Note: Descriptions are shown in the official language in which they were submitted.
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FIRE BARRIER COMPONENT
FIELD OF THE INVENTION
The present invention relates to a factory
manufactured prefabricated fire barrier component where a
firestop insulation product such as mineral wool is
preinstalled into a sleeve or frame and is designed to
release and seal the opening in the event of a fire. The
product can be used on its own or in groups, and can be
installed with or without a framing assembly.
BACKGROUND OF THE INVENTION
Fire stop assemblies are required to prevent the
spread of fire through openings in a wall, floor or other
structural barrier of a building structure. The openings
are typically provided through fire rated assemblies to
allow conduits, piping and other penetrating members to
pass through the barrier. These fire stop assemblies
often provide some protection about the access port
during a non-fire condition and in the event of a fire
are designed to stop the fire from progressing through
the port. Many fire stops are field fabricated at the
building site by installers using methods that make it
difficult to ensure the appropriate material compression
and depth of material installation. They can also be very
difficult to install.
Many of these fire stop assemblies use
intumescent materials which foam and greatly expand when
exposed to a fire condition. For fire stop assemblies of
a large size for example for providing a fire stop for a
port having a longitudinal direction in excess of two
feet, some additional structural components may be
required when using intumescent materials to keep it from
separating or falling out during a fire condition. In
addition, the use of intumescent material increases the
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cost of the fire stop assembly and the intumescent
material on its own may not meet certain fire codes which
require the barrier to withstand a restricted temperature
transmission requirement or remain intact after an
exposure to a pressurized stream of water.
There remains a need to provide an effective fire
stop assembly that can be properly installed on a job
site with minimal installer effort, training, or skill
level and allows quick installation of additional
penetrants without major effort or rework.
STJMMARY OF THE PRESENT INVENTION
A fire barrier component according to the present
invention comprises an elongated outer sleeve of a molded
material and generally fixed cross section and a
compressed fire stop material retained and protected
interior to the outer sleeve.
According to an aspect of the invention the outer
sleeve is of a material that is consumable in a fire.
According to an aspect of the invention the outer
sleeve is of an extruded plastic material.
In yet a different aspect of the invention the
fire barrier component has a rated fire stop application
and the compressed fire stop material is a non-
combustible material for the rated fire stop application.
In yet a further aspect of the invention the
compressed fire stop material is compressed mineral wool.
In a further aspect of the invention the
compressed fire stop material is a compressed glass fiber
material.
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In a preferred aspect of the invention the outer
sleeve is of a rectangular cross-section.
In a preferred aspect of the invention the outer
sleeve is a one-piece extruded tube designed to release
the compressed insulation material upon exposure to heat
or fire.
The fire barrier component according to an aspect
of the present invention, has an outer sleeve of a
profile to retain a compressed fire stop material
therein. The outer sleeve is partially consumed and/or
fails when exposed to a fire condition thereby releasing
and/or exposing the compressed fire stop material. The
sleeve may be of a plastic or other material capable of
being consumed by flame or heat of a fire.
In a different aspect of the invention the outer
sleeve is an elongate component of a single piece or
multi-piece construction that is configurable to allow
the insertion of the compressed fire stop material and to
retain the compressed fire stop material therein. In one
form, the elongate component includes a bottom channel
and a top coverplate. In a different aspect of the
elongate outer sleeve is a single extruded component with
a live hinge running the length thereof with the sleeve
being initially manufactured in the open condition. This
single extruded component operates in a clamshell manner.
In a further embodiment of the invention the
outer sleeve is manufactured of a single extrusion where
this extrusion has a male connector and a female
connector. The extrusion is reversible to define the
outer sleeve basically the single extrusion is cut into
two pieces with one reversed to collectively define the
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outer sleeve about the compressed fire stop material.
The fire barrier component when the outer sleeve
is of a plastic material, is of significant structural
integrity to protect the fire stop material from the
normal day to day environment which may tend to
deteriorate or expose the fire stop material to potential
damage. In addition, the plastic outer sleeve can easily
be cleaned as may be required over time. If desired end
caps can be provided on the tubes to essentially close
these members. In addition, the fire barrier component
can be manufactured in relatively long lengths and then
cut to appropriate size for insertion in a fire barrier
assembly or for a customized configuration in the field.
Basically this is a building component for defining a
fire barrier.
It has been found that by providing a compressed
fire stop material within the outer sleeve certain
advantages are possible. Basically, the sleeve forms a
restraining member and the compressed fire stop material
may be compressed from 10% to 200%. A compression range
of 30% to 80% is satisfactory for most applications. In
the event of a fire the outer sleeve may be partially
consumed or at least will be weakened and the barrier
thereof will allow the expansion of the compressible fire
stop material. The failed outer sleeve allows the
expanded fire stop material to form a positive fire stop
layer and it will also serve to protect the remaining
portion of the sleeve as an insulating layer. It has
been found during testing that the sleeve can be
completely consumed on one side while the two side edges
of the sleeve and the back-face of the sleeve remain
generally intact throughout the fire test. Any consumed
portion of the sleeve is immediately compensated by the
expanding compressed fire stop material. As can be
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appreciated the compressed fire stop material would also
expand against any wires or pipe which are immediately
adjacent thereto.
