross-sectional view of a fire-resistant glazing according to a first embodiment of the present invention;

[0095] FIG. 3 illustrates a schematic cross-sectional view of a fire-resistant glazing according to a second embodiment of the present invention;

[0096] FIG. 4 illustrates a schematic cross-sectional view of a fire-resistant glazing according to a third embodiment of the present invention;

[0097] In relation to FIG. 1 there is provided a conventional fire-resistant glazing 1 which comprises a first sheet of glazing material 10 comprising a first major face 11, a second major face 12 and an edge face 13; and a second sheet of glazing material 20 comprising a first major face 21, a second major face 22 and an edge face 23. The second sheet of glazing material 20 is in a spaced-apart face-to-face arrangement with the first sheet of glazing material 10 and the first major face 11 of the first sheet of glazing material 10 faces the first major face 21 of the second sheet of glazing material 20.

[0098] The fire-resistant glazing 1 further comprises an intumescent layer 30 located between the first sheet of glazing material 10 and the second sheet of glazing material 20.

[0099] A spacer 50, is provided between the sheets of glazing material 10, 20. The spacer is conventionally provided to maintain the distance between the first and second sheets of glazing material 10, 20. Spacers are often provided around substantially the entire periphery of the glazing. In addition, the spacer 50 may help to reduce the ingress of air, which may cause the intumescent layer 30 to become hazy or discoloured and thereby reduce visibility through the fire-resistant glazing 1 over time.

[0100] A secondary sealant 55 is provided between the sheets of glazing material. The secondary sealant 55 is conventionally applied to provide mechanical stability to the glazing such that the glazing sheets are not separated during handling and transport. In addition, the secondary sealant 55 helps to reduce the ingress of air, which may cause the intumescent layer 30 to become hazy or discoloured and thereby reduce visibility through the fire-resistant glazing 1 over time.

[0101] The fire-resistant glazing 1 is mounted within a frame 70, and held in place using beads 75. The beads may be solid, such as a rubber, or a putty or mastic. A frame cavity 80 is formed between the fire-resistant glazing 1, the frame 70, and the beads 75.

[0102] While this conventional glazing has many advantages, it suffers from the drawbacks described above. In particular, during a fire incident this frame cavity 80 may provide a conduit for heat and/or smoke around the fire-resistant glazing 1.

[0103] In the following further embodiments of the first aspect of the present described in relation to FIGS. 2 to 4, like numbers are used to represent features that are equivalent to the first embodiment depicted by FIG. 1. In the following FIGS. 2 to 4 the glazing frame 70, beads 75, and frame cavity 80 are not shown-however, the skilled person will readily appreciate that the fire-resistant glazings shown in FIG. 2-4 may be readily incorporated in a glazing frame in the same manner as that depicted in FIG. 1.

[0104] FIG. 2 illustrates a schematic cross-sectional view of a fire-resistant glazing 1 according to a first embodiment of the present invention.

[0105] The fire-resistant glazing 1 according to the first embodiment of the present invention is constructed in a similar manner to the conventional fire-resistant glazing of FIG. 1. However, the fire-resistant glazing 1 further comprises an intumescent edge mass 40, and the intumescent edge mass 40 is located at least partially between the first sheet of glazing material 10 and the second sheet of glazing material 20.

[0106] The intumescent edge mass 40 preferably substantially fills any gap arising between the first and second sheets of glazing material 10, 20 such that no air gaps are present between he first and second sheets of glazing material 10, 20.

[0107] The fire-resistant glazing according to the first embodiment of the present invention may include a groove 57 parallel to the glazing edge formed either in the secondary sealant 55 and/or by recessing the secondary sealant 55. The intumescent edge mass 40 preferably substantially fills the groove 57 such that it is located at least partially between the first sheet of glazing material 10 and the second sheet of glazing material 20.

[0108] The groove 57 may be formed by partial removal of the secondary sealant 55 using a tool either before, during or after curing the secondary sealant 55. Depending on the profile of the tool used to create the groove 57, the profile of the secondary sealant 55 may be convex, concave, or a combination thereof following curing.

