Not Applicable
Not Applicable
The present invention relates generally to fire-barriers for installing in expansion-joint-spaces and more particularly to pre-assembled fire-barriers constructed with male and female coupling ends for one-step drop-in installation of the barriers into straight-line and intersection expansion-spaces.
The background information discussed below is presented to better illustrate the novelty and usefulness of the present invention. This background information is not admitted prior art. The particular versions of the invention as described below are provided, in part, as illustrative and exemplary. Thus, the described versions should not be taken as limiting. Additionally, the invention is not limited to the examples provided.
Buildings and other structures are known to experience stress from many sources, such as extreme and/or repetitive changes in temperature, the force of high impinging winds, compression and expansion forces due to seismic events, settling of subsoil, building remodels, and excavation on or near the site. To minimize the effect of these stresses on the buildings or other structures, building codes now require that all structures must be constructed with spaces between adjacent wall, floor, and ceiling building units. These spaces commonly referred to as “expansion-spaces,” “expansion-spaces” or “expansion-joint-spaces” allow differential building movement to take place without risking damage to the structure, and thus are frequently referred to as “dynamic expansion-spaces”.
While expansion-spaces improve the life-time integrity of structures, they present a major risk in the event of a fire because the channels created by the expansion-spaces act as chimney flues providing pathways for gases, flame, and smoke to spread rapidly throughout the structure. To counter the flue effect, building codes for commercial or public structures generally require fire-barriers to be installed in the expansion-spaces to reduce or prevent the spread of flames, smoke, and gas through the spaces into adjoining areas. Fire-barriers protect both the structure and those who are within the structure by extending the time available for inhabitants to leave and for fire fighters to get to the fire.
During a fire, buildings and their fire-barriers are subject to even greater stress than usual, making it essential that the fire-barriers are able to retain their integrity. Accordingly, fire-barriers are legally mandated to be tested, rated, and certified. There are two currently mandated tests. One measures the ability of a fire barrier to maintain its structural integrity under compressional and tensional motion. This test is referred to as the “cycle” test and its parameters are specified by ASTM 1399. The other test is referred to as the “fire” or “burn” test and its parameters are specified by UL 2079. The two tests are conducted in sequence. A fire barrier is first cycled 500 times between the compression forces and tension forces and then, if the barrier passes the cycle test, it is placed into a furnace where it is tested for its ability to resist and prevent flame, heat, and gases from passing through the barrier.
Two classes of fire-barriers are needed to have fire-stop protection in most structures. One class includes straight-line fire-barriers; the other class includes all of the variously shaped intersection-space barriers designed and built for fitting into the geometrically complex spaces created by the intersection of a two or more expansion-spaces. In the past, the only code tested and certified fire-barriers commercially available were the straight-line fire-barriers. These barriers were, and still are, made to be installed in the expansion spaces between the straight, continuous segments of walls, ceilings, or floor units. However, whenever expansion-joint-spaces intersect, multi-directional, multi-dimensional intersection-spaces are created. Examples of intersecting joint spaces include the “cross-shaped” intersection-space that results from the intersection of two straight-line expansion-joint-spaces that intersect at a 90 degree angle, or where the joint space between two spaced adjacent interior walls abuts the space between an exterior wall and the two spaced adjacent interior walls creating a “T”-shaped intersection-space.
The present Inventor recognized that what is presently used to fill the intersection-spaces could likely not pass the cycle and fire tests. This is because barriers to fit into the intersection spaces are constructed on-site from parts of sectioned straight-line barriers. One problem with this is that when any tested and rated fire-barrier is modified, it immediately loses its rating, and because it is mandated to use only certified barriers, builders must have their engineers inspect the constructed on-site barriers so that these engineers can certify the barriers. That does not mean, however, that these on site constructions are capable of passing the extension/compression and fire-test, which could result in a building and its occupants being at a serious risk in the event of a fire. Moreover, during the installation process, one barrier is often shorter than the joint-space into which it is being installed. Thus, several barriers or sections of barriers need to be spliced together. The present Inventor feared that the spliced seams may or may not be air-tight and could allow hot air, smoke, toxic gases to travel throughout the expansion-joint-spaces of a building. Furthermore, as the connections formed during the requiring splicing procedures, are sometimes simply staples, and as spliced barriers have been known to be installed by non-specialists, they may not stand up to even relatively mild stresses of tension/compression and/or shear movements.
