U.S. patent application number 13/455078 was filed with the patent office on 2012-12-06 for line element lead-through with support structure.
Invention is credited to Michael Drexl, Manfred Klein, Herbert Munzenberger.
Application Number | 20120304979 13/455078 |
Document ID | / |
Family ID | 47260711 |
Filed Date | 2012-12-06 |
United States Patent
Application |
20120304979 |
Kind Code |
A1 |
Munzenberger; Herbert ; et
al. |
December 6, 2012 |
Line Element Lead-Through with Support Structure
Abstract
In order to produce a line element lead-through that is
resistant to fire and flue gas for simple installation into one or
more paneled drywalls, whereby the line element lead-through can be
used in a matching component opening and is also sealed against
fire and flue gas when empty, a line element lead-through is
suggested with a molded element closed on at least one side of an
elastically deformable intumescent material as a sleeve, especially
formed as a truncated cone or a cylinder, with the criterion that
the opening cross section of the sleeve corresponds to maximum 60%
of the cross section of the component pass-through. Embedded within
the molded element is a support structure.
Inventors: |
Munzenberger; Herbert;
(Wiesbaden, DE) ; Drexl; Michael; (US) ;
Klein; Manfred; (Kaufering, DE) |
Family ID: |
47260711 |
Appl. No.: |
13/455078 |
Filed: |
April 24, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13403396 |
Feb 23, 2012 |
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13455078 |
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13300321 |
Nov 18, 2011 |
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13403396 |
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Current U.S.
Class: |
126/314 |
Current CPC
Class: |
H02G 3/088 20130101;
F16L 5/04 20130101; H02G 3/22 20130101 |
Class at
Publication: |
126/314 |
International
Class: |
F23J 13/02 20060101
F23J013/02 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 19, 2010 |
DE |
102010044161.9 |
Feb 23, 2011 |
DE |
102011004575.9 |
Claims
1. A line element lead-through sealed against fire and flue gas for
component openings, said line element lead-though including: a
molded element configured as a sleeve of an elastic deformable
intumescent material that is closed on at least one side with the
characteristic that the opening cross section of the sleeve
corresponds to maximum 60% of the cross section of the component
opening, wherein embedded within the molded element is a support
structure.
2. The line element lead-through according to claim 1, wherein the
support structure includes a grid structure that is formed of at
least glass fibers.
3. The line element lead-through according to claim 1, wherein the
support structure includes a fabric or a mat.
4. The line element lead-through according to claim 1, wherein the
support structure is completely embedded in a foamed body of the
molded element.
5. The line element lead-through according to claim 1, wherein the
support structure is flexible.
6. The line element lead-through according to claim 1, wherein the
support structure is rigid.
7. The line element lead-through according to claim 1, wherein the
support structure is completely embedded in the molded element.
8. The line element lead-through according to claim 1, wherein,
when a first portion of the molded element is burned into an ash
crust, the support structure structurally connects the ash crust to
a second portion of the molded element that is unburned.
9. The line element lead-through according to claim 1, wherein the
support structure restrains an expansion of the elastic deformable
intumescent material.
10. The line element lead-through according to claim 1, wherein the
molded element is configured as one piece from the elastic
deformable intumescent material.
11. The line element lead-through according to claim 1, wherein the
molded element is configured as a truncated cone, and wherein the
support structure is configured as the truncated cone.
12. The line element lead-through according to claim 1, wherein the
molded element is configured as a cylinder, and wherein the support
structure is configured as the cylinder.
13. The line element lead-through according to claim 1, wherein the
molded element is made of at least a polyurethane foam with
intumescence capability.
14. The line element lead-through according to claim 1, wherein the
molded element is provided on its face surface with a flange-like
edging that points radially outward.
15. The line element lead-through according to claim 14, wherein
the support structure does not extend into the flange-like
edging.
16. The line element lead-through according to claim 1, wherein the
molded element is closed at its cover surface in order to form a
seal.
17. The line element lead-through according to claim 16, wherein
the material of the seal is thinner, at least in some areas, than
the rest of the molded element.
18. The line element lead-through according to claim 17, wherein
the thinner areas of the seal also have specified breaking
points.
19. The line element lead-through according to claim 16, wherein
the seal is configured as a membrane.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S.
patent application Ser. No. 13/403,396, filed Feb. 23, 2012, which
claims benefit from and priority to German Patent Application No.
DE 10 2011 004 575.9, filed Feb. 23, 2011.
[0002] The present application is also a continuation-in-part of
U.S. patent application Ser. No. 13/300,321, filed ______, which
claims benefit from and priority to German Patent Application No.
DE 10 2010 044 161.9, filed Nov. 19, 2010.
[0003] The above-identified applications are hereby incorporated
herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0004] For fire protection purposes, lead-throughs of line
elements, e.g., pipes or cables or the like, through walls or
ceilings must be provided with a so-called barrier or a fitting in
order to prevent flames and especially smoke and poisonous gases
from spreading from room to room or between floors if there is a
fire.
[0005] In the fittings of rooms, the lead-throughs and lead-through
openings for cables, pipes and the like are problematic since they
were not installed until after completion of the entire
installation, i.e., retrofit, and also can only be retrofitted
after the routing of the cables and pipes.
