U.S. patent application number 12/855639 was filed with the patent office on 2010-12-23 for fire-barrier systems having male and female coupling ends providing for one-step drop-in installation into straight-line and intersecting expansion-spaces.
This patent application is currently assigned to FIRELINE 520, LLC. Invention is credited to Alan Shaw.
Application Number | 20100319287 12/855639 |
Document ID | / |
Family ID | 43353066 |
Filed Date | 2010-12-23 |
United States Patent
Application |
20100319287 |
Kind Code |
A1 |
Shaw; Alan |
December 23, 2010 |
FIRE-BARRIER SYSTEMS HAVING MALE AND FEMALE COUPLING ENDS PROVIDING
FOR ONE-STEP DROP-IN INSTALLATION INTO STRAIGHT-LINE AND
INTERSECTING EXPANSION-SPACES
Abstract
Fire-barriers systems, including pre-assembled intersection and
straight-line fire-barriers having either male-coupling ends,
female-coupling ends or both types provide for the elimination of
on-site cutting and construction for easy, rapid, and safe
one-step, drop-in installation and coupling. Both the intersection
and straight-line fire-barriers are constructed as single-piece
continuous units for use in intersection spaces formed by
intersection of expansion-joint-spaces and in straight-line
architectural expansion-joint-spaces to prevent migration of gases,
flame, and smoke throughout a building. Indirect attachment of the
layers to each other and to their solid support brackets provides
for no continuous opening throughout the barriers preventing
passage of smoke, fire, and gases therethrough. Each style barrier
is provided with an optional one-step, one-person, drop-in,
reusable, width adjustable installation tool.
Inventors: |
Shaw; Alan; (Lockport,
NY) |
Correspondence
Address: |
PATRICIA M. COSTANZO;PATS PENDING
P.O. BOX 101
ELMA
NY
14059
US
|
Assignee: |
FIRELINE 520, LLC
Buffalo
NY
|
Family ID: |
43353066 |
Appl. No.: |
12/855639 |
Filed: |
August 12, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11863932 |
Sep 28, 2007 |
|
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12855639 |
|
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60847951 |
Sep 28, 2006 |
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Current U.S.
Class: |
52/396.01 ;
52/407.5 |
Current CPC
Class: |
E04B 1/948 20130101 |
Class at
Publication: |
52/396.01 ;
52/407.5 |
International
Class: |
E04B 1/94 20060101
E04B001/94; E04B 1/68 20060101 E04B001/68 |
Claims
1. A fire-barrier for sealing a dynamic expansion-space between
building units, comprising: a plurality of layers containing, at
least one protective blanket (6) at least one insulation blanket
(14, 24, and/or 34), and at least one fire-resistant support sheet
(8), at least two support brackets (30, 32) each to be fastened to
an opposing building unit, and at least one fastener (40a, 50a,
40b, or 50b) for attaching at least one of said layers to at least
another one of said layers and to at least one support bracket (30,
32) providing that when the layers are all so attached no fastener
penetrates all of the layers.
2. The fire-barrier, as recited in claim 1, further comprising some
of said plurality of layers stacked one on top of each other
providing for at least a first stack of said layers positioned
parallel and adjacent to each other and some other of said
plurality of layers stacked one on top of each other providing for
at least a second stack of some of said layers positioned parallel
and adjacent to each other, said first stack and said second stack
positioned parallel and adjacent to each other so that the long
axis of each stack is aligned in the same plane and being
lengthwise offset from each other providing for one lengthwise end
to have a male projection coupling structure and for the other
lengthwise end to have a female receiving coupling structure.
3. The fire-barrier, as recited in claim 1, further comprising said
plurality of layers being all of the same length.
4. The fire-barrier, as recited in claim 1, wherein said
fire-barrier is structured for sealing a straight-line dynamic
expansion-space.
5. The fire-barrier, as recited in claim 1, wherein said
fire-barrier is structured for sealing an intersection dynamic
expansion-space.
6. The fire-barrier, as recited in claim 1, wherein said brackets
are solid, rigid L-brackets.
