CA2640007A1 - Pre-assembled fire barrier systems having male and female interdigitating coupling ends providing for one-step drop-in installation of the barriers into straight-line and intersecting expansion joints - Google Patents

Pre-assembled fire barrier systems having male and female interdigitating coupling ends providing for one-step drop-in installation of the barriers into straight-line and intersecting expansion joints Download PDF

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Publication number
CA2640007A1
CA2640007A1 CA 2640007 CA2640007A CA2640007A1 CA 2640007 A1 CA2640007 A1 CA 2640007A1 CA 2640007 CA2640007 CA 2640007 CA 2640007 A CA2640007 A CA 2640007A CA 2640007 A1 CA2640007 A1 CA 2640007A1
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fire
fire barrier
coupling
barriers
layer
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CA 2640007
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French (fr)
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CA2640007C (en
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Alan Shaw
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InPro Corp
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Fireline 520 LLC
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Abstract

Fire barriers systems, including pre-assembled male- and female-interdigitating coupling ended multi-directional and straight-line fire barriers provided for the elimination of most of on-site cutting or construction for easy, rapid, and safer one-step, drop-in installation are taught. Both the multi-directional and straight-line fire barriers are constructed as single-piece continuous units with a choice of having two male coupling ends, two female, or a male and a female for use in multi-directional corner formed by intersection expansion joint spaces and in straight-line architectural expansion joint spaces to prevent migration of gases, flame, and smoke throughout a building where each style barrier is provided with a one-step, one-person, drop-in, reusable, width adjustable installation tool.

Description

PRE-ASSEMBLED FIRE BARRIER SYSTEMS HAVING MALE AND FEMALE
INTERDIGITATING COUPLING ENDS PROVIDING FOR ONE-STEP DROP-IN
INSTALLATION OF THE BARRIERS INTO STRAIGHT-LINE AND
INTERSECTING EXPANSION JOINTS
BACKGROUND OF THE INVENTION
The present invention relates generally to fire barriers for fitting into expansion joints and more particularly to pre-assembled fire barriers constructed with male and female connections interdigitating connection ends for one-step drop-in installation of the barriers into straight-line and intersecting expansion joints.
The background information discussed below is presented to better illustrate the novelty and usefulness of the present invention. This background information is not admitted prior art. The particular versions of the invention as described below are provided, in part, as illustrative and exemplary. Thus,'the described versions should not be taken as limiting. Additionally, the invention is not limited to the examples provided.
Modem building codes require that the stresses experienced by buildings from forces such as: extreme and/or repetitive changes in temperature, the force of high winds impinging on the building, multi-directional forces due to seismic events, settling of subsoil, building remodels, and excavation on or near the site, must be taken into account in the building design. To accommodate these stresses, buildings must now be constructed with code-mandated spaces between wall, floor, and ceiling structures. These spaces, commonly referred to as "expansion joints," allow differential building movement to take place without risking damage to the structure.
While expansion joints improve the life-time integrity of the structure, they also present a major risk to the structure in the event of a fire because it is likely that the space created by the expansion joints will act as chimney flues providing pathways for gases, flame, and smoke to spread rapidly throughout the structure. To counter the flue effect, building codes for commercial structures generally require fire barriers to be installed in the expansion joints to prevent or to reduce the rate of flames and smoke passing through the joints into adjoining areas. Fire barriers, also referred to as "fire-stops," protect both the building and the inhabitants of the building to extend the time available for inhabitants to leave the building and for fire fighters to get to the fire.

During a fire, building joints are likely to be subject to even greater stress than usual, making it essential that the fire barriers retain their integrity to prevent the migration of gases, flame, and smoke. Accordingly, fire barriers are legally mandated to be tested, rated, and certified. There are two currently mandated tests. One measures the ability of a fire barrier to maintain its structural integrity under compressional and tensional motion.
This test is referred to as the "cycle" test and its parameters are specified by ASTM 1399.
The other test is referred to as the "fire" or "burn" test and its parameters are specified by UL 2079. The two tests are conducted in sequence. A fire barrier is first cycled between forces of compression and tension 500 times and then, if the barrier passes that test, it is placed into a furnace where it is tested for its ability to resist and prevents flame, heat, and gases from passing through the barrier.
Two kinds of fire barriers are needed in order to have fire-stop protection in a building: straight-line fire barriers and multi-directional barriers for fitting into the multi-directional and often, multi-dimensional spaces created by the intersection of straight-line expansion joints. In the past, the only fire barriers commercially available and tested were the straight-line, i.e., one dimensional fire barriers. These barriers are made to be installed between the straight segments of walls, ceilings, or floor units that are separated by the mandated expansion joint space.
Where mandated expansion joint space intersect, multi-directional or multi-dimensional expansion joint spaces are created. Examples of multi-directional or multi-dimensional joint spaces include the "cross-shaped" right-angled intersection area that results from the intersection of two straight-line expansion joint spaces or where expansion spaces created when the expansion space between two interior walls abuts an exterior wall creating a "T"-shaped intersection expansion joint space. It follows that multi-directional expansion joints require multi-directional fire barriers to fit into the joints. Moreover, to the best of our knowledge, there are no tested and rated fire barriers, straight-line and/or multi-dimensional corner models that are constructed with the advantage of having male and female end constructions for interdigitated one-step drop-in assembly.
