MOISTURE IMPERMEABLE FIRE-BARRIERS

Abstract

A preferred example of a pre-assembled, moisture, water, and gas impermeable fire-barrier system for use in expansion-joint spaces includes a fire-barrier having a first multi-layer of outermost protective cloth layer overlain by an insulation blanket overlain by stainless steel foil, a second multi-layer, overlaying and fixedly attached to the first multi-layer, containing an insulation blanket, overlain by a limited layer of intumescent material, overlain by impermeable silicon cloth to completely or partially surround the barrier, and a first attachment apparatus for attaching a first long edge of the fire-barrier to a building unit and a second attachment apparatus for attaching the opposing second long edge to an opposing spaced building unit, which attachment apparatus may be fixedly attached to the barrier, and where the barrier system may be fitted with a drain aperture and a drainage hose emanating from the aperture, the hose protected from the heat of a fire.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This Continuation-in-Part application claims benefit to Non-Provisional Patent application Ser. No. 12/185,160 filed Aug. 4, 2008 and to Provisional Application No. 60/953,703 filed Aug. 3, 2007.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

The present invention relates generally to fire-barriers and more particularly to moisture impermeable fire-barriers.

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.

Modern building codes require that stresses experienced by buildings from 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, for example, must be taken into account in the building design. To accommodate these stresses, buildings must be constructed with a code-mandated space between adjacent wall, floor, and/or ceiling structures. These spaces, referred to as “expansion-joint spaces,” allow differential building motions to take place without risking damage to the whole structure.

While expansion-joint spaces improve the life-time integrity of the structure, they also present a major fire risk to the structure. During a fire, the mandated expansion-joint spaces serve as chimney flues providing pathways for gases, flame, and smoke to spread rapidly throughout a structure. To counter the chimney flue effect, building codes for commercial and public structures require the installation of fire-barriers in the expansion-joint spaces. The fire-barriers are supposed to prevent or to reduce the rate of flames and smoke passing through the joints into adjoining areas of the building to extend the time available for inhabitants to leave the building and for fire fighters to get to the fire.

During their lifetime however, fire-barriers undergo various types of structural stress. For example, each time a structure is subjected to movement, whether from earthquake activity, ground settling, wind, or temperature contraction or expansion, the fire-barriers installed in the expansion-joint spaces are subject to the forces of expansion and compression in a variety of directions. The ability of fire-barriers to maintain their integrity, after or while being stressed, is of course put to the ultimate test during a fire. When fire-barriers fail, loss of both life and property can be the result. This makes it essential that the fire-barriers are designed and manufactured to retain their integrity during their entire lifetime. Accordingly, fire-barriers are legally mandated to be tested, rated, and certified before being installed. 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. Fire-barriers that are sold as tested are assumed to be able to perform to the parameters tested.

The importance of correctly installing and maintaining tested and certified fire-barriers is increasingly recognized by building officials, owners, insurance companies, contractors, and the public. Once a fire-barrier passes any of the tests described above, the testing certification will hold only as long as the barrier remains unaltered. Thus, fire-barriers always should be manufactured exactly according to their testing certification requirements, in a testing agency approved facility, and by a testing agency approved method. Once manufactured according to testing agency requirement, the barriers are ready for installation as they are. That is, they should not be altered. The mission of the international nonprofit National Fire Protection Agency (NFPA) is to reduce, worldwide, the burden of fire and other hazards on the quality of life by providing and advocating consensus codes and standards. See, for example, the 2009 edition of NFPA 221: Standard for High Challenge Fire Walls, Fire Walls, and Fire-barrier Walls).

The International Building Code now mandates sprinkler systems in public buildings such as malls, entertainment areas, and stadiums, high rises, medical facilities, jails, and airplane hangers. Additionally, sprinklers are becoming required in schools and even in private homes. In states that do not have separate requirements for sprinklers in schools, laws or fire codes that require them in buildings above a certain seize or height would apply to schools that have these characteristics. Further, many states have adopted the NFPA Life Safety Code, which requires fire sprinklers in basements of all new schools and, with exceptions, in basements of existing schools. Also, in some states, it is the local jurisdiction or school district, rather than state law that determines sprinkler requirements. Thus, although there may be no statewide requirement, there may be local requirements. In addition to developing standards for fire-barriers, NFPA has also developed NFPA 13: Standard for the Installation of Sprinkler Systems. Current Edition is 2010; Next Edition will be 2013. NFPA13. The requirements to install a sprinkler system complying with NFPA 13 can usually be found in one of the following sources: building code; federal, state or local regulations; insurer's requirements; accreditation requirements; or owner's request.

SUMMARY

At the heart of the present invention is the inventor's realization that many, if not most or all, currently installed fire-barriers, even those with mandated covers, are at risk of coming into contact with various forms of moisture. This is of utmost importance because recently it was recognized that when moisture comes into contact with a barrier, the barrier likely will be weakened to the point of having the effectiveness of the barrier irrevocably destroyed. Thus, fire regulations now require a moisture impermeable cover to be placed over the barrier, to protect it from damage due to water or other fluids or chemicals.