7. The fire-barrier, as recited in claim 6, wherein one of each of
said L-brackets projects from each side of the expansion-space to
maintain said layers within said expansion space.
8. The fire-barrier, as recited in claim 1, wherein said at least
one protective blanket (6) supports at least one fire-resistant
support sheet (8).
9. The fire-barrier, as recited in claim 1, wherein said at least
one fire-resistant support sheet (8) supports at least one
insulation blanket (14, 24, and/or 34).
10. A fire-barrier for sealing a dynamic expansion-space between
building units, comprising: a plurality of layers containing, at
least one protective blanket (6) supporting at least one
fire-resistant support sheet (8) supporting at least one insulation
blanket (14, 24, and/or 34), said plurality of layers stacked one
on top of each other providing for at least a first stack of some
of said layers positioned parallel and adjacent to each other and a
second stack of some of said layers positioned parallel and
adjacent to each other, said first stack and said second stack
positioned parallel and adjacent to each other so that the long
axis of each stack is aligned in the same plane, and are lengthwise
offset from each other providing for one lengthwise end to have a
male projection coupling structure and for the other lengthwise end
to have a female receiving coupling structure, and at least one
fastener (40a, 50a, 40b, or 50b) for attaching one of said layers
to at least another one of said layers and to at least one support
bracket (30, 32) providing that when the layers are all so attached
no fastener penetrates all of the layers.
11. The fire-barrier, as recited in claim 10, further comprising at
least two support brackets (30, 32) each to be fastened to an
opposing building unit.
12. The fire-barrier, as recited in claim 11, further comprising at
least one fastener (40a, 50a, 40b, or 50b) for attaching one of
said layers to at least another one of said layers and to at least
one support bracket (30, 32) providing that when the layers are all
so attached no fastener penetrates all of the layers.
13. The fire-barrier, as recited in claim 10, wherein said
fire-barrier is structured for sealing a straight-line dynamic
expansion-space.
14. The fire-barrier, as recited in claim 10, wherein said
fire-barrier is structured for sealing an intersection dynamic
expansion-space.
15. The fire-barrier, as recited in claim 10, wherein said brackets
are solid, rigid L-brackets.
16. The fire-barrier, as recited in claim 15, wherein one of each
of said L-brackets projects from each side of the expansion-space
to maintain said layers within said expansion space.
17. The fire-barrier, as recited in claim 10, wherein said at least
one protective blanket (6) supports at least one fire-resistant
support sheet (8).
18. The fire-barrier, as recited in claim 10, wherein said at least
one fire-resistant support sheet (8) supports at least one
insulation blanket (14, 24, and/or 34).
19. The fire-barrier, as recited in claim 12, wherein intumescent
material is applied within the coupling area created when said male
projection coupling structure of one of said fire-barriers is
coupled with said female receiving coupling structure of another of
said fire-barriers.
20. A fire-barrier for sealing a dynamic expansion-space between
building units, comprising: a plurality of layers containing, at
least one protective blanket (6) supporting at least one
fire-resistant support sheet (8) supporting at least one insulation
blanket (14, 24, and/or 34), at least two support brackets (30, 32)
each to be fastened to an opposing building unit, and at least one
fastener (40a, 50a, 40b, or 50b) for attaching one of said layers
to at least another one of said layers and to at least one support
bracket (30, 32) providing that when the layers are all so attached
no fastener penetrates all of the layers; said plurality of layers
stacked one on top of each other providing for at least a first
stack of some of said layers positioned parallel and adjacent to
each other and a second stack of some of said layers positioned
parallel and adjacent to each other, said first stack and said
second stack positioned parallel and adjacent to each other so that
the long axis of each stack is aligned in the same plane and being
lengthwise offset from each other provide for one lengthwise end to
have a male projection coupling structure and for the other
lengthwise end to have a female receiving coupling structure.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] 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.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM
LISTING COMPACT DISK APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 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.
[0005] 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.
[0006] 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".
[0007] 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.
[0008] 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.
[0009] 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.
SUMMARY
[0010] 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.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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).
