U.S. patent application number 12/508310 was filed with the patent office on 2011-01-27 for fire barrier.
This patent application is currently assigned to BALCO, INC. Invention is credited to Johnnie Daniel Hulburn, JR..
Application Number | 20110016808 12/508310 |
Document ID | / |
Family ID | 43496073 |
Filed Date | 2011-01-27 |
United States Patent
Application |
20110016808 |
Kind Code |
A1 |
Hulburn, JR.; Johnnie
Daniel |
January 27, 2011 |
FIRE BARRIER
Abstract
A fire barrier operable to be placed within a gap formed between
two surfaces. The fire barrier may generally include a first
intumescent section, a first foam section coupled with the first
intumescent section, and a second intumescent section coupled with
the first foam section generally opposite the first intumescent
section. In some embodiments, the fire barrier may include a
plurality of intumescent sections and a plurality of foam sections
with each foam section being positioned between at least two of the
intumescent sections.
Inventors: |
Hulburn, JR.; Johnnie Daniel;
(Wichita, KS) |
Correspondence
Address: |
Hovey Williams LLP
10801 Mastin Blvd., Suite 1000
Overland Park
KS
66210
US
|
Assignee: |
BALCO, INC
Wichita
KS
|
Family ID: |
43496073 |
Appl. No.: |
12/508310 |
Filed: |
July 23, 2009 |
Current U.S.
Class: |
52/232 ;
52/309.4; 52/404.1 |
Current CPC
Class: |
E04B 1/948 20130101 |
Class at
Publication: |
52/232 ;
52/309.4; 52/404.1 |
International
Class: |
E04B 1/94 20060101
E04B001/94; E04C 2/20 20060101 E04C002/20 |
Claims
1. A fire barrier operable to be placed within a gap formed between
two surfaces, the barrier comprising: a first intumescent section
formed of intumescent material that expands and forms a
non-flammable char when exposed to fire; a first foam section
coupled with the first intumescent section, the first foam section
being formed of fire-resistant but not fireproof foam material that
burns at least partially away when exposed to fire; and a second
intumescent section formed of intumescent material that expands and
forms a non-flammable char when exposed to fire, the second
intumescent section being coupled with the first foam section
generally opposite the first intumescent section.
2. The fire barrier of claim 1, wherein the first foam section is
adhered to the intumescent sections.
3. The fire barrier of claim 1, wherein the first foam section and
intumescent sections are at least partially encapsulated within a
high-temperature material.
4. The fire barrier of claim 3, wherein the high-temperature
material is selected from the group consisting of a metallic foil,
a fiberglass scrim, a high-temperature textile, and combinations
thereof.
5. The fire barrier of claim 1, wherein the intumescent sections
and the first foam section present generally the same length.
6. The fire barrier of claim 1, wherein the first foam section is
comprised of flexible polyurethane foam.
7. The fire barrier of claim 1, further including-- a second foam
section coupled with the second intumescent section generally
opposite the first foam section, and a third intumescent section
coupled with the second foam section generally opposite the second
intumescent section.
8. The fire barrier of claim 7, further including-- a third foam
section coupled with the third intumescent section generally
opposite the second foam section, a fourth intumescent section
coupled with the third foam section generally opposite the third
intumescent section, a fourth foam section coupled with the fourth
intumescent section generally opposite the third foam section, and
a fifth intumescent section coupled with the fourth foam section
generally opposite the fourth intumescent section.
9. The fire barrier of claim 1, wherein the intumescent sections
and the first foam section are compressible for placement within
the gap.
10. The fire barrier of claim 1, further including a support
section operable to be positioned within the gap to support the
intumescent sections and the foam section within the gap.
11. A fire barrier operable to be placed within a gap formed
between two surfaces, the barrier comprising: a plurality of
intumescent sections formed of intumescent material that expands
and forms a non-flammable char when exposed to fire; and a
plurality of flexible foam sections formed of fire-resistant but
not fireproof material that burns at least partially away when
exposed to fire, at least one of the foam sections being positioned
between at least two of the intumescent sections.
12. The fire barrier of claim 11, wherein the foam sections and the
intumescent sections present generally the same length and at least
one of the foam sections abuts two of the intumescent sections
substantially along its length.
13. The fire barrier of claim 11, wherein at least one of the foam
sections is adhered to two of the intumescent sections.
14. The fire barrier of claim 11, wherein at least one of the foam
sections and two of the intumescent sections are generally
rectangular.
15. The fire barrier of claim 11, wherein the foam sections and the
intumescent sections are operable to be compressed for placement
within the gap.
