Glass block structure with phenolic resin framework

Abstract

A glass block structure supported by a flexible phenolic resin framework is disclosed. The phenolic resin framework is bonded to the individual glass blocks with an adhesive substance that is placed so as to lie at or near the corners of the blocks. The phenolic resin that makes up the supporting framework may advantageously be formed in a pultrusion process wherein the resin is embedded with glass-like strands. Further heat-tolerance and adhesion may be obtained from the use of a high-heat tolerant putty applied between the phenolic resin and the glass blocks. The flexibility of the phenolic resin allows the block structure to be preassembled and then transported to an installation site as a single, ready-to-install unit.

1 . A heat-tolerant, fire-resistant translucent structure comprising: 
 at least two glass blocks;    at least one flexible support piece separating said glass blocks and maintaining a distance between said glass blocks, said support piece comprising at least one flexible strip connected to a substantially flat, flexible tray, said tray substantially perpendicular to said strip, the at least one strip and the tray each comprising a phenolic resin;    an adhesive substance between at least one of said glass blocks and said support piece;    an installation frame forming a perimeter of said translucent structure, said installation frame comprising a phenolic resin; and    wherein the at least one flexible support piece, and the installation frame in combination with the at least two glass blocks are heat-tolerant and fire-resistant.    
   
   
       2 . The heat-tolerant, fire-resistant translucent structure of  claim 1 , wherein said at least one flexible strip comprises opposing flexible strips integrally joined to the substantially flat, flexible tray, said tray substantially perpendicular to said strips so that the support piece forms an I-shape in cross-section, said support piece located in said heat-tolerant, fire-resistant translucent structure such that said tray is adjacent to a bottom surface of at least one of said glass blocks and such that at least a portion of each of said strips is adjacent to a front surface and a back surface respectively of said at least one glass block.  
   
   
       3 . The heat-tolerant, fire-resistant translucent structure of  claim 1 , wherein said at least one flexible support piece and said installation frame are formed in a pultrusion process.  
   
   
       4 . The heat-tolerant, fire-resistant translucent structure of  claim 1 , wherein the at least one flexible support piece and the installation frame are formed from phenolic resin embedded with glass-like strands.  
   
   
       5 . The glass-like strands of  claim 4  further comprising fiberglass.  
   
   
       6 . The heat-tolerant, fire-resistant translucent structure of  claim 1 , wherein the heat-tolerant, fire-resistant translucent structure will withstand the high temperatures experienced during a fire for several minutes.  
   
   
       7 . The heat-tolerant, fire-resistant translucent structure of  claim 1 , wherein the heat-tolerant, fire-resistant translucent structure satisfies the requirements established by the American Society for Testing and Materials Positive Pressure Fire Test of Window Assemblies.  
   
   
       8 . A heat-tolerant, fire-resistant translucent structure comprising: 
 at least two glass blocks;    at least one flexible support piece separating said glass blocks and maintaining a distance between said glass blocks, said support piece comprising at least one flexible strip integrally joined to a substantially flat, flexible tray, said tray substantially perpendicular to said strip, said support piece located in said heat-tolerant, fire-resistant translucent structure such that said tray is adjacent to a bottom surface of at least one of said glass blocks and such that at least a portion of said strip is adjacent to a front surface of said at least one glass block, the at least one flexible strip and the tray each comprising a phenolic resin embedded with fiberglass strands, said flexible support piece tending to permit the transportation of said heat-tolerant, fire-resistant translucent structure from a first location where said heat-tolerant, fire-resistant translucent structure is assembled to a second location where said heat-tolerant, fire-resistant translucent structure may be installed by permitting members of said heat-tolerant, fire-resistant translucent structure to flex and bend slightly with respect to each other without breaking during transportation of said heat-tolerant, fire-resistant translucent structure; and    an adhesive substance between at least one of said glass blocks and said support piece.    
   
   
       9 . The heat-tolerant, fire-resistant translucent structure of  claim 8 , wherein said at least one flexible support piece is formed in a pultrusion process.  
   
   
       10 . The heat-tolerant, fire-resistant translucent structure of  claim 8 , wherein the at least one flexible support piece is formed from phenolic resin embedded with glass-like strands.  
   
   
       11 . The glass-like strands of  claim 10  further comprising fiberglass.  
   
   
       12 . The heat-tolerant, fire-resistant translucent structure of  claim 8 , wherein the heat-tolerant, fire-resistant translucent structure will withstand the high temperatures experienced during a fire for several minutes.  
   
   
       13 . The heat-tolerant, fire-resistant translucent structure of  claim 8 , wherein the heat-tolerant, fire-resistant translucent structure satisfies the requirements established by the American Society for Testing and Materials Positive Pressure Fire Test of Window Assemblies.  
   
   
       14 . A method of forming a heat-tolerant, fire-resistant translucent structure from a plurality of glass blocks, the method comprising: 
 (1) adhering with an adhesive a first side of a first flexible support piece to a first side of a first glass block at an assembly location;    (2) adhering with an adhesive a second side of said first flexible support piece to a first side of a second glass block at the assembly location, the first flexible support piece maintaining a distance between said first and second glass blocks; and    (3) adhering with an adhesive a flexible installation frame around a perimeter of said plurality of glass blocks at the assembly location, thereby forming the heat-tolerant, fire-resistant translucent structure.    
   
   
       15 . The method of  claim 14  further comprising: 
 (4) transporting as a unit the heat-tolerant, fire-resistant translucent structure to an installation location different than the assembly location.    
   
   
       16 . The first flexible support piece and flexible installation frame of  claim 14  further comprising phenolic resin embedded with fiberglass strands.  
   
   
       17 . The first flexible support piece and flexible installation frame of  claim 14 , wherein the first flexible support piece and flexible installation frame are formed by pultrusion.  
   
   
       18 . The method of  claim 14 , wherein the heat-tolerant, fire-resistant translucent structure formed can withstand fire being exposed to one face of the heat-tolerant, fire-resistant translucent structure without any flaming occurring on the unexposed face.  
   
   
       19 . The method of  claim 14 , wherein the heat-tolerant, fire-resistant translucent structure formed can withstand the American Society for Testing and Materials Positive Pressure Fire Test of Window Assemblies without developing any through-openings in the plurality of glass blocks, the first flexible support piece and the flexible installation frame.  
   
   
       20 . The method of  claim 14 , wherein the heat-tolerant, fire-resistant translucent structure formed satisfies the requirements established by the American Society for Testing and Materials Positive Pressure Fire Test of Window Assemblies.