[0015] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] 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:
[0017] FIG. 1 is a diagrammatic cross-section view of a fire
barrier constructed according to the principles of the present
invention installed in an expansion joint.
[0018] FIG. 2a is a perspective view of a partial section of the
fire barrier, as illustrated in FIG. 1, to more clearly illustrate
an attachment means for attaching the first layer sheets of the
fire barrier to each other and to an L-bracket 30a to form a first
layer, and another attachment means 50a and 53a for attaching the
L-bracket to a second layer section and how pins 50a are used to
provide attachment means for an installation tool when the barrier
is ready to install.
[0019] FIG. 2b is a side plan view of the partial section of the
straight-line fire barrier, as illustrated in FIG. 2, illustrating
the addition of another layer of fire barrier material.
[0020] FIG. 3 is an exploded perspective view of a partial section
of the L-bracket to more clearly illustrate an example of
attachment means that may be used to attach an installation tool to
the L-bracket.
[0021] FIG. 4 is a cross-sectional cartoon of the straight-line
fire barrier, as illustrated in FIG. 1, to more clearly illustrate
the layer construction of the straight-line barrier having one male
coupling end and one female coupling end.
[0022] FIG. 5 is a top plan view to illustrate how straight-line
fire-barriers having one male coupling end and one female coupling
end interdigitate with each other to provide a complete fire
barrier system with no on-site fire barrier construction or
trimming required.
[0023] FIG. 6 is a perspective view of a horizontal/vertical,
90.degree. L-shaped fire barrier with one male and one female end,
for interdigitated coupling with, for example the complementary
ends of an abutting straight-line fire barrier illustrated in FIG.
9.
[0024] FIG. 7 is a perspective view of a straight-line fire barrier
with a male and female coupling end for coupling this barrier with
the horizontal/vertical, 90.degree. L-shaped fire barrier, as
illustrated in FIG. 6.
[0025] FIG. 8 is a perspective view illustrating how the
installation tool of the present invention provides for easy the
drop-in installation of a ten foot section of the straight-line
fire barrier.
DEFINITIONS
[0026] 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.
A LIST OF THE REFERENCE NUMBERS AND RELATED PARTS OF THE
INVENTION
[0027] F Female coupling end. [0028] M Male coupling end. [0029] 2
Intumescent strip material. [0030] 4 Caulk. [0031] 6 Protective
cloth. [0032] 8 Fire resistant sheet, metal foil, for example,
adhered to 6. [0033] 10 A straight-line fire barrier. [0034] 14 A
first insulation blanket. [0035] 24 A second insulation blanket.
[0036] 30 Inner L-bracket. [0037] 30a First leg of inner L-bracket
30. [0038] 30b Second leg of inner L-bracket 30. [0039] 32 Outer
L-bracket. [0040] 32a First leg of outer L-bracket 32. [0041] 32b
Second leg of outer L-bracket 32. [0042] 34 Third insulation
blanket. [0043] 36 Attachment means for attaching fire barrier to
building unit 90 through L-bracket 30. [0044] 40a Pin fastener and
friction-fit washer set providing for attachment of first
insulation blanket 14 and second insulation blanket 24 to each
other and to L-bracket 30a. [0045] 40b Pin fastener and
friction-fit washer set providing for attachment of first
insulation blanket 14 and second insulation blanket 24 to each
other and to L-bracket 30b. [0046] 42a Friction-fit washer. [0047]
42b Friction-fit washer. [0048] 44a Friction fit washer. [0049] 44b
Friction fit washer. [0050] 45a Pin fastener with friction-fit
washer to provide means to detachably attach an installation tool
to the fire barrier. [0051] 45b Pin fastener with friction-fit
washer to provide means to detachably attach an installation tool
to the fire barrier. [0052] 46 Spacer. [0053] 48 Friction fit
washer. [0054] 50a Pin fastener with friction-fit washer providing
for attachment of third insulation blanket 34 to L-bracket 30a.