16. The fire barrier of claim 11, further including a support
section operable to be positioned within the gap to support the
foam sections and intumescent sections within the gap.
17. The fire barrier of claim 11, wherein the intumescent sections
and foam sections are encapsulated within a high-temperature
material.
18. The fire barrier of claim 11, wherein the foam sections are
comprised of flexible polyurethane foam.
19. A fire barrier operable to be placed within a gap formed
between two surfaces, the barrier comprising: a plurality of
generally rectangular intumescent sections each presenting a first
length; and a plurality of generally rectangular flexible
polyurethane foam sections each presenting a second length
generally equal to the first length, each of the foam sections
being adhered to at least two of the intumescent sections such that
each foam section is positioned between at least two of the
intumescent sections, the foam sections and the intumescent
sections being compressible for placement within the gap.
20. The fire barrier of claim 19, further including a support
section operable to be positioned within the gap to support the
foam sections and intumescent sections within the gap.
21. The fire barrier of claim 19, wherein the intumescent sections
and foam sections are encapsulated within a high-temperature
material.
Description
BACKGROUND
[0001] 1. Field
[0002] Embodiments of the present invention relate to fire
barriers. More particularly, various embodiments of the invention
provide a fire barrier having a plurality of alternating
intumescent and foam sections.
[0003] 2. Description of the Related Art
[0004] It is often desirable to position fire-resistive materials
such as intumescent sheets within joints formed between roof, wall,
floor, and ceiling members. Unfortunately, prior art fire barriers
often fail to properly orient intumescent sheets within joints and
are susceptible to joint expansion and contraction.
SUMMARY
[0005] Embodiments of the present invention solve the
above-described problems and provide a distinct advance in the art
of fire barriers. More particularly, various embodiments of the
invention provide a fire barrier including a plurality of
intumescent sections which may be securely and properly positioned
within a gap.
[0006] The fire barrier may generally include a first intumescent
section, a first foam section coupled with the first intumescent
section, and a second intumescent section coupled with the first
foam section generally opposite the first intumescent section. In
some embodiments, the fire barrier may include a plurality of
alternating intumescent sections and foam sections with at least
some of the foam sections being positioned between at least two of
the intumescent sections.
[0007] The foam sections support and properly space the intumescent
sections and permit the fire barrier to be compressed and placed
within a gap that is narrower than the uncompressed width of the
fire barrier. The compressibility of the foam sections helps retain
the position of the fire barrier in the gap even if the gap shifts,
expands, contracts, or otherwise changes over time.
[0008] The intumescent sections are preferably formed of
substantially fireproof and highly intumescent material that
expands up to 35 times its original thickness when exposed to fire.
The foam sections are treated so as to be fire retardant but not
fireproof.
[0009] When the fire barrier is exposed to fire, the foam sections
burn partially or completely away and the intumescent sections
expand and form a char that fills the voids left by the foam
sections. The char has a low thermal conductivity and will not
support or transfer flame or fire. In some situations, all of the
foam sections burn away entirely and are replaced with the expanded
intumescent char. In other situations, the intumescent char
infiltrates the foam and imparts to it its fire resistant
properties. In still other situations, some portions of the foam
burn away and are replaced by the expanded intumescent char and
other portions of the foam are infiltrated by the intumescent
char.
[0010] Other aspects and advantages of the present invention will
be apparent from the following detailed description and the
accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0011] Embodiments of the present invention are described in detail
below with reference to the attached drawing figures, wherein:
[0012] FIG. 1 is a perspective view of a fire barrier constructed
in accordance with various embodiments of the present
invention;
[0013] FIG. 2 is a perspective view of the fire barrier of FIG. 1
showing the fire barrier encapsulated by a high-temperature
material;
[0014] FIG. 3 is a side view of another fire barrier constructed in
accordance with various embodiments of the present invention, the
fire barrier shown installed within a gap formed between two
surfaces;
[0015] FIG. 4 is a side view of the fire barrier of FIG. 1 shown
installed within a gap formed between two surfaces;
[0016] FIG. 5 is a cross-sectional view of the fire barrier of FIG.
1 shown installed within a gap formed between two surfaces; and
[0017] FIG. 6 is another cross-sectional view of the fire barrier
of FIG. 1 shown installed within a gap formed between two
surfaces.
[0018] The drawing figures do not limit the present invention to
the specific embodiments disclosed and described herein. The
drawings are not necessarily to scale, emphasis instead being
placed upon clearly illustrating the principles of the
invention.