[0006] In many cases, the wall lead-throughs either remain open or
are only closed in a preliminary manner with mineral wool or stone
wool cut to size. In order to pass the cables and lines through,
these stoppers must be removed again, whereby after the lines and
cables are passed through, the lead-throughs have to finally be
closed using fire-resistant mortar, stone wool or mineral wool
inserts.
[0007] However, it is often necessary that lines must be routed
long after the installation is complete. This is the case, above
all, when new rooms are produced in older buildings. For this
purpose, drywall is often used. However, even during remodeling
and/or renovation of public buildings, schools, hospitals, office
buildings and special buildings, drywalls are created more and more
frequently. The firewalls are often such drywalls. The drywalls
often are made of sandwich-type plasterboard and are hollow or
filled with mineral wool. Therefore, it is possible to route
installations, especially distribution of cables, in these
walls.
[0008] In addition to the classic cable lead-throughs, cables are
frequently threaded out from these walls. For smaller individual
cables, no complicated fire protection measures must be taken.
Sealing with plaster or sealing compound is sufficient. Thicker
cables, small cable bundles, empty pipes or several individual
cables would have to be sealed depending on the configuration, with
the approved fire protection system. The rules on how all of this
must be designed are different, so the skilled tradesman is
uncertain during the installation of how the line lead-through must
be sealed. In addition, to date it was necessary to close the line
lead-throughs so that they are sealed against fire and flue gas
immediately after installation of the cables. During production of
lead-throughs in fire-resistant components that are only equipped
with lines much later, the problem resulted that up to the time the
openings are equipped they have to be sealed so that they are
fire-tight and sealed against flue gas. Equipping the openings
required several work steps for leading the lines through and
sealing the spaces that developed again so they are sealed against
fire and flue gas. To date, this has not been possible using simple
devices.
[0009] The cable boxes that were previously commonly used are
complicated, especially when later fitting them with cables and/or
pipes. The difficulty arises in that the (subsequent) openings have
to be sealed against flue gas.
[0010] EP 0321664 discloses a seal for lead-throughs in walls,
ceilings, etc. that is sealed against flue gas and fire that
includes a molded element designed as a conical stopper of an
elastically deformable intumescent material. The stopper is
deformable with dimensional stability so it can be pressed through
the lead-through and can seal it tightly. In the stopper,
lead-through holes can be formed for sealed holding of pipes and/or
lines. However, the lead-through holes must be adapted to the
respective pipe and/or line diameters, in order to be able to seal
tightly. Thus, a considerable amount of work is required for
subsequent equipping of the stopper with cables or lines, which
makes the system inflexible and susceptible to errors. When they
are equipped with several cables or lines, the problem also results
that because of its thickness the material does not seal the
gussets and gaps that occur, so these have to additionally be
sealed with special sealing compounds.
[0011] An arrangement for a lead-through of a long molded part
through a wall that is sealed against flue gas is known from EP 2
273 637 A2. The fire protection element includes a sleeve of
intumescent material or a plastic sleeve with an inner and/or outer
coating of intumescent material. However, the arrangement itself is
not sealed against flue gas, so it cannot be used if the component
lead-through is not equipped. In addition, the arrangement has the
disadvantage that equipping it with several long molded parts (line
elements) is impossible because of the less flexible sleeve.
[0012] Generally, compliance with the 60% rule for cable seals with
official approval causes great problems, according to which only up
to max. 60% of the opening cross section must be filled with cables
for openings in firewalls and ceilings. In practice, this is
difficult to evaluate when this limit is reached or exceeded.
BRIEF SUMMARY OF THE INVENTION
[0013] Some embodiments according to the present invention provide
a line element lead-through that is resistant to fire and flue gas
for simple installation into one or more paneled drywalls, whereby
the line element lead-through can be used in a matching component
opening and is also sealed against fire and flue gas when empty. A
line element lead-through can be provided with a molded element
closed on at least one side of an elastically deformable
intumescent material as a sleeve (e.g., configured as a truncated
cone or a cylinder) characterized by a criterion that the opening
cross section of the sleeve corresponds to maximum 60% of the cross
section of the component pass-through.
[0014] In some embodiments, embedded within the molded element is a
support structure. The support structure can be, for example, a
thin, flat grid structure formed of at least glass fibers as
supporting elements. The grid structure can be embedded (e.g.,
embedded completely) in a foamed body of the molded element.
[0015] One or more embodiments provide a line element lead-through
that is simple in design, easy to handle and cost-effective for
lead-throughs in component parts like fire protection ceilings and
walls that can be installed in a simple way after creation of the
components and permits a sealing of the lead-throughs that is fire
and flue gas resistant even if the lead-throughs are not
equipped.
[0016] According to one or more embodiments, the line element
lead-through is characterized by a molded element of an elastically
deformable intumescent material designed as a sleeve and closed on
at least one side.
[0017] One or more embodiments provide a fire protection element
having a foamed body, which is made at least partially of an
ash-forming and, if applicable, intumescent mixture.
[0018] Fire protection elements made of, for example, foamed
material with intumescent additives can be used, for example, to
seal cable and pipe lead-throughs so they are flue-gas-proof as
well as heat and fire-resistant. The foamed material according to
one or more embodiments serves as a matrix for fire-protection
additives. Fire protection elements with a rectangular block shape,
for example, are used for bulkheading large lead-throughs. In one
or more embodiments, the fire protection elements are made of, for
example, a polymer matrix into which various additives such as
intumescent materials, ash-crust formers and ash-crust stabilizers
are introduced.