Thus, it appears that fire barriers currently being provided for multi-directional expansion joints are frequently required to be constructed on-site from spliced together parts of sectioned straight-line barriers. Moreover, when such barriers are installed their ends are not capable of being interdigitated, thus requiring addition splicing. However, when code-tested and listed straight-line fire barriers are altered, such as when they are cut into pieces and the pieces are spliced together, the fire barrier's performance is no longer certified by the testing agency as the seams created by splicing have not been tested.
Thus, these seams may or may not be air-tight and could allow hot air, smoke, toxic gases to travel throughout the expansion joint spaces of a building. Furthermore, as the connections formed during the requiring splicing procedures, are sometimes simply staples, and as spliced barriers have been known to be installed by non-specialists, they may not stand up to even relatively mild stresses of tension/compression and/or shear movements.
Furthermore, on-site assemblage of fire barriers for intersecting joints is time consuming and often requires more than one installation person, which adds significantly to the total construction cost. Although, some fire barriers are installed by specialty fire barrier system contractors, to save time and reduce cost, fire barriers are too frequently installed by construction laborers. Site assembly of intersecting connections or straight-line connections is a time consuming job, often taking up to an hour a connection, and, as mentioned, often requires more than one installation person. This extra time and extra labor adds to the total construction cost. Furthermore on-site assembly of intersecting or straight-line connections between adjoining fire barriers introduces health and safety concerns to those who are doing the installation work. Cutting fiber glass (or similar material) introduces breathable sized fibers into the workplace atmosphere.
Moreover, on-site assembling frequently exposes workers hands and arms to being cut by the thin sheets of stainless steel that are often a part of a fire barrier. It would be beneficial to the worker and the contractor to have fire barriers, both those for fitting into straight-line expansion spaces and those for fitting into intersecting expansion spaces that are pre-assembled with male and female connecting ends for one-step drop-in installation of all of the styles of barriers into their respective expansion spaces. Such an improved product would greatly reduce both the time it takes to install the barriers and the health risks, thus cutting the cost of construction and worker's liability insurance.
The importance of correctly installed, tested, and listed fire barrier systems in buildings is increasingly recognized by building officials, owners, insurance companies, contractors, and the public. Assemblies that require on-site assemblage may look, at firs glance, like an approved fire barrier system, but there is always the danger that on-site assemblage, even of connections, will result in the installation of an untested and unlisted system which, in turn, may pose fire safety and work-place health risks.
It is clear then that what is urgently needed are pre-fabricated fire-barrier systems capable of passing the required fire and movement tests that include: (1) multi-directional fire barriers having male and female interdigitating connecting ends that can be installed in a one-step drop-in process, and (2) straight-line fire banriers having male and female interdigitating connecting ends for connection to other straight-line or intersection space fitting fire barriers.
Also clearly needed are re-useable, easily size-adjustable, installation tools that would provide for one person, one-step, drop-in installation of pre-fabricated male and female ended straight-line and multi-directional/multi-dimensional fire barriers.

SUMMARY
Accordingly, the invention described herein addresses this heretofore unmet need by providing pre-fabricated fire-barrier systems that include: (1) multi-directional fire barriers having male and female interdigitating connecting ends that can be installed in a one-step drop-in process, and (2) straight-line fire barriers having male and female interdigitating connecting ends for connection to other straight-line or intersection space fitting fire barriers that provide for one person, one-step, drop-in installation of pre-fabricated male and female ended straight-line and multi-directional/multi-dimensional fire barriers. The male and female ended barriers are designed to be delivered to the work site ready to install. The interdigitating connection ended fire barriers of the present invention do not cost anymore to manufacture than do those that do not have male/female coupling abilities. Moreover, when installed with their accompanying installation tools, they save even more time and cost, improve work site safety, and reduce the general fire safety risk that is created when a contractor doesn't understand the detailed requirements of fire barrier installation, especially when the fire barriers are being installed in intersecting expansion joint spaces.
The fire barriers of the present invention are unique in several ways. One point of novelty is the variety of multi-directional and multi-dimensional barriers that are pre-assembled, as well as straight-line barriers, each having interdigitating coupling ends. One example, provided herein as a favored embodiment, is an L-shaped (also referred to as a horizontal/vertical L) multi-directional fire barrier that is installed in a one-step, drop-in process into a L-shaped expansion joint space created by the convergence of the expansion spaces between two building structures, such as a floor and a wall or a wall and a ceiling.
The L-shape, as illustrated, is only one of a large number of possible configurations that are embodied with the principles of the present invention. The invention contemplates one-piece male/female connection ended cross-shaped, T-shaped, and L-shaped barriers.
It should be noted that L-shaped barriers besides having horizontal and vertical arms, may also be manufactured having horizontal/horizontal arms. All of the barriers are available having female connections, male connections, or with both, depending on the specific configuration of the expansion spaces requiring fire barriers providing not only for one-step, drop-in installation, but also providing for interdigitating coupling ends that require only a beading of fire-resistant caulk to be applied over the seams between the two coupled barriers. Except for a possible specialty situation where the architect has changed configurations at the last moments, no cutting or stapling of the overlapping connection ends is required. Each style of male and female ended fire barrier is supplied with its own reusable installation tool that provides for even quicker, easier, and safer one-step, drop-in installation of both the pre-assembled, female and male ended multi-directional/multi-dimensional and straight-line fire barriers. The installation tools are not only reusable, but also easily and rapidly size-adjust for use with different sized versions of the same style barriers.