[0109] For example, as depicted in in FIG. 2, the secondary sealant 55 may be provided with a concave profile. Where secondary sealant 55 is provided with a concave profile and the groove is sufficiently wide that both the first faces 11, 21 of the first and second sheets of glazing material 10, 20 are exposed, the intumescent edge mass may preferably extend between surfaces 11 and 21. In such an arrangement, the intumescent edge mass is described herein as contiguous and the intumescent edge mass may be entirely located within groove 57, be aligned with edge faces 13 and 23, or may extend beyond edge faces 13 and 23. A contiguous intumescent edge mass 40 may also be formed where the secondary sealant is recessed from the glazing edge.

[0110] Alternatively, where the secondary sealant 55 is provided with a concave profile and the groove 57 is narrow and the secondary sealant 55 is not recessed from the glazing edge, the intumescent edge mass 40 may not contact the first faces 11, 21 of the first and second sheets of glazing material 10, 20.

[0111] Alternatively, where the secondary sealant 55 is provided with a convex profile, the intumescent edge mass 40 may be provided on each surface 11 and 21 with a separation between the intumescent edge mass 40 sections on each surface, such an intumescent edge mass 40 is referred to herein as non-contiguous.

[0112] The groove 57 may be formed by using a tool following application of the secondary sealant 55, or by not completely filling the void between the first and second sheets of glazing material 10, 20 with secondary sealant 55 during application. Incomplete filling of the void between the first and second sheets of glazing material 10, 20 with secondary sealant may include the use of a nozzle or a mask.

[0113] As illustrated in FIG. 2, the intumescent edge mass 40 may protrude beyond one or both of the edge faces 13, 23 of the sheets of glazing material 10, 20. Hereafter, such an arrangement of the intumescent edge mass 40 is described as protruding with respect to the first and second sheets of glazing material respectively. Alternatively the intumescent edge mass 40 may be entirely located between the sheets of glazing material 10, 20 and as such may not extend beyond the one or both edge faces 13, 23 of the sheets of glazing material 10, 20. Hereafter, such an arrangement of the intumescent edge mass 40 is described as recessed with respect to the first and second sheets of glazing material respectively. Alternatively, the intumescent edge mass may be aligned with one or both edge faces 13, 23 of the sheets of glazing material 10, 20. Hereafter, such an arrangement of the intumescent edge mass 40 is described as aligned with respect to the first and second sheets of glazing material respectively.

[0114] It is generally preferable that the intumescent edge mass 40 is protruding, such that it may expand more quickly and in multiple directions to provide a cooling and/or heat/smoke blocking foam that fills any air gap between the glazing and a frame. However, an intumescent edge mass 40 that is recessed or aligned may be more compatible with some frame designs.

[0115] Where the glazing comprises multiple sheets of glazing material arranged in a repeating pattern separated by multiple cavities and/or intumescent layers, preferably a portion of intumescent mass is between some or all of the first major faces of the sheets of glazing material. In addition, such intumescent edge masses may be contiguous or non-contiguous and may preferably be recessed or protruding beyond edge faces 13 and 23. The additional cavities may comprise intumescent layers, insulating gases such as argon, or vacuum. For example, the glazing may be a multiple, for example triple, glazing unit incorporating at least one fire-resistant intumescent layer and one or more gas filled cavities.

[0116] In FIG. 2, the edge faces 13, 23 of the sheets of glazing material 10, 20 are provided with an intumescent edge mass 40. Preferably, the intumescent edge mass extends substantially along the entire length of each glass sheet. The intumescent edge mass may be continuous or intermittent, i.e. non-continuous, along the length of each glass edge.

[0117] In FIG. 3, the second major faces 12, 22 of the first and second sheets of glazing material are provided with an intumescent edge mass 40.

[0118] Such an arrangement is advantageous, as the intumescent edge mass 40 preferably both covers and protects the edges 13, 23 of the sheets of glazing material 10, 20, and encapsulates the edge region of the fire-resistant glazing. However, the intumescent edge mass 40 should not be applied upon the second major face 12, 22 to the extent that it is visible when installed in the frame (not shown). In particular, it should not extend beyond the glazing beads (not shown).