[0019] In one or more embodiments, the heat and fire-resistant
properties of the fire protection elements are produced in the
event of a fire in which the fire protection element burns away on
the outside and forms a layer of ash. The layer of ash then
provides thermal insulation. An object of one or more embodiments
is that the layer of ash is as stable as possible so that it does
not fall off from the rest of the fire protection element. The
object can be achieved, at least in part according to one or more
embodiments, by chemical additives in the foamed material, for
example. In the case of large fire protection elements or large
lead-throughs that are to be sealed, for example, adequate
mechanical stability of the ash crust itself as well as
sufficiently stable adherence of the ash crust to the still
unburned portion of the fire protection element is preserved even
when there is advanced fire development.
[0020] In the case of larger fire protection elements such as fire
protection blocks, for example, it is frequently observed that when
there is advanced burn-off of the fire-protection block, the ash
that has already formed falls off or the still unburned portion of
the fire-protection block falls out of the bulkhead. This can be
attributed for one to the matrix beginning to melt in the case of a
fire, whereby the intumescence of the additives is initially able
to take place. However, the zone of the liquid matrix weakens the
bond with the already formed ash crust. In addition, the
intumescence can contribute to the still unburned portion of the
fire-protection block being pushed out of the bulkhead. This can
become problematic particularly in the case of large ceiling
bulkheads.
[0021] The weakening of the bond between the ash crust and the
still unburned portion of the fire-protection block can become a
problem in the case of the hose stream test required in the U.S.,
in which the crust must be able to withstand a strong water stream
after the fire.
[0022] It is an object of one or more embodiments to strengthen the
bond between the ash crust and the unburned portion of the fire
protection element. For this purpose, applying a wire mesh on the
outside of the fire protection element or attaching the fire
protection element to a wire mesh are known, which prevents the
layer of ash from falling off. Especially with respect to ceiling
bulkheads, it is advantageous that the ash does not detach from the
substrate and fall off the bulkhead in thick layers. Then the
underlying layer would namely be burned, which would reduce the
mechanical strength of the fire protection element as well as its
resistance time against burn-through. Crossbars, intermediate
layers made of glass-fiber fabric or the like, which close the fire
protection element at the bottom, are also known.
[0023] An object of one or more embodiments is to improve a fire
protection element such that the ash crust originating in the event
of a fire is kept on the fire protection element in the most stable
manner possible.
[0024] The fire protection element according to one or more
embodiments features at least one carrier component, which is
designed as a thin, flat part. In some embodiments, the carrier
component can be a prefabricated carrier component embedded in the
body, which is covered by the body on one of its two flat sides,
preferably completely covered.
[0025] The fire protection element is not defined as a specific
form. According to one or more embodiments, the component may
assume any imaginable form which is used for bulkhead lead-throughs
for the purpose of fire protection. Forms that are a possibility
for this are stones in the form of bricks, mats, plugs for sealing
round openings, wall lead-throughs for individual cables (bushings)
just to name a few as examples.
[0026] In one or more embodiments, the carrier component is
fastened subsequently to the fire protection element. It may be
affixed to the fire protection element in a manner known to a
person skilled in the art so that the carrier component is covered
on one side by the body of the fire protection element.
[0027] In one or more embodiments, the fire protection element does
not provide any carrier components or auxiliary means such as wire
mesh, supports or glass-fiber fabric that are subsequently attached
on the outside. Rather the stability of the ash crust is achieved
by a carrier component embedded in the body, preferably one that is
completely embedded. In one or more embodiments, a fire protection
element has a foamed body, which is made at least partially of an
ash-forming and, if applicable, intumescent mixture, and at least
one prefabricated carrier component embedded in the body. In one or
more embodiments, the carrier component can be a thin, flat part,
which is covered by the body on at least one flat side, preferably
on three sides, especially preferably completely.
[0028] In one or more embodiments, the carrier component is not a
thick, voluminous component, but a flat part whose thickness is
preferably a maximum of approximately 2 mm. This thickness can be
measured perpendicular to the main extension direction of the part.
This carrier component also differs in this respect from the
honeycomb-shaped component provided in German Patent Document No.
DE 10 2005 013 724 B4. The fire protection element according to one
or more embodiments is very easy to produce in contrast to the
honeycomb-shaped component; in particular, the formation of large
bubbles in the body from numerous to-be-filled chambers that are
separated from each other by bulkheads is ruled out because of the
thin, flat geometry of the carrier component.
[0029] In one or more embodiments, the flat part can be formed by
placing fibers or fibrous elements, which are not necessarily
connected to one another, adjacent to one another. The threads can
be integrated therein in the direction of the burning away of the
component, because otherwise the effect according might not be
achieved.
[0030] In one or more embodiments, so that in the event of fire the
carrier component has the best possible connection between the
already formed (e.g., intumescent) ash crust and the still unburned
portion of the fire protection element, it should be covered by the
body on at least three sides, for example, or on all sides. The
carrier component can form an outer side of the fire protection
element. The carrier component preferably does not extend up to the
outer side of the body.
[0031] In one or more embodiments, the carrier component can be a
flexible part, in particular, which is designed not to be rigid,
but imparts the fire protection element with stability once it is
embedded in the body during foaming.
