Patent Description:
In particular, the present invention relates to a portal frame structure, which is inserted in the opening of the outer wall and fixed to the outer wall for the purpose of housing and supporting a respective fixture be it a window, a windowed door or a door. The portal frame structure defines a made-to-measure housing for the respective fixture, delimits the space having suitably finished surfaces, and thermally and acoustically insulates the fixture from the outer wall and prevents the formation of thermal bridges along the outer wall around the fixtures.

Generally, the portal frame structure is made in large part of high-density polystyrene, which has good compactness properties, mechanical resistance, workability, thermal and acoustic insulation.

However, this material is combustible and some countries have banned its use in the building sector and other countries are adopting analogous measures.

Document <CIT> discloses a prefabricated structure made of steel struts, insulating material and cladding panel. The stiffness of the prefabricated structure is provided by the frame made of steel struts.

Document <CIT> discloses a building panel, comprising a load-bearing structure composed of a plurality of metal profiles, of which at least two head profiles placed at two opposite ends of the panel and two or more load metal profiles parallel to each other and perpendicular to said head profiles and fastened to said head profiles, thermally and acoustically insulating material interposed between said profiles and a first and second structural gypsum or cement fibre plates coupled on the opposite faces of the load-bearing structure. The metallic profiles prejudice the thermal insulation and does not teach to assemble panel to make a portal frame.

Document <CIT> discloses a frame for a window or a door with a lower crossbar, a middle crossbar an upper crossbar and two uprights, which each connect the lower cross to the middle crossbar and the upper crossbar, wherein the two uprights as well as the upper and the lower crossbar consist of a heat-insulating material, in which at least one reinforcing metal profile is introduced.

Metal profiles are conductive and cannot be easily introduced into a heat-insulating material.

One object of the present invention is to provide a portal frame structure of the above-identified type which remedies the drawbacks of the prior art.

In accordance with the present invention, a portal frame structure for finishing and equipping an opening of an outer wall of a building is provided, the portal frame structure comprising at least a first and a second elongated element and transverse elements integral with the first and the second elongated elements, said first and second lateral elongated elements are parallel and each one of the first and the second lateral elongated elements comprising at least one mat made of an insulating and incombustible material selected from mineral wool and fibreglass; and at least one reinforcement panel, said reinforcing panel being integral with the mat and extending along the greater part of a main face of the mat, characterized in that each one of the first and second elongated elements is made by coupling said mat to one respective reinforcement panel so as to form said lateral elongated element and is assembled to the transverse elements so as to manufacture said portal frame structure, wherein the first and the second lateral elongated elements face one another.

This way, mats made of mineral wool or fibreglass can be used, which are capable of meeting the most stringent fire prevention regulations but are not capable of fully carrying out a load-bearing function in the portal frame structure. Mineral wool and fibreglass allow classifying the portal frame structure in high classes of reaction to fire, in particular in the classes A1, A2 and B of the European classification EN <NUM>-<NUM>.

The reinforcement panel, which adheres, for example by gluing, to a main face of the mat has the function of defining the outer finishing surface of the space of the opening and, in combination with the mat, of making the first and the second elongated elements self-supporting. The reinforcement panel is generally thin and made of a high-density material such as, for example, fibre cement and, thus, subject to bending if subjected to a bending moment, while the mat is much thicker than the reinforcement panel but has a lower density and, thus, is more deformable. In practice, a mineral wool or fibreglass having a density comprised between <NUM> and <NUM>/mc is selected. The joining of the mat having a large thickness to the reinforcement panel having a reduced thickness takes care of the reciprocal structural weaknesses of the mat and of the reinforcement panel and makes the first and the second elongated elements sufficiently self-supporting.

In addition, the proposed solution has the advantage of greatly reducing the use of materials derived from oil.

In particular, the transverse elements comprise a third upper elongated element, which rests on the first and the second elongated elements at their upper ends and is fixed to the first and to the second elongated elements and comprises a mat made of an insulating and incombustible material such as, for example, mineral wool or fibreglass; and at least one reinforcement panel, which is integral with the mat and extends along the greater part of a main face of the mat.