Thus, the present Inventor recognized that without a better fire-barrier system, life and property would continue to be at increased risk whenever there was a fire. He contemplated that to be able to have code-tested and rated geometrically complex intersection-space fitting fire-barriers, each barrier should be designed and constructed to have a one-continuous piece construction, and have no openings through the thickness of the barrier so as to prevent providing a pathway for the travel of smoke, fire, or gases. Additionally, the barriers should be constructed and pre-assembled in a certified facility according to the specifications required for barriers that have passed both the expansion/construction and the fire test. He also believed that there could be better ways to connect adjacent barriers to each other than the procedures currently used.
Furthermore, the present Inventor realized that on-site assemblage and splicing of fire-barriers for intersecting spaces is not only inherently an unsafe practice, it is time consuming and often requires more than one installation person, which adds significantly to the total construction cost. Moreover, he realized that on-site assembling could and likely did expose workers hands and arms to being cut by the thin sheets of stainless steel that are often a part of a fire barrier, and that whenever the installers would cut the fiber glass (or similar material) blankets breathable sized fibers are introduced into the workplace atmosphere resulting in increased worker's insurance. The present inventor recognized how beneficial to the worker, the contractor, and the building owner it would be to have fire-barriers, both those for fitting into straight-line expansion spaces and those for fitting into intersecting-expansion-spaces, pre-assembled with male and female coupling ends that provide not only for one-step drop-in installation of all of the styles of barriers into their respective expansion spaces, but for self-coupling of each barrier to its adjacent barrier as part of the drop-in installation. Such an improved product would greatly reduce both the time it takes to install the barriers and the health risks, thus cutting the cost of construction and worker's liability insurance.
Accordingly, the present Inventor designed and made both straight-line and intersection-space fire-barriers according to the following inventive principles. All fire-barriers described herein are pre-fabricated in a certified facility following a certified procedure that is mandated by the specifications of the fire and cycle tests. Fire-barrier systems following the principles of the present invention include: (1) fire-barriers, having male and female coupling ends, that designed as one-piece contiguous units to be installed in a one-step, drop-in process into intersection-joint-spaces, and (2) fire-barriers of the straight-line style also designed as one-piece contiguous units having male and female coupling ends, that can be installed in a one-step, drop-in process into straight-line expansion joint spaces, with both types of barriers having the same male/female coupling capability providing for one person, one-step, drop-in installation that saves installation time and improves worker safety. The male and female ended barriers are designed to be delivered to the work site ready to install. The male/female coupling ended fire-barriers of the present invention do not cost anymore to manufacture than do those that do not have male/female coupling abilities. Moreover, if installed with optional, fire-barrier specific, installation tools, even more time and cost is saved, work-site safety is greatly improved, and the general fire safety risk that is created when a contractor doesn't understand the detailed requirements of fire barrier installation is reduced, especially when the fire-barriers are being installed in intersecting expansion-joint-spaces.
The fire-barriers of the present invention are unique in several ways. One point of novelty is the variety of intersection-space barriers that are pre-assembled, as well as straight-line barriers, both styles having female/male coupling ends. One example, provided herein as a favored embodiment, is an L-shaped (also referred to as a horizontal/vertical L) fire barrier that is installed in a one-step, drop-in process into a L-shaped intersecting-expansion-joint-space created by the convergence of the expansion spaces between two building structures, such as a floor and a wall or a wall and a ceiling. The L-shape, as illustrated, is only one of a large number of possible configurations that are embodied with the principles of the present invention. The invention contemplates one-piece male/female coupling ended cross-shaped, T-shaped, and L-shaped barriers. It should be noted that L-shaped barriers may also be manufactured having horizontal/horizontal arms. All of the barriers are available having female connections, male connections, or both, depending on the specific configuration of the expansion spaces requiring fire-barriers that provide not only for one-step, drop-in installation, but also provide for interdigitating coupling ends that require only a bead of fire-resistant caulk to be applied over the seams between the two coupled barriers. No cutting or stapling of the overlapping coupling ends is required. Each style of male and female ended fire barrier is supplied with its own optional reusable installation tool that provides for even quicker, easier, and safer one-step, drop-in installation of both the pre-assembled, female and male ended multi-directional/multi-dimensional and straight-line fire-barriers. The installation tools are not only reusable, but also easily and rapidly size-adjustable for use with differently sized versions of the same style barriers. The fire-barriers illustrated in the present invention have passed the test referred to as the “cycle” test (ASTM 1399) and the “fire” or “burn” test (UL 2079).
