A FRAME SYSTEM

Field of the Invention

The present invention relates to a frame system and, in particular, to a frame system for use in a fire rated wall system at least partially formed of glass blocks.

Background of the Invention

It is known to provide a frame system for a glass block wall system which includes first and second frame portions which define horizontal and vertical channels for receiving glass blocks during use. However, such a frame system is relatively expensive to manufacture because it is necessary to produce frames of multiple widths so as to fit with varying sized structures.

Summary of the Invention

In accordance with a first aspect of the present invention, there is provided a frame system for a glass block wall construction, the frame system comprising: a plurality of first frame members and a plurality of second frame members, the cross sectional shape of each frame member being substantially L-shaped; and a plurality of connectors, each connector being engageable with a first frame member and with a second frame member so as to define with the first and second frame members a substantially U-shaped frame portion.

In one embodiment, the frame system further comprises at least one tie member arranged to engage during use with an array of glass blocks disposed in the frame system, each tie member being fixable to a structure which receives the frame system during use. The tie member may be receivable during use between adjacently disposed glass blocks of a

glass block array disposed during use in the frame system. The tie member may be substantially L-shaped and the tie member may be adjustable in length in two orthogonal directions. In one arrangement, the tie member includes first and second tie member portions, and a substantially L-shaped third tie member portion telescopically engaged with the first and second tie member portions.

In one arrangement, the frame system further comprises at least one compressible member, which may be IBS expansion foam material, disposable during use between the frame system and a glass block array disposed during use in the frame system.

In one embodiment, the frame system further comprises a plurality of elongate reinforcing members disposable during use between adjacent glass blocks of a glass block array disposed during use in the frame system and/or disposable during use between a glass block array disposed during use in the frame system and frame portions of the frame system.

In one arrangement, each frame member includes a projection and each connector includes a recess which may be in the form of a channel for receiving a projection. Each projection may include at least one barb.

In one embodiment, the frame system further comprises support means arranged to support an array of glass blocks disposed during use in the frame system at a predetermined location relative to the frame system, the support means being selectively height adjustable.

The support means may comprise a base portion receivable in a frame portion and a support member slidably engageable with the base member so as to selectively modify the height of the support means.

The support member may be arranged so as to receive and support a horizontally extending reinforcing member during use. For this purpose, the support member may comprise a plurality of side walls and at least one cross member extending between the side walls. Each cross member may include at least one cut-out portion for receiving a reinforcing member during use.

The support means may be arranged such that reducing the height of the support means causes a portion of the support member to protrude from the base member, the protruding portion being cut during use so as to set the height of the support means .

The frame system may further comprise a spacer disposable during use between adjacently disposed glass blocks so as to define a predetermined spacing between the glass blocks . The spacer may be engageable with the support means and the support means may be arranged so that the spacer is maintained in a predetermined orientation and location relative to the support means when the spacer is disposed on a support member.

The spacer may be arranged to receive and support horizontally extending reinforcing members during use and/or vertically extending reinforcing members during use. For this purpose, the spacer may comprise apertures and/or grooves. In one arrangement, the spacer is substantially cross-shaped having a first elongate member which extends generally horizontally during use and a second elongate member which extends generally vertically during use, the first elongate member including at least one channel and the second elongate member including apertures for receiving a generally horizontally extending reinforcing member during use, and the second elongate member including at least one groove for receiving a

generally vertically extending reinforcing member during use.

In one embodiment, the connectors are sufficiently wide such that the frame system is able to receive two glass blocks at each location in the glass block array. In an alternative embodiment, the width of the connectors is such that one glass block is receivable at each location in the glass block array.

In accordance with a second aspect of the present invention, there is provided a glass block wall system comprising: a plurality of frame portions configured so as to form a frame; and a glass block array disposed in the frame; each frame portion comprising a plurality of first frame members and a plurality of second frame members, the cross-sectional shape of each frame member being substantially L-shaped; and each frame portion comprising a plurality of connectors, each connector being engaged with a first frame member and with a second frame member so as to define with the first and second frame members a substantially U-shaped frame portion.

In accordance with a third aspect of the present invention, there is provided a frame system for a glass block wall construction, the frame system comprising: a plurality of frame portions connectable together so as to form a frame; and support means arranged to support a glass block array disposed in the frame system during use; the support means being selectively height adjustable by a user such that during use the height location of the glass block array is adjustable.

