Adjustable spacer

Abstract

An adjustable spacer 100 is disclosed, for fixing an outer frame for a door (such as a fire door) or window closure in an opening of a building. The adjustable spacer has a female portion 110 mounted in an aperture of an outer frame which defines a bore through the frame. The spacer also has a male portion 120 which cooperates with the bore and is accessible from the closure, or inner, face of the frame. The male portion extends beyond the surface of the door frame and is braced in contact with the opening. There may be a screw thread 121 for extending the male portion, which may be engaged with a standard tool. The female portion may have fasteners 112 fastening it to the frame, where the fasteners are angled away from the bore of the female portion. The male portion may have an enlarged face 123 to brace against the opening. A door frame with an intumescent seal, a kit of parts and method of securing the outer frame are also disclosed.

Description

FIELD The present teachings relate to an adjustable spacer. In addition the present teachings relate to an outer frame, door frame assembly, a kit of parts and a method of securing an outer frame in an opening. BACKGROUND A door frame is often smaller than the opening in which it needs to be mounted. In order to secure a frame within an opening, traditionally a frame is offered up to the opening, and then wedges or packers are used to manoeuvre the door into the correct position and secure it in place. This is a time-consuming process and may need repeating some weeks or months later if there is movement between the frame and the opening as the frame settles. In the case of fire doors, there is a requirement for the door to delay the passage of smoke, flames, or noxious gas by a set amount of time, usually 30 minutes or an hour. Whilst the door will be appropriately designed to achieve this, it is also important to ensure that smoke, flames, and noxious gases cannot pass around the door via the gap between the doorframe and the opening in which it is mounted. In order to achieve this, an intumescent seal can be fitted between the outer frame and the opening. Traditionally, installing this seal (which is usually foam or mastic) is inhibited by the presence of the wedges. Similarly, the seal can block access to the wedges if adjustment of the frame is required after initial installation. To provide a suitable aesthetic finish, the outer frame is typically fitted with an architrave and the subsequent adjustment requires removal of the architrave to access the wedges, adding a further labour intensive step to the process. SUMMARY The present teachings seek to overcome, or at least mitigate, the problems of the prior art. The present teachings provide an adjustable spacer, an outer frame, a door frame assembly, a kit of parts and a method of securing an outer frame of claims 1, 13, 18, 19 and 21 respectively according to the appended claims. A first aspect of the present teachings provides an adjustable spacer for a securing an outer frame for mounting a moveable door or window closure in an opening. The adjustable spacer may comprise: a female portion configured to be mounted in an aperture of the outer frame in a fixed relationship to the outer frame and to extend transversely therethrough to define a bore through the outer frame from a closure face to an opening face; and / or a male portion configured to cooperate with the bore and be physically accessible from the closure face, so as to be selectively extendible beyond a transverse surface of the door frame and be braced in contact with the opening so as to set a desired spacing therebetween. Advantageously this may simplify and speed up the process of installing an outer frame, and / or adjusting an outer frame in situ, once it is installed. The adjustable spacer may comprise a threaded connection for selectively extending the male portion. Advantageously, this minimises the number and complexity of the components required to extend the male portion. The female portion of the adjustable spacer may further comprise one or more fasteners. The female portion may be mountable to the outer frame with the one or more fasteners. Advantageously, this improves the security of the adjustable spacer to the outer frame. The one or more fasteners may be arranged to be angled in a direction away from bore of the female portion. Advantageously, this provides a secure connection to the outer frame, and reduces the chance of interaction between the fasteners and female portion itself. The one or more fasteners may be screws. Advantageously, this is easy to install with standard tools. The male portion may be configured to be extendable using a standard tool. By standard tool, a tool that may conform to a known standard and is available off the shelf is meant. Non-exhaustive examples include Allen / hex keys, flat or cross-head screwdrivers of various kinds, Torx head tools, metric or imperial wrenches / spanners. Advantageously this does not require tools or training that is not already possessed by the user. The male portion may have a female interface to engage with a male portion of a standard tool. Advantageously this avoids a requirement for projecting parts to be accessible by a tool so the male part can sit flush to the outer frame. The male portion may comprise an enlarged face configured to be braced with the opening. Advantageously, this increases the contact surface area between the opening and the adjustable spacer, and enhances the stability of the interface. The male portion may comprise a through-aperture. Advantageously, this allows for a fastener to pass through the male portion in order to, for example, secure the male portion to the opening. The male portion may be configured to be selectively extendible by at least 10mm. The male portion may be configured to be selectively extendible by at least 15mm. The male portion may be configured to be selectively extendible by at least 20mm. Advantageously this allows a frame to be fitted to an opening that is significantly larger than the outer frame. A second aspect of the present teachings provides an outer frame