Even though a barrier cover plate and a fire-barrier are correctly installed into an expansion joint space, the present inventor realized that it is difficult if not impossible, to prevent moisture from reaching barriers. For example, fire-barriers, especially those installed between adjacent floor units, are subjected to daily stress from exposure to moisture, especially from water and cleaning chemicals used for floor washing that can leak through the smallest of openings even when a boot has been installed. Heavy rain combined with strong wind can provide for water to permeate even very small openings in the sides of buildings, causing wetting of the sides and bottoms of barriers. Water escaping from planters, especially from built-in planter units can reach barriers. The Inventor realized that water from repeated condensation events can impair or destroy the effectiveness of a barrier. In some instances, sections of, if not an entire structure, are open to the outdoors, where rain and melted snow can collect on the floors. Public facilities, such as open stadiums are regularly subjected to the effects of rain and snow. Fire-barrier failure in any of these facilities is likely to result in unnecessary hazard to life and to the facility. And now that life-saving sprinkler systems are becoming more and more required, fire-barriers are subject to water damage from fire sprinkler water that is released during isolated fire events. Such water can wet nearby barriers from the top, bottom, or side depending of the relationship of the barrier to the water emanating from the sprinklers. As mentioned above, repeated exposure to moisture results in deterioration of the barrier.

Furthermore, the presence of the cover presents a problem. The protective moisture impermeable fire-barrier covers (referred to in the industry as “boots”) are usually about 4 inches thick. However, currently manufactured building units are frequently constructed from pre-cast concrete slabs that are only 4½ inches thick, leaving only ½ inch of space for the installation of a fire-barrier into expansion spaces between floor units. Moreover, it is imperative that the boot does not protrude above the floor surface, as it would not only create a tripping hazard, it would additionally expose itself to damage. If the boots are damaged by, for example, machines that are used to wash, maintain, or repair a floor, it is likely that moisture will reach the barriers. Thus, the thickness of presently available boots required to protect presently vulnerable fire-barriers and the minimal thickness of the pre-cast floor sections act to eliminate both top and side-mounting of fire-barrier into floor joint spaces.

Additionally, the weight of water collecting on the surface of a barrier creates added weight stress on the barrier and on the means used to attach the barrier to the building structures, in addition to weakening the barrier from, for example, the growth of mold and mildew on the damp materials. Often, one or more of the multiple layers of materials in a typical fire-barrier is a metal layer adding to the weight of each barrier. Because of their weight, fire-barriers are often secured to building units using heavy duty screws, bolts, tacks, and the like. The required number of these attachments means is presently calculated considering the strength of the attachment means, the strength of the barrier material, and the weight of the barrier. The increase in a barrier's weight due to the presence of moisture or water greatly increases its weight, thus, compromises the integrity of the attachments and of the barrier. Failed barriers, regardless of the reason for the failure, pose life-threatening consequences.

Accordingly, the inventor conceived and developed a set of principles to result in the manufacture of fire-barriers that are, and will remain, safe from the detrimental effects of moisture and water for the life of the barrier. These principles provide for fire-barriers that are both gas and water impermeable. The impermeability properties of the barriers are manufactured according to the need. Barriers that are situated so that water can reach only the top surface are manufactured to have a completely impermeable top surface. Alternatively, the barriers made according to the principles of the present invention, can be manufactured to be water impermeable on the top and sides or on the top, sides, and bottom. If desired, of course any combination of sides, top, and bottom can be manufactured with water impermeable surfaces. Furthermore, the principles taught herein provide for a full-complement of fire-barriers to be manufactured to be water impermeable. The series of barriers having impermeable surfaces include barriers variously shaped and sized to fit into straight-line expansion spaces, as well as barriers shaped and sized to fit into multidimensional/multidirectional expansion spaces created by the intersection of a plurality of expansions spaces of a different orientation, direction, or plane, or any combination there of. The barriers taught herein are built according to their tested and certified requirements, in a testing agency approved facility, and using a testing agency approved method, ready for drop-in, one-step installation upon delivery to the site, without any alterations being required. Because these barriers are fully water, moisture, and gas impermeable, as discussed above, they may be installed over, within, or under the desired building units that bound the spaces. That is, the method of installation is not limited as it is when boots are required. The barriers are constructed so that they remain impermeable even when supporting water puddling on their surface regardless of the amount of water or the length of time in contact with the water. These barriers are designed, constructed, and installed with the weight of any standing water taken into consideration when planning their support means. With this safeguard in place, the impermeable barriers can use the weight as an added safeguard in keeping the barrier fitting snugly against the building units to which they may be attached.

Alternatively, if desired, the water, moisture, and gas impermeable barriers may be fitted with a drain and a drainage hose providing for drainage of any water that does collect within the barrier, especially for when the barriers are to be used in floor to floor or floor to ceiling expansion-joint spaces, or any other joint spaces that frequently could be a likely repository for water and/or other liquids. The drainage tube is constructed so the when there is a fire the drainage opening is automatically plugged. The heat of the fire destroys the tube but at the same time melts the tube material so that it functionally plugs the drain opening.