[0032] The carrier component in one or more embodiments has a
structure which ensures a connection between the ash crust and the
still unburned portion of the component beyond the melting zone.
This can be achieved by fibers or threads arranged side-by-side
like a mat. According to one or more embodiments, the carrier
component includes a grid structure through which the foam
extends.
[0033] Some embodiments provide that a fabric is used as the
carrier component.
[0034] Some embodiments provide that the carrier component has a
mesh size and the threads of the fabric have a thread size, which
are in a specific ratio to each other. The thread size does not
relate to the size of an individual thread, but to the thickness of
the fabric. The ratio of the mesh size to the thread size should be
in the range of approximately 1 to 200, in particular, in the range
of approximately 12 to 18.
[0035] The threads of the fabric can have a thread size between
approximately 0.05 mm and approximately 1 mm in some embodiments;
between approximately 0.1 mm and approximately 0.8 mm in other
embodiments; and approximately 0.2 mm in yet other embodiments. The
fabric can have a mesh size of approximately 1 mm to approximately
50 mm in some embodiments, approximately 2 mm to approximately 20
mm in other embodiments, and approximately 3 mm to approximately 5
mm in yet other embodiments.
[0036] According to one or more embodiments, the carrier component
is made of, for example, a temperature-resistant material (e.g., an
inorganic material). Temperature-resistant within the scope of one
or more embodiments means that the materials have a higher melting
point than the matrix material. Such materials include, for
example, carbon, ceramic, basalt, mineral fibers, glass fibers,
natural fibers and composites with plastics. Even perforated
sheeting, expanded metals, fabric made of metals such as aluminum,
which are created in such a way that they do not impair the
flexible properties of the fire protection element, may be used as
the carrier component according to one or more embodiments.
[0037] One or more embodiments provide that materials be used as
the carrier component, which permit a simple processing, such as
cutting the fire protection element to size with a carpet
knife.
[0038] Although some embodiments provide for fireproof carrier
components, depending upon the thickness of the layer between the
outer side of the fire protection element and the carrier
component, other embodiments provide that combustible materials can
be used for the carrier component. In this case, it may be
advantageous that the layer of ash that develops in the event of
fire is designed to be thick enough.
[0039] For clarification purposes, some embodiments will be
described more precisely on the basis of a fire-protection block
without restricting the present invention to a fire-protection
block.
[0040] In some embodiments, the arrangement of the component in the
fire protection element is not limited as long as the carrier
component is embedded in the direction of the burning of the fire
protection element. In one or more embodiments, the carrier
component may be arranged as close as possible to the outer side of
the fire protection element. It may extend, for example, along at
least one outer side of the body. In the case of a fire protection
element in the shape of a rectangular solid, for example, which is
installed in a lead-through in such a way that its longer side
extends into the lead-through so that the burning takes place
starting from the smaller side surface of the rectangular solid,
the carrier component should extend at least along the base surface
of the rectangular solid.
[0041] Some embodiments provide that the carrier component extends
completely along an outer side. Other embodiments provide that the
carrier component extends along several outer sides of the
body.
[0042] Alternatively or additionally, a component that is embedded
in the carrier component in a bent or kinked manner can be
provided. For example, the carrier component may run in a wavy
manner or be bent in a V-shaped manner. In addition, overlapping or
intersecting carrier components may also be used.
[0043] These and other advantages, aspects and novel features of
the present invention, as well as details of one or more
illustrated embodiments thereof, will be more fully understood from
the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1 shows a line element lead-through according to a
first embodiment according to the present invention.
[0045] FIG. 2 shows a cross section through the line element
lead-through shown in FIG. 1.
[0046] FIG. 3 shows a cross section through a line element
lead-through according to FIG. 1 inserted in a component opening
equipped with a cable.
[0047] FIG. 4 shows a line element lead-through according to a
second embodiment according to the present invention.
[0048] FIG. 5 shows a cross section through a line element
lead-through according to FIG. 4 inserted in a component opening
and equipped with a cable.
[0049] FIG. 6 shows a first embodiment of a carrier component
according to the present invention.
[0050] FIG. 7 shows a second embodiment of a carrier component
according to the present invention.
[0051] FIG. 8 shows a third embodiment of a carrier component
according to the present invention.
[0052] FIG. 9 shows a fourth embodiment of a carrier component
according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0053] In the sense of one or more embodiments of the present
invention, the following definitions are used: [0054] "elastically
deformable" means that the material of which the line element
lead-through is made of is sufficiently elastic so that pressing it
together is possible without problems, i.e., without exerting a
great deal of force, say by hand, and the line element lead-through
again assumes its original shape; [0055] "form fitting" means that
the line element lead-through contacts the inner wall of the
component lead-through directly not only in one spot but over a
certain area and forms a contact surface; [0056] "intumescent
material" means an intumescent foam material that carbonizes at
temperatures starting at approximately 150.degree. C. and/or the
effect of flame with multiple increases in volume; an intumescent
material according to one or more embodiments of the present
invention that can be used is described, for example, in DE 3917518
or U.S. Pat. No. 3,574,664; [0057] "ash forming" means that the
foam carbonizes without significant intumescence; [0058] "line
element" means cables like electrical cables, lines, empty pipes,
pipes, bundles of lines or pipes and the like; [0059] "seal" means
that in a one-piece hollow molded element, the base and/or the
cover surface is closed; [0060] "opening cross section" means the
cross section of the line element lead-through that can be equipped
with cables.