DETAILED DESCRIPTION
[0019] The following detailed description of various embodiments of
the invention references the accompanying drawings that illustrate
specific embodiments in which the invention can be practiced. The
embodiments are intended to describe aspects of the invention in
sufficient detail to enable those skilled in the art to practice
the invention. Other embodiments can be utilized and changes can be
made without departing from the scope of the present invention. The
following detailed description is, therefore, not to be taken in a
limiting sense. The scope of the present invention is defined only
by the appended claims, along with the full scope of equivalents to
which such claims are entitled.
[0020] Referring to FIGS. 1-6, embodiments of the present invention
provide a fire barrier 10 operable to be positioned within a gap A
formed between two surfaces B, C. The barrier 10 may be installed
within gaps between surfaces including roof, wall, floor, ceiling
members, combinations thereof, or any other gaps, joints, or spaces
formed between building and construction elements. Each surface B,
C may include a plurality of sides, such as top, right, left, and
bottom sides.
[0021] The barrier 10 broadly includes at least one intumescent
section 12 and at least one foam section 14. In some embodiments,
the barrier 10 includes a plurality of intumescent sections 12 and
a plurality of foam sections 14. In other embodiments, the barrier
10 includes two intumescent sections 12a, 12b positioned on
opposite sides of one foam section 14, as is shown in FIG. 3, which
may be configured for utilization with one-inch gaps. In some other
embodiments, the barrier 10 includes five intumescent sections 12a,
12b, 12c, 12d, 12e positioned on opposite sides of four foam
sections 14a, 14b, 14c, 14d, as is shown in FIG. 1, which may be
configured for utilization with four-inch gaps. However, the
barrier 10 may employ any number of foam and intumescent sections
positioned in any configuration for installation in any sized gaps
and is not limited to the specific configurations discussed
herein.
[0022] Each intumescent section 12 may include any intumescent
material operable to expand and/or swell when exposed to heat. In
various embodiments, each intumescent section 12 includes an
intumescent material extruded onto a film such as wax paper,
mineral wool, artificial fiber ribbons, polyethylene film,
polypropylene film, polyurethane film, polyester film, combinations
thereof, and the like. The intumescent sections 12 may be comprised
of a C.sub.2-C.sub.8 alkyl diamine phosphate fire retardant, as
disclosed in U.S. Pat. No. 6,207,085, which is incorporated herein
by specific reference. The intumescent sections may also be formed
from Metacaulk.RTM. Joint Strips or Metacaulk.RTM. BlazeSeal Strips
provided by RectorSeal of Houston, Tex.
[0023] In some embodiments, the intumescent sections are formed of
highly intumescent material that expands up to 35 times its
original thickness when exposed to fire. The intumescent material
also exhibits multi-stage intumescence. For example, the material
may experience a first intumescent reaction at a lower temperature
range where it expands a first amount. This first reaction may
occur at about 350.degree. F. and up to about 500.degree. F. The
material may then experience a second intumescent reaction at an
intermediate temperature range where it expands a second amount.
This second reaction may occur at about 500.degree. F. to about
750.degree. F. The material may then experience a third intumescent
reaction at a higher temperature range where it expands a third
amount. This third reaction may occur at temperatures greater than
750.degree. F. The specific temperature ranges are examples only
and are not important, but the property of having intumescence that
occurs at different temperature ranges is important.
[0024] Each intumescent section 12 preferably presents a generally
rectangular configuration to generally form a cuboid. Thus,
"rectangular" as utilized herein refers to both two-dimensional and
three-dimensional rectangles. However, the intumescent sections 12
may present any form or configuration and are not limited to
rectangular configurations. Thus, in some embodiments some of the
intumescent sections 12 may present a first geometric configuration
while some of the other intumescent sections 12 may present a
second geometric configuration. Consequently, each of the
intumescent sections 12 may present a unique geometric or
structural configuration.
[0025] The volume provided by each of the intumescent sections 12
may be selected to correspond to the dimensions of the gap A. In
some embodiments, it may be desirable to position only one
intumescent section 12 within the gap A while in other embodiments
it may be desirable to position a plurality of intumescent sections
12 within the gap A. The intumescent sections 12 may present any
volume or dimensions to desirably fill at least a portion of the
gap A.
[0026] The foam sections 14 are generally operable to couple with
one or more of the intumescent sections 12 to preferably form the
sandwich-like configuration shown in FIGS. 1 and 3. Each foam
section 14 is preferably formed of a flexible foam material to
enable the intumescent sections 12 and foam sections 14 to be
compressed within the gap A, as is discussed in more detail below.
In some embodiments, one or more of the foam sections 14 may be
comprised of flexible polyurethane foam.