This way, also the upper element is capable of ensuring the thermal and acoustic insulation and of being incombustible.

In particular, the transverse elements comprise a fourth elongated element facing and parallel to the third elongated element and supporting the first and the second elongated elements; the fourth elongated element being fixed to the first and to the second elongated elements and comprising a mat made of an insulating and incombustible material such as, for example, mineral wool or fibreglass; and at least one reinforcement panel, which is integral with the mat and extends at least partially along a main face of the mat.

This way, the portal frame structure comprises a base and defines a square entirely acoustically and thermally insulated from the outer wall.

In particular, each of the first and the second lateral elongated elements comprises a further reinforcement panel integral with the mat.

This way, the further reinforcement panel allows further stiffening the first and the second elongated elements.

In particular, the reinforcement panel and the further reinforcement panel cover the greater part of the respective main faces of the mat.

This way, the reinforcement panel and the further reinforcement panel carry out the functions of containing and protecting the mat.

In particular, the further reinforcement panel has a protruding portion with respect to the mat for mounting an inner fixture along the protruding portion, in particular the further reinforcement panel partially extends along the main face opposite the face integral with the reinforcement panel.

This way, the further reinforcement panel also carries out the function of counter-frame.

In particular, each of the first and the second elongated elements comprises a plurality of containment elements extending between each reinforcement panel and the further reinforcement panel so as to enclose the mat between the reinforcement panel, the further reinforcement panel and the containment elements.

This configuration is necessary when the consistency of the mat is of a particularly low density.

In particular, the containment elements comprise strips, the opposite ends thereof are fixed to the reinforcement panel and to the further reinforcement panel, said strips being discretely distributed along the elongated element.

This way, it is possible to contain the weight of the first and of the second elongated elements.

In particular, the containment elements comprise a front panel arranged at right angles between the reinforcement panel and the further reinforcement panel.

This way, the mat is encased in a reinforcement structure.

In accordance with a variant of the present invention, the further reinforcement panel is embedded in the mat for the benefit of the structural simplicity of the first and of the second elongated elements.

In particular, each of the first and the second elongated elements comprises two mats and two respective reinforcement panels, one of which adheres to both incombustible insulating mats.

This way, it is possible to form different configurations depending on the depth of the mats such as, for example, to manufacture counter-frames.

In particular, the first and the second lateral elongated elements comprise respective recesses which extend in the mat; each recess housing a U-shaped guide, in particular the guide is made of a metal material.

This way, the first and the second elongated elements have the function of guiding the shutters.

In particular, the third elongated element comprises three insulating mats fixed to respective reinforcement panels, which are assembled so as to form a tunnel configured to house a shutter; the inner surface of the tunnel being defined by the free faces of the self-supporting panels.

This way, also the tunnel housing the shutter is incombustible.

In particular, the reinforcement panel is made of a material selected from fibre cement, magnesium oxide, calcium hydrosilicate; marble;; resin; and ceramic.

The above-mentioned incombustible materials, besides ensuring a high level of surface finishing contribute to giving the portal frame structure an excellent class of reaction to fire according to the European classification EN <NUM>-<NUM>.

In particular, the further reinforcement panel is made of a material selected from, fibre cement, magnesium oxide, calcium hydrosilicate, resin, ceramic, and a wood-based material, in particular a wood-based material containing magnesium oxide and/or fibreglass and/or metal additives.

This way, also the use of a wood-based material normally used for manufacturing the counter-frame does not prejudice the high class of reaction to fire of the entire portal frame structure given the meagreness of the mass of the wood-based material with respect to the entire portal frame structure.

A further object of the present invention is to provide a method for manufacturing a portal frame structure which is exempt from the drawbacks of the prior art.

In accordance with the present invention, a method for manufacturing a portal frame structure as described in the foregoing is provided, the method comprising:.