These and other advantages of the present invention are made possible by providing the features outlined as follows. Fire barriers providing for interdigitatingly coupling-ends for use in architectural expansion joint spaces, the fire barriers having in particular: at least one coupling end shaped to interdigitatingly receive a mating coupling end of another like fire barrier or having at least one coupling end shaped for interditgitatal insertion into a receiving mating coupling end of another like fire barrier providing for drop-in installation of said fire barriers in architectural expansion joint spaces.
The fire barrier further having at least one male interdigitatingly coupling end for receiving at least one female interdigitatingly coupling end of another fire barrier.
The fire barrier also described as having at least one female interdigitatingly coupling end for receiving at least one male interdigitatingly coupling end of another fire barrier.

The fire barrier additionally described as having two male interdigitatingly coupling ends each for receiving a female interdigitatingly coupling end of another like-ended fire barrier.
The fire barrier alternatively having two female interdigitatingly coupling ends each for receiving a male interdigitatingly coupling end of another like-ended fire barrier.
The fire barrier of the present invention consisting of: at least one layer of fire resistant barrier material attached to at least one fire-resistant mechanical attachment means providing for attachment of the fire barrier to structural building units forming the architectural expansion joint spaces.
The fire barrier further having attachment means for detachably attaching an installation tool.
The fire barrier wherein the pre-assembled interdigitatingly coupling-ended fire barrier is a straight-line fire barrier shaped for use in straight line architectural expansion joints.
The fire barrier wherein the pre-assembled interdigitatingly coupling-ended fire barrier is a multi-directional fire barrier shaped for use in multi-directional architectural expansion joint spaces formed by the intersection of a plurality of architectural expansion joint spaces.
The fire barrier further having at least one layer of protective cloth.
The fire barrier further having at least one layer of protective cloth, and at least one layer of flexible stainless steel sheet, the one layer of flexible stainless steel sheet resting upon an upper surface of the protective cloth.
The fire barrier further having at least one layer of a protective cloth, at least one layer of flexible stainless steel sheet, the one layer of flexible stainless steel sheet supported on an upper surface of the protective cloth, and at least a first insulation blanket layer supported on an upper surface of the layer of flexible stainless steel sheet.
The fire barrier further having at least one layer of a protective cloth, at least one layer of flexible stainless steel sheet, the one layer of flexible stainless steel sheet supported on an upper surface of the protective cloth, at least a first insulation blanket layer supported on a upper surface of the layer of flexible stainless steel sheet, and at least a second insulation blanket layer supported on an upper surface of the first insulation blanket layer.
The fire barrier further having at least one layer of a protective cloth, at least one layer of flexible stainless steel sheet, the one layer of flexible stainless steel sheet supported on an upper surface of the protective cloth, at least a first insulation blanket layer supported on a upper surface of the layer of flexible stainless steel sheet, and at least a second insulation blanket layer supported on a upper surface of the first insulation blanket layer, where attachment means provide for attachment of the fire barrier layers to each other and to structural building units.
The fire barrier further having at least one layer of a protective cloth, at least one layer of flexible stainless steel sheet, the one layer of flexible stainless steel sheet supported on an upper surface of the protective cloth, at least a first insulation blanket layer supported on a upper surface of the layer of flexible stainless steel sheet, at least a second insulation blanket layer supported on a upper surface of the first insulation blanket layer, where attachment means provide for attachment of the fire barrier layers to each other and to structural building units, and attachment means attached to the barrier layers providing for detachable attachment of the fire barrier to an installation tool.
A fire barrier system including, prefabricated, drop-in, interdigitating, multi-directional fire barriers for use in multi-directional architectural expansion joint spaces formed by the intersection of a plurality of architectural expansion joint spaces having male and female interdigitating coupling ends for coupling to other like interdigitating fire barriers.
A fire barrier system including, prefabricated, drop-in, interdigitating, multi-directional fire barriers for use in multi-directional architectural expansion joint spaces formed by the intersection of a plurality of architectural expansion joint spaces having male and female interdigitating coupling ends for coupling to other like interdigitating fire barriers, and prefabricated, drop-in, interdigitating, straight line fire barriers having male and female coupling ends for coupling to other like interdigitating fire barriers.
A fire barrier system including, prefabricated, drop-in, interdigitating, multi-directional fire barriers having male and female interdigitating coupling ends for coupling to other like interdigitating fire barriers, prefabricated, drop-in, interdigitating, straight line fire barriers having male and female coupling ends for coupling to other like interdigitating fire barriers, lifting installation tools for installing the multi-directional fire barriers and the straight line fire barriers.
A fire barrier system including, prefabricated, drop-in, interdigitating, multi-directional fire barriers for use in intersecting expansion joint spaces having male and female interdigitating coupling ends for coupling to other like interdigitating fire barriers, prefabricated, drop-in, interdigitating, straight line fire barriers for use in straight-line expansion joint spaces having male and female coupling ends for coupling to other like interdigitating fire barriers, lifting installation tools for installing the multi-directional fire barriers and the straight line fire barriers.
