U.S. patent application number 10/205180 was filed with the patent office on 2004-01-29 for modular device to create a passage through a partition.
Invention is credited to Cobian, Paul J., Radke, DuWayne C., Reier, Matthew D., Yoshida, George W..
Application Number | 20040016190 10/205180 |
Document ID | / |
Family ID | 30770012 |
Filed Date | 2004-01-29 |
United States Patent
Application |
20040016190 |
Kind Code |
A1 |
Radke, DuWayne C. ; et
al. |
January 29, 2004 |
Modular device to create a passage through a partition
Abstract
A modular device for providing a passage through a partition in
a structure. The modular device includes a riser housing comprising
a chamber fluidly coupling a base opening in a base portion with a
distal opening at a distal end and a shaped cavity housing
comprising a shaped cavity, a primary opening and a secondary
opening. A connector assembly releasably coupling the distal
opening at the distal end of the riser housing to the secondary
opening on the shaped cavity housing. An intumescent material is
preferably located in the chamber.
Inventors: |
Radke, DuWayne C.;
(Woodbury, MN) ; Cobian, Paul J.; (Woodbury,
MN) ; Reier, Matthew D.; (St. Paul, MN) ;
Yoshida, George W.; (Woodbury, MN) |
Correspondence
Address: |
3M INNOVATIVE PROPERTIES COMPANY
PO BOX 33427
ST. PAUL
MN
55133-3427
US
|
Family ID: |
30770012 |
Appl. No.: |
10/205180 |
Filed: |
July 26, 2002 |
Current U.S.
Class: |
52/232 ;
52/220.8 |
Current CPC
Class: |
E04G 15/061 20130101;
F16L 5/04 20130101 |
Class at
Publication: |
52/232 ;
52/220.8 |
International
Class: |
E04B 001/92 |
Claims
What is claimed is:
1. A modular device for providing a passage through a partition in
a structure, the modular device comprising: a riser housing
comprising a chamber fluidly coupling a base opening in a base
portion with a distal opening at a distal end; a shaped cavity
housing comprising a shaped cavity, a primary opening and a
secondary opening; and a connector assembly releasably coupling the
distal opening at the distal end of the riser housing to the
secondary opening on the shaped cavity housing.
2. The modular device of claim 1 comprising a firestop material
located in the chamber.
3. The modular device of claim 2 comprising a flame retardant char
forming material arranged within the chamber adjacent to the
firestop material.
4. The modular device of claim 2 comprising a flame-retardant char
forming material is arranged within said firestop material.
5. The modular device of claim 2 comprising an annular band of a
flame retardant char forming material arranged concentrically
within the firestop material.
6. The modular device of claim 2 comprising a polyvinyl chloride
flame retardant char forming material.
7. The modular device of claim 1 comprising a firestop material
located in the base member.
8. The modular device of claim 1 wherein the connector assembly
comprises a plurality of flexible engagement members located on the
shaped cavity housing adjacent to the secondary opening adapted to
releasably engage with the riser housing.
9. The modular device of claim 1 wherein the connector assembly is
integrally molded as part of the shaped cavity housing.
10. The modular device of claim 1 wherein the connector assembly
provides a snap-fit relationship between the riser housing and the
shaped cavity housing.
11. The modular device of claim 1 comprising a breakable lid
extending substantially across the primary opening of the shaped
cavity housing.
12. The modular device of claim 1 comprising a temporary insert
located in the shaped cavity.
13. The modular device of claim 1 wherein the shaped cavity housing
comprises a reinforcing portion adapted to be molded into the
partition.
14. The modular device of claim 1 wherein the shaped cavity housing
comprises at least one mounting holes.
15. The modular device of claim 1 wherein the shaped cavity housing
comprises a mounting structure adapted to releasably engage with a
device external to the partition.
16. The modular device of claim 1 comprising support members
releasably attachable to the shaped cavity housing.
17. The modular device of claim 16 wherein the support members
comprise cut outs for adjusting the length thereof.
18. The modular device of claim 1 wherein the riser housing
comprises at least one frangible connection transecting the riser
housing defining a removable band.
19. The modular device of claim 18 wherein the removable band
comprises a pull tab.
20. The modular device of claim 18 wherein removable band includes
indicia indicating the length of the modular device.
21. The modular device of claim 1 wherein the base opening and the
distal opening on the riser housing are arranged generally along a
longitudinal axis.
22. The modular device of claim 1 wherein the base portion
comprises a flange with mounting holes.