[0055] 50b Pin fastener with friction-fit washer providing for
attachment of third insulation blanket 34 to L-bracket 30b. [0056]
52a Friction fit washer. [0057] 52b Friction fit washer.
[0058] 53a Friction fit washer. [0059] 70 A horizontal L-shape
corner intersection fire barrier with a male and a female coupling
end. [0060] 72 Metal channel. [0061] 73 Pins [0062] 75 A straight
line fire barrier with male and female type coupling ends. [0063]
90 A generic building unit. [0064] 90a First building unit. [0065]
90b Second building unit. [0066] 100 Installation tool. [0067] 102
Tool grasping means.
DETAILED DESCRIPTION
[0068] 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.
[0069] FIG. 1, a cross-sectional, diagrammatic view, illustrates an
example of the various layers a fire barrier made according to the
principles of the present invention might have. Note that the
construction of all fire-barriers made according to the principles
of the present invention requires that while one or more layers are
attached to one or more other layers in the barrier, there is no
instance where all of the layers are attached to each other at one
particular point. That is, there is no attachment that penetrates
all of the layers from one outer side of the barrier to the other
outer side of the barrier. This is essential, because if there were
to be an opening from one outer side of the barrier to the other
outer side of the barrier, a route would be provided for the
passage of fire, smoke, or gases. Thus, this exemplar multi-layered
barrier consists of several full-length layers that in this example
are all of the same length and include protective cloth 6 forming
the bottom or outside layer of the barrier, which is the side that
faces the surfaces of the building units 90a and 90b making up the
expansion joint space into which the barrier is installed and the
space, itself. Positioned on the upper surface of protective cloth
6 is flexible fire-resistant support sheet 8 that could be a
stainless steel foil sheet, for example, upon which is first
insulation blanket 14. Positioned on the upper surface blanket 14
is second insulation blanket 24. Pin fastener 40a and friction-fit
washer 42a provide for attachment of a first end of protective
cloth 6, flexible stainless steel sheet 8, first insulation blanket
14 and a first end of second insulation blanket 24 to each other
and to second leg 33a of L-bracket 30a. Pin fastener 40b and
friction-fit washer 42b provide for attachment of a second end of
protective cloth 6, flexible stainless steel sheet 8, first
insulation blanket 14 and a second end of second insulation blanket
24 to each other and to and between second leg 32b of L-bracket 32
and second leg 30b of L-bracket 30. Positioned on the upper surface
blanket 24 is third insulation blanket 34. Pin fastener 50a and
friction-fit washer 52a provide for attachment of a first end of
third insulation blanket 34 to second leg 30b of L-bracket 30. Pin
fastener 50b and friction-fit washer 52b provide for attachment of
a second end of third insulation blanket 34 to second leg 30b of
L-bracket 30. Working together, the attachment set made up of pin
40a and friction-fit washer 42a and the attachment set made up of
pin fastener 50a and friction-fit washer 52a provide for indirect
attachment of one end of all of the layers to each other and to one
set L-brackets 30 and 32. Similarly, the attachment set made up of
pin fastener 40b and friction-fit washer 42b and the attachment set
made up of pin fastener 50b and friction-fit washer 52b provide for
indirect attachment of the other end of all of the layers to each
other and to the other set of L-bracket 30 and 32. The attachment
pin fasteners may be inserted into a select number of cloth and
foil layers by either using the pins to pierce the cloth and foil
layers, or by providing the cloth and foil layers with pre-formed
apertures for the insertion of the pins. L-brackets are provided
with pre-formed apertures for the insertion of the pins. It is
important to note that the indirect attachment of the layers to
each other and to the L-brackets ensures that there is no opening
that penetrates through the entire structure. This provides another
safeguard against leakage of smoke, fire, or gases through the
barrier. This structure also provides added strength to the
barrier. It should be understood that while the number of layers
might increase or decrease, according to the principles of the
present invention the layers are always attached to each other and
to and between the L-brackets in a way that ensures that there is
never a continuous opening created, that is, there is never any one
attachment\ that penetrates through all of the layers, including
brackets. The attachment penetration is always offset, regardless
of the number of layers. Attachment 36 provides for attachment of
leg 32a of L-bracket 32 and of leg 30a of L-bracket 30 to building
unit 90a. Another attachment means 36 provides for attachment of
first leg 32a of L-bracket 32 and of leg 30a of L-bracket 30 to
building unit 90b. If the contractor plans on using the
installation tool of the present invention to install the barrier
into its accepting expansion joint space, before the barrier is
attached to upper L-bracket 30, pin fasteners 45a and 45b are
inserted into a receiving aperture (not shown) from the bottom of
the first legs 30a and 30a and brackets 30 to protrude entirely
through and up out of the first legs of the L-brackets to provide
attachment means for an installation tool that is discussed below.