A pre-assembled interdigitatingly coupling-ended horizontal/vertical L-shaped fire barrier for use in horizontal/vertical intersecting architectural expansion joint spaces, having: a pre-assembled interdigitatingly coupling-ended horizontal/vertical L-shaped fire barrier for use in horizontal/vertical intersecting architectural expansion joint spaces having at least one coupling end shaped for interdigitatingly receiving a mating coupling end of another like coupling fire barrier or having at least one coupling end shaped for interdigitatingly insertion into a receiving mating coupling end of another like coupling fire barrier providing for drop-in installation of the L-shaped fire barriers into architectural expansion joint spaces, the L-shaped fire barrier having a first fire barrier L-leg and a second fire barrier L-leg, the first fire barrier L-leg a contiguous part of and positioned approximately 90 degrees to second fire barrier L-leg providing for a one piece corner L-shaped interdigitatingly coupling-ended fire barrier.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that these and other objects, features, and advantages of the present invention may be more fully comprehended, the invention will now be described, by way of example, with reference to the accompanying drawings, wherein like reference characters indicate like parts throughout the several figures, and in which:
FIG. la is a diagrammatic cross-section view of a straight-line fire barrier constructed according to the principles of the present invention installed in an expansion joint.
FIG. lb-1 is a perspective view of a partial section of the straight-line fire barrier, as illustrated in FIG. la, to more clearly illustrate an attachment means for attaching the first layer sheets of the fire barrier to each other and to an L-bracket 42a to form a first layer, and another attachment means 50a and 53a for attaching the L-bracket to a second layer section and how pins 50a are used to provide attachment means for an installation tool when the barrier is ready to install.
FIG. lb-2 is a side plan view of the partial section of the straight-line fire barrier, as illustrated in FIG. lb-1, illustrating the addition of another layer of fire barrier material.
FIG. 1b-3 is a front plan view of the partial section of the straight-line fire ban~ier, as illustrated in FIG. lb-1, illustrating one example of how the pin attachment means may be spaced.
FIG. lc is an exploded perspective view of a partial section of the L-bracket to more clearly illustrate an example of attachment means that may be used to attach an installation tool to the L-bracket.
FIG. Id is a cross-sectional cartoon of the straight-line fire barrier, as illustrated in FIG. la, to more clearly illustrate the layer construction of the straight-line barrier having one male coupling end and one female coupling end.
FIG. 2a is a top plan view to illustrate how straight-line fire barriers having one male coupling end and one female coupling end interdigitate with each other to provide a complete fire barrier system with no on-site fire barrier construction or trimming required.
FIG. 2b is a perspective view of a horizontal/vertical 90 degree angled multi-directional corner fire barrier with one male and one female type ends, for interdigitated coupling with, for example the straight line fire barrier illustrated in FIG.
2c.
FIG. 2c is a perspective view of a straight line fire barrier with male and female type ends for interdigitating with the horizontal/vertical multi-directional corner fire barrier illustrated in FIG. 2b, for example.
FIG. 3 is a perspective view illustrating how the installation tool of the present invention provides for easy the drop-in installation of a ten foot section of the straight-line fire barrier even for two women who are not typical members of a construction crew.

DEFINITIONS
Building units, as used herein, refers to structures such as walls, floors, ceilings, and the like, and may be referred to as structural units.
Intumescent as used herein, refers to those materials having properties that cause them to expand (or intumesce) to several times their original size when activated by high temperatures to prevent the spread of flames and smoke to other parts of a building, for example passive fire-seals contain intumescent compounds.
Insulation blanket, as used herein, refers to any number of insulation materials, including fiber blankets made from alumina, zirconia, and silica spun ceramic fibers, fiberglass, and the like.
High-temperature thread, as used herein, refers to any thread that is fire resistant or any thread that will not support combustion, such as a ceramic thread.
Interdigitate, as used herein, refers to the action of interlocking, coupling, connecting, interweaving, or commingling.
Interdi ig tatingly, as used herein, refers to the action of interlocking, coupling, connecting, interweaving, or commingling.
Interdigitation, as used herein, refers to the act of interlocking or the condition of being interlocked, coupled, connected, or interpenetrated.
Intersecting architectural expansion joint spaces, as used herein, refers to expansion joint spaces that intersect into each other from different spatial orientations to form multi-directional or multi-directional/multi-dimensional expansion joint spaces, as opposed to a straight line expansion joint space abutting another straight line expansion joint space in a collinear contiguous fashion.
Metallic backiniz layer, as used herein, refers to fire resistant metal or metallicized foil, such as stainless steel, or the like.
Multi-directional and/or multi-dimensional architectural expansion join or joint, as used herein refers to any joint that is formed by the convergence of more than two expansion joint spaces, such as when the expansion spaces between wall units or wall and floor units intersect. These joints spaces between building units may act like chimney flues carrying gases, hot air, flame, and smoke throughout a structure.
Multi-directional and/or multi-dimensional fire resistant barrier, as used herein, refers to any fire barrier that is shaped to functionally fit into a multi-directional and/or multi-dimensional architectural expansion joint space.
Protective cloth, as used herein, refers to a flexible, strong, protective, fire-resistant material that is designed to mechanically support the insulation material and to protect the insulation material from mechanical damage, as the insulation is mechanically weak and can be easily damaged by tearing or ripping either accidentally or intentionally during or after installation thus largely compromising the integrity of the fire resistant barrier. The fire resistant layers, such as a layer of insulation material together with a layer of intumescent material, can freely move with respect to the one or more protective layers or they may be attached together via threads or other attaching means. Protective cloths may be manufactured from continuous filament amorphous silica yarns, polymeric material, fiber reinforced polymeric material, high-temperature resistant woven textiles, or a metalized, fiberglass cloth, among others. Metalized cloth may include fibers of stainless steel, aluminum, or copper, for example. Protective materials may also include metal foils or metal screens. Protective cloths also include cloths that are woven to provide for shear, including lateral, motion.