This way, the portal frame structure is structurally stable and ready to be inserted in an opening of the outer wall.

Other characteristics and advantages of the present invention will be apparent from the following description of non-limiting embodiment examples thereof, with reference to the accompanying figures, wherein:.

With reference to <FIG>, reference numeral <NUM> indicates, as a whole, a portal frame structure arranged in an opening of an outer wall <NUM> of a building. In general, the portal frame structure <NUM> carries out the functions of supporting an inner fixture <NUM> and an outer fixture or shutter; of insulating the fixtures <NUM> and <NUM> from the outer wall <NUM> and of finishing the free surfaces.

In the illustrated case, the outer fixture <NUM> is defined by a roller shutter and the load-bearing structure <NUM> also carries out the functions of guiding the roller shutter in the opening and closing movements and of housing the outer fixture <NUM>.

In embodiments not illustrated in the accompanying figures, the inner and outer fixtures are of a different type and the portal frame structure has a configuration adapted to the configuration of the fixtures without however departing from the scope of protection of the present invention of the appended claims.

In some cases, the outer fixture is absent.

The outer wall <NUM> comprises a load-bearing or infill wall <NUM>; an outer insulating cladding <NUM>; an outer finishing layer <NUM>; and an inner finishing layer <NUM>. The stratigraphy of the outer wall <NUM> illustrated in <FIG> has a purely illustrative purpose and, in practice, can assume configurations different from the one illustrated.

The portal frame structure <NUM> illustrated in <FIG> comprises four elongated elements <NUM>, <NUM>, <NUM> and <NUM> assembled with one another at the respective opposite ends: two lateral elongated elements <NUM> and <NUM>, and two transverse elongated elements <NUM> and <NUM> of which a upper elongated element <NUM> and a lower elongated element <NUM>. The portal frame structure <NUM> is fixed to the outer wall <NUM> by means of cramps, which are not illustrated in <FIG> and are cemented in the outer wall.

The lateral elongated elements <NUM> and <NUM>, are arranged at the sides of the opening and are parallel and face one another. The upper elongated element <NUM> rests on the elongated elements <NUM> and <NUM> at their upper ends and is fixed to the elongated elements <NUM> and <NUM>. The lower elongated element <NUM> faces and is parallel to the upper elongated element <NUM> and directly supports the lateral elongated elements <NUM> and <NUM>, and is fixed thereto.

Each of the elongated elements <NUM>, <NUM>, <NUM>, and <NUM> comprises a mat <NUM>, <NUM>, <NUM>; and a reinforcement panel <NUM>, <NUM>, <NUM> which is integral with the respective mat <NUM>, <NUM>, <NUM> and extends, at least partially, along a main face of the mat <NUM>, <NUM>, <NUM>.

Each mat <NUM>, <NUM>, <NUM> has the shape of a parallelepiped and has insulating properties with regard both to the acoustic transmission and the heat transmission and is made of an incombustible material. In particular, each mat <NUM>, <NUM>, <NUM> is made of an insulating and incombustible material in particular selected from fibre glass and mineral wool. The definition incombustible refers to the European classification EN <NUM>-<NUM>. Even if both these materials have a high density, they are not capable of defining a portal frame structure with a stable shape. For this reason, each mat <NUM>, <NUM>, <NUM> is glued along a wide main face of the same to the respective reinforcement panel <NUM>, <NUM>, <NUM> so as to allow prefabricating the portal frame structure <NUM> prior to the installation of the portal frame structure <NUM> in the opening of the outer wall <NUM>. In accordance with the tests performed, a satisfactory gluing has been obtained with a hygro-hardening polyurethane adhesive.

With reference to <FIG>, the elongated element <NUM>, <NUM> comprises, besides the mat <NUM> and the reinforcement panel <NUM>, a further reinforcement panel <NUM>, which is integral with the mat <NUM>, and has a protruding portion with respect to the mat <NUM> for mounting an inner fixture <NUM> along the protruding portion. In particular, the reinforcement panel <NUM> is glued to the mat <NUM> and partially extends along the main face opposite the main face integral with the reinforcement panel <NUM>. The reinforcement panel <NUM> and the further reinforcement panel <NUM> cover the greater part of the respective main faces of the mat <NUM> hence the elongated element <NUM> and, analogously, the elongated element <NUM> have a sandwich configuration.