One fire-barrier of the present invention is shaped and sized as required for installation into floor to floor expansion-joint spaces of an open-air baseball stadium, where the floors are heavily trod and frequently exposed to rain, melting snow and ice, and salty water. In this instance, the barrier would be bottom mounted to provide ample room for the inset installation of a cover to avoid any tripping hazards and so that the barrier's mounting hardware is not exposed to the elements. Such a barrier could also be fitted with drainage hoses to prevent the build-up of any fluid if that were to be desired. The prefabricated fire-barriers of the present invention are produced in various lengths as desired. However, because of the weight of the barriers and the difficulty in handling very long barriers, the length of the barriers is usually limited to, for example, 10 feet. Moreover, if the weight of the barrier dictates, a barrier is often manufacture to be four feet long. Therefore, when the expansion joint space is longer than that the manufactured barriers, two or more barriers must be installed end to end to accommodate the length of the joint space. The barriers of the present invention are pre-assembled and delivered to the site ready for one-step, easy, rapid installation by one or at most two installers. The barriers, either partially or completely encapsulated by an impermeable layer of material, are pre-assembled to have male and female butt-end connections that prevent any possible leaking from end to end seams. For seams made up of butt-end to butt-end connections, a butt-cover is available to ensure that there is no leakage of any collected fluids except through the drainage system. The seam-butt cover also ensures that there in no penetration of smoke or fire into the barrier from below the barrier.

Using silicone cloth to partially or totally encapsulating a barrier, is one example of how to make the barrier totally moisture impermeable. It should be understood that all fire-barriers must both be made to be gas and flame impermeability and to be able to maintain their gas and flame impermeability in order to be a fully-functional fire-barrier. The materials used to construct each barrier are fire resistant to degrees defined by the tests that the barriers are required to pass before they can be used. These materials are of exceptional strength and are firmly and sturdily attached to the attachment frame which is used in conjunction with the fire-barrier materials to attach the barrier to building units.

Fire-barriers that present all of the above benefits are described more fully below.

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. 1a is a diagrammatic cross-section and partially perspective view of a straight-line top-mount moisture and gas impermeable fire-barrier having a self-draining system according to the principles of the present invention installed into a floor expansion-joint.

FIG. 1b is a diagrammatic perspective side-view of the moisture impermeable fire-barrier with a self-draining system, as shown in FIG. 1a.

FIG. 2a is a diagrammatic perspective view of a straight-line top-mount fire-barrier totally encased within a moisture and gas impermeable membrane and also having a self-draining system according to the principles of the present invention ready for installation into a floor expansion-joint.

FIG. 2b is a diagrammatic perspective side-view of the moisture impermeable fire-barrier shown in FIG. 2a.

FIG. 3 is a diagrammatic perspective view of a straight-line bottom-mount fire-barrier totally encased within a moisture and gas impermeable membrane according to the principles of the present invention ready for installation.

FIG. 3a is a partial diagrammatic perspective view of parts of two bottom-mount straight-line fire-barriers of the present invention butt joined with a butt cover about to be installed over the join providing added protection to the join from moisture leaking through and to assure that no fire, heat, or smoke can enter the barrier from fire activity below the barrier.

FIG. 3b is a diagrammatic perspective view of partial sections of two straight-line fire-barrier sections having male/female connection means.

FIG. 4 is a cross-sectional view of a bottom-mount moisture impermeable fire-barrier of the present invention installed in an expansion-joint using a retainer system and illustrating the self-draining system.

FIG. 5 is a diagrammatic perspective view of a multi-dimensional-fire-barrier structure having only female connecting ends mounted into an L-shaped expansion joint created by the intersection of a wall expansion joint with a floor expansion joint.

FIG. 6 is a photograph showing the experimental results of a straight-line bottom-mount moisture and gas impermeable fire-barrier of the present invention filled with water illustrating the water impermeability of the barrier and a plugged optional drain hose.

FIG. 7 is another photograph showing the experimental results of a straight-line bottom-mount moisture and gas impermeable fire-barrier of the present invention filled with water illustrating the water impermeability of the barrier and a plugged drain aperture on the inner surface of the barrier.

FIG. 8a is a diagrammatic perspective view of a straight-line fire-barrier of the present invention being bottom-mounted between two spaced floor units using the installation tool specific for this barrier and this installation.