23. The modular device of claim 1 wherein the riser housing
comprises a generally cylindrical shape.
24. A modular device adapted to be cast in place to provide a
passage through a molded partition in a structure, the modular
device comprising: a riser housing comprising a chamber fluidly
coupling a base opening in a base portion with a distal opening at
a distal end; a shaped cavity housing comprising a shaped cavity, a
primary opening and a secondary opening; and a connector assembly
releasably coupling the distal opening at the distal end of the
riser housing to the secondary opening on the shaped cavity
housing.
25. The modular device of claim 24 comprising a firestop material
located in the chamber.
26. The modular device of claim 24 wherein the connector assembly
comprises a plurality of flexible engagement members located on the
shaped cavity housing adjacent to the secondary opening adapted to
releasably engage the riser housing.
27. The modular device of claim 24 comprising a breakable lid
extending substantially across the primary opening of the shaped
cavity housing.
28. The modular device of claim 24 comprising a temporary insert
located in the shaped cavity.
29. The modular device of claim 24 wherein the shaped cavity
housing comprises a reinforcing portion adapted to be molded into
the partition.
30. The modular device of claim 24 wherein the shaped cavity
housing comprises a mounting structure adapted to releasably engage
with a device external to the partition.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a modular devices
for passing cables, pipes, and the like through a partition, such
as a floor, and in particular, to a modular cast in place device
for forming through-penetrations in molded partitions. The present
modular device can be used with or without a firestop material.
BACKGROUND OF THE INVENTION
[0002] During the construction of buildings, it is necessary to
provide openings or passages through the building floors, walls,
and ceilings to permit the running of wires, cables, pipes, and the
like. Through-penetrations in molded partitions, such as poured
concrete partitions, may be formed by various techniques including
knocking holes in the partition after it has been formed, or using
a mold or form that is arranged on a concrete form before the
concrete is poured. Due to the variety of sizes and shapes needed
for through-penetrations, contractors typically need to stock a
large number of different forms. When the correct form is not
available, workers often "make do" with a form of the wrong shape
and/or size, causing the need for extensive rework after the
concrete cures.
[0003] Additionally, through-penetrations provide one mechanism by
which fire and smoke may spread from one compartment of the
building to another. Intumescent firestop materials that expand and
close an opening in the partition in the event of a fire are often
required to minimize the migration of fire and smoke between
compartments. The intumescent material is typically attached to the
through-penetration after the concrete cures, increasing labor
costs. If the intumescent material is not correctly installed and
fails during a fire, the consequences can be catastrophic.
[0004] Cast-in-place devices for providing a through-penetration in
a partition, typically with an intumescent material to close the
passageway and prevent the spread of fire and smoke in the event of
a fire, are known in the patented art. The Harbeke U.S. Pat. No.
4,669,759, for example, discloses a firestop stack coupling
including intumescent material which expands to close off a pipe
passing through the coupling in the event of a fire. The Harbeke
U.S. Pat. No. 4,888,925 discloses a fire retardant fluid coupling
assembly having a metallic band wrapped about an intumescent
collar.
[0005] The Roth U.S. Pat. No. 5,347,767 discloses a smoke and fire
protection device for providing a heat sealable raceway for running
wires and cables through a concrete wall, ceiling, or floor. The
device includes a thermally expansive material which, in the event
of a fire, expands causing the raceway to collapse, thus preventing
fire and/or smoke from passing through the wall, ceiling, or floor.
The raceway slidably fits within a tubular housing allowing the
raceway to extend through the sleeve to either side of the device,
thereby allowing an installer to couple additional sections of the
raceway at a convenient location remote from the device. The sleeve
has a length sized to accommodate the thickness of the particular
mounting location. Since the sleeve is sized to accommodate a
particular partition thickness, the user must pre-select the
appropriate size sleeve for a particular job, thereby requiring
installers to keep a large number of different size devices on
hand.
[0006] The Rejecki U.S. Pat. No. 5,390,465 discloses a pass through
firestop device for installation in a building wall or floor to
provide a pass through opening for pipes, tubing, and the like. The
device includes an axially open first end and a tubular body having
a second end closed by a transverse wall. A ring of intumescent
material fills the axially open first end. The device is installed
during the formation of the building partitions by attaching the
device to form elements and then pouring the floor or wall
structure. After the floor is poured, the upper end section of the
tubular body is removed by cutting it flush with the upper surface
of the floor.