In a preferred aspect of the invention the
elongate outer sleeve includes a series of knockout ports
in the length thereof to allow a wire or pipe to pass
through the barrier. This provides a simple arrangement
for easy retrofit in the future for a specific
l0 application. Generally these fire stop assemblies do
allow removal of an elongate fire stop component however
the use of the knockout port allows a wire to pass
therethrough at a convenient location or where removal of
the entire component is not necessary or desired as the
amount of expansion needed is relatively small. At a
future point in time if this barrier component needs to
be removed it is easily cut.
In yet a further aspect of the invention the
barrier component can be manufactured in long lengths and
cut to the appropriate size either for shipping or for
the specific application.
BRIEF DESCRIPTION OF THE DRAWINGS
The above as well as other advantages and
features of the present invention will be described in
greater detail according to the preferred embodiments of
the present invention in which;
Figure 1 is a partial perspective view of three
fire barrier components placed in side by side
relationship;
Figure 2 is a plan view of a series of fire
barrier components secured in a circular frame to close a
passage through a building structure;
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Figure 3 is a cross section through a two-piece
fire barrier component;
Figure 4 is a schematic view of the outer sleeve
manufactured by a single extrusion component; and
Figure 5 is a sectional view through a fire a
barrier component which is manufactured with a live hinge
to allow closure thereof.
DETAILED DESCRIPTION ACCORDING TO THE PREFERRED
EMBODIMENTS OF THE PRESENT INVENTION IN WHICH:
The fire barrier components 2 shown in Figure 1
have an elongate outer sleeve 4 of a generally
rectangular configuration which retains and protects the
compressed fire stop material 6. The compressed fire
stop material 6 is preferably a mineral wool or other
fire barrier material and the outer sleeve 4 is
preferably a thin walled PVC enclosure. Other cross
sections of the outer sleeve 4 can be used.
As can be appreciated from Figure 1 these
rectangular fire barrier components can be manufactured
in long lengths and can be placed side by side for
forming the fabricated barrier 10.
Figure 2 shows a circular retaining frame 20
securing the barrier components 22 within the frame. As
can be appreciated the components 22 can be field cut to
different lengths and the ends of these components can be
cut to generally form to the shape of the circular
retaining frame 20. The factory made components 22 can
be used as part of a factory manufactured fire barrier
assembly or these components can be used as a fire
retardant building component that can be cut and/or used
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in combination to suit a particular onsite requirement.
It is preferred that each of the fire barrier
components 2 be of a generally rectangular section where
the compressed fire stop material 6 is compressed between
the two opposed sidewalls of the outer sleeve identified
as 6a and 6b. Typically, the fire barrier components 2
are installed in the orientation shown in Figure 1 for a
horizontal access port. The bottom surface 12 is the
surface that is likely to be exposed to a fire condition.
It is this portion of the outer sleeves that is first to
fail in a fire condition and the failure of this portion
allows the compressed fire block material to be exposed
to the fire condition from below and to expand. Somewhat
surprisingly, it is not necessary that the outer sleeve
be of a non-combustible material.. It may be desired to
make it of a non-combustible material or a material which
burns or fails in a particular manner. For example, this
could be of a PVDF material of an appropriate firing
rating. The outer sleeve could also be of a co-extruded
material and have an outer protective surface.
The fire barrier components of Figure 1 are each
individual components however if desired it is possible
to provide interior partitions to the barrier component.
It may be desired to effectively have three channels
within a barrier component and knockout ports 14 can be
provided in the top and bottom surfaces of the fire
barrier component as shown in Figure 1. It may be
desired that the knockout ports are only associated with
the center channel of the three channels whereby the wire
or pipe can be forced through the center channel. Some
damage or dislocation of the compressible fire barrier
material may occur but it would be limited to only a
small portion and the component would continue to
function in its intended manner. Fire stop sealants can
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be applied on top of the component about any penetrants
if desired or necessary. By dividing the components into
the channels the damage is limited, and the channels
either side of the center channel serve to provide
additional capacity when the fire condition occurs. As
can be appreciated the failure of the bottom surface of
the component would allow all of the compressed mineral
wool material to expand laterally and correct for any
small gaps or deficiencies resulting from the removed
compressed fire stop material. Preferably any interior
portions within the barrier component are thin walled.
A further advantage of the knockout ports is that
only a limited surface of the outer sleeve is removed
while allowing the worker a clear indication of how to
use the factory made fire barriers component having a
quality controlled known performance due to the
compressed fill material.