[0061] Some embodiments according to the present invention relate
to a line element lead-through that is sealed against fire and flue
gas for passages in walls and ceilings. Some embodiment relates to
a line lead-through of an intumescent foam. Some embodiments relate
to a line lead-through with a support structure embedded (e.g.,
completely embedded) therein.
[0062] The line element lead-through according to one or more
embodiments of the present invention is advantageously formed so
that it can be slid manually into a circular or oval passage
through the wall. Because of a slight excess dimension of the shape
designed as a sleeve and the elastically deformable material, after
sliding in, the line element feed-through contacts the inner wall
of the passage with a specified pressure and seals it. More
precisely, this is achieved when the outer diameter of the line
element lead-through is somewhat larger than that of the diameter
of the component opening. In some embodiments, the outer diameter
is approximately 1 mm to approximately 5 mm larger than the
diameter of the component opening. In other embodiments, the outer
diameter is approximately 2 mm to approximately 3 mm larger than
the diameter of the component opening.
[0063] The elastically deformable material of which this is made of
also makes possible sealing against fire and flue gas after the
introduction of at least one line. The cables passed through
compress the pierced wall of the line element lead-through and thus
generate an extensive sealing against flue gas.
[0064] The general construction approval no. Z-19.15-349 prescribes
that the entire permissible cross section of the installation,
related to the respective outer dimensions, must be no more than
60% of the rough opening in total, the so-called 60% rule.
Accordingly, the line element lead-through according to one or more
embodiments of the present invention is designed so that the free
opening of the truncated cone corresponds to the opening cross
section and thus 60% of the cross section of the component opening.
Thus, the opening of the truncated cone can be filled completely
with line elements without violating the 60% rule. Cables and empty
pipes are led through individually or as bundles up to this max.
inner diameter.
[0065] According to one or more embodiments of the present
invention, the molded element is made of an ash-forming and/or
intumescent foam. This makes it possible to create the component
lead-throughs prophylactically and in spite of them being filled,
sealing them at temperatures starting from approx. 150.degree. C.
and/or with the effective flame against passage of air and/or smoke
and only passing the line elements through when necessary.
[0066] In one or more embodiments, the line element lead-through is
designed as one piece.
[0067] In one or more embodiments, the line element lead-through is
provided on the base surface with a flange-like edging that points
radially outward. This prevents, for example, sliding the line
element lead-through too far into the opening, preventing the line
element lead-through, for example, from falling into the hollow
space of drywalls. In addition, the edging additionally seals the
component opening in the case of a fire whether it is filled with a
line element or not.
[0068] According to one or more embodiments of the present
invention, the molded element of the line element lead-through is
closed on its cover surface in order to form a seal. In general, it
does not matter whether the base or the cover surface of the molded
element is closed, or both. Both permit a sealing of the component
passage that is sealed against fire and flue gas. However, a molded
element that is closed on one side is simpler and less expensive to
manufacture without any sacrifice to its functionality, so this
embodiment may be highly preferred whereby it is especially
preferred if the molded element is closed on its cover surface.
[0069] The wall thickness of the molded element should be selected
depending on the size of the component passage to be sealed and
accordingly the size of the line element lead-through to be used so
that, for example, there is no negative effect on the flexibility
of the line element lead-through and, for another, a form-fitting
seal of the component passage is ensured. However, the wall of the
molded element must be at least thick enough so that the cross
section of the free opening to be equipped is no greater than 60%
of the cross section of the component opening. If the wall
thickness is too great, the line element lead-through is not
form-fit on the component passage and the outer wall of the
component, which means that sealing against flue gas is no longer
ensured.
[0070] Preferably the wall thickness d.sub.1 is approximately 5 mm
to approximately 20 mm, more preferably approximately 8 mm to
approximately 16 mm, but at least thick enough so that the 60% rule
is not violated. For a hole of approximately 4 cm O (diameter), the
area of approximately 12.6 cm.sup.2 must be filled approximately
7.5 cm.sup.2 according to the 60% rule, this corresponds to a 0 of
approximately 3.1 cm. Thus the wall thickness must be at least
approximately 5 mm. For a hole with approximately 6 cm O, the wall
thickness would thus be approximately 7 mm and for approximately 10
cm O it would be approximately 11 mm.
[0071] With a wall thickness of less than approximately 5 mm, the
material of the line element lead-through is not adequate to create
adequate intumescence and an adequately stable ash crust for
sealing the component passage in the case of fire. In addition,
during (subsequent) equipping of the line element lead-through with
line elements, the molded element would be susceptible to cracks so
sealing against flue gas could no longer be ensured.
[0072] The wall thickness d.sub.2 of the seal is less than the
remaining molded part in order to make it easier to pierce it with
a line element. However, it must be selected such that after
piercing, the seal lies form-fit on the line element so that in
case of fire an adequate sealing against flue gas is ensured.
Preferably the wall thickness is approximately 2 mm to
approximately 8 mm, more preferably approximately 3 mm to
approximately 6 mm.
[0073] In one or more embodiments of the present invention, the
seal has predetermined breaking points to make it easier to pierce
the seal. The specified breaking points are distinguished in that
the material of the molded element is thinner at these points than
the wall, preferably between approximately 1 mm and approximately 4
mm, and more preferably between approximately 2 mm and
approximately 3 mm. In addition, these spots have a specific shape.