In accordance with a fourth aspect of the present invention, there is provided a method of constructing a glass block frame system, said method comprising: providing a plurality first frame members and a plurality of second frame members, the cross-sectional shape of each frame member being substantially L-shaped; providing a plurality of connectors, each connector being engaged with a first frame member and with a second frame member so as to define with the first and second frame members a substantially U-shaped cross section; connecting the frame portions together so as to form a frame ; and disposing a glass block array in the frame.

In accordance with a fifth aspect of the present invention, there is provided a method of constructing a glass block frame system, said method comprising: providing a plurality frame portions; connecting the frame portions together so as to form a frame; providing height adjustable support means arranged to support a glass block array disposed in the frame system during use and adjusting the height of the support means according to a desired location for a glass block array disposed during use in the frame system; and disposing a glass block array in the frame such that the glass block array is supported by the support means.

Brief Description of the Drawings

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

Figure 1 is a diagrammatic representation of a wall system including a frame system in accordance with an embodiment of the present invention;

Figure 2 is a diagrammatic cross sectional view taken along the line II-II in Figure 1 in the direction of the arrows ;

Figure 3 is a diagrammatic perspective view of an adjacently disposed pair of first and second frame members of the frame system shown in Figures 1 and 2 ; Figure 4 is a diagrammatic perspective view of a connector of the frame system shown in Figures 1 and 2 ;

Figure 5 is a diagrammatic perspective view of the first and second frame members shown in Figure 3 engaged with the connector shown in Figure 4 ; Figure 6 is a diagrammatic perspective view of a tie member of the frame system shown in Figures 1 and 2 ;

Figure 7 is a flow chart illustrating an example method of installing a frame system in accordance with an embodiment of the present invention. Figure 8 is a diagrammatic representation of a portion of a wall system in accordance with an alternative embodiment of the present invention;

Figure 9 is a diagrammatic plan view of a base member of the alternative wall system shown in Figure 8; Figure 10 is a diagrammatic side view of the base member shown in Figure 9 ;

Figure 11 is a diagrammatic side view of a support member of the alternative wall system shown in Figure 8;

Figure 12 is a diagrammatic front view of the support member shown in Figure 11;

Figure 13 is a diagrammatic plan view of the support member shown in Figures 11 and 12;

Figure 14 is a diagrammatic front view of a spacer of the alternative wall system shown in Figure 8; Figure 15 is a diagrammatic plan view of the spacer shown in Figure 14 ; and

Figure 16 is a diagrammatic side view of the spacer shown in Figures 14 and 15.

Description of an Embodiment of the Invention

Referring to the drawings, in Figures 1 to 6, there is shown a frame system 10 which forms part of a wall system 12 of the type including multiple glass blocks arranged in a two dimensional array. The wall system 12 is fixed to a structure 14 which in this example is a window frame, and the glass blocks 16 are held in position by the frame system 10.

The frame system 10 includes two first frame portions 18, in this example disposed horizontally at upper and lower ends of the frame system 10, and two second frame portions 20, in this example disposed at sides of the frame system 10.

Each of the first and second frame portions 18, 20 includes a pair of oppositely disposed first and second frame members 22 and 24 respectively, as shown more particularly in Figure 3. During use, the first and second frame members 22, 24 are connected together to form a first or second frame member 18, 20 using a connector 26 shown more particularly in Figure 4. A first frame portion 18 including first and second frame members 22, 24 connected together using a connector 26 is shown in Figure 5.

As shown in Figure 3 , each of the first and second frame members 22, 24 is generally elongate and has a generally L-shaped cross section.

Each of the first and second frame members 22, 24 includes a projection 28, each projection 28 including at least one barb 30, in this example two barbs 30.

The connector 26 includes two oppositely disposed channels 34 and a generally planar body portion 36 disposed between the channels 34.

The projections 28 and the channels 34 are arranged such that when a projection 28 is disposed in a channel 34, an interference fit is formed which restricts withdrawal of the projection 28 from the channel 34. In this way, by engaging the projections 28 of a pair of adjacently disposed first and second frame members 22, 24 in the channels 34 of a connector 26, it is possible to connect the first and second frame members 22, 24 together so as to form a rigid frame portion 18, 20.