[0007] The Munzenberger et al. U.S. Pat. No. 6,161,873 discloses a
masonry lead-in fixture having a housing including an axially
extending through bore, a radially protruding attachment flange
provided at least at one end of the housing, an intumescent
material which, in case of fire, closes the bore, and a disc-shaped
partition located in the housing which extends over the inner
diameter of the bore which is broken when pipe, cable, or the like
is pushed through the fixture. The fixture includes a lengthening
pipe formed of a plastic material that is cut-off to a desired
length.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention is directed to a modular device for
providing a passage through a partition in a structure. The modular
device includes a riser housing comprising a chamber fluidly
coupling a base opening in a base portion with a distal opening at
a distal end. A shaped cavity housing comprising a shaped cavity
with a primary opening and a secondary opening is provided. A
connector assembly releasably couples the distal opening at the
distal end of the riser housing to the secondary opening on the
shaped cavity housing.
[0009] In one embodiment, a firestop material is located in the
chamber and/or the base portion. A flame retardant char forming
material can optionally be arranged within the chamber adjacent to
the firestop material. The term firestop material refers generally
to intumescent, endothermic, and ablative materials useful in
resisting the spread of fire and smoke from one compartment of a
structure to another. In one embodiment, the flame retardant char
forming material is an annular band arranged concentrically within
the firestop material. The flame retardant char forming material
serves to strengthen the expanded intumescent material such that
the resulting mass forms a fire barrier that can pass the hose
stream portion of ASTM E 814 Fire Test Standard.
[0010] In one embodiment, the connector assembly includes a
plurality of flexible engagement members located on the shaped
cavity housing adjacent to the secondary opening. The engagement
members are adapted to releasably engage with ribs on the riser
housing. The connector assembly can be integrally molded as part of
the shaped cavity housing. Alternatively, the connector assembly
can be a separate component. The connector assembly preferably
provides a snap-fit relationship between the riser housing and the
shaped cavity housing. The connector assembly can be a variety of
other structures, including bayonet connectors, threaded
structures, mechanical fasteners, and the like.
[0011] The modular device includes a cap that is attached to the
shaped cavity housing to cover the primary opening. In one
embodiment, the cap includes cantilevers that snap onto the
circumferential ribs, thereby securely attaching the cap to the
shaped cavity housing. In one embodiment, the cap is a breakable
lid positioned substantially across the primary opening of the
shaped cavity housing to prevent the molded material from filling
the shaped cavity. Alternatively, a temporary insert can be located
in the shaped cavity.
[0012] The shaped cavity housing can include reinforcing portions
adapted to be molded into the partition. The shaped cavity housing
can also include mounting holes for attaching fixtures or
structures external to the partition.
[0013] The riser portion preferably includes a plurality of equally
sized transverse bands each including a manually engagable pull tab
to facilitate manual removal of the associated bands with or
without the aid of a manually operated hand tool. By removing
successive bands, a user can adjust the length of the device (i.e.
shorten) in accordance with the thickness of the partition into
which the device is installed. It will be recognized that providing
more bands will increase the range of partition thicknesses that
can be accommodated by the device, and increasing the number of
bands per unit length will increase the ability of the device to
more closely match the thickness of the partition. In addition, the
pull tabs on each band may be provided with indicia indicating the
length of the device at the band and corresponding to the thickness
of the partition. Each band may also include one or more radially
outwardly extending circumferential ribs that provide the bands
and, consequently, the riser with added hoop strength, and also
provide a projection for making snap connections with other
components of the present modular device.
[0014] Frangible connections can be provided to facilitate removal
of the transverse bands. The frangible connection can be formed in
the riser housing by providing a line of weakness in the housing
by, for example, scoring, notching, or creasing the housing, or by
molding or machining the housing to have a thin region in the wall,
thereby allowing a user to easily tear the housing along the line
of weakness. The frangible connection defines a removable band that
can be readily removed by a user, typically with the aid of a hand
tool such as pliers, to shorten the length of the housing to
accommodate the thickness of the partition into which the device is
installed. The removable band preferably includes a pull tab that
provides a grasping location for a user to remove the band from the
housing along the frangible connection, thereby facilitating manual
removal of the band.
[0015] The modular device may also include an extension member
adapted to connect with the riser portion to increase the length of
the device and allow the device to be used with partitions having
thicknesses greater than the standard length of the device. The
outer diameter of the extension is preferably sized so that
standard size plastic pipe can fit over and connect with the
extension to provide additional extension for the device.