for a closure comprising at least one adjustable spacer of the first aspect. The frame may comprise a channel or recess on its closure face. Advantageously, if a channel is used, this allows for an intumescent seal to be installed within the outer frame to provide additional fire protection, in the case of a fire door. The adjustable spacers of the outer frame may be configured to be adjusted from within the channel. Advantageously, this allows for the spacers to be adjusted in place, in order to accommodate expansion or contraction of the outer frame, or movement in the opening, but be hidden by a cover in normal use. The outer frame may further comprise an intumescent seal located in the channel. Advantageously, this provides additional fire resistance, whilst hiding the spacers in normal use. For non-fire rated doors a continuous channel may not be required, but a suitable recess in alignment with the male portion and a complementary cover may alternatively be used to maintain a suitable appearance of the closure face of the outer frame. The outer frame may comprise a plurality of adjustable spacers. The adjustable spacers may be mounted around the frame at intervals, for example intervals of around 500mm or less. Advantageously, this allows for a secure mounting of the outer frame in the opening, accounting for unevenness in the profile of the opening. A third aspect of the present teachings provides a door frame assembly comprising the outer frame of the second aspect, and an intumescent seal located in the void between the outer frame and the opening. Advantageously, the use of spacers of the present teachings makes the fitting of intumescent seals in this void easier, as there is improved access compared to prior art packers. A fourth aspect of the present teachings provides a kit of parts comprising an outer frame for an opening and at least one adjustable spacer of the first aspect. The kit of parts may further comprise an intumescent seal. A fifth aspect of the present teachings provides a method for securing an outer frame in an opening comprising: locating the outer frame comprising a plurality of adjustable spacers of the first aspect, and extending the male portions until an outer faces of the male portions are braced in contact with the opening, so as to set a desired spacing therebetween. The method may further comprise locating an intumescent seal between the outer frame and the opening. The outer frame described in the method may comprise a channel on its closure face. The adjustable spacers described in the method may be extendible from within the channel. The method may further comprise a step of locating a cover within the channel. BRIEF DESCRIPTION OF DRAWINGS Embodiments will now be described, by way of example only, with reference to the accompanying Figures, in which: Figure 1A is a front view of an outer frame secured in an opening by a plurality of adjustable spacers according to an embodiment of the present teachings; Figure IB is a similar front view of the outer frame secured in the opening by the plurality of adjustable spacers to Figure 1A, but with a door hung within the frame. Figure 2 is a close-up isometric view of one of the adjustable spacers of Figure 1 with the male portion in an extended position; Figure 3 is an end view of the adjustable spacer of Figure 2; Figure 4 is an isometric cross section of a female portion of the adjustable spacer of Figure 2 mounted within the outer frame; Figure 5A is an isometric view of the adjustable spacer of Figure 2 in a retracted position, within the outer frame; Figure 5B is an isometric view of the adjustable spacer of Figure 5A, in an extended position; Figure 5C is an isometric view of the adjustable spacer of Figure 5B, with intumescent seals attached; Figure 6 is an isometric cross section view of an adjustable spacer mounted in an outer frame of a further embodiment, with a tool to extend the male portion of the adjustable spacer; and Figure 7 is an isometric cross section view of the adjustable spacer in a hollow outer frame according to the embodiment of Figure 6. DETAILED DESCRIPTION In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of various embodiments and the teachings. However, those skilled in the art will understand that: the present teachings may be practiced without these specific details or with known equivalents of these specific details; that the present teachings are not limited to the described embodiments; and, that the present teachings may be practiced in a variety of alternative embodiments. It will also be appreciated that well known methods, procedures, components, and systems may not have been described in detail. It will be understood that a frame assembly 10 of an embodiment of the present teachings is designed to be mounted level with the floor, with vertical frame members of the frame in an absolute vertical orientation at substantially 90° to the floor (assuming a horizontal floor), and the top frame member in an absolute horizontal orientation. Given this it should be understood that vertical or generally vertical means substantially 90° to the floor, and horizontal means generally parallel to the floor. In some embodiments a further frame member may be mounted at floor level or above floor level but substantially parallel thereto. It should also be understood that the frame assembly is intended to me mounted in an opening of a wall or partition, and the space inside of the frame is intended to mount a closure (e.g. a door or window). This means that the face of the frame that will be facing the wall is referred to below as the opening face, and the face of the frame onto which a door or other closure would be hung, is referred to as the closure face. The construction of the arrangement is now described in relation to the Figures. Referring firstly to Figure 1A, the frame assembly of an embodiment of the present teachings is generally indicated at 10. The frame assembly 10 has an outer frame 14 including a plurality of adjustable spacers 100, arranged within an opening 12. The outer frame 14 is formed by two vertical members 14a, with a cross member 14b forming the