[0027] In some embodiments, the foam sections are flexible urethane
foams formed of polyether-based urethane polymers that have been
treated to be fire retardant but not fireproof. For example, the
foam sections may be HR foams provided by the Sunshine Foam Company
of Cincinnati, Ohio.
[0028] Each foam section 14 preferably presents a generally
rectangular configuration such that each foam section 14 generally
forms a cuboid in a similar manner to the intumescent sections 12
discussed above. However, the foam sections 14 may present any form
or configuration and are not limited to rectangular configurations.
Thus, in some embodiments some of the foam sections 14 may present
a first geometric configuration while some of the other foam
sections 14 may present a second geometric configuration.
Consequently, each of the foam sections 14 may present a unique
geometric or structural configuration.
[0029] In some embodiments, as shown in FIG. 1, the foam sections
14 may present a length and a width that is generally similar to
the length and width of the intumescent sections 12 such that the
foam sections 14 dimensionally vary from the dimensions of the
intumescent sections 12 only in thickness. Preferably, the foam
sections 14 are substantially thicker than the intumescent sections
12. Such a configuration provides proper spacing between the
intumescent sections 12 to facilitate proper positioning within the
gap A and fire barrier functionality. However, the foam sections 14
may vary from the configuration of the intumescent sections 12 such
that any foam section 14 may be larger or smaller in any dimension
than any intumescent section 12. Further, any foam section 14 may
present the same dimensions as any of the intumescent sections
12.
[0030] Each of the intumescent sections 12 preferably abuts at
least one of the foam sections 14. In some embodiments, each of the
foam sections 14 preferably abuts at least two of the intumescent
sections 12. Further, in some embodiments, various sections 12, 14
may abut each other substantially along their lengths. For example,
as shown in FIG. 1, each foam section 14 may abut at least two of
the intumescent sections 12 substantially along its length. Thus,
the fire barrier 10 may present a substantially rectangular
configuration where the intumescent sections 12 and foam sections
14 are each configured as cuboids having similar lengths and
widths. However, the fire barrier 10 may present any geometric or
structural configuration by including intumescent sections 12 and
foam sections 14 having any dimensions.
[0031] The intumescent sections 12 and the foam sections 14 may be
coupled or otherwise joined together utilizing fastening elements
such as nails, screws, staples, bolts, pins, combinations thereof,
and the like. In some embodiments, the intumescent sections 12 and
foam sections 14 may be bonded together utilizing an adhesive such
as tape. In other embodiments, the sections 12, 14 may additionally
or alternatively be bonded together through heat bonding. For
instance, various sections 12,14 may be laminated together
utilizing heat and the intumescent sections 12 may be extruded onto
the laminated foam sections 14.
[0032] In some embodiments, as shown in FIG. 2, the barrier 10 may
include a high-temperature material 16 to at least partially
encapsulate the intumescent sections 12 and the foam sections 14.
The high-temperature material 16 may be any generally heat or fire
resistant material, including but not limited to metallic foils,
fiberglass scrims, high-temperature textiles, and combinations
thereof. The intumescent sections 12 and foam sections 14 may be
fully enveloped by the high-temperature material 16 or the
high-temperature material 16 may be positioned on or over only a
portion of the intumescent sections 12 and foam sections 14.
[0033] Preferably, the high-temperature material 16 surrounds the
exposed sides of the intumescent sections 12 and foam sections 14
while leaving the tops and bottoms of the sections 12, 14
uncovered, as shown in FIG. 2. Such a configuration allows the
barrier 10 to generally retain its shape when compressed and
facilitates proper positioning of the barrier 10. In some
embodiments, the high-temperature material 16 may be adhered to the
various sections 12,14.
[0034] In various embodiments, as shown in FIGS. 4-5, the barrier
10 may additionally include or otherwise utilize one or more
support sections 18. Each support section 18 may be comprised of
any generally heat or fire resistant material, including but not
limited to metallic foils, fiberglass scrims, high-temperature
textiles, and combinations thereof.
[0035] The support sections 18 are generally operable to be placed
within the gap A to support the intumescent sections 12 and the
foam sections 14. For example, one or more support sections 18 may
be installed and/or positioned within the gap A and the intumescent
sections 12 and foam sections 14 may rest upon the support sections
18 and/or be compressed into the support sections 18 to ensure
proper placement of the barrier 10 within the gap A. Additionally
or alternatively, the support sections 18 may be coupled with the
intumescent sections 12 and/or foam sections 14 utilizing adhesives
and/or mechanical fasteners.
[0036] In some embodiments, as shown in FIG. 5, the barrier 10 may
include two support sections 18 positioned in proximity to each end
of the intumescent sections 12 and foam sections 14. Utilization of
more than one support section 18 facilitates proper placement of
the fire barrier 10 within the gap A even if the gap A expands or
contracts.