The frame system 10 in this example includes multiple connectors disposed at spaced locations around the frame.

It will be understood that while a secure connection is formed between the frame portions 18, 20 and the connector 26, in the present example the projections 28 and the channels 34 are configured so that by applying sufficient force the projections 28 are removable from the channels 34.

It will also be understood that since the connectors 26 are engageable with the first and second frame members 22, 24, it is possible to provide a frame system 10 which includes standardised first and second frame members 22, 24, and connectors 26 of differing sizes, with the connectors 26 being chosen depending on the desired frame width. For example, for a wall system which includes one glass block at each position in the array, as shown in Figure 2, a relatively small connector 26 may be used, and for a wall system which includes two adjacently disposed glass blocks at each position in the glass block array, a relatively large connector 26 may be used. In this way,

expensive manufacture of multiple frame portions of varying widths is avoided.

The wall system 12 also includes a compressible member 40, in this example formed of IBS expansion foam, the compressible member 40 being of generally elongate rectangular configuration and disposed at least at sides and top portions of the frame system 10. The compressible members 40 serve to allow a degree of expansion of the glass blocks during use, for example in the event of high temperatures such as during a fire.

In this example, the glass blocks 16 are bonded together using mortar 42 disposed between adjacent glass blocks 16 and between glass blocks disposed at sides of the glass block array and the first and second frame portions 18, 20.

The wall system 12 in this example also includes reinforcing members 44 which in this embodiment are elongate steel rods . Two reinforcing members extend between each two adjacent rows and columns of the glass block array and between glass blocks disposed at sides of the glass block array and the first and second frame portions 18, 20.

The wall system 12 further includes tie members 50 shown more particularly in Figure 6. Each tie member 50 includes a first tie portion 52 of generally flat rectangular configuration, a second tie portion 54 of generally flat rectangular configuration, and a third tie portion 56 telescopically received in the first and second tie portions 52, 54. The third tie portion 56 is generally L-shaped and comprises two parallel L-shaped members.

Each tie member 50 is incorporated into the wall system 12 such that one of the first and second tie portions 52, 54 is disposed between an adjacently disposed pair of rows of glass blocks and/or between an adjacently disposed pair of columns of glass blocks, and the other of the first and second tie portions 52, 54 is fixed to the structure 14 in any suitable way, for example using a screw 60. Since the tie member 50 is telescopic in two orthogonal directions, the tie members 50 allow the glass blocks 16 in the glass block array to expand and contract with temperature. At the same time, the tie members 50 assist in maintaining the glass blocks 16 in position relative to the structure 14, for example in the event of high temperature such as during a fire .

It will be appreciated that the present wall system configuration is particularly suitable for situations requiring a high fire rating. With the present wall system 12, during high temperatures such as during a fire, the reinforcing members 44 and the tie members 50 will retain the glass blocks relative to the structure 14 even though the first and second frame portions 18, 20 may be affected by the fire to an extent that the first and second frame portions 18, 20 are no longer able to retain the glass blocks 16 in position.

In one construction method as illustrated by steps 72 to 80 in the flow diagram 70 shown in Figure 7, a user first selects the connectors 26 according to the desired frame width and engages multiple connectors between adjacently disposed first and second frame members 22, 24 at spaced locations around the frame. Bottom and side portions of the frame system 10 are then fixed to the desired structure 14 using any suitable fixing device, for example screws 62. When the frame system 10 has been fixed in position, the connectors 26 may be removed, for example by cutting through the body portions 36 using a suitable

cutting device such as an angle grinder and disengaging the channels 34 from the projections 28. In this way, the connectors serve to ensure that the correct spacing between adjacent first and second frame members 22, 24 is achieved during fixing of the frame system 10 to the structure 14.

The glass block array is then constructed by disposing glass blocks 16 in the frame system 10, disposing two reinforcing members 44 between each adjacent pair of rows and columns in the array, installing tie members 50 between selected adjacent rows and/or columns, fixing the tie members 50 to the structure 14, disposing compressible members 40 between glass blocks 16 disposed at sides of the glass block array and the structure 14, and filling spaces between adjacent glass blocks 16 and between the glass block array and the first and second frame portions 18, 20 with mortar.