head of the frame. In the embodiment of Figure 1A, the vertical members 14a and cross member 14b are made of wood. In other embodiments, the members could be made of a composite material, metal etc. In further embodiments not intended to be fire-rated, the members could be made of uPVC, metal or any other appropriate material. In this embodiment, the outer frame 10 is configured to be installed in an opening 12 in an internal wall 11 of a building, the internal wall 11 being a masonry wall, stud wall, or a wall or partition of any other appropriate building material. The outer frame 14 comprises an opening face 18, facing outwardly, that is, towards the opening 12, and a closure face 17, facing inwardly, that is, towards the space in which a door 13 would be hung. Following the installation of the outer frame 14 in the opening 12 using the plurality of adjustable spacers 100, the door 13 can be hung within the outer frame 14. Frame assemblies 10 of the type disclosed are used to secure fire doors in public, commercial and domestic properties. It is therefore necessary that the frame assembly meets requirements for fire protection. This includes proper securing of the frame, and seals to delay the movement of smoke, flames, and noxious gases through the opening. In the embodiment of Figure 1A, the plurality of adjustable spacers 100 are distributed at an interval of 500mm or less around the outer frame 14. It will be appreciated that in other embodiments, any number of adjustable spacers 100 could be distributed at any suitable interval along the outer frame 14. Figures 2, 3 and 4 show one adjustable spacer 100 in isolation, comprising a female portion 110 and a male portion 120. In this embodiment the male and female portions are manufactured from mild steel, but depending upon the intended use (e.g. if not intended for fire doors), then other materials may be suitable, such as aluminium, brass or plastics such as polyamide, ABS or PET. The female portion 110 has a cylindrical region 113, a collar 114, and is provided with a through bore 115 axially aligned with the cylindrical portion and the collar. The through bore 115 has a female thread 111 in this arrangement. The outer surface of the cylindrical region 113 is provided with ribbing 118 to aid interference engagement with the outer frame 14, but in other embodiments other textures may be provided, such as knurling, or the outer surface may be smooth. The collar 114 of the female portion 110, in this embodiment, has a counterbore 116 incorporating four of apertures 117 through which fasteners 112 can be inserted. The apertures 117 are countersunk in this embodiment, so a corresponding fastener 112 can sit substantially flush with the counterbore 116. The female portion 110 is shown mounted in the outer frame 14 in Figure 4. In this embodiment the fasteners 112 are screws, but in other embodiments may be nails or staples (not shown), for example. In this embodiment the apertures 117 are angled so the fasteners 112 are angled away from the cylindrical region 113 of the female portion 110, e.g. at around 45°. This allows for a more secure connection, especially when outer frame 14 is thin, and also ensures that the fasteners 112 do not interfere with the body of the female portion 110. It will be appreciated that in other embodiments the apertures 117 may be arranged to secure the fasteners in any suitable way, or orientation, for example parallel to the axis of the through bore 115 via apertures (not shown) provided on the opening face of the collar 114. The number of apertures 117 may be adjusted as required to provide secure retention of the female portion 110. In alternative embodiments the fasteners 112 and apertures 117 may be omitted and the female portion 110 secured by adhesive or solely by the ribbing 118 or other integral mechanical securement. With particular reference to Figures 2 and 3, in this embodiment the male portion 120 has a head 127 and a shank 128. A male thread 121 is provided on an external surface of the shank, which is complementary to the female thread 111. The shank 128 is provided with an axial cavity 129 which is aligned with an aperture 124 of smaller diameter in the head 127 to define a bore extending axially through the male portion 120. The cavity 129 is provided with a tool interface 122. In this embodiment, the tool interface is a female interface designed to interact with the male interface of a tool, for example a standard Allen key 125 (Figure 5B), Torx wrench, screwdriver, or any other suitable tool. It will be appreciated that a benefit of a female interface is that the length of the male thread 121 can be maximised and access to the aperture 124 is not impeded. However in alternative embodiments the tool interface could be male. The head 127 provides an enlarged end face 123 to contact the opening 12. The advantage of the enlarged face 123 is that it provides a larger surface area to contact with the opening 12 to provide a more secure connection and to avoid overloading a small area of the opening 12 which may cause damage. In this embodiment the end face is substantially smooth, but in other embodiments may be textured. The through aperture 124 allows for an additional outward fastener 126 to be fitted through the male portion 120 to provide an improved connection between the adjustable spacer 100 and the opening 12. The fastener 126 may be a screw (Figure 6) but may alternatively be a nail etc. suitable for the material of the opening. It will be appreciated that in alternative embodiments the through aperture 124 may be omitted. In Figure 3 the cavity 129 and aperture 124 of smaller diameter can be seen. On the visible side of the male portion 120, flats 122 forming the tool interface can be seen, forming part of the axial cavity 129. With reference to Figures 5A and 5B, the adjustable spacer 100 is depicted installed in an outer frame 14 according to an embodiment of the present teachings. The female portion 110 is installed in the outer frame 14 in the same manner Figure 4 so the collar 114 is recessed into the outer frame. Figure 5A shows the adjustable spacer 100 in the retracted