For example, the specified breaking points can be circular,
star-shaped or cross-shaped, whereby the geometry of the specified
breaking point is not restricted. For example, the specified
breaking point can also include several individual specified
breaking points, circles of different diameters lying inside each
other.
[0074] In a preferred embodiment, the molded element is designed as
a truncated cone. Because of this, there is a certain flexibility
when the line element lead-through is not completely filled, say
with only one line element or a line element with a diameter that
is smaller than the opening diameter of the line element, without
having a negative influence on the sealing against flue gas.
[0075] In one or more embodiments, the seal is designed as a
membrane.
[0076] In an embodiment according to the present invention, the
molded element is designed as a truncated cone. Because of the
shape designed as a truncated cone, a case is achieved in which the
user has a certain amount of freedom during selection of the line
elements so that a line element lead-through can hold and seal at
least one line element of different thickness/diameter.
[0077] In another alternative embodiment, the molded element is
designed as a cylinder. In this way, better sealing against flue
gas can be achieved since the longish element can better compensate
or bridge unevenness in the walls of the component passage.
[0078] The length l of the molded element is preferably
approximately 3 cm to approximately 6 cm, and more preferably
approximately 3.5 cm to approximately 5 cm, no matter whether it is
designed as a truncated cone or a cylinder.
[0079] On its outside, the cylindrical molded element preferably
has at least one bead running around it radially that is arranged
at a distance from the flange-like edging. When there are several
beads, these are also arranged at a distance from each other. The
(first) bead is arranged at a distance from the flange-like edging
so that with a sandwich-type plasterboard, a lock is formed
directly behind it that prevents or will make it more difficult for
the line element lead-through to fall out or be pulled out
unintentionally when the line element is pulled through or if there
is a light pull on the line element lead-through. In Germany, the
thickness of a standard sandwich-type plasterboard panel is
approximately 12.5 mm and in the USA approximately 16 mm, so the
distance of the (first) bead from the flange-like edging is
approximately 12.5 mm or approximately 16 mm, respectively,
starting from the edge of the flange-like edging contacting the
component. If thicker walls are required, generally two (double
panels) or more of the sandwich-type plasterboards are placed
behind each other. In order to prevent pulling it out
unintentionally from the double paneled wall, a second bead is
provided that according to one or more embodiments of the present
invention is arranged at a distance from the first bead so that the
distance of the second bead with respect to the flange-like edging
is the thickness of the paneling, namely approximately 25 mm or
approximately 32 mm, respectively, starting from the edge of the
flange-like edging contacting the component. If no flange-like
edging is provided, the distances are measured from the front edge
of the line element lead-through.
[0080] In axial direction, the bead has a thickness from
approximately 4 mm to approximately 6 mm. The thickness in radial
direction is approximately 2 mm to approximately 4 mm.
[0081] In one embodiment of the cylindrical molded element, the
seal in the molded element is mounted at a distance from the end
that is opposite the opening, i.e., that is located in the
component hole in the component after introduction of the line
element lead-through. The part of the molded element projecting
beyond the seal then forms a guide, which makes it easier to pass
line elements from the inside of the drywall.
[0082] The molded element is manufactured using mold-foaming with
reaction foams (RIM) according to DE 3917518, e.g., with Fomox.RTM.
fire-resistant foam or with the material HILTI CP 65GN that forms
an insulating layer. Materials that can be used for the purposes of
one or more embodiments of the present invention are known from EP
0061024 A1, EP 0051106 A1, EP 0043952 A1, EP 0158165 A1, EP
0116846A1 and U.S. Pat. No. 3,396,129A as well as EP 1347549 A1.
Preferably the molded element is made of polyurethane foam capable
of intumescence as known from EP 0061024 A1, DE 3025309 A1, DE
3041731 A1, DE 3302416 A and DE 3411 327 A1. The above-reference
applications are hereby incorporated herein by reference in their
entirety.
[0083] Exemplary embodiments according to one or more embodiments
of the present invention will be explained in the following with
the use of the drawings.
[0084] FIG. 1 shows a line element lead-through of a molded element
1 designed as a truncated cone with a flange-like edging 2 that
points radially outward according to one embodiment of the present
invention in which the base surface of the truncated cone forms the
opening 3 and the closed cover surface of the truncated cone forms
the seal 4. In this figure, the specified breaking point 5 in the
form of a star can be seen that is designed on the seal 4.
[0085] FIG. 2 shows the truncated cone shape of the molded element
1 with a length l, wherein the material thickness d.sub.1 of the
edging 2 is not included, a wall thickness of the molded element
d.sub.1, and a wall thickness d.sub.2 of the seal 4. The thinner
specified breaking point 5 that is arranged in the center of the
seal is also indicated opposite the wall thickness d.sub.2 of the
seal 4.
[0086] FIG. 3 shows the barrier of an opening 7 in a component 6
with line element lead-through according to FIG. 1 according to one
or more embodiments of the present invention, through which a line
element 8 in the form of a cable is passed. From the embodiment
shown in FIG. 3 in which the outer diameter of the molded element
1, in which the edging 2 is not considered, is slightly larger than
the diameter D of the component opening 7, it is clear how the
excess dimension of the outer diameter of the molded element leads
to a greater contact surface 10 between the inner wall 9 of the
component opening 7, whereby good sealing against flue gas is
achieved, and on the other, a friction fitting self-locking of the
line element lead-through is achieved. Thus, the line element
lead-through can be fastened adequately tightly in the component
opening 7 without additional tools, whereby falling out is
prevented and unintended pulling out is made more difficult. In
addition, it can be seen how the seal 4 seals the line element
8.