Attachment means 44a and 44b, which in this example are each a
friction fit washer, hold pin fasteners 45a and 45b secure to the
L-bracket.
[0070] FIG. 2a, a perspective view, illustrates a partial section
of the fire barrier illustrated in FIG. 1 to more clearly show how
pin fastener 40a and friction-fit washer 42a may be utilized to
provide for securing protective blanket 6, metallic sheet 8, and
the two insulation blanket layers 14 and 24 to each other and to
and between the second legs 32b and 30b of L-brackets 30 and 32.
Pin fastener 50a is positioned to protrude through and extend some
distance from the surface of second leg 30b of L-bracket 30, so
that with friction-fit washer 52a, in this example, the attachment
of third insulation blanket 34 to second leg 30b of L-bracket 30 is
achieved, as shown in FIG. 2b, which is a side elevation view of
the partial section of the fire barrier that is illustrated in FIG.
2a. As discussed above, if the installation tool of the present
invention is to be used to install the fire barrier, pins 45a are
inserted into and through first leg 30a of L-bracket 30 before it
is attached to the barrier, so that a length of the pin protrudes
upwards from the outer surface of first leg 30a to extend some
distance from that outer surface to provide for attachment of an
installation tool to the barrier for installation of the barrier
into a joint space. It should be understood that the number of
layers required by the fire-barriers manufactured according to the
principles of the present invention is not limited by this, or any
other, example given herein. The number of layers required per fire
barrier is determined by many factors, such as the composition and
thickness of the material comprising each layer, the width and
depth of the expansion space into which the barrier is to be
installed, and the degree of fire-protection that is specified for
the building. Again, depending on such factors as the thickness of
the various material layers, the total barrier thickness, and the
composition of the layers, various other configurations of pins and
washers, 53a and 50a may be utilized and various distances between
the attachment means may be employed without departing from the
scope of the invention.
[0071] FIG. 3, is an exploded perspective view of a partial section
of an L-bracket to more clearly illustrate an example of one of the
installation tool attachment devices of the present invention that
may be used to install the pre-assembled fire barrier in either a
straight-line expansion joint space or an intersection-space. To
temporarily, but securely, attach an installation tool to the fire
barrier for installation purposes, one part of an installation tool
is attached to one of the L-brackets of a barrier and another part
of the tool is attached to the complementary L-bracket of the fire
barrier. To do this, there must be some preparation before the
barrier is fully assembled. That is, when an installation tool is
to be used to install the barrier, before the barrier is attached
to its L-brackets 30, a pin 45a is inserted through leg 30a of each
L-bracket 30. The pin is held in place by friction fit washer 44a.
When the fire barrier's construction is complete, installation tool
60 is temporarily attached to leg 30a of L-bracket 30 by inserting
pin 45a through aperture 62 of a connecting plate of installation
tool 60. Spacer 46 is placed over pin 45a so that it rests on the
outer surface of the connecting plate of installation tool 60.
Spacer 46 ensures the space needed when it is time to cut pin 45a
for the removal of the installation tool from the fire barrier.
Friction fit washer 48 is positioned over pin 45a to rest on spacer
46 to secure attachment of the tool to the barrier. When the
installation tool is no longer needed, it is easily and rapidly
removed from the fire barrier by cutting through pin 45a, thus
breaking the connection between the fire barrier and the
installation tool. If the installation tool is not to be used in
the installation of the barrier, this step does not take place.