[0119] FIG. 4 depicts an embodiment of the invention wherein the intumescent edge mass 40 is provided with a protection layer 60. Such a protection layer 60 protects the fire-resistant glazing 1 during storage, transportation and installation. Preferably, the protection layer 60 is provided across the entire exposed surface of the intumescent edge mass 40. Preferably, the protection layer 60 is removed prior to installation of the glazing 1. Alternatively, the protection layer remains upon the intumescent edge mass 40 following installation of the glazing 1, but does not impair the intumescent response of the intumescent edge mass upon exposure to heat or fire.

[0120] In FIGS. 2, 3 and 4 fire-resistant glazings including a spacer and a secondary seal are depicted. However, the skilled person will readily appreciate upon consideration of the figures and the specification that a groove may be formed in an intumescent layer in a similar fashion, where a spacer and secondary seal are not provided. Therefore, all features relating to grooves in secondary sealants may also be applied to grooves in intumescent layers to allow an intumescent edge mass to be provided between the sheets of glazing material.

[0121] In a further modification of each of the embodiments described above, one or more of the first major faces of each sheet of glazing material may comprise an enamel coating (not shown). The enamel coating may also extend around the periphery of one or more sheets of glazing material in the fire resistant glazing. Enamel coatings may provide an aesthetically pleasing edge region to the fire-resistant glazing. The enamel coating may also protect the primary and/or secondary seals from degradation by UV light. When applied, the enamel coating may extend from between 15 mm to 20 mm from the edge of the sheet of glazing material.

[0122] Whilst an enamel coating is not shown in the figures, each recited embodiment may be compatible with an enamel coating. As such, an enamel coating may be present between the intumescent edge mass and the sheet of glazing material without a reduction in fire-resistant properties of the fire resistant glazing.

[0123] In addition, whilst edge faces 13, 23, are illustrated substantially aligned, alternatively, the edge face of one or more sheets of glazing may protrude out of alignment with the edge face of a second or further sheet of glazing material. That is, the sheets of glazing material may be staggered. That is, each embodiment may be provided with aligned sheets of glazing material, or staggered sheets of glazing material. Nevertheless, the skilled person will readily appreciate that such an arrangement results in a glazing edge that may be offered to the frame during installation.

[0124] Whilst in the embodiments described above only two sheets of glazing material are depicted, the embodiments of the present invention described also cover embodiments of fire resistant glazings with three, four, or more sheets of glazing material.

[0125] In addition, the embodiments described above may form a part of or a whole fire-resistant glazing. That is, the embodiments may be repeated, or combined together, to form fire-resistant glazings with multiple intumescent layers and/or multiple intumescent edge mass portions. This arrangement is particularly beneficial when fire-resistant glazings are required which provided longer fire-resistance time.

[0126] The inventive glazings according to the present invention may be provided with an edge tape for encapsulating the edge of the glazing to prevent water ingress. The intumescent edge mass may be applied under the edge tape, or over the edge tape. However, where the intumescent edge mass is applied under the edge tape, the intumescent edge mass must have a high enough foaming pressure to expand through the tape. Alternatively, the tape should be perforated in the area of the intumescent edge mass to allow expansion through the tape. Such edge tapes should be sufficiently thin and flexible to conform to the profile of the glazing edge and/or the profile of the secondary seal, to prevent trapping air within the glazing edge region.

[0127] A further advantage of the present invention is that the intumescent edge mass protects the secondary sealant from decomposition in the event of a fire, and upon foaming forms a tertiary barrier such that the intumescent edge mass may substantially retain the intumescent layer within the fire-resistant glazing for a longer time than a comparable fire-resistant glazing without the intumescent edge mass, while still providing fire protection with the glazing rebate area. This leads to an increased lifetime of the glazing unit because the fire is not able to move around the edges, and premature release of the intumescent layer into the rebate area can be reduced.