[0016] The modular device preferably includes a retaining ring
arranged within the base portion that serves to retain the firestop
material in the base portion. The retaining ring may be coded with
color or other indicia to indicate the quantity of firestop
material provided in the device which, in turn, corresponds with
the application of the modular device. An adapter may also be
provided that connects with the base portion to allow the modular
device to be coupled to a contoured surface such as a fluted or
corrugated deck.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0017] The present invention will be further described with
reference to the accompanying drawings, in which:
[0018] FIG. 1 is a perspective view of a modular device in
accordance with the present invention.
[0019] FIG. 2 is a bottom view of the modular device of FIG. 1.
[0020] FIG. 3a is a sectional view taken along line 3a-3a in FIG.
2.
[0021] FIG. 3b is a sectional view taken along line 3b-3b in FIG. 2
showing the modular device with a firestop material arranged
therein.
[0022] FIG. 4 is a detailed sectional view taken along line 4-4 of
FIG. 1.
[0023] FIG. 5 is an exploded perspective view of a modular device
including a cap, an extension member and an adapter in accordance
with the present invention.
[0024] FIG. 6 is a sectional view showing the modular device of
FIG. 3b installed in a molded partition.
[0025] FIG. 7 is a sectional view of an alternate embodiment of the
invention showing a pipe passing through the modular device.
[0026] FIG. 8 is a perspective view of a modular device including
an attached shaped cavity housing in accordance with the present
invention.
[0027] FIG. 9 is an exploded view of the modular device of FIG.
8.
[0028] FIG. 10 is top view of an alternate modular device in
accordance with the present invention.
[0029] FIG. 11 is a side sectional view of the modular device of
FIG. 10 cast in place in concrete.
[0030] FIG. 12 is a perspective view of the modular device of FIG.
10.
[0031] FIG. 13 is top view of an alternate modular device in
accordance with the present invention.
[0032] FIG. 14 is a side sectional view of the modular device of
FIG. 13 cast in place in concrete.
[0033] FIG. 15 is a perspective view of the modular device of FIG.
13.
DETAILED DESCRIPTION OF THE INVENTION
[0034] FIGS. 1-6 show a modular device 2 for providing a
through-penetration in a floor, wall, ceiling, or the like. The
term through-penetration or passage generally refers to an opening
in a floor, wall, ceiling, or the like that is separate and
distinct from the cables, wires, pipes, or other items that pass
through it from one compartment of a structure to another. For
example, plumbing refers to a system of pipes and fixtures
concerned with the introduction, distribution and disposal of water
in a building. The present through-penetration or passage provides
an opening for plumbing to pass through a partition, but does not
perform any of the plumbing functions.
[0035] The present modular device 2 is particularly suited for
forming a through-penetration or passage through a molded
partition. As used herein, molded partition refers to a partition
formed from a flowable material, such as for example concrete or
structural foam, that sets or cures to create a more rigid
structure. The modular device 2 is located in a mold or form having
the desired shape and the flowable material is delivered. Once the
flowable material is set or cured, the mold or form is removed. In
this embodiment, the molded device 2 is cast in place. For example,
the modular device 2 is secured to a wooden concrete form 46 (FIG.
6) or other surface, such as a fluted deck using an adapter 40
(FIG. 5), and concrete is poured into the form, thereby embedding
the modular device 2 in the concrete forming the molded partition
44.
[0036] The modular device 2 includes a generally cylindrical hollow
housing 4 having a base opening 6, a distal opening 8, and a
chamber 10 extending longitudinally from the first end 6 to the
distal opening 8. An intumescent firestop material 26 (FIGS. 3b, 6
and 7) can optionally be arranged in the modular device 2,
typically adjacent the base opening 8. It will be recognized that
the housing 4 may have any shape. For example, the shape of the
housing 4 can change along its length. In some embodiments, the
housing 4 has a regular cross section along its length, such as a
circle, an oval, a square, a rectangle, or any other polygonal.
[0037] In one embodiment, base portion 4a is attached to the
housing 4. The base portion 4a can be integrally molded to the
housing 4 or can be a separate component to the present modular
device. The base portion 4a includes a longitudinally extending
annular side wall 14 extending from the open first end 6 toward the
open second end 8, radially outwardly extending flange portions 15
extending outwardly in opposite directions from the base portion 4a
adjacent the open second end 8, a radially inwardly extending
shoulder portion 17 extending inwardly from the sidewall 14, and a
riser portion 4b having a longitudinally extending annular side
wall 16 extending from the shoulder portion 17 to the distal
opening 8. The base portion 4a preferably has a larger diameter
than the riser portion 4b giving the housing 4 a two-tiered tapered
configuration in which the base portion 4a has a greater
cross-sectional area than the riser portion 4b.