[0087] FIG. 4 shows a line element lead-through of a molded element
1 designed as a cylinder with a flange-like edging 2, an opening 3,
a seal 4 and two beads 11 and 12 according to a second alternative
embodiment according to the present invention.
[0088] FIG. 5 shows the barrier of an opening 7 in a component 6
that is made of two sandwich-type plasterboards (double paneled
drywall) with the line element lead-through according to the
embodiment according to FIG. 4 when equipped with a line element 8.
It can be seen from this that the second bead 12 engages behind the
second plasterboard panel and thus forms a lock against
unintentional pulling out of the line element lead-through. Because
of the elastically deformable material of which the molded element
1 is made of, the first bead 11 is compressed, whereby additionally
a clamping of the line element lead-through with the inner wall 7
of the component opening 6 is achieved.
[0089] In some embodiments, the molded element 1, for example,
designed as a truncated cone or a cylinder as illustrated in FIGS.
1-5 can benefit from incorporating a carrier component 18 such as,
for example, a mesh or grid formed of glass fibers, for example,
that are embedded in the molded element 1. The carrier component 18
can be entirely embedded in the molded element 1. The carrier
component 18 can alternatively be partially embedded in the molded
element 1 such that an outer surface of the carrier component 18 is
exposed on the outer surface of the molded element 1. The carrier
component 18 can be in the shape of a truncated cone and embedded
in the molded element 1 configured as a truncated cone as
illustrated in FIG. 2. The carrier component 18 can alternatively
be in the shape of a cylinder and embedded in the molded element 1
configured as a cylinder as illustrated in FIG. 4. The grid may
extend from one end of the molded element 1 to the other side of
the molded element 1. In some embodiments, the grid does not extend
into the flange edges 2.
[0090] In some embodiments, the carrier component 18 provides a
support structure for the molded element 1. In addition, if the
molded element 1 is exposed to heat and produces ash crust, the ash
crust is more likely to stay attached to unburned portions of the
molded element 1 because the ash crust and the unburned portions
are connected by the carrier component 18. In addition, the carrier
component 18 controls the expansion of the molded element 1 when
exposed to heat. The intumescent foam or mixture of the molded
element 1, when exposed to heat, expands. However, the carrier
component 18 controls the expansions so that the molded element 1
does not expand in an unrestrained and undirected manner, thus
reducing the negative effects on the structural integrity of the
molded element 1.
[0091] Although generally discussed, at times below, with respect
to a fire protection element 13, for example, in the form of a
rectangular block, the carrier component 18 can be used with other
shapes and other applications such as, noted above, with respect to
a line element lead-through of a molded element 1.
[0092] FIG. 6 shows a fire protection element 13. In some
embodiments, the fire protection element 13 can be used in ceiling
openings to seal cable and/or pipe lead-throughs. In some
embodiments, the fire protection element 13 can be in the form of a
line element lead-through of a molded element 1 designed as a
truncated cone or as a cylinder as illustrated in FIGS. 1-5.
[0093] Referring to FIG. 1, the fire protection element 13 has a
rectangular block-shaped body having several outer sides, more
precisely, side surfaces 15 as well as an upper side and a lower
side 14 or 16.
[0094] In some embodiments, the fire protection element 13 can be
made, in part, of an ash-forming and, if applicable, intumescent
mixture, which is added to a foaming substance. This mixture
together with the foaming substance, preferably polyurethane,
produces a foamed body after foaming and hardening. One or more
carrier components 18 can be embedded in this foamed body. FIG. 6
depicts a carrier component 18 which has a U-shape. However, the
present invention need not be so limited in shape or
application.
[0095] A very thin, flat, prefabricated component can be used as
the carrier component. A commercially available reinforcement
fabric made of textile glass material can be used.
[0096] In some embodiments, the carrier component is designed to be
flexible, in particular not inherently rigid.
[0097] In some embodiments, the carrier component includes a fabric
having several threads 20 which have a thickness of between
approximately 0.1 and approximately 1 mm, preferably approximately
0.2 to approximately 0.3 mm.
[0098] The carrier component 18 has numerous openings, the size of
which is defined by a so-called mesh size. The mesh size is between
approximately 1 and approximately 50 mm, preferably approximately
3.5 to approximately 4.5 mm. The mesh size is defined as the
smallest distance between adjacent grid elements (e.g., threads in
the case of fabric). The mesh size is designated as "a" in FIG.
6.
[0099] The mesh size a is proportional to the thread size, and
specifically its ratio is approximately 1 to 200, in particular
approximately 10 to 50 and especially preferably approximately 12
to 18.
[0100] Inorganic and/or organic materials or even combustible
materials can be used as the material for the carrier component.
Materials like carbon, ceramic, basalt, mineral fibers, glass
fibers, natural fibers and composites with plastic in use as well
as pure plastics which have a higher melting point than the matrix
material can be used.
[0101] In some embodiments, the carrier component 18 is so thin and
flexible that it may be cut with a knife, in particular a type of
carpet knife or with a pair of scissors. Ideally, the carrier
component is produced from a glass-fiber material, wherein metal
may also be used however.