position, with the male portion 120 sat within the counterbore 116 of the female portion 110 so it is also flush or recessed. Figure 5B shows the adjustable spacer 100 in an extended position with the male portion 120 proud of the female portion 110. In this embodiment the male portion 120 is configured to extend by a minimum of 10mm, however it would be appreciated by the skilled person that the male portion 120 could be easily configured to extend by any distance required to bridge the gap between the opening face of the outer frame 14 and the edge of the opening 12, for example a minimum of 15mm, or a minimum of 20mm, if provided with a shank 128 of suitable length. According to the present embodiment there is a channel 15 located in the closure face of the outer frame 14. The channel may be fitted with a seal, for example an intumescent seal 16 to improve the fire protection capability of the door frame 10. As shown in Figure 4, the adjustable spacer 100 is located in the outer frame so the tool interface 122 of the male portion 120 can be accessed via the channel 15. A description of a method for installing the arrangement is now provided with reference to the Figures. Referring back to Figures 5A and 5B, the adjustable spacers 100 are configured to extend between the opening face of the outer frame 14 and the edge of the opening 12. In the specific embodiment of Figure 1A, holes are drilled into the frame at intervals of 500mm. The holes are counterbored in order for the collar 114 of the female portion 110 to sit flush with the opening face 18 of the outer frame 14. It will be understood that it is advantageous in this embodiment to install the female portion 110 flush with the outer frame as it does not limit the minimum size of the space between the outer frame 14 and the opening 12. It will be appreciated that in other embodiments it may be advantageous for the collar 114 of the female portion 110 to sit proud of the outer frame 14, for example when the outer frame 14 is hollow. This can be seen in Figure 6. Fasteners are then installed through the apertures 117 in the female portion 110 to secure it to the outer frame 14. The male portions 120 are then inserted into the female potions 110 so that they are in the retracted position, as seen in figure 5A. The outer frame 14 can then be offered up to the opening 12. The male portion 120 of at least one adjustable spacer 100 on opposing vertical members 14a are then extended by turning a standard tool 125. When the enlarged face 123 of the male portions 120 contacts the edge of the opening 12, the outer frame 14 is frictionally held in place. In order to properly align the outer frame 14, the gaps to the opening are measured, as is whether the vertical members 14a are plumb and the head 14b is horizontal. If this is not the case, the male portions 120 of the adjustable spacers 100 are extended or retracted until the until the alignment is achieved. All of the male portions 120 of the extendable spacers 100 can then be extended until they make contact with the edge of and are braced against the opening 12. At this stage, if further security is desired, fasteners 126 (as seen in Figure 6) can be inserted through the apertures 124 of the male portions and then secured into the opening 12. A final check for alignment may then be made. Once the outer frame 14 is secured (either with or without the addition fasteners 126), an intumescent seal 19 is fitted into the space between the outer frame 14 and the opening 12. The intumescent seal 16 may comprise foam strips, mastic or a combination of the two. The compact nature of the adjustable spacer minimises its interference with the fitting of such an intumescent seal 19 in a continuous manner around the opening 12. Architraves (not shown) can then be installed over the gap containing the adjustable members 100 to provide a neat appearance. To be fully compliant with fire regulations a further intumescent seal, which may be a strip 16 sized to fit within the channel 15, is provided between the outer frame 14 and the door 13. When fitted this covers the tool interface 122, providing a neat appearance. If at a later stage additional alteration of the adjustable spacers 100 is required, the intumescent seal 16 can be removed from the channel 15 allowing access to the tool interface 122 of the male portion 120. Once the alteration is completed, the intumescent seal 16 can be replaced. According to the current embodiment, when the outer frame 14 is sufficient secured within the opening 12, the door 13 can be hung within the frame as shown in Figure IB. It will be understood that although the description relates to an internal fire door, the arrangement would be appropriate for other internal or external doors and windows to be fitted and held within an opening, when it provides a simpler installation process and may be selected for this reason. An example where this may be used is in the case of mounting a non-fire rated uPVC door as shown in the further embodiment of Figures 6 and 7. The adjustable spacer 100 can be seen installed in a non-fire rate uPVC outer frame 24 in figures 6 and 7. As the outer frame 24 is hollow, the collar 114 of the female portion 110 of the adjustable spacer 100 is proud of the frame 24 rather than flush with it, as shown in previous embodiments. As can be seen, no modification is required to the adjustable spacer 100 itself, in order to install it in a hollow frame, but in some embodiments the ribbing may be replaced by an external thread to aid fitting. The one or more embodiments are described above by way of example only and it will be appreciated that the variations are possible without departing from the scope of protection afforded by the appended claims. For example, the threaded connection between the male and female portion may be replaced by an alternative cooperating mechanism, such as a ratchet or ball and ramp mechanism. If not used as a fire door, the channel in the outer frame may be replaced by a discrete recess for each adjustable spacer, such as a countersunk recess, which may then be covered by another suitable cover, such as a push-fit plug or cap.