FIG. 8b is an elevation view of the barrier and installation tool as illustrated in FIG. 8a

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.
• Cover, as used herein, means to protect and/or conceal.
• Cover up, as used herein, means to cover completely, enfold for protection and concealment.
• Encase, as used herein, means to surround entirely.
• Enclose, as used herein, means to shut in; to enclose in on all sides, as to surround.
• Envelope, as used herein, means to enclose.
• Wrap, as used herein, means to wind, fold, or bind around an object as to cover it for protection.
• 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.
• Impermeable membrane, as used herein, refers to a material that does not allow the passage of a fluid, such as water, other liquids, and/or gases. The impermeable material disclosed herein includes a flexible, fluid-impermeable, sealing layer that is used for waterproofing by applying one or more layers of the membrane material onto a surface and/or object to be protected. Such impermeable blanket layers are made of a variety of materials, such as, but not limited to, silicone, fiberglass fabric coated with silicone rubber, coal tar, bitumen and synthetic polymers that are formed as sheet-like substances of desired sealing properties. Material and substance properties of impermeable membranes used herein meet the requirements of any particular structure, building, authority, climate, chemical and physical environment, required durability, cost effectiveness and the like. It should be noted that impermeable membranes come as moisture impermeable and moisture and vapor impermeable, depending on properties of the material, such as its porosity. If desired, a moisture but not vapor impermeable membrane is contemplated for use by the present invention.
• 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. The intumescent occurs in many forms and may be, for example an intumescent layer, strip, or paste, such as a caulking material.
• 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.
• Metallic backing 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 two or more structural units, such as the convergence of three wall units or two walls and a floor unit. These intersection joint spaces create passages between building units that 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 spaces that are formed by the intersection of variously oriented expansion-joint spaces, such as when a floor expansion-joint space intersects a wall 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.
• Retainer, as used herein, refers to a means used to attach fire-barriers to building units. For example one top-mount system uses “L” brackets that are first attached to the barrier and then attached to a building unit. Similar brackets are used for mounting bottom-mount and side-mount systems.
• Seaming, as used herein, refers to connecting one part to another part, for example where a cloth is folded and the two parts of the cloth that have been brought together by the folding are subsequently “seamed” together along a predetermined line. The seaming may utilize stitching, using an adhesive, stapling, pinning, or any other means that will connect the two parts to each other.
• Structural unit, as used herein, refers to such building unit constructs as a wall, floor, ceiling, or the like and may be referred to as building units. These units are often pre-constructed concrete, or of a like material, slabs or panels and can be about 4 inches thick which poses a challenge for the installation of a fire-barrier and the, recently, mandated rubber protective boot.
• Tri-dimensional, as used herein, refers to either an expansion-joint that has three member body parts, such as a T-shaped expansion-joint where the T-joint is made up of three co-joint-arms or to a fire-barrier that is functionally shaped to accommodate a T-shaped joint.

Tests:

• Fire testing per UL 20 79
• Cycle test ASTME 1399 (expansion, compression test)

A List of the Reference Numbers and Related Parts of the Invention

• 10 Fluid and moisture impermeable fire-barrier.
• 11 Attachment means for securing the barrier's layers together.
• 12 Impermeable membrane, such as waterproof Silicon Cloth.
• 14 Insulation blanket.
• 15 Intumescent strip material.
• 16 Attachment means, such as pins and washers.
• 17 Metal foil.
• 18 Protective cloth.
• 19 Attachment means.
• 20 Drain system.
• 21 Inner aperture.
• 22 Impermeable caulk material.
• 23 Outer aperture.
• 24 Plastic tubing.
• 26 Impermeable fire-resistant caulk material.
• 28 Flexible metal fire-resistant tubing.
• 29 Attachment means, such as washers and nuts.
• 30 Fluid.
• 32 One fire-barrier section impermeable to fluid and moisture.
• 34 Another fire-barrier section impermeable to fluid and moisture.
• 40 Folds.
• 44 Retainer.
• 46 Optional tool holding part.
• 50 Intumescent caulking.
• 60 A join or butt between two fluid and moisture impermeable fire-barriers.
• 70 A butt or splice cover connector.
• 80 Fluid catchment means.
• 90 A building unit.
• 94 Nails.
• 100 A moisture impermeable fire-barrier installed into a floor/wall expansion space join.
• 200 Male connection end.
• 202 Female connection end.
• 300 Test tank.
• 350 Installation tool.
• 302 Base plate.
• 304 Track.
• 306 Vertical rail.
• 308 Horizontal sliding plate.
• 310 Roller assembly.
• 312 Holding bracket.

DETAILED DESCRIPTION

To provide an understanding of the basic structure of the moisture and gas impermeable barriers contemplated herein, we now refer to the drawings to illustrate exemplary versions of the invention. It should be noted that the disclosed invention is disposed to versions in various sizes, such as shapes, lengths, widths, and thicknesses, as well as to the one or many the multi-directional, multi-dimensional body sections to accommodate the large variety of expansion-joint spaces that require fire-barriers, in addition to variation in shapes, contents, number and composition of 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. 1a is a cross-sectional diagrammatic view of a straight-line top-mount moisture-impermeable fire-barrier of the present invention installed in an expansion-joint space of a given width formed by opposing building units 90. It is to be understood that the invention is available is multi-directional fire-barrier systems, as well as in straight-line versions. In this example, gas, fluid, and moisture impermeable fire-barrier 10 includes an outer multi-layer and an inner-multi-layer of fire-barrier materials. The outer multi-layer of the fire-barrier, as illustrated, comprises outermost protective cloth 18, such as fire-resistant fiberglass material, overlain by a layer of insulation blanket 14, which is overlain by a sheet of stainless steel foil 17. In this example, the inner-multi-layer of the moisture-impermeable fire-barrier comprises another layer of insulation blanket 14 overlain by a layer of impermeable material 12, an example of which is silicon cloth, where the top surface edges of the inner-multi-layer are overlaid by intumescent material (not shown). Also illustrated are attachment means 16, such as pins that are used to attach the barrier to a building unit. In this example, pins 11 attach the individual layers that make up fire-barrier 10 to each other.