Another advantage provided by the principles of the present invention include the fact that there is no opening or gap that penetrates through the layers as compared to some other systems, such as those that use loosely woven screening as innermost and outermost layers to provide support for the inner insulation layers. The loosely woven screening combined with the fact that the insulation layers supported by the screening are not as long as the bounding screen layers provides for gaps through which fire, gases, and smoke can penetrate. The attachment support brackets of the present invention include solid, rigid, fire resistant flanges (L-brackets are used in the illustrated examples) that support the layers of the fire-barriers of the present invention which layers are all attached to each other and to the brackets, but which layers are attached indirectly. That is, some of the layers are attached to an outmost solid support bracket while other layers are attached to an inner solid bracket with the brackets being attached to each other leaving no opportunity for gaps. Additionally, because the layers are attached indirectly, no opening is created through the total thickness of the fire barriers of the present invention.
In order that these and other objects, features, and advantages of the present invention may be more fully comprehended, the invention will now be described, by way of example, with reference to the accompanying drawings, wherein like reference characters indicate like parts throughout the several figures, and in which:
a is a perspective view of a partial section of the fire barrier, as illustrated in
b is a side plan view of the partial section of the straight-line fire barrier, as illustrated in
Building units, as used herein, refers to structures such as walls, floors, ceilings, and the like, and may be referred to as structural units.
Expansion-space, as used herein, refers to the spaces between adjacent wall, floor, and ceiling building units that are mandated by present day building codes to prevent the stresses suffered by buildings and other structures from temperature changes, earthquake motions, and wind, for example do not compromise the integrity of the buildings or other structures. These spaces are commonly referred to as “expansion-spaces” or “expansion-joint-spaces” and allow differential building movement to take place without risking damage to the structure, and are, thus, often referred to as dynamic expansion-spaces. Included under the term of expansion-space are the spaces created when two or more expansion-spaces intersect, creating an intersection-space that is much more geometrically complex; also see the definition for “Intersecting-spaces” below.
High-temperature thread, as used herein, refers to any thread that is fire resistant or any thread that will not support combustion, such as a ceramic thread.
Insulation blanket, as used herein, refers to any number of insulation materials, including fiber blankets made from alumina, zirconia, and silica spun ceramic fibers, fiberglass, and the like.
Interdigitate, as used herein, refers to the action of interlocking, coupling, connecting, interweaving, or commingling.
Interdigitatingly, as used herein, is the adverb that refers to the action of interlocking, coupling, connecting, interweaving, or commingling.
Interdigitation, as used herein, refers to the act of interlocking or the condition of being interlocked, coupled, connected, or interpenetrated, as is male-female coupling.
Intersecting-spaces, architectural expansion-joint-spaces, as used herein, refers to expansion-joint-spaces that intersect into each other from different spatial orientations to form multi-directional or multi-directional/multi-dimensional expansion-joint-spaces also referred to as “intersection-spaces,” as opposed to a straight line expansion joint space. V fire-barriers sized and shaped for installation into accepting intersection-spaces formed by the spaced intersection of at least two expansion-joint spaces that each occur between different sets of two adjacent spaced structural building units, each of said expansion-joint spaces defined by a plane, said plane defined by a set of three non-colinear points with each point defined by a set of x, y, z coordinates from the same coordinate system with no two of said coordinate sets being identical,
Intersection architectural-expansion join or joint, as used herein refers to any joint that is formed by the convergence of two or more expansion-joint-spaces, such as when the expansion spaces between wall units intersect and are also referred to as “intersection-spaces”. These spaces between building units may act like chimney flues carrying gases, hot air, flame, and smoke throughout a structure.
Intersection fire resistant barrier, as used herein, refers to any fire barrier that is shaped to functionally fit into a multi-directional and/or multi-dimensional architectural expansion joint space.
Intumescent as used herein, refers to those materials having properties that cause them to expand (or intumesce) to several times their original size when activated by high temperatures to prevent the spread of flames and smoke to other parts of a building, for example passive fire-seals contain intumescent compounds.