Claims

1. An adjustable spacer for a securing an outer frame for mounting a moveable door or window closure in an opening, the adjustable spacer comprising:a female portion configured to be mounted in an aperture of the outer frame in a fixed relationship to the outer frame and to extend transversely therethrough to define a bore through the outer frame from a closure face to an opening face; anda male portion configured to cooperate with the bore and be physically accessible from the closure face, so as to be selectively extendible beyond a transverse surface of the door frame and be braced in contact with the opening so as to set a desired spacing therebetween.

2. The adjustable spacer of claim 1 comprising a threaded connection for selectively extending the male portion.

3. The adjustable spacer of claim 1 wherein the female portion further comprises one or more fasteners and is mountable to the outer frame with the one or more fasteners.

4. The adjustable spacer of claim 3 wherein the one or more fasteners are arranged to be angled in a direction away from bore of the female portion.

5. The adjustable spacer of clam 4 wherein the one or more fasteners are screws.

6. The adjustable spacer of claim 1 where the male portion is configured to beextendable using a standard tool.

7. The adjustable spacer of claim 6 wherein the male portion has a female interface to engage with a male portion of a standard tool.

8. The adjustable spacer of claim 1 wherein the male portion comprises an enlarged face configured to be braced with the opening.

9. The adjustable spacer of claim 1 wherein the male portion comprises a through-aperture.

10. The adjustable spacer of claim 1 wherein the male portion is configured to be selectively extendible by at least 10mm.

11. The adjustable spacer of claim 10 wherein the male portion is configured to be selectively extendible by at least 15mm.

12. The adjustable spacer of claim 11 wherein the male portion is configured to be selectively extendible by at least 20mm.

13. An outer frame for a closure comprising at least one adjustable spacer according to any of claims 1 to 12.

14. The outer frame of claim 13 wherein the outer frame comprises a channel on its closure face.

15. The outer frame of claim 14 wherein the adjustable spacers are configured to be adjusted from within the channel.

16. The outer frame of claims 14 or 15 further comprising an intumescent seal located in the channel.

17. The outer frame of any of claims 13 to 16 comprising a plurality of adjustable spacers, the adjustable spacers being mounted around the frame at intervals of 500mm or less.

18. A door frame assembly comprising the outer frame of any one of claims 13 to 17, and a door, further comprising an intumescent seal located in the void between the outer frame and the opening.

19. A kit of parts comprising:an outer frame for an opening; andat least one adjustable spacer according to any one of claims 1 to 12.

20. The kit of parts of claim 19, further comprising an intumescent seal.

21. A method of securing an outer frame in an opening comprising the steps of:locating the outer frame comprising a plurality of adjustable spacers of any one of claims 1 to 12 within the opening; andextending the male portions until an outer faces of the male portions are braced in contact with the opening, so as to set a desired spacing therebetween.

22. The method of claim 21 further comprising a step of locating an intumescent seal5 between the outer frame and the opening.

23. The method of claim 21, wherein the outer frame further comprises a channel onits closure face.10 24. The method of claim 23 wherein the adjustable spacers are extended from anaccess location within the channel.

25. The method of claim 23 or 24 further comprising a step of locating a cover within the channel.

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