[0038] Riser portion 4b includes a plurality of circumferential
bands 18a, 18b, 18c, 18d (referred to collectively as "18")
connected by frangible connections 20a, 20b, 20c, 20d (referred to
collectively as "20"). The frangible connections 20 allow one or
more bands 18 of the riser 4b to be quickly, easily, accurately,
and cleanly removed by a user, typically with the aid of a manually
operated hand tool such as pliers, at pre-selected intervals so the
modular device 2 can be used in partitions having a variety of
thicknesses.
[0039] Each frangible connection 20 is preferably located adjacent
to one of the circumferential bands 18. After one of the frangible
connections 20 is removed, a circumferential band 18 is preferably
located near distal end 8a of the riser portion 4b to facilitate
attachment to other components of the present modular device, as
will be discussed in detail below.
[0040] Each circumferential band 18 preferably forms a continuous
360 degree loop which forms a section of the riser portion 4b that
can be readily removed by a user to shorten the riser portion 4b
and thereby match the thickness of the partition into which the
device is installed. Each band 18 includes a pair of
circumferential ribs 18a' (FIG. 4) that provide hoop strength and
provide a structure for attaching other components of the modular
device 2. The frangible connections 20 are lines of weakness formed
by, for example, molding or machining the riser to have thin areas
of material connecting adjacent bands 18 that can be manually
broken by a user to separate adjacent bands.
[0041] Each band 18 includes a pull tab 22a, 22b, 22c, 22d
(referred to collectively as "22") extending radially outwardly
from the bands 18. The pull tabs 22 facilitate removal of the
associated frangible connection 20 by providing the user a location
to grasp and pull, typically with the aid of a hand tool such as
pliers, thereby tearing the associated frangible connection 20 to
remove the circumferential band 18 from the riser 4b. Each pull tab
22a-d may be marked with indicia indicating the length or height of
the device at that pull tab.
[0042] In one embodiment, the base portion 4a contains an annular
recess 24 for receiving an optional firestop material 26 (FIGS. 3b,
5, 6 and 7). The firestop material 26 is provided in the form of an
annular ring as shown in FIG. 5 that extends along the inner
surface of the sidewall portion 14 from the base opening 8 to the
shoulder portion 17. The firestop material 26 may be held in place
in the recess 24 with adhesive, using mechanical fasteners, or by
using a retaining ring 38 (FIG. 5) described more fully below. To
facilitate the installation of a pipe through the device 2, the
inner surface of the firestop material 26 if preferably aligned
with the inner surface of the riser portion 4b, that is, the inner
diameter of the firestop material 26 and the riser 4b are the same,
whereby the diameter of the chamber 10 is generally the same along
the entire length of the device 2. In some embodiments,
manufacturing can be facilitated if the inner diameter of the
firestop material 26 is slightly larger than the inner diameter of
the riser 4b.
[0043] The recess 24 is defined by the sidewall portion 14 and the
shoulder portion 17 of the base portion 4a. In accordance with
another characterizing feature of the invention, the inner surfaces
of the sidewall portion 14 and the shoulder portion 17 facing the
chamber 10 include rib portions 14a and 17a, respectively. The
sidewall ribs 14a extend radially inwardly from the sidewall 14 and
extend longitudinally from adjacent the flange 15 to the shoulder
portion 17. The shoulder portion rib 17a is an annular projection
extending outwardly from the shoulder portion 17 in the direction
of the first opening 6. The side wall portion ribs 14a maintain the
firestop material 26 in spaced relation from the sidewall portion
14 and create an air gap 27 between the firestop material 26 and
the side wall portion 14 which, in the event of a fire, allows the
entire axial length of the firestop material to be exposed to
heated air, thereby aiding rapid, complete, and uniform expansion
of the firestop material which in turn closes the
through-penetration.
[0044] Referring now to FIG. 5, the modular device 2 is provided
with a cap 28 that attaches to the riser portion 4b and covers the
distal opening 8. The cap 28 prevents concrete being poured during
the formation of a partition from entering the device 2. The cap 28
includes snap connectors 30 that allow the cap to be manually snap
fit onto the riser portion 4b at any of the via any of the
circumferential bands 18.