Seaming, as used herein, refers to connecting one part to another part, for example where a cloth is folded and the two parts of the cloth that have been brought together by the folding are subsequently "seamed" together along a predetermined line. The seaming may utilize stitching, using an adhesive, stapling, pinning, or any other means that will connect the two parts to each other.
Strapping, as used herein, refers to off-the-shelf fire-resistant strapping used in construction and fabrication for holding, binding, and/or attaching, such as commonly available steel strapping.
Structural unit, as used herein, refers to such constructs as a wall, floor, ceiling, or the like and may be referred to as building units.
Tri-dimensional, as used herein, refers to either an expansion joint that has three intersecting extension joint spaces, such as a T-shaped expansion joint intersection or to a fire barrier that is functionally shaped to accommodate a T-shaped joint.

A List of the Reference Numbers and Related Parts of the Invention F Female coupling end.
M Male coupling end.
2 Intumescent strip material.
4 Caulk.
6 Protective cloth.
8 Fire resistant sheet, metal foil, for example, adhered to 6.
10 A straight-line fire barrier.
14 A first insulation blanket.
24 A second insulation blanket.
30a L-bracket.
30b L-bracket.
32a First leg of L-bracket 30a.
32b First leg of L-bracket 30b.
33a Second leg of L-bracket 30a.
33b Second leg of L-bracket 30b.
34 Third insulation blanket.
36 Attachment means for attaching fire barrier to building unit 90 through L-bracket 30.
40a Pin and friction-fit washer set providing for attachment of first insulation blanket 14 and second insulation blanket 24 to each other and to L-bracket 30a.
40b Pin and friction-fit washer set providing for attachment of first insulation blanket 14 and second insulation blanket 24 to each other and to L-bracket 30b.
44a Friction fit washer.
44b Friction fit washer.
45a Pin with friction-fit washer to provide means to detachably attach an installation tool to the fire barrier.
45b Pin with friction-fit washer to provide means to detachably attach an installation tool to the fire barrier.
46 Spacer.
48 Friction fit washer.
50a Pin with friction-fit washer providing for attachment of third insulation blanket 34 to L-bracket 30a.
50b Pin with friction-fit washer providing for attachment of third insulation blanket 34 to L-bracket 30b.
52a Friction fit washer.
52b Friction fit washer.
53a Friction fit washer.
70 A horizontal/vertical multi-directional corner fire bairier with male and female coupling ends.
72 Metal channel.
73 Pins 75 A straight line fire barrier with male and female type coupling ends.
90 A generic building unit.
90a First building unit.
90b Second building unit.
100 Installation tool.
102 Tool grasping means.
DETAILED DESCRIPTION
Referring now to the drawings which show views of exemplary versions of the barriers and their related installation tools contemplated by this invention.
The drawings also illustrate how the above discussed disadvantages have been overcome. It should be noted that the disclosed invention is disposed to versions in various sizes, such as lengths, widths, depths, in addition to variation in shapes, contents, layers, materials, and attachment means. Therefore, the versions described herein are provided with the understanding that the present disclosure is intended as illustrative and is not intended to limit the invention to the versions described.
FIG. la, a cross-sectional, diagrammatic view of a preferred embodiment of the present invention, illustrates, in particular, the structural components of a straight-line fire barrier. This multiple layered barrier comprises protective cloth 6 forming the bottom layer of the barrier. Resting upon and attached to the upper surface of protective cloth 6 is flexible stainless steel sheet 8 upon which and attached to is first insulation blanket 14.
Resting on the upper surface of and attached to blanket 14 is second insulation blanket 24.
Pin 40a and friction-fit washer 42a provide for attachment of a first end of protective cloth 6, flexible stainless steel sheet 8, first insulation blanket 14 and a first end of second insulation blanket 24 to each other and to second leg 33a of L-bracket 30a.
Pin 40b and friction-fit washer 42b provide for attachment of a second end of protective cloth 6, flexible stainless steel sheet 8, first insulation blanket 14 and a second end of second insulation blanket 24 to each other and to second leg 33b of L-bracket 30b.
Pin 50a and friction-fit washer 52a provide for attachment of a first end of third insulation blanket 34 to second leg 33a of L-bracket 30a. Pin 50b and friction-fit washer 52b provide for attachment of a second end of first insulation blanket 34 to second leg 33b of L-bracket 30b. Working together, the attachment set made up of pin 40a and friction-fit washer 42a and the attachment set made up of pin 50a and friction-fit washer 52a provide for attachment of all of the layers to each other and to the L-bracket 30a.
Similarly the attachment set made up of pin 40b and friction-fit washer 42b and the attachment set made up of pin 50b and friction-fit washer 52b provide for attachment of all of the layers to each other and to L-bracket 30b. Attachment means 36 provides for attachment of first leg 32a of L-bracket 30a to building unit 90a. Another attachment means 36 provides for attachment of first leg 32b of L-bracket 30b to building unit 90b. Pin 45a is positioned so that a length of the pin protrudes through first leg 32a of L-bracket 30a to provide an attachment means for one side of an installation tool that is discussed below.
Pin 45b is positioned so that a length of the pin protrudes through first leg 32b of L-bracket 30b and is held secure to the L-bracket by attachment means 44a, which in this example is a friction fit washer, to provide an attachment means for another side of an installation tool that is discussed below.