[0072] FIG. 4 is a cross-sectional cartoon view of a fire barrier
to more clearly illustrate the female end and male end construction
of a layered barrier. For the sake of clarity, L-brackets are
removed from this view. The male and female coupling ends of the
barrier are made by the off-set positioning of the various layers
of the fire barrier. All of the full-length layers, as shown in
this example and as mentioned with respect to the barrier shown in
FIG. 1, are of the same length and include an outer layer of
protective cloth, a layer of metal foil, and one or more layers of
insulation blanket. Offsetting stacks that each contain some number
of these layers of the same length provides for a projecting male
end and a receiving female end. In this example, protective cloth 6
forms the bottom outer layer. Positioned on the upper surface of
protective cloth 6 is fire resistant layer 8, which in this example
is a flexible stainless steel foil, but could be any desired fire
resistant supporting material. As mentioned, full-length protective
cloth 6 and fire resistant layer 8 have the same length. Thus, each
of these two layers extends the length of its adjacent layer and
can not extend past the ends of its adjacent layer. This means that
there is no extension of one layer over the end surfaces of another
layer to prevent gaps from forming by the folding up, or down, of
one layer to cover the ends of its adjacent layer, or additional,
layers. Such gaps would provide for penetration of fire, smoke, and
gases, which is exactly what fire-barriers are made to prevent.
This would cause the barrier to fail the fire test it is mandated
to pass before it can be used for its intended purpose. In this
illustration, fire resistant sheet 8 is attached to the upper
surface of protective cloth 6 using adhesive. The method of
attachment is dictated by the needs of the user of the
fire-barrier. In addition to adhesive, the fire resistant sheet may
be attached to the protective by sewing, stapling, bolting, or any
other known or yet to be known means for attaching the two sheets.
Alternatively, if desired, the two sheets do not have to be
attached before installation. The next full-length layer,
positioned on the upper surface of layer 8, is insulation blanket
14, which as seen from FIG. 4 has the same length as layers 6 and
8. To form the male/female connecting ends, the next full-length
layer, insulation blanket 24, is positioned on the upper surface of
blanket 14 in an offset manner. The offset positioning of blanket
24 over blanket 14 provides for the barrier to have female,
receiving end F and male projecting end M. In this example,
caulking 4 is applied between insulation blanket 14 and insulation
blanket 24 for extra secure attachment of the two blankets to each
other to ensure that there is no possible way for fire, smoke, or
gas to penetrate through the barrier. Caulking 4 may also be used
between insulation blanket 24 and insulation blanket 34. On the
exposed, under-surface of the overlapped male end M of blanket 24
is a partial-length sheet of metal foil 8 that extends from the end
of blanket 24 a desired distance between blanket 24 and blanket 14.
Covering the exposed, under-surface, section of metal foil 8 is a
partial-length layer of protective cloth 6 with the exposed edges
of cloth 6 lined with intumescent strips 2. In the embodiment
illustrated, the intumescent strip is attached to protective cloth
6 using staples, it is, however, to be understood that stapling is
not a required attachment means, as the attachment is just as well
accomplished using pins, caulking, sewing or any other known or yet
to be know means for attaching two such sheets. During installation
the male end of one barrier is simply, quickly interdigitated with
the female end of a second barrier providing for, precise,
custom-contoured, snug overlapping coupling of the male end and the
female end requiring no on-site splicing operations. Caulking is
used to provide an extra level of security for the attachment of
the male and female ends. Other means for securing the attachment,
such as adhesive or staples, among others may be used, if
desired.