[0102] The production of the fire protection element will be
explained further below.
[0103] In some embodiments, the carrier component 18 is cut and
then bent into a U-shape, for example.
[0104] Referring to FIG. 6, the two sides 30 as well as a base
surface 32 are provided, which are assigned to two side surfaces 15
as well as the lower side 16.
[0105] The carrier component 18 is inserted into a mold part 34,
which has a surrounding frame as well as a base. The size of the
carrier component 18 is selected such that the surfaces 30 and 32
are somewhat smaller than the associated surfaces in the recess of
the mold part. After putting the carrier component 18 into the
recess 36 in the mold part 34, the carrier component 18 is
positioned in such a way that it is at a short distance from the
mold part 34 on all sides.
[0106] Then a flowable mixture is poured into the recess 36,
wherein possibly even beforehand, prior to inserting the carrier
component 18, a portion of this mass could be introduced in the
region of the base of the mold part 34. Finally, the mold part is
closed on the upper side by a cover (not shown). The introduced
mass is, for example, polyurethane with an ash-forming and, if
applicable, intumescent mixture. The mass foams up and penetrates
the carrier component 18 because of the numerous openings. After
hardening, the carrier component 18 is preferably completely inside
the formed, foamed body. To simplify the fabrication of the fire
protection element 13, the surface 32 may also form a base surface
of the fire protection element 13. The carrier component 18
together with the foamed body forms the fire protection element 13.
Due to the grid structure, the ash crust holds very stably in the
event of fire to the rest of the fire protection element. In
addition, the entire fire protection element 13 is imparted with a
greater mechanical strength.
[0107] FIG. 7 shows another embodiment of the carrier component 18,
which is designed to be wavy in this case and this wave shape is
accommodated completely in the foamed body. This wave shape, which
may be accommodated transversely or longitudinally in the foamed
body, provides very stable support for the carrier component in the
body, which is also beneficial for supporting the ash crust.
Namely, if the ash crust falls away partially so that the carrier
component is exposed or subjected to too much thermal stress, the
entire carrier component does not fall off or burn off abruptly,
but only a portion thereof. The remaining part continues to be
available as a support via the new crust that then forms.
[0108] An annular carrier component 18 is used in FIG. 8, which
runs near to the outer sides 15. In this case, a carrier component
is not provided in the region of the upper or lower side 14 or 16.
The threads of this grid structure as well may be aligned in a
different manner; they do not have to extend parallel to the main
extension direction (circular direction). Incidentally, this may
also apply to the embodiment according to FIG. 7, in which a grid
structure (e.g., a fabric) is provided. Various properties
associated with the carrier component with respect to FIG. 6 may
also be present with respect to other embodiments.
[0109] In the case of the embodiment according to FIG. 9, several
carrier components 18, 18' are provided, and namely in the form of
carrier components running kinked or bent in a V-shaped manner,
which are partially slotted so that they may be inserted into one
another. This produces a type of cross structure. In this case as
well, just like with the other embodiments, the carrier component
18, 18' is completely accommodated in the foamed body.
[0110] Although some embodiments contemplate that the carrier
component is completely embedded in a foamed body or other
structure, other embodiments contemplate that only a portion of the
carrier component is embedded in the foamed body or other
structure. Still other embodiments contemplate that the carrier
component is mostly on the outside of the foamed body or other
structure.
[0111] Although, at times, described as non-rigid carrier
components, some embodiments contemplate using rigid carrier
components. Rigid components can improve positioning thereof when
introducing the flowing mass and/or during the subsequent
foaming.
[0112] Some embodiments provide a rigid design that can provide the
carrier component with an additional structure or an additional
supporting substance, for example, in that the previously flexible
carrier component is shaped and then brought to a permanent shape
via metal supports or plastic sheathing.
[0113] In the event of fire, the carrier component can act as a
reinforcement by making the layer of ash more stable on the one
hand, i.e., by strengthening the bond between the layer of ash and
the unburned portion of the fire protection element so that the
fire protection element withstands stress such as, for example, in
the so-called hose stream test (in accordance with the ASTM test
standard). On the other hand, the carrier component can make sure
that the intumescence does not take place in an unrestrained and
undirected manner, but a compression and therefore a greater
stability of the layer of ash are achieved by the diminished
intumescence. In addition, when using the fire protection element
as a ceiling bulkhead, the carrier component can prevent the layer
of ash from falling off, whereby the fire element remains stable
for a longer period of time.
[0114] Some embodiments provide that additional auxiliary means for
external support of the fire protection element are not provided.
As a result, the production and installation of the fire protection
element can be simplified.
[0115] Some embodiments provide that no additional top layers or
the like be affixed on the outer side of the fire protection
element.
[0116] Some embodiments provide that the flat sides of a thin, flat
carrier component 18 are the sides of the largest surfaces;
referring to FIG. 6, the upper and lower sides for the section 32,
and in terms of section 30 the inner and outer sides.
[0117] While particular elements, embodiments, and applications of
the present invention have been shown and described, it is
understood that the present invention is not limited thereto
because modifications may be made by those skilled in the art,
particularly in light of the foregoing teaching. It is therefore
contemplated by the appended claims to cover such modifications and
incorporate those features which come within the spirit and scope
of the present invention.
* * * * *