Male-Female Connections, as used herein, refers to connection in the mechanical and electrical trades and manufacturing where each of a pair of mating connectors is conventionally assigned the designation male or female. The “female” connector, or female coupling end, is generally a receptacle that connects to and holds the “male” connector, or male coupling end, to provide for a coupling of two parts. The assignment is by direct analogy with genitalia and sexual intercourse; the part bearing one or more protrusions, or which fits inside the other, being designated male and the part containing the corresponding indentations or fitting outside the other being female. Thus, the verb to mate being is used to describe connecting two ends together, as an extension of this analogy.
Metallic backing layer, as used herein, refers to fire resistant metal or metallicized foil, such as stainless steel, or the like.
Protective cloth, as used herein, refers to a flexible, strong, protective, fire-resistant material that is designed to mechanically support the insulation material and to protect the insulation material from mechanical damage, as the insulation is mechanically weak and can be easily damaged by tearing or ripping either accidentally or intentionally during or after installation thus largely compromising the integrity of the fire resistant barrier. The fire resistant layers, such as a layer of insulation material together with a layer of intumescent material, can freely move with respect to the one or more protective layers or they may be attached together via threads or other attaching means. Protective cloths may be manufactured from continuous filament amorphous silica yarns, polymeric material, fiber reinforced polymeric material, high-temperature resistant woven textiles, or a metalized, fiberglass cloth, among others. Metalized cloth may include fibers of stainless steel, aluminum, or copper, for example. Protective materials may also include metal foils or metal screens. Protective cloths also include cloths that are woven to provide for shear, including lateral, motion.
Seaming, as used herein, refers to connecting one part to another part, for example where a cloth is folded and the two parts of the cloth that have been brought together by the folding are subsequently “seamed” together along a predetermined line. The seaming may utilize stitching, using an adhesive, stapling, pinning, or any other means that will connect the two parts to each other.
Structural unit, as used herein, refers to such constructs as a wall, floor, ceiling, or the like and may be referred to as building units.
Tri-dimensional, as used herein, refers to either an expansion joint that has three intersecting extension joint spaces, such as a T-shaped expansion joint intersection or to a fire barrier that is functionally shaped to accommodate a T-shaped joint.
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a Friction fit washer.
Referring now to the drawings which show views of exemplary versions of the barriers and their related installation tools contemplated by this invention. The drawings also illustrate how the above discussed disadvantages have been overcome. It should be noted that the disclosed invention is disposed to versions in various sizes, such as lengths, widths, depths, in addition to variation in shapes, contents, layers, materials, and attachment means. Therefore, the versions described herein are provided with the understanding that the present disclosure is intended as illustrative and is not intended to limit the invention to the versions described.
a, a perspective view, illustrates a partial section of the fire barrier illustrated in
The structural configuration of a tool may vary considerably without departing from the spirit of the invention to provide for tools that provide for easy, one-step, lifting, and installing of a fire barrier of any of the shapes that are possible following the principles of the present invention . The tool may be piece constructed or may be molded. There are as many tool styles as there are differently shaped fire-barriers, so that the tool fits over each of variously shaped barriers, such as the T-shaped installation tool that is shaped for installing a T-shaped intersection fire barrier.
Thus it has been shown that the present invention comprises male and female ended intersection and straight line fire-barriers for easy and rapid interdigitated coupling of the straight-line barriers with straight-line barriers, straight-line barriers with intersection barriers, and intersection barriers with intersection barriers providing rapid, safe installation of the barriers while requiring no on-site cutting or construction; that all of the variously styled barriers are constructed as pre-assembled single-piece male/female coupling ended units for use in intersection and straight architectural expansion-joint-spaces to prevent the migration of gases, flame, and smoke through a structure; and that each style barrier is provided with a one-step, one-person, drop-in, reusable, width adjustable installation tool.
This Application for patent claims the benefit of U.S. Non-Provisional patent application Ser. No. 11/863,932 that claims the benefit of U.S. Provisional Patent Application No. 60/847,951 filed Sep. 28, 2006.
Number | Date | Country | |
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60847951 | Sep 2006 | US |
Number | Date | Country | |
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Parent | 11863932 | Sep 2007 | US |
Child | 12855639 | US |