[0073] FIG. 5, a schematic, top plan view, is presented to
illustrate how straight-line barriers 10 having male/female type
coupling end structures, M and F referred to as overlap areas of
the fire-barriers in the drawing, couple with adjacent
straight-line barriers 10, and with the
horizontal/horizontal-armed, 90.degree. corner intersection-space
fire-barriers 70 that also having mating male/female type coupling
ends, M and F. It should be noted that in FIG. 5 the coupling is
shown to be accomplished sideways to show how the coupling is
accomplished. This is done so that the coupling method for an
entire room may be understood using only one figure. It should also
be noted in FIG. 5 that for each pair of straight-line
fire-barriers that have coupling straight-line barriers, there is a
space between the two fire-barriers coupled to each other, which
space is provided to accentuate the male/female coupling of the
barriers and that this space does not exist in a real system. In
fact, when fire-barriers are constructed according to the
principles of the present invention, all potential for space or
openings within the coupling areas is eliminated as discussed
above. Thus, looking at FIG. 5 it is obvious how easily and rapidly
a fire barrier system of the present invention may be installed in
expansion-joint-spaces about the entire perimeter of a room without
requiring any on-site construction or trimming significantly
reduces the time required for installation and the person power
required for installation, thus reducing the cost of the fire
barrier protection part of the job, while simultaneously decreasing
the risk to workers by decreasing, if not eliminating, respirable
particles in the working atmosphere and reducing the danger to
workers of being cut by the sharp edged metal foil that is
frequently used in the construction of the fire-barriers.
Accordingly, as protection is increased by the pre-assembled, one
piece barriers and their over-lapping coupling ends, the cost of
fire hazard insurance should be reduced as should worker's
compensation insurance.
[0074] FIG. 6, a perspective view, illustrates a
horizontal/vertical, L-shaped, 90.degree. corner intersection fire
barrier with a male M and a female F coupling end. This barrier, as
are all the barriers of the present invention, is provided to the
job site as a pre-assembled, one-piece unit ready for one-step,
drop-in installation. The drawing shown in FIG. 6 demonstrates how
this particular barrier, and, in fact, how any corner barrier
having two coupling ends, is constructed with a male end and a
female end for interdigitization of, in this case, a 90.degree.
corner horizontal arm/vertical arm intersection barrier with, most
likely, a straight-line barrier. The male coupling end, as
illustrated in FIG. 6, is to be interdigitated with the female
coupling end of the straight-line fire barrier, such as the one,
illustrated in FIG. 7. Alternatively, the female coupling end, as
illustrated in FIG. 6, is to be interdigitated with the male
coupling end of the straight line fire barrier illustrated in FIG.
7. Of course, if required, all styles of coupling ended barriers
may be provided with two, or more, ends as male coupling ends or
both ends as female coupling ends. Similarly, corner fire-barriers
that have more than two coupling ends, such as T-shaped and
cross-shaped barriers may be provided with all female, all male, or
a variety of female and male ends. In the example illustrated in
FIG. 6, only protective cloth 6 with attached intumescent stripping
2, fire resistant metal channel 72, and pins 73 that provide means
for attaching the barrier layers to each other are shown.
[0075] FIG. 7, a perspective view, illustrates straight line fire
barrier 75 according to the principles of the present invention
provided with a male coupling end and a female coupling end, one of
which may be used for interdigitation with the female or male
coupling end, respectively, of the horizontal/vertical corner
intersection fire barrier illustrated in FIG. 6.
[0076] FIG. 8 shows exemplary straight line fire barrier 10 with
two installation tools 100 detachably attached to it. Each tool's
frame is constructed of a first set of two elongate strips 110 of a
sturdy and light-weight material, such as aluminum or plastic, with
the long axis of the strips oriented in the same direction as the
long axis of the barrier to which they is attached and arranged
parallel to and spaced from one another, and a second set of two
elongate strips arranged parallel to and spaced from one another
and positioned over the second set of strips and in this position
the two sets are attached to each other, so that the two sets form
a construct similar to a number sign "#" but where the angles
between all crossing strips are all at approximately right angles.
The lower set of strips has means for being detachably attached to
the fire barrier, as is explained in more detail above. The upper
set of strips has a grasping means, such as handle 102 for easy
lifting of the tool and the barrier to which it is connected. FIG.
8 shows how the installation tool just described provides for easy
one-step, drop-in installation of a ten foot section of the
straight-line fire barrier.
[0077] 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.
[0078] 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.
* * * * *