FIG. lb-1 is a perspective view of a partial section of the straight-line fire barrier illustrated in FIG. la to more clearly illustrate how pins 40a and friction-fit washers 42a provide for securing the first layers to each other and attaching the first layers to L-bracket 30a. First fire barrier layer, in this example consists of an outer protective cloth 6 followed by flexible metallic sheet 8, first insulation blanket 14, and second insulation blanket 24. Pins 50a, positioned to protrude through and extend some distance from the surface of second leg 33a of L-bracket 30a, and friction-fit washers 52a provide means to attach third insulation blanket 24 to second leg 33a of L-bracket 30a (as shown in FIG.
lb-2). Pins 45a are positioned so that the pin part of the pin protrudes through and extends some distance from the outer surface of first leg 32a of L-bracket 30a providing means for attachment of an installation tool to them barrier for installation of the barrier into a joint space. FIG. lb-2, a side plan view of the partial section of the straight-line fire barrier, similar to that illustrated in FIG. lb-1, illustrates the addition of another layer of fire barrier material to the first two layers and the L-bracket of the example illustrated here. It should be understood that the number of fire barriers material use is not limited by this, or any other, example given herein. The number of layers required will be determined by many factors, such as the composition of the material and the width of expansion space into which the barrier is to be installed, to name just two.
FIG. lb-3 is a front plan view of the partial section of the straight-line fire barrier, as illustrated in FIG.
1b-1, illustrating one example of how the pin attachment means may be spaced.
Again, depending on such factors as the thickness of the various material sheets, the desired thickness of the barrier, and the composition of the barrier sheets, various other configurations of pins and washers, 53a and 50a may be utilized and various distances between the attachment means may be employed without departing from the scope of the invention.
FIG. lc, an exploded perspective view of a partial section of the L-bracket, more clearly illustrates an example of attachment means that are used to attach an installation tool to the L-bracket when the barrier is ready to install. Before the barrier is assembled and attached to the L-bracket, pin 45a is inserted through leg 32a of L-bracket 30a. The pin is held in place by friction fit washer 44a. When it is time to install pre-assembled fire barrier in an expansion space, aperture 62 of installation tool 60 is placed over pin 45a.
To secure the installation tool 60 to arm 32a of L-bracket 30a and to provide for easy removal of the tool from the fire barrier, spacer 46 is placed over pin 45a so that it rests on the outer surface of installation tool 60. Friction fit washer 48 is positioned over pin 45a to rest on spacer 46 to secure attachment of the tool to the barrier.
FIG. ld is a cross-sectional cartoon view of a straight-line fire barrier, to more clearly illustrate the female end and male end construction of a layered straight-line barrier. For the sake of clarity, no L-bracket is shown in this view.
Protective cloth 6 forms the bottom sheet of the barrier. Resting on the upper surface of protective cloth 6 is fire resistant sheet 8, which is illustrated as a flexible stainless steel foil, but could be any desired fire resistant supporting material. In this example, fire resistant sheet 8 is attached to the upper surface of protective cloth 6 using adhesive. The method of attachment is dictated by the needs of the user of the fire barriers. In addition to adhesive, the fire resistant sheet may be attached to the protective by sewing, stapling, bolting, or any other known or yet to be known means for attaching the two sheets. Alternatively, if desired, the two sheets do not have to be attached before installation. The next layer, resting on steel sheet 8, is formed of first insulation blanket 14. Resting on the upper surface of blanket 14 in an offset manner is second insulation blanket 24. The offset positioning of blanket 24 over blanket 14 provides for the barrier to have a female, receiving end F and a male projecting end M. Between first insulation blanket 14 and second insulation blanket 24 caulking 4 may be applied for extra secure attachment of the two blankets to each other. Caulking 4 may also be used between insulation blanket 24 and insulation blanket 34. On the exposed surface of the overlapped male end M of blanket 24 and extending to a desired length between blanket 24 and blanket 14 is a sheet of metal foi18.
Attached to the exposed part of this sheet of metal foil 8 is a layer of protective cloth 6 with its boarders lined with intumescent strips 2. In the embodiment illustrated, the intumescent strip is attached to protective cloth 6 using staples, it is, however, to be understood that stapling is not a required attachment means, as the attachment is just as well accomplished using pins, caulking, sewing or any other known or yet to be know means for attaching two such sheets. During installation the male end of one straight-line section is simply and quickly interdigitated with the female end of a second straight-line section providing for overlapping connections that require no on-site splicing operations. Caulking is used to secure the attachment of the male and female ends, although any other means for securing the attachment, such as adhesive or staples, among others may be used, if desired.
FIG. 2a, a schematic, top plan view, illustrates how straight-line sections having male/female type coupling end structures interdigitate with multi-directional corner fire barriers having mating male/female type coupling structures. It should be noted that in FIG. 2a the coupling is shown to be accomplished sideways to how the coupling is in reality. This is done so that the coupling method for an entire room may be understood.
Thus, looking at FIG. 2a it is easy to understand how easily and rapidly a fire barrier system of the present invention may be installed about the entire perimeter of a room, including floor to wall, wall to wall, and wall to ceiling expansion joint spaces without requiring any on-site construction or trimming. This significantly reduces the time required for installation and the person power required for installation, thus reducing the cost of the fire barrier protection part of the job, while simultaneously decreasing the risk to workers by decreasing, if not eliminating, respirable particles in the working atmosphere and reducing the danger to workers of being cut by the sharp edged metal foil that is frequently used in the construction of the fire barriers. Thus, as protection is increased by the pre-assembled, one piece barriers and their over-lapping coupling ends, the cost of fire hazard insurance should be reduced as should worker's compensation insurance.