Each of the elongated elements <NUM> and <NUM> has a recess which extends in the mat <NUM> and a corresponding incision in the reinforcement panel <NUM> and comprises a U-shaped guide <NUM> housed in the recess and in the incision so as to guide the outer fixture <NUM> or shutter (<FIG>).

In the variant of <FIG>, the reinforcement panel <NUM> does not protrude with respect to the mat <NUM> and the lateral elongated element <NUM>, <NUM> comprises a protruding metal plate <NUM>, which is fixed to the reinforcement panel <NUM> and defines the counter-frame for housing the inner fixture.

<FIG> and <FIG> illustrate a variant <NUM> of the elongated element <NUM> (<FIG>) and, analogously, a variant <NUM> of the elongated element <NUM> (<FIG>). In accordance with this variant, in <FIG> the reinforcement panel <NUM>, <NUM> comprises a mat <NUM> which is enclosed between a reinforcement panel <NUM>, a reinforcement panel <NUM> and a plurality of containment elements, which comprise strips <NUM> the opposite ends thereof are fixed to the reinforcement panels <NUM> and <NUM> and a front panel <NUM> arranged at right angles between the reinforcement panels <NUM> and <NUM>.

In the illustrated embodiment, the mat <NUM> has a recess while the reinforcement panel <NUM> comprises a corresponding recess housing a guide <NUM>, which has a wall flush with a face of the mat <NUM>.

The mat <NUM> has a further recess for partially housing the reinforcement panel <NUM>, which has a face flush with a face of the insulating and incombustible mat <NUM>. Each strip <NUM> is fixed to the reinforcement panel <NUM> and to the guide <NUM>, which, in turn, is fixed to the reinforcement panel <NUM>. The strips <NUM>, instead, are preferably made of metal and fixed by means of screws.

In a variant not illustrated of <FIG>, the strips <NUM> are partially replaced by a panel which extends along the face opposite the face that adheres to the panel <NUM> and is directly connected to the reinforcement panel <NUM> and to the panel <NUM> by means of connecting strips. The panel <NUM> is replaced by connecting strips between the panel <NUM> and the panel <NUM>.

<FIG> illustrates a variant <NUM> of the elongated element <NUM> (<FIG>) and analogously a variant <NUM> of the elongated element <NUM> (<FIG>). Each of the first and the second lateral elongated elements <NUM>, <NUM> comprises two mats <NUM> and <NUM> and two respective reinforcement panels <NUM>, <NUM>, the first of which adheres to both mats <NUM> and <NUM>. The mat <NUM> has a depth which is approximately half the depth of the mat <NUM> and is arranged in an overlapping manner so as to form a striker plate for a fixture (not illustrated) and approximately half the depth of the mat <NUM>.

Each lateral elongated element <NUM>, <NUM> comprises a further reinforcement panel <NUM> buried in the mat <NUM>.

With reference to <FIG>, each mat <NUM>, <NUM> has a respective reinforcement panel <NUM>, <NUM> and a respective further reinforcement panel 35A, 35B glued to the main faces. The mat <NUM> houses a guide 26A.

In the variants described with reference to <FIG>, the reinforcement panels <NUM>, <NUM>, <NUM> protrude with respect to the respective mats <NUM>, <NUM>, <NUM>, it being understood that, in accordance with variants not illustrated, the reinforcement panels <NUM>, <NUM>, <NUM> are flush with the respective mats <NUM>, <NUM>, <NUM>.

With reference to <FIG>, the upper elongated element <NUM> comprises three mats <NUM> integral with respective reinforcement panels <NUM>, which are assembled with one another forming a tunnel <NUM> housing the outer fixture <NUM>. The reinforcement panels <NUM> define the inner face of the tunnel <NUM>.