It may be anticipated that in many cases, water will collect in an installed fire-barrier. For example, fire-barriers are routinely installed in floor to floor joint spaces. It is to be expected, especially in large public buildings, that the floors are regularly washed with copious amount of water and cleaning chemicals. The people who wash the floors are routine building cleaners who, one might expect, do not think about protecting such items as the completely hidden from their view fire-barriers beneath the floors. Any water and/or other liquid that is able to collect in the lowest area of the U-shaped, installed, moisture impermeable fire-barrier would irreparably damage the fire-barrier. According to the principles of the present invention, optional drain 20 provides drainage for any liquid that collects on the inner surface of the impermeable layer. Drain 20 is protected against leakage by an application of impermeable, fire resistant, caulk 22. Gravity provides the force that drains the water through the aperture on the surface of the impermeable layer at the lowest depression of the u-shaped fire-barrier into inner-opening 21 to and through plastic tubing 24 and outer aperture 23 that also is sealed against leakage by an application of impermeable fire-resistant caulk 26 to continue through the plastic tubing that extends out through the lower outer surface of the barrier. Because the tubing used in this example is plastic and would quickly be affected by heat from a fire, and perhaps from other environmental conditions, it is protected by an outer layer of flexible metal fire-resistant tubing 28. After passing through the length of the metal tubing, a length of the plastic tubing emanates out of metal fire-resistant tubing 28. Liquid 30 traveling through the tubing will eventually be collected by some kind of fluid catch means 80. Intumescent caulking 50 is inserted between the outer surface of plastic tubing 24 and the inner surface of metal tubing 28 near the end of tubing 24. In the event of a fire, intumescent caulking 50 will expand to provide a seal about the opening. Metal tubing 28 will force the expansion of intumescent caulking toward the plastic tubing which will cause the tubing to collapse upon itself and, thus, create a seal preventing any fire, hot air, gases, or smoke from getting through the barrier and spreading to other areas of the building.

FIG. 1b, a diagrammatic perspective side-view of a moisture impermeable fire-barrier, illustrates the positioning of drain system 20 in short section 32 of the fire-barrier equidistant from both open ends of the section of impermeable fire-barrier. The length of each impermeable fire-barrier section is, to some extent, dependent on the weight of the barrier, as well as the length of the joint space that requires a barrier. If the barrier is constructed with extra layers of material, for example to provide for a barrier having a higher fire-rating (i.e., in terms of hours the barrier can withstand the destructive forces of a full-scale fire), then the barrier will weigh more and might have to be designed to be shorter than a barrier rated for fewer hours and made of a reduced thickness.

FIG. 2a, a diagrammatic perspective view, illustrates straight-line top-mount, completely moisture-impermeable, totally encased in a water and vapor impermeable membrane, fire-barrier according to the principles of the present invention installed in an expansion-joint of a desired width formed by opposing building units 90. It is to be understood that this embodiment of the invention also is available is multi-directional fire-barrier systems, as well as in straight-line versions. In this example, gas, fluid, and moisture impermeable fire-barrier 10 includes impermeable outer layer 12 completely covering a multi-layer layer fire-barrier. Complete covering indicates that all sides, top, bottom, and ends of the fire-barrier are protected from moisture by an impermeable cover layer. The structure of the fire-barrier that is encased by impermeable membrane 12 can be described as having one layer of protective cloth 18, such as a fire-resistant fiberglass material that could be, for example, Z-600 cloth, overlain by a layer of insulation blanket 14, which is overlain by a sheet of stainless steel foil 17; over the steel foil is another layer of insulation blanket 14 forming the basic inner structure of the illustrated fire-barrier. Wrapped about the entire inner basic fire-barrier structure is a layer of gas and moisture impermeable material 12, an example of which is silicon cloth, where the top surface edges of the inner multi-layer are overlaid by intumescent material (not shown). The layers making up the barrier are attached to each other, and such attachment can be done in many ways. In some embodiments the layers may be sewn together. In other embodiments the layers are attached to each other using attachment means, for example, as pins and washers 11. The completely moisture impermeable fire-barrier is shown attached to building units 90, in this example, by the use of tack-weld pins 16. There are many attachment means that may be used to attach a fire-barrier to a building unit in addition to the means mentioned and all are contemplated for use with the present invention and include screw, bolts, nails or a fire-resistant adhesive. One favored embodiment uses a retainer attachment apparatus to attach a fire-barrier to the building structures that define the expansion-joint space. The retainer attachment is generally fixedly attached to the fire-barrier at the time of manufacture. For all specified joint space widths and depths, the fire-barriers are fully pre-assembled at the factory and are ready for on-site installation.