FIG. 2b, a perspective view, illustrates an L-shaped, 90 degree horizontal/vertical multi-directional corner fire barrier with one male M and one female F
coupling end. This barrier, as are all the barriers, is provided to the job site as a pre-assembled, one-piece unit ready for one-step drop-in installation. The drawing shown is FIG. 2b demonstrates how this particular barrier, and, in fact, how any corner barrier having two coupling ends, is constructed with a male end and a female end for interdigitization of, in this case, a corner barrier with a straight-line barrier. The male coupling end, as illustrated in FIG. 2b, is to be interdigitated with the female coupling end of the straight line fire barrier illustrated in FIG. 2c. Alternatively, the female coupling end, as illustrated in FIG. 2b, is interdigitated with the male coupling end of the straight line fire barrier illustrated in FIG. 2c. Of course, if desired, all styles of the two coupling ended barriers may be provided with both ends as male coupling ends or both ends as female coupling ends. Similarly, corner fire barriers that have more than two coupling ends, such as T-shaped and cross-shaped barriers may be provided with all female, all male, or a variety of female and male ends.
In the example illustrated in FIG. 2b, only protective cloth 6 with attached intumescent stripping 2, fire resistant metal channel 72, and pins 73 that provide means for attaching the barrier layers to each other are shown.
FIG. 2c, a perspective view, illustrates straight line fire barrier 75 provided with a male coupling end and a female coupling end, one of which may be used for interdigitation with the female or male coupling end, respectively, of the horizontal/vertical multi-directional corner fire barrier illustrated in FIG.
2b.
FIG. 3 shows an exemplary straight line fire barrier 10 with installation tool detachably attachment to it. The tool's frame, as shown, is constructed of a first set of two elongate strips of some sturdy and light-weight material, such as aluminum or plastic, oriented in the same direction and arranged parallel to and spaced from one another, and a second set of two elongate strips oriented in the same direction and arranged parallel to and spaced from one another. The first set of strips is positioned over the second set and the two sets are attached to each other, so that the two sets form a construct similar to a number sign "#" but where the angles between all crossing strips are all right angles. The lower set of strips has means for being detachably attached to the fire barrier, as is explained in more detail above. The upper set of strips has a grasping means, such as a handle for easy lifting of the tool and the barrier to which it is connected.
FIG. 3 shows how the installation tool just described provides for easy one-step, drop-in installation of a ten foot section of the straight-line fire barrier, even for two women who are not typical members of a construction crew.
The above description of the tool's structure may vary considerably without departing from the spirit of the invention, which to provide for a tool that provides for easy, one-step, lifting and installing of a fire barrier. The tool may be piece constructed or may be molded. There are as many tool styles as there are differently shaped fire barriers, so that the tool fits over each of variously shaped barriers, such as the T-shaped installation tool that is shaped for installing a T-shaped multi-dimensional fire barrier.
Thus it has been shown that the present invention comprises male and female ended multi-directional and straight line fire barriers for easy and rapid interdigitated coupling of the straight-line barriers with straight-line barriers, straight-line barriers with multi-directional barriers, and multi-directional barriers with multi-directional barriers providing rapid, safe installation of the barriers while requiring no on-site cutting or construction; that all of the variously styled barriers are constructed as pre-assembled single-piece male/female coupling ended units for use in multi-directional and straight architectural expansion joint spaces to prevent the migration of gases, flame, and smoke through a structure; and that each style barrier is provided with a one-step, one-person, drop-in, reusable, width adjustable installation tool.

Claims (20)

CLAIMS:
1. An interdigitatingly coupling-ended fire barrier for use in architectural expansion joint spaces, comprising:
a pre-assembled interdigitatingly coupling-ended fire barrier having at least one coupling end shaped to interdigitatingly receive a mating coupling end of another like fire barrier or having at least one coupling end shaped for interditgitatal insertion into a receiving mating coupling end of another like fire barrier providing for drop-in installation of said fire barriers in architectural expansion joint spaces.
2. The fire barrier, as recited in Claim 1, for use in architectural expansion joints, further comprising:
said pre-assembled fire barrier having at least one male interdigitatingly coupling end for receiving at least one female interdigitatingly coupling end of another fire barrier.
3. The fire barrier, as recited in Claim 2, for use in architectural expansion joints, further comprising:
said pre-assembled fire barrier having at least one female interdigitatingly coupling end for receiving at least one male interdigitatingly coupling end of another fire barrier.
4. The fire barrier, as recited in Claim 1, further comprising two male interdigitatingly coupling ends each for receiving a female interdigitatingly coupling end of another like-ended fire barrier.
5. The fire barrier, as recited in Claim 1, further comprising two female interdigitatingly coupling ends each for receiving a male interdigitatingly coupling end of another like-ended fire barrier.
6. The fire barrier, as recited in Claim 1, further comprising:
at least one layer of fire resistant barrier material attached to at least one fire-resistant mechanical attachment means providing for attachment of said fire barrier to structural building units forming said architectural expansion joint spaces.
7. The fire barrier, as recited in Claim 6, further comprising attachment means for detachably attaching an installation tool.