With reference to <FIG>, the elongated element <NUM> comprises a further panel <NUM>, which has the function of partially enclosing the tunnel <NUM> at the bottom leaving a slot for the passage of the shutter or the outer fixture <NUM>.

In accordance with a variant not illustrated, the upper elongated element <NUM> comprises a single mat and a single reinforcement panel. This simplified solution is adopted when it is not necessary to house the outer fixture.

With reference to <FIG>, the elongated element <NUM> comprises the mat <NUM> and the reinforcement panel <NUM> arranged above the mat <NUM> and partially protruding with respect to the mat <NUM>.

In general, the reinforcement panels <NUM>, <NUM>, <NUM>, <NUM> having a finishing function are made of a material selected from fibre cement, magnesium oxide, calcium hydrosilicate; marble and ceramic.

The reinforcement panels <NUM>, <NUM> are made of a material selected from fibre cement, magnesium oxide, calcium hydrosilicate, resin, ceramic or of a wood-based material, in particular a wood-based material containing magnesium oxide and/or fibreglass and/or metal additives.

The reinforcement panels <NUM> are made of an incombustible material, preferably calcium hydrosilicate.

Finally, it is to be understood that variations can be made to the present invention with respect to the described embodiment without however departing from the scope of protection of the appended claims.

For example, <FIG> shows a portal frame structure <NUM> comprising the lateral elongated elements <NUM> and <NUM> and two transverse stiffening bars <NUM> while the upper elongated element <NUM> and the lower elongated element <NUM> are omitted. Once the portal frame structure <NUM> has been installed, the transverse bars <NUM> are removed.

<FIG> shows a portal frame structure <NUM>, which comprises the lateral elongated elements <NUM> and <NUM>, the upper elongated element <NUM> and two transverse stiffening bars <NUM> while the lower elongated element <NUM> is omitted.

Claim 1:
A portal frame structure for finishing and equipping an opening of an outer wall of a building, the portal frame structure (<NUM>; <NUM>; <NUM>; <NUM>) comprising at least a first and a second lateral elongated element (<NUM>; <NUM>; <NUM>, <NUM>; <NUM>; <NUM>) and transverse elements (<NUM>; <NUM>; <NUM>) integral with the first and the second lateral elongated elements (<NUM>; <NUM>; <NUM>, <NUM>; <NUM>; <NUM>), said first and second lateral elongated elements (<NUM>; <NUM>; <NUM>, <NUM>; <NUM>; <NUM>) are parallel and each one of the first and the second lateral elongated elements (<NUM>; <NUM>; <NUM>, <NUM>; <NUM>; <NUM>) comprising at least one mat (<NUM>; <NUM>; <NUM>, <NUM>) made of an insulating and incombustible material selected from mineral wool and fibreglass; and at least one reinforcement panel (<NUM>; <NUM>; <NUM>, <NUM>), said reinforcing panel (<NUM>; <NUM>; <NUM>, <NUM>) being integral with the mat (<NUM>; <NUM>; <NUM>, <NUM>) and extending along the greater part of a main face of the mat (<NUM>; <NUM>; <NUM>, <NUM>), characterized in that each one of the first and second elongated elements (<NUM>; <NUM>; <NUM>, <NUM>; <NUM>; <NUM>) is made by coupling said mat (<NUM>, <NUM>; <NUM>, <NUM>) to one respective reinforcement panel (<NUM>; <NUM>; <NUM>; <NUM>) so as to form said lateral elongated element (<NUM>; <NUM>; <NUM>, <NUM>; <NUM>; <NUM>) and is assembled to the transverse elements (<NUM>; <NUM>; <NUM>) so as to manufacture said portal frame structure (<NUM>; <NUM>; <NUM>; <NUM>), wherein the first and the second lateral elongated elements (<NUM>; <NUM>; <NUM>, <NUM>; <NUM>; <NUM>) face one another.