[0045] The modular device 2 may also be provided with an extension
member 32 that attaches to the top of the riser portion 4b adjacent
the open second end 8. The extension member 32 contains cut-outs 34
aligned with tabs 22 on the riser portion 4b that allow the
extension member 32 to be placed in overlapping relation with the
riser portion 4b. Snap connections 36 are provided that allow the
extension member 32 to be attached circumferential bands 18 on the
riser portion 4b.
[0046] The extension member 32 serves to increase the height of the
modular device 2 for use in partitions in which the thickness of
the partition is greater than the standard height of the modular
device 2. The extension member 32 is also preferably sized so that
standard size plastic pipe can fit over the top of the extension
member 32 to provide further extension. The outer diameter of the
extension member 32 corresponds to the inner diameter of a standard
size plastic pipe, such that the plastic pipe is adapted to fit
over the extension member 32. In this embodiment, the extension
member comprises an adapter for attaching other components to the
present modular device 2.
[0047] The device includes an annular gasket 37 arranged in the
recess 24 between the firestop material 26 and the shoulder portion
17. The gasket 37 is formed of an elastomeric material and serves
to form a smoke and water seal at ambient conditions with the pipe
installed prior to expansion of the firestop material. The modular
device 2 is also provided with an annular retaining ring 38 that
attaches to the base portion 4a of the device and retains the
firestop material 26. The retaining ring 38 includes tabs 39 to
facilitate attachment of the retaining ring 38 to the base portion
4a. The tabs 39 are aligned with and extend through slots 41
provided in the base portion 4a. Once the retaining ring 38 is
installed in the modular device 2, the tabs 39 are bent outwardly
to secure the retaining ring 38 in place and also anchor the
modular device 2 in the partition. In embodiments where the modular
device 2 is inserted into a molded partition, the tabs 39 are
securely anchored in the concrete, for example.
[0048] Since the quantity of firestop material 26 provided in the
modular device 2 will vary depending on the type of installation
(for example, more firestop material will be provided in the device
when it is used with a plastic pipe than a metal pipe), the
retaining ring 38 may be provided with color coding to indicate the
quantity of firestop material installed in the device and/or the
type of pipe in the installation. This way, after the modular
device 2 has been installed in a partition, the quantity of
firestop material and the type of installation (i.e. a plastic pipe
or a metal pipe installation) can be quickly and easily identified
by visual inspection, eliminating the need to remove the retaining
ring to make such a determination.
[0049] In addition, the modular device 2 may be provided with an
adapter 40 that attaches to the base portion flange 15 and allows
the modular device 2 to be used on contoured surfaces such as a
fluted deck. The adapter 40 includes a hollow tubular extension
portion 40a, an outwardly extending flange portion 40b, and snap
connectors 42 that snap connect with the base portion 4a of the
modular device 2.
[0050] The present modular device 2 is preferably formed of a
synthetic plastic material such as polyethylene. The firestop
material 26 may include an intumescent compound, an endothermic
compound, or both an intumescent compound and an endothermic
compound. Exemplary intumescent compounds include intumescent
graphite such as intercalated graphite and acid treated graphite,
hydrated alkali metal silicates, vermiculite, perlite, and NaBSi.
Exemplary endothermic compounds include aluminum trihydrate (ATH),
Al(OH).sub.3 hydrated zinc borate (ZnB.sub.2O.sub.4.6H.sub.2O),
calcium sulfate (CaSO.sub.4.2H.sub.2O) also known as gypsum,
magnesium ammonium phosphate (MgNH.sub.4PO.sub.4.6H.sub.- 2O),
magnesium hydroxide (Mg(OH).sub.2), encapsulated H.sub.2O, and
magnesium ammonium phosphate hexahydrate,
MgO.2B.sub.2O.sub.3.9H.sub.2O. A preferred firestop material 26 is
INTERAM Ultra GS Graphite mat available from 3M Company, St. Paul,
Minn.
[0051] FIG. 6 illustrates the modular device 2 installed in a
concrete floor 44. The modular device 2 is installed by first
securing the base portion 4a to wooden concrete form 46 with
fasteners 48, and then pouring concrete into the form 46, thereby
embedding the device in the concrete. The cap 28 is then removed
and any unnecessary bands 18a-d are removed by grasping and pulling
the pull tabs 22a-d. It will also be recognized that if the
thickness of the partition is known, excess bands can be removed
prior to installation and pouring of the concrete.
[0052] FIG. 7 illustrates the modular device 2 with fire stop
material 26 is cast in place in a concrete floor 44. A metal pipe
62 is shown passing through the modular device 2. The modular
device 2 in FIG. 7 is similar to the one shown in FIG. 6 except it
further includes a flame retardant char forming insert 64 arranged
between the intumescent firestop material 26 and the metal pipe 62.