[0128] However, in some cases it is desirable for the intumescent layer and/or gases evolved by the intumescent layer during a fire incident to vent into the rebate area. To allow the controlled venting of intumescent layer and/or gases evolved by the intumescent layer during a fire incident, in some embodiments the intumescent edge mass is non-continuous, such that the intumescent edge mass is either not present or not contiguous at a portion of the glazing edge. Preferably, where the intumescent edge mass is non-continuous, preferably the area where the intumescent edge mass is not present or is non-contiguous is proximate to a glazing corner. The frame at the corner is better able to withstand venting pressure, as opposed to frame edges which may bow or crack under venting pressure, which may allow the passage of smoke and/or heat. In addition, the area where the intumescent edge mass is not present or is non-contiguous should not be proximate to glazing hinges, as these may be damaged by venting pressure, thereby allowing the glazing to move which may allow the passage of smoke and/or heat.

[0129] In some embodiments at least 60%, preferably at least 80%, of the length of at least one glazing edge comprises intumescent edge mass and the at least one glazing edge comprises an area where the intumescent edge mass is not present. In some embodiments at least 60%, preferably at least 80%, of all glazing edges comprise intumescent edge mass and all glazing edges comprise an area where the intumescent edge mass is not present.

[0130] In some embodiments at least 60%, preferably at least 80%, of the length of at least one glazing edge comprises intumescent edge mass and the at least one glazing edge comprises an area where the intumescent edge mass is not contiguous. In some embodiments at least 60%, preferably at least 80%, of all glazing edges comprise intumescent edge mass and all glazing edges comprise an area where the intumescent edge mass is not contiguous.

[0131] As used herein, proximate to a glazing corner is defined as within 10% of the length of the glazing edge length. As used herein, proximate to a glazing hinge is defined as within 10% of the length of the glazing edge.

EXAMPLES

[0132] Fire resistant glazings according to the present invention were prepared as illustrated in FIG. 2 with two sheets of 6 mm toughened float glass arranged with 6 mm of intumescent material located therebetween. The glazing included a thermoplastic spacer and a secondary sealant of polysulfide. A portion of the secondary sealant was removed by tooling to form a groove parallel to the glazing edge and the intumescent edge mass was applied over the edge faces of the sheets of glazing material and also over secondary sealant within the groove.

[0133] A range of different intumescent edge mass materials were tested. These included Kerafix Firestop Putty, Roku 1000, PYRO-SAFE DG-SC, and Roku AC, each obtainable from Rolf Kuhn GmbH.

[0134] The example glazings were fixed into a frame using a rack such that the edges of the glazing were visible, and it was observed that for each glazing an air gap of around 5 cm was present between the edge of the glazing and the frame.

[0135] The glazings were then submitted to a fire test according to safety standard Class EI, in accordance with EN 138501-1, incorporated herein by reference, wherein a flame is applied to the glazing using a burner. When the fire test was initiated the light from the flame was observed through the air gap.

[0136] In a comparative example, constructed as in FIG. 1 in which no intumescent edge mass is applied to the glazing, the air gap remains throughout the fire test, and is not sealed. Heat and smoke may pass between the glazing edge and the frame.

[0137] However, when glazings according to the present invention incorporating the intumescent edge mass were tested, the gap was filled with intumescent foam which prevents the passage of heat and/or smoke.

[0138] The intumescent edge mass materials were applied as 4 mm lines to a glass sheet not incorporated in a fire-resistant glazing to investigate their expansion. This test involved heating each intumescent edge mass material to 450? C. for 30 minutes without a load. The properties of intumescent mass materials are provided below in table 1.

TABLE-US-00001 TABLE 1 Intumescent Mass Density Reaction Expansion Foaming Direction of Intumescent Water Material kg/m.sup.3 temperature Ratio Pressure N/mm.sup.2 action Material Resistant Kerafix 1390 140 14.5-20 >0.8 Three- Acrylate No Putty dimensional Roku 1000 1250 185 6-10 >0.3 Three- Graphite No dimensional Roku AC 1360-1840 200 1.9-5 0 Two- Acrylate No dimensional PYRO-SAFE 1300 150 15-26.5 1.00-1.90 Three- Graphite Yes DG-SC dimensional