As explained above, any water and/or other liquid that is able to collect in the lowest area of the moisture impermeable fire-barrier would irreparably damage the fire-barrier. Optional drain 20 provides drainage for any liquid that collects on the inner surface of the impermeable layer and is protected against leakage by an application of impermeable, fire resistant, caulk 22. Any collected liquid drains through the aperture on the surface of the impermeable layer at the lowest depression of the u-shaped fire-barrier into inner-opening 21 to and through plastic tubing 24 and outer aperture 23 that also is sealed against leakage by an application of impermeable fire-resistant caulk 26 to continue through the plastic tubing that extends out through the lower outer surface of the barrier. Because the tubing used in this example is plastic and would quickly be affected by heat from a fire, and perhaps from other environmental conditions, it is protected by an outer layer of flexible metal fire-resistant tubing 28. After passing through the length of the metal tubing, a length of the plastic tubing emanates out of metal fire-resistant tubing 28. Liquid 30 traveling through the tubing will eventually be collected by some kind of fluid catch means 80. Intumescent caulking 50 is inserted between the outer surface of plastic tubing 24 and the inner surface of metal tubing 28 near the end of tubing 24. In the event of a fire, intumescent caulking 50 will expand to provide a seal about the opening. Metal tubing 28 will force the expansion of intumescent caulking toward the plastic tubing which will cause the tubing to collapse upon itself and, thus, create a seal.

FIG. 2b, a diagrammatic perspective side-view of a moisture impermeable fire-barrier, illustrates the positioning of drain system 20 in short section 32 of the fire-barrier equidistant from both open ends of the section of impermeable fire-barrier. The length of each impermeable fire-barrier section is, to some extent, dependent on the weight of the barrier, as well as the length of the joint space that requires a barrier.

FIG. 3, a perspective view, illustrates a bottom-mount, moisture impermeable fire-barrier of the present invention ready for installation in an expansion-joint. In this example, gas, fluid, and moisture impermeable fire-barrier 10 includes impermeable outer layer 12 completely covering a multi-layer layer fire-barrier, as was discussed above in relation to FIGS. 2a and 2b, which means that all sides, top, bottom, and ends of the fire-barrier are protected from moisture by an impermeable cover layer. The bottom-mount fire-barrier system provides for installing the fire-barrier/retainer unit either from above the floor through the expansion-joint space, from beneath the floor, or from both. In the illustrated embodiment, pins 11 securely attach the layers of the barrier each other, while attachment means 16 securely attach each long side of the fire-barrier to a metal retainer mounting bracket. Each retainer is situated above the flange extension of the fire-barrier layer and, in turn underlies the bottom surface of a building unit. Attaching the fairly rigid retainer to the flexible fire-barrier provides for the barrier to be held tightly against the bottom surface of the building unit providing for a tight and secure attachment. Folds 40 represent the fact that at each long of the impermeable silicon cloth is folded and tucked between the layers that make up the barrier. The barrier illustrated in FIG. 3 is constructed having male connection end 200 and female connection end 202 that each provide not only a simple one-step process of joining one barrier to another, but a join that ensures that no water, gas, hot air, or fire can pass through the barrier.

FIG. 3a, a diagrammatic perspective view, illustrates butt join 60 of two top-mount straight-line fire-barrier partial sections 32 and 34. Section 32 is illustrated as butting up against section 34 at join line 60. Butt cover 70 is secured over join line 60 with all exposed joins caulked. FIG. 3b, a diagrammatic perspective view, illustrates partial sections of two fire-barrier sections of the present invention being joined to each other using male 200 and female 203 connection structures.