8. The fire barrier, as recited in Claim 1, further wherein said pre-assembled interdigitatingly coupling-ended fire barrier is a straight-line fire barrier shaped for use in straight line architectural expansion joints.
9. The fire barrier, as recited in Claim 1, further wherein said pre-assembled interdigitatingly coupling-ended fire barrier is a multi-directional fire barrier shaped for use in multi-directional architectural expansion joint spaces formed by the intersection of a plurality of architectural expansion joint spaces.
10. The fire barrier, as recited in Claim 6, further comprising:
at least one layer of protective cloth.
11. The fire barrier, as recited in Claim 10, further comprising:
at least one layer of protective cloth, and at least one layer of flexible stainless steel sheet, said one layer of flexible stainless steel sheet resting upon an upper surface of said protective cloth.
12. The fire barrier, as recited in Claim 11, further comprising:
at least one layer of a protective cloth, at least one layer of flexible stainless steel sheet, said one layer of flexible stainless steel sheet supported on an upper surface of said protective cloth, and at least a first insulation blanket layer supported on an upper surface of said layer of flexible stainless steel sheet.
13. The fire barrier, as recited in Claim 12, further comprising:
at least one layer of a protective cloth, at least one layer of flexible stainless steel sheet, said one layer of flexible stainless steel sheet supported on an upper surface of said protective cloth, at least a first insulation blanket layer supported on a upper surface of said layer of flexible stainless steel sheet, and at least a second insulation blanket layer supported on an upper surface of said first insulation blanket layer.
14. The fire barrier, as recited in Claim 13, further comprising:
at least one layer of a protective cloth, at least one layer of flexible stainless steel sheet, said one layer of flexible stainless steel sheet supported on an upper surface of said protective cloth, at least a first insulation blanket layer supported on a upper surface of said layer of flexible stainless steel sheet, and at least a second insulation blanket layer supported on a upper surface of said first insulation blanket layer, where attachment means provide for attachment of said fire barrier layers to each other and to structural building units.
15. The fire barrier, as recited in Claim 14, further comprising:
at least one layer of a protective cloth, at least one layer of flexible stainless steel sheet, said one layer of flexible stainless steel sheet supported on an upper surface of said protective cloth, at least a first insulation blanket layer supported on a upper surface of said layer of flexible stainless steel sheet, at least a second insulation blanket layer supported on a upper surface of said first insulation blanket layer, where attachment means provide for attachment of said fire barrier layers to each other and to structural building units, and attachment means attached to the barrier layers providing for detachable attachment of the fire barrier to an installation tool.
16. Fire barrier systems, comprising:
a fire barrier system including, prefabricated, drop-in, interdigitating, multi-directional fire barriers for use in multi-directional architectural expansion joint spaces formed by the intersection of a plurality of architectural expansion joint spaces having male and female interdigitating coupling ends for coupling to other like interdigitating fire barriers.
17. The fire barrier systems, as recited in Claim 16, further comprising:
a fire barrier system including, prefabricated, drop-in, interdigitating, multi-directional fire barriers for use in multi-directional architectural expansion joint spaces formed by the intersection of a plurality of architectural expansion joint spaces having male and female interdigitating coupling ends for coupling to other like interdigitating fire barriers, and prefabricated, drop-in, interdigitating, straight line fire barriers having male and female coupling ends for coupling to other like interdigitating fire barriers,
18. The fire barrier systems, as recited in Claim 17, further comprising:
a fire barrier system including, prefabricated, drop-in, interdigitating, multi-directional fire barriers having male and female interdigitating coupling ends for coupling to other like interdigitating fire barriers, prefabricated, drop-in, interdigitating, straight line fire barriers having male and female coupling ends for coupling to other like interdigitating fire barriers, lifting installation tools for installing said multi-directional fire barriers and said straight line fire barriers.
19. The fire barrier systems, as recited in Claim 18, further comprising:
a fire barrier system including, prefabricated, drop-in, interdigitating, multi-directional fire barriers for use in intersecting expansion joint spaces having male and female interdigitating coupling ends for coupling to other like interdigitating fire barriers, prefabricated, drop-in, interdigitating, straight line fire barriers for use in straight-line expansion joint spaces having male and female coupling ends for coupling to other like interdigitating fire barriers, lifting installation tools for installing said multi-directional fire barriers and said straight line fire barriers.
20. A pre-assembled interdigitatingly coupling-ended horizontal/vertical L-shaped fire barrier for use in horizontal/vertical intersecting architectural expansion joint spaces, comprising:
a pre-assembled interdigitatingly coupling-ended horizontal/vertical L-shaped fire barrier for use in horizontal/vertical intersecting architectural expansion joint spaces having at least one coupling end shaped for interdigitatingly receiving a mating coupling end of another like coupling fire barrier or having at least one coupling end shaped for interdigitatingly insertion into a receiving mating coupling end of another like coupling fire barrier providing for drop-in installation of said L-shaped fire barriers into architectural expansion joint spaces, said L-shaped fire barrier comprising a first fire barrier L-leg and a second fire barrier L-leg, said first fire barrier L-leg a contiguous part of and positioned approximately 90 degrees to second fire barrier L-leg providing for a one piece corner L-shaped interdigitatingly coupling-ended fire barrier.
CA2640007A 2007-09-28 2008-09-29 Pre-assembled fire barrier systems having male and female interdigitating coupling ends providing for one-step drop-in installation of the barriers into straight-line and intersecting expansion joints Active CA2640007C (en)

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