[0037] In operation, the barrier 10 may be positioned within the
gap A utilizing any methods. Preferably, the barrier 10 is
positioned in the gap A such that the seams or spaces formed
between the various intumescent sections 12 and foam sections 14
run generally perpendicular to the gap A opening, and thus
generally parallel to the gap's walls, as is shown in FIGS. 3-6.
Thus, in some embodiments, no single intumescent section 12 or foam
section 14 spans the entire width of the gap A. However, the fire
barrier 10 may be positioned within the gap A in any
orientation.
[0038] In some embodiments, the width of the barrier 10 may be
larger than the width of the gap A such that the barrier 10 may be
compressed for placement within the gap A. The compression of the
barrier 10, and in particular the compression of the intumescent
sections 12 and foam sections 14, enables the barrier 10 to be
secured within the gap A by exerting a force against the sides of
the gap A. Additionally or alternatively, the barrier 10 may be
secured within the gap A by utilizing adhesives or mechanical
fasteners, such as nails, screws, pins, bolts, combinations
thereof, and the like, to attach or otherwise couple the barrier 10
to the sides of the gap A.
[0039] In embodiments where the barrier 10 includes the
high-temperature material 16 to envelop at least a portion of the
sections 12, 14, the barrier 10 may be positioned within the gap A
through compression in a similar manner to that discussed above.
Additionally or alternatively, the high-temperature material 16 may
be affixed or otherwise coupled with the gap A by utilizing
adhesives or mechanical fasteners, such as those discussed
above.
[0040] The compression of the intumescent sections 12 and foam
sections 14 within the gap A and/or the fastening of the sections
12, 14 within the gap A facilitates proper placement of the barrier
10 by enabling the barrier to retain its position within the gap A
even if the gap A shifts, expands, contracts, or otherwise changes
form due to environmental or structural factors.
[0041] In embodiments where the barrier 10 includes one or more of
the support sections 18, the support sections 18 may be positioned
within the gap A before the installation of the various intumescent
sections 12 and foam sections 14. The intumescent sections 12 and
foam sections 14 may then be compressed into the one or more
support sections 18 to retain the various sections 12, 14, 18
within the gap A. Additionally, the support sections 18 may be
compressed into the various intumescent sections 12 and foam
sections 14 before or after the various sections 12, 14 are
positioned within the gap A. As discussed above, the intumescent
sections 12 and foam sections 14 may additionally or alternatively
be coupled with the support sections 18 utilizing adhesives and/or
fasteners.
[0042] The support sections 18 may additionally or alternatively be
positioned within the gap A utilizing adhesives and/or fasteners.
For example, one support section 18 may be coupled with the gap
walls utilizing adhesives and/or fasteners, such as the various
fasteners discussed above, and then the intumescent sections 12 and
foam sections 14 may be positioned on and/or compressed into the
installed support section 18. Additional support sections 18 may
then be installed to further support the intumescent sections 12
and foam sections 14, as is shown in FIG. 5.
[0043] In some embodiments, a joint cover 20 may be installed in
combination with the barrier 10 to cover the gap A. The joint cover
20 may comprise a metallic floating or non-floating cover, as is
shown in FIGS. 3-4. In other embodiments, the joint cover 20 may
comprise a flexible elastomer seal, as shown in FIG. 6, a stainless
steel foil cover, a compression seal system that employs
elastomeric concretes or adhesives, and/or any conventional joint
cover or joint seal system. Thus, the utilization of the barrier 10
does not restrict or otherwise prohibit the use of conventional and
non-conventional joint covers.
[0044] When the fire barrier 10 is exposed to fire, the foam
sections burn partially or completely away and the intumescent
sections expand and form a char that fills the voids left by the
foam sections. The char has a low thermal conductivity and will not
support or transfer flame or fire. Applicant has observed that in
some situations, all of the foam sections burn away entirely and
are replaced with the expanded intumescent char. In other
situations, the intumescent char infiltrates the foam and imparts
to it its fire resistant properties. In still other situations,
some portions of the foam burn away and are replaced by the
expanded intumescent char and other portions of the foam are
infiltrated by the intumescent char. Although applicant is unsure
why the foam sections sometimes burn away partially or entirely and
sometimes are instead infiltrated by the intumescent char, the
temperature and duration of the fire seem to be factors.
[0045] Although the invention has been described with reference to
the preferred embodiment illustrated in the attached drawing
figures, it is noted that equivalents may be employed and
substitutions made herein without departing from the scope of the
invention as recited in the claims.
* * * * *