FIG. 4, a perspective view, illustrates a bottom-mount, moisture impermeable fire-barrier of the present invention being installed in what could be a floor to floor formed expansion-joint space. The bottom-mount fire-barrier system provides for installing the fire-barrier/retainer unit either from above the floor through the expansion-joint space, from beneath the floor, or from both. In this illustrated embodiment, the fire-barrier is securely attached to metal retainer mounting bracket 44 by attachment means 19 whose size is exaggerated for ease of viewing. Attachment means 19 extends through the barrier to the leg of the retainer that is positioned against the bottom of building unit 90. Attachment means 19 may be any desired attachment means, such using a nail gun to insert nails 94. A nail gun or nailer is a type of tool used to drive fasteners into a material that is usually driven by electromagnetism, compressed air, or, for powder-actuated tools, a small explosive charge. One example of such a nail gun is a Hilti gun that inserts fasteners through the barrier/retainer into the pre-cast concrete floor in the present example. Note that by being mounted below the floor, there is adequate space in the expansion joint for a required rubber boot to be installed. It is contemplated that retainer 44 be manufactured as part of the structure of impermeable fire-barriers of the present invention whenever it is needed for, or whenever it will greatly ease, the installation of the barrier. Such cases would include very wide bottom mount installations and/or very heavy and/or bulky barriers. Similarly, there are cases for impermeable fire-barrier to be manufacture without a retainer. Such embodiments include smaller and/or top or side mounted barriers. As discussed, in this example, the elongate fire-barrier illustrated has a length with two opposing long sides, which provide the attachment areas for attaching the fire-barrier/retainer to building units, and a u-shaped drooping center or mid-section between. Note that there is a separate retainer structure 44 for each long side of the fire-barrier. Each retainer illustrated comprises four retainer arms or plates, thus has a four arm cross-sectional profile. There are two vertical retainer arms and two horizontal retainer arms. When installed, the downwardly extending part of the vertical arm of the retainer of the fire-barrier/retainer system is positioned to extend into the space between fire-barrier layers, while the vertical upwardly extending portion of the retainer arm is positioned against the sides of the building units that define the expansion joint space to provide a secure and close connection of the fire-barrier/retainer system to the building units by acting in concert with the other arms to keep the fire-barrier is a correct position tight against the building unit surfaces. One part of the horizontal retainer arm is situated between the flange extension of one fire-barrier layer and the bottom surface of the building unit. While attachment means 19 attaches the fire-barrier to the retainer arm, attachment means 94 attached the barrier/retainer system to building unit 90 to provide addition support for the fire-barrier and to support the function of the other arms. The other, in this case, shorter opposing part of the horizontal retainer arm extends into the joint space to cover the exposed end of the inner-most fire-barrier layer, as illustrated, and also to provide a lifting support for the installation tool, when the installation tool is to be used. Alternatively, optional support for installation tool 46 may be used to support the tool, so the tool in turn can support the barrier until the barrier is secured into place using, for example, attachment means 94. It is to be understood that there are many variations on the shape and size of a retainer. The arms could be of a variety of widths and lengths, and some arms could be eliminated. Note that in the illustration, one retainer arm of a first retainer is affixed between the layers of the first long side of the fire-barrier and one retainer arm of a second retainer is affixed between the layers of the opposing second long side of the fire-barrier to form the fire-barrier/retainer system for bottom mounting the system into an expansion joint space. Attaching the fairly rigid retainer to the flexible fire-barrier provides for the barrier to be held tightly against the bottom surface of the floor unit providing for a tight and secure attachment (as illustrated).

FIG. 5, a perspective view, illustrates one of the moisture impermeable fire-barriers being sized, styled, and used as a one-piece drop-in installation for a multi-dimensional, multi-directional body part fire-barrier in an L-shaped extension space formed by the intersection of a horizontal and vertical extension joint spaces. Note that this barrier is provided with two female connection ends to be used to connect to two male connection ends of two other barriers.

The moisture impermeability of the silicon cloth layer was tested by filling an installed fire-barrier having the silicon cloth layer with water. In this test water remained on the surface of the silicon layer for 120 days when the water finally evaporated. Photographs were taken to substantiate the test results and are shown in FIGS. 6 and 7. The water holding ability of the silicon cloth 12 is clearly shown. Each of the photographs is a picture of a two-layer, straight line, fire-barrier completed encapsulated by an impermeable layer of silicon cloth. Attachment to building units is simulated by the walls of experimental water holding support device 300. FIG. 6 shows the inner droop of “installed” barrier 14 filled with water 30 and drainage tube 24 hanging down from the bottom of the barrier. For the experiment, the drainage aperture was closed to show how water impermeable and how strong these fire-barriers are. FIG. 7 also shows the inner droop of an “installed” barrier filled with water, but in this photo, aperture 21 (closed for this example) can be seen. The moisture impermeability of the silicon cloth layer was repeatedly tested by filling an “installed” fire-barrier protected by the impermeable silicon cloth with water. In this test water remained on the surface of the silicon layer for 120 days when the water finally evaporated.

FIG. 8a, a diagrammatic perspective view, illustrates a straight-line barrier being mounted between two spaced floor units using installation tool 350 specific for this barrier and this installation. The frame of installation tool 350, as illustrated in the figure, consists of a pair of horizontally oriented spaced tracks 304, slidably attached at a ninety degree angle to each of tracks 304 is one of two horizontal sliding plates 308, protruding through and extending above and below each sliding plate 308 forming a ninety degree angle are two spaced vertical rails 306, a base plate 302 connects each end pair of each of the two spaced tracks 304. Roller assembly 310 provides for horizontal sliding plate 308 to be slidably adjusted, thus, providing for the installation tool to be width adjustable. Holding bracket 312 (shown in FIG. 8b) is attached to the lower end of each of spaced vertical rails 306. To prepare the impermeable fire-barrier retainer system for installation, one of the holding brackets 312 of the installation tool are attached to one long side of a fire-barrier and the other bracket is attached to the opposing long side of the fire-barrier. The entire system, installation tool and impermeable fire-barrier retainer system, can now be lifted holding the handles that are provided on the installation tool. Depending on the weight of the barrier, the installation tool and impermeable fire-barrier retainer system can be lifted and put into the expansion-joint by one or two installers. The width of the installation is adjusted so that base plates 302 rest on the surface of the to building unit 90 to support the barrier/retainer, while the retainer of the barrier retainer system is being fixedly attached to the side and or bottom of the building units 90. The use of the tool provides for rapid and easy installation by a minimum number of installers.