Although the knockout ports are desirable it is
also possible to merely drill through the outer sleeve as
may be required using conventional tools commonly
available. With this arrangement for certain
applications where only a single wire or small pipe needs
to additionally pass through the barrier, the installer
can merely use one of the ports rather than removing an
entire barrier component. As can be appreciated, the
removal of an entire component creates a significant gap
that can be avoided when the expansion requirements to
accommodate a pipe or wire are quite minimal.
various designs for the outer sleeve are shown
with respect to Figures 3, 4 and 5. All of these designs
have the common advantage of defining a structure where
the insertion of the compressed fire stop material 6 is
easily accomplished. Furthermore, each of these
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structures, once the material has been inserted allow the
tube to be closed and locked. The specific designs show
a snap fit lock type arrangement but other arrangements
are possible. Furthermore, it may be desired to provide
an overlap fit or provide for welding of the lock
arrangement. The purpose of the open capabilities of the
structures of Figures 3 through 5 is from a manufacturing
point of view as it is desirable to manufacture this
barrier component in long lengths or on a continuous
basis.
As can be appreciated from a consideration of
Figure 5 it would be possible to allow the extrusion of
the component and the subsequent insertion of the
compressible fill material as part of a continuous
manufacturing process. The continuous extruded component
can then be cut to desired lengths for shipping or
storage. As previously described it may be desirable to
permanently close the sleeve as opening of the sleeve
after the compressed material has been inserted is not
normally required.
In the present design it is desirable that the
fire stop material be compressed at least laterally.
Preferably, this material is compressed to at least one
third of its non-compressed state. Some compression in
the longitudinal or top to bottom direction is possible
and desired. The extent of this compression would be
much less. For many applications it is desirable merely
to provide the expansion in one direction for better
control and it also simplifies the manufacturing process.
The outer sleeve cross section of Figure 3 shows
a two-piece outer sleeve 30, a clamp on cover 32 and a
base channel 34. Snap locks 36 allow the cover to be
secured and retained on the base channel 34. As can be
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appreciated compressible fire stop material may be easily
loaded in the base channel 34 and the cover 32 may then
be locked on the channel.
5 The two-piece extrusion of Figure 4 has the two-
piece one extrusion structure 40 made up of the first
component 42 and the second component 44. These are the
same component but merely reversed in orientation. At
one end of the extrusion is the male connector 46 and on
10 the opposite end of the extrusion is the female connector
48.
The embodiment of Figure 5 shows a one-piece open
outer sleeve 60. A live hinge 62 is provided between the
first half component 64 and the second half component 66.
Once the compressed fire material has been loaded in the
one-piece open sleeve 60 the two halves may be brought
into engagement with the male connector 68 inserted and
locked in the female connector 70. Due to the flexibility
of plastic the live hinge could be deleted and the sleeve
merely forced open to insert the fire stop material. The
sleeve can then be longitudinally secured in a suitable
manner.
The fire barrier component as described with
respect to the drawings simplifies the manufacture of
factory produced fire stop assemblies where the barrier
component is inserted preferably and retained within a
structural frame or system. The component may be cut to
the appropriate length and the user can easily modify the
structure in the field as required to suit the different
conduits or pipes that may have to pass through the
assembly.
It is also possible to use the fire barrier
component for the construction of customized barriers in
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the field or to protect particular surfaces. For
example, in some applications it is desirable to provide
additional fire stop insulation beneath the deck of a
ship and the varying components could be installed to
provide both the fire barrier and insulation properties.
It is also possible that the fire barrier component can
be used for closing of large ports in walls that may be
present for future expansion. Basically the fire barrier
component is easily cut on the jobsite using a circular
saw or other cutting device and this allows the user to
easily customize the structure. This flexibility
increases the number of applications where the fire
barrier component can be used.
The fire barrier component has been described
with respect to its ability to expand laterally when
exposed to a fire condition. This lateral expansion
against other like components provides a cooperative
effect. There are applications where the component can
be installed in the opposite orientation to provide
higher insulation properties when the component is
exposed to a fire condition. Basically rather than the
components expanding against one another the compressed
fill material expands downwardly. This expansion
increases the amount of insulation due to the expansion
of the fire stop material. Therefore in applications
where space may be limited this pre-compressed state
effectively provides more clearance until such time as a
fire condition occurs.
The fire barrier component has been described for
providing a single layer fire stop barrier. It is also
possible in certain applications to greatly improve the
fire barrier capability by providing a second layer of
fire barrier components above a first layer.
Furthermore, the orientation of this second layer can be
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changed. For example, the first layer and the second
layer could be effectively rotated 90 degrees to each
other. Therefore it is possible to use this fire barrier
component in alternate manners and this again increases
the number of applications that component can be used.
Although various preferred embodiments of the
present invention have been described in detail, it will
be appreciated by those skilled in the art that
variations may be made without departing from the spirit
of the invention or the scope of the appended claims.