Referring to Figures 8 to 16, an alternative wall system

90 is shown. Like and similar features are indicated with like reference numerals.

The alternative wall system 90 may include at least some of the features which form part of the wall system shown in Figures 1 to 6 and/or the features of the wall system 90 shown in Figures 8 to 16 may be in addition to the features of the wall system 12 shown in Figures 1 to 6.

The wall system 90 includes adjustable support means 100 which is modifiable so as to define varying distances between a lowermost row of glass blocks 16 and the lowermost first frame portion 18.

In this example, the support means 100 is arranged to engage with a spacer 102 which serves to ensure that a

predetermined spacing is defined between adjacently disposed glass blocks 16.

The support means 100 includes a base member 104 shown more particularly in Figures 9 and 10 and a support member 106 shown more particularly in Figures 11 to 13.

In the present example, the support means 100 and the spacer 102 are formed of plastics material, although it will be understood that other suitable materials are envisaged.

The base member 104 includes a base wall 108 which defines a generally rectangular shape, and two receiving portions 109 each of which is disposed generally centrally of a longitudinal side of the rectangle defined by the base wall 108.

Each of the receiving portions 109 includes a slot 110 which opens to a slit 112.

The support member 106 includes two side walls 114 joined by two cross members 116, each of which includes two cutout portions 118. In this example, the cross members 116 are disposed at different locations relative to the side walls 114. As will be discussed in more detail below, the cut-out portions 118 serve to receive and support reinforcing members 44.

An uppermost end of each of the side walls 114 is also provided with two ears 120 which serve to engage with a spacer 102 and thereby maintain the spacer 102 in a predetermined orientation and location when the spacer 102 is disposed on the support member 106.

The base member 104 and the support member 106 engage with each other by inserting the side walls 114 in the slots

110, the side walls 114 being moveable relative to the slots 110 so as to enable the height of the ears 120 above the base wall 108 to be adjusted. With the present embodiment, an increased range of possible movement of the support member 106 relative to the base member 104 is achieved by providing the slits 112 and engaging the support member 106 with the base member 104 such that the lowermost cross member 116 aligns with the slits 112.

The spacer 102 is of generally cross-like configuration and includes a first elongate member 130 which extends generally horizontally during use and a second elongate member 140 which extends generally vertically during use. In this example, the first and second members 130, 140 are integrally formed with each other.

As shown in Figure 15, the first member 130 includes a plurality of fins 142 which define two channels 144 for receiving reinforcing members 44 in a generally horizontal orientation during use.

The second member 140 includes oppositely facing grooves 146, each of which is shaped so as to receive a reinforcing member 44 in a generally vertical orientation during use.

The second member 140 also includes apertures 148 which enable the reinforcing members 44 to pass through the second member 140 when the reinforcing members 44 are received in the channels 144.

During operation, a user first determines the height above the first frame portion 18 at which it is desired to dispose a lowermost row of glass blocks 16 and, based on this, the position of the support member 106 relative to the base member 104 is selected by sliding the support member 106 to an appropriate position relative to the base

member 104. Any excess material which appears as protruding portions 152 shown in Figure 8 is then removed by cutting the side walls 114. In most situations, a plurality of support means 100 will be required in order to provide sufficient support for the glass blocks 16 proposed to be included in the desired wall system. The support means 100 are then disposed in the first frame portion 18 and a spacer 102 is engaged with each support member 106. Reinforcing members 44 are then passed through the apertures 148 in the spacers 102 so that the reinforcing members 44 sit in the channels 144 and extend in a generally horizontal direction. Further reinforcing members 44 are also disposed in one or more of the cut-out portions 118 so as to extend in a generally horizontal direction. Further reinforcing members 44 are also disposed in respective grooves 146 so as to extend in a generally vertical direction. Glass blocks are then laid between adjacent spacers 102 on the horizontally extending reinforcing members 44, and spacers between adjacent glass blocks 16 and between the glass block array and the first and second frame portions 18, 20 are filled with mortar (not shown) .

It will be appreciated that by providing support means 100 which are selectively height adjustable, it is possible to ensure that the glass block array is correctly positioned relative to the frame for a range of frame sizes.

Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.