FIG. 8b, an elevation view illustrates how the installation tool supports the fire-barrier/retainer for secure attaching of the barrier to spaced building units. The installation, as shown, is used for bottom mounting of the barrier/retainer to spaced floor to floor building units and to spaced floor to wall building units.

Claims

1. A product, comprising,

a moisture impermeable fire-barrier not affected by moisture or water constructed of: a fire-barrier, and an impermeable membrane,

said membrane attached to and enveloping at least one side of said fire-barrier such that said membrane prohibits moisture or water from coming into contact with said at least one side.

2. The product, as recited in claim 1, wherein said impermeable membrane completely envelopes said fire-barrier.

3. The product, as recited in claim 1, wherein said moisture impermeable fire-barrier is sized and styled to fit into accepting expansion-joint spaces.

4. The product, as recited in claim 1, wherein said moisture impermeable fire-barrier is sized and styled to fit into accepting straight-line expansion-joint spaces.

5. The product, as recited in claim 1, wherein said moisture impermeable fire-barrier is sized and styled to fit into accepting expansion-joint spaces formed by the intersection of multiple expansion-joint spaces.

6. The product, as recited in claim 1, wherein said impermeable membrane is impermeable to water.

7. The product, as recited in claim 1, wherein said impermeable membrane is impermeable to water vapor.

8. The product, as recited in claim 1, wherein said impermeable membrane is silicone cloth.

9. The product, as recited in claim 1, wherein said moisture impermeable fire-barrier is fitted with a drain.

10. The product, as recited in claim 9, wherein said drain has a drain aperture fitted into said moisture impermeable fire-barrier and a drain hose emanating from said drain aperture therethrough.

11. The product, as recited in claim 10, wherein said drain hose is plastic tubing positioned into and through a flexible metal fire-resistant tubing providing protection for said plastic tubing.

12. The product, as recited in claim 11, wherein a join between the drain aperture and the impermeable membrane and the plastic tubing has a tight seal due to an impermeable caulk material applied about said join such that the impermeability of said moisture impermeable fire-barrier is maintained by caulking.

13. The product, as recited in claim 1, wherein said moisture impermeable fire-barrier is made of at least one layer of fire-resistant material attached to at least one adjacent layer of said moisture impermeable material, said fire-barrier having a first side, a spaced apart and opposing second side.

14. The product, as recited in claim 1, wherein said moisture impermeable fire-barrier further comprises an attachment apparatus for attaching said fire-barrier to spaced building units defining the expansion-joint spaces.

15. The product, as recited in claim 14, wherein said attachment apparatus further comprises a first retainer part for attachment to said first side and a second part for attachment to said spaced, opposing second side of said fire-barrier providing a fire-barrier retainer system.

16. The product, as recited in claim 15, wherein said first retainer part when attached to said first side provides for attachment of said first side to one of said building units and wherein said second retainer part when attached to said second side provides for attachment of said second side to a second of said building units, where the first and second building units define an expansion-joint space.

17. The product, as recited in claim 1, wherein each of said moisture impermeable fire-barrier's two ends where one end is formed into either a male or female shaped connecting end and the other end is formed into either a male or female shaped connecting end providing for male/female joining of adjacent fire-barriers having complementary male or female connecting ends.

18. A product, comprising,

a moisture impermeable fire-barrier not affected by moisture or water comprised of: an impermeable membrane; a fire-barrier made of at least one layer of fire-resistant material, said membrane attached to and enveloping at least one side of said fire-barrier such that said membrane prohibits moisture or water from coming into contact with said at least one side forming a moisture impermeable fire-barrier, said moisture impermeable fire-barrier sized and styled to fit into accepting expansion-joint spaces, said fire-barrier having a first long side, a spaced apart and opposing second long side, and a first retainer part for attachment to said first long side and a second part for attachment to said spaced, opposing second long side of said fire-barrier, said first and second retainer parts providing for attachment of said first long side to a first building unit and for attachment of said second long side to a second building unit, where the first and second building units define an expansion-joint space. each of said moisture impermeable fire-barrier's two ends formed into either a male or female shaped connecting end and the other end formed into either a male or female shaped connecting end providing for male/female joining of adjacent fire-barriers having complementary male or female connecting ends.

19. The product, as recited in claim 18, wherein said impermeable membrane completely envelopes said fire-barrier.

20. A method of making a moisture impermeable fire-barrier not affected by moisture or water, comprising:

providing a fire-barrier made of at least one layer of fire-resistant material, and

providing an impermeable membrane,

attaching said membrane to and enveloping at least one side of said fire-barrier such that said membrane prohibits moisture or water from coming into contact with said at least one side,

sizing and styling said moisture impermeable fire-barrier to fit into accepting expansion-joint spaces,

forming each of said moisture impermeable fire-barrier's two ends into either a male or female shaped connecting end and the other end formed into either a male or female shaped connecting end providing for male/female joining of adjacent fire-barriers having complementary male or female connecting ends.