It has been found that by providing a flame retardant char forming
material between the intumescent material 26 and the pipe 62, a
fire barrier capable of passing the hose stream portion of the ASTM
E814 test standard is created. Providing the char forming insert 64
is particularly useful when the modular device 2 is used as a
firestop for a metal pipe passing through an opening in a
floor.
[0053] The insert 64 can be a continuous annular band that is
secured within the modular device 2 using adhesive, mechanical
fasteners, or the retaining ring 38 described above. Alternatively,
the insert 64 can be a discontinuous arcuate band that can be
compressed like a spring clip so that the insert can be positioned
within the intumescent material 26 and held in place by the spring
force.
[0054] The insert 64 is formed of a flame-retardant material (i.e.
one that does not support combustion) that does not melt and which
forms a char when exposed to high temperatures such as those
encountered in a fire. In this manner, insert 64 works in
combination with the expanded intumescent material 26 to provide a
fire, smoke, and water barrier in the annular space around the
metal pipe that enables the device to pass the hose stream portion
of the ASTM E814 test standard.
[0055] The particular material selected for the insert 64 is not
critical to the invention hereof, so long as it provides the
desired function. Suitable flame retardant materials that form a
char include halogenated polymers such as polychloroprene,
polyvinyl chloride and polyvinylidene fluoride; chlorine flame
retardant compounds such as perchloropenta-cyclodecane and
chlorinated paraffins; bromine flame retardant compounds such as
decabromodiphenyl oxide, octabromodiphenyl oxide, and
tetrabromodipentaerythritol; phosphorous compounds such as ammonium
polyphosphate and tributylphosphate; compounds including both
chlorine and phosphorous such as 1,3 dichloro-2-propanol phosphate
and 2-chloroethanol phosphate; and nonhalogenated polymers such as
hydrated zinc borate and boric oxide. A preferred flame retardant
char forming material for the insert is polyvinyl chloride.
[0056] FIGS. 8 and 9 illustrate an alternate modular device 100 in
accordance with the present invention. Distal end 8a of riser
housing 4b is shown releasably attached to a shaped cavity housing
102. The shaped cavity housing 102 of FIG. 8 includes a series of
sidewalls 124 and a wall 126 opposite the primary opening 120. The
wall 126 includes the secondary opening 104 that is aligned with
the distal opening 8 (see FIG. 3a) on the riser housing 4b. Chamber
10 of the riser housing 4b (see FIG. 3a) is in fluid communication
with shaped cavity 106 of the shaped cavity housing 102 and the
base opening 6 in the base member 4a. In some embodiments, base
member 4a may optionally include an intumescent material 128.
[0057] The shaped cavity housing 102 includes a primary opening 120
that provides access to the shaped cavity 106. The shaped cavity
housing 102, however, can be any size or shape, depending on the
application. It is not necessary for the primary opening 120 to
extend the full length of the horizontal cross section of the
shaped cavity housing 102. In some embodiments, the primary opening
120 may be smaller than the horizontal cross section of the shaped
cavity 106.
[0058] A temporary insert 122 may optionally be located in the
shaped cavity 106 in lieu of the cap 28 illustrated in FIG. 5.
Alternatively, a covering can be provided that extends across the
primary opening 120 to prevent concrete or other moldable material
from entering into the shaped cavity 106 during the formation of
the molded partition.
[0059] The size and shape of the shaped cavity 106 is designed to
accommodate plumbing required to connect the drain and overflow of
a bathtub. Bathtubs require two connections: a drain under the tub
and an overflow at one end of the tub. The piping for these two
locations must come together for a common connection at the end of
the tub and at floor level for passing through the partition. The
drain location under a bathtub must have a cavity in the concrete
floor in order to allow room for the installer to reach in and make
the necessary piping connections. Bathtub installation typically
requires a tub box about 8 inches by 10 inches by 2 inches deep and
slightly off to one side molded in the concrete floor. The modular
device 100 of FIGS. 8 and 9 permits the generally cylindrical
hollow housing 4 of FIG. 1 to be used in combination with a variety
of shaped cavities, such as the tub box illustrated in FIGS. 8 and
9.
[0060] As best illustrated in FIG. 9, lower surface 108 of the
shaped cavity housing 102 includes a connector assembly 110 for
releasably coupling with distal end 8a of the riser housing 4b. In
the illustrated embodiment, the lower surface 108 includes a
plurality of snap connections 112 that engage with one of the
circumferential bands 18 on the riser housing 4b. Any releasable
connection between the riser housing 4b and the lower surface 108
of the shaped cavity housing 102 can be used, such as for example
bayonet connectors, threaded members, mechanical fasteners, and the
like.
[0061] Depending on the size and shape of the shaped cavity housing
102, additional support members 114 may optionally be used. In the
illustrated embodiment, the support members 114 are configured to
engage with recess 116 on the shaped cavity housing 102. The
support members 114 preferably include cutouts 118 that facilitate
shortening to accommodate riser housings of different heights.
Alternatively, the support members 114 can include frangible
connections 20 such as are used on the riser housing 4b.
[0062] FIGS. 10, 11 and 12 illustrate an alternate modular device
140 in accordance with the present invention. Commercially
available shower drains have flanges that may protrude below the
floor level after installation. A cavity in the concrete floor is
required to provide the space for this flange. Shaped cavity
housing 142 is designed to receive commercially available shower
drains.
[0063] As best illustrated in FIG. 11, the shaped cavity housing
142 includes engagement members 144 that form a snap fit
relationship with the circumferential bands 18 on the riser housing
4b. The engagement members 144 are preferably constructed as a
portion of support ribs 146 located on lower surface 148 of the
shaped cavity housing 142.
[0064] Chamber 10 in the riser member 4b is in fluid communication
with the secondary opening 152 to shaped cavity 156 and the base
opening 6 on the base member 4a. The base opening 6 and the distal
opening 8 on the riser housing 4b are preferably arranged generally
along longitudinal axis 158. An intumescent material 160 can
optionally be located in the chamber 10, and in particular, in the
base member 4a. A temporary insert 154 may optionally be located in
the shaped cavity 156 in lieu of the cap 28 illustrated in FIG. 5.
Alternatively, a covering over the primary opening 150 can be
used.
[0065] FIGS. 13, 14 and 15 illustrate an alternate modular device
170 in accordance with the present invention. Shaped cavity housing
172 is releasably attached to the riser housing 4b by engagement
numbers 174 in a snap fit relationship with circumferential bands
18. Breakable cap 176 extends across primary opening 178 of the
shaped cavity housing 172. As best illustrated in FIG. 14, shaped
cavity 180 located below the breakable cap 178 is in fluid
communication with chamber 10 of the riser housing 4b and the base
opening 6 in the base member 4a. An intumescent material 190 can be
optionally located in the chamber 10, and in particular, in the
base member 4a.
[0066] The shaped cavity housing 172 includes a reinforcing portion
182 that increases the overall structural integrity of the
component, but also is preferably imbedded in the molded partition
44 (see FIG. 14). For example, FIG. 14 illustrates the modular
device 170 cast in place in a concrete floor. The reinforcing
portion 182 acts to secure the shaped cavity housing 172 within the
molded material (e.g., concrete) of the molded partition 44.
[0067] The shaped cavity housing 172 also includes a plurality of
mounting holes 184 adapted to secure fixtures and other devices to
the modular device 170. For example, commercially available water
closets can be bolted to the mounting holes 184 of the shaped
cavity housing 172. Securing the water closet directly to the
shaped cavity housing 172 has the added benefit of centering the
water closet over the passage formed by the modular device 170. The
modular device 170 provides the conduit through which the plumbing
for the water closet passes, but is not intended to replace the
plumbing.
[0068] In one embodiment, threaded inserts 188 can be located in
the mounting holes 184. The threaded inserts can be constructed of
a variety of materials, such as steel, brass, copper, high-density
polymeric materials and the like. Although the typical water closet
only requires two mounting holes, the present shaped cavity housing
172 includes eight mounting holes 184. This feature permits the
water closet to be rotated to a variety of positions, permitting a
more flexible installation options.
[0069] All of the patents and patent applications disclosed herein,
including those set forth in the Background of the Invention, are
hereby incorporated by reference. Although specific embodiments of
this invention have been shown and described herein, it is to be
understood that these embodiments are merely illustrative of the
many possible specific arrangements that can be devised in
application of the principles of the invention. Numerous and varied
other arrangements can be devised in accordance with these
principles by those of ordinary skill in the art without departing
from the scope and spirit of the invention. Thus, the scope of the
present invention should not be limited to the structures described
in this application, but only by the structures described by the
language of the claims and the equivalents of those structures.
* * * * *