Fire barriers for multi-dimensional architectural expansion joints
Multi-layered, multi-directional, multi-dimensional and planar fire barriers for use in flue-like spaces formed by angled intersections of architectural expansion joints comprise a plurality of fire resistant material layers. The fire barriers are shaped for use in 2-way planar L-shaped expansion joint spaces, T-shaped, cross-shaped, V-shaped, and vertical/horizontal L-shaped corner expansion joint spaces, for example. A fire barrier may comprise at least one mechanically supporting layer; at least one insulating layer, and at least one layer of intumescent material, wherein the insulating layer is disposed between the mechanical support layer and the intumescent layer and the layered barrier is protected by an underlying protective cloth. The barrier, which prohibits the travel of fire, heat, or smoke through the flue-like channels created by the expansion joints of a structure, is provided ready to install in a one-step, drop-in process using a ready to assemble, width-adjustable, installation tool provided in a kit.
This Continuation Application claims the benefit of U.S. application Ser. No. 10/854,392 filed May 26, 2004.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTNot Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIXNot Applicable
BACKGROUND OF THE INVENTIONThe present invention relates generally to fire barriers and more particularly to one-step, drop-in installation, fire barriers for multi-dimensional, multi-directional, architectural 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.
Customarily, buildings were built with static joints. Modern building codes, however, require that building design and construction now take into account factors that can, over time, change the physical dimensions of a structure. These factors include extreme or repetitive changes in temperature, the force of wind impinging on the building, forces due to seismic events, settling of the subsoil, remodeling of the building, or excavation on or near the site, among other factors. To accommodate the stress on the building caused by these factors without compromising the integrity of the building, architects and builders may design the structure in sub-units where the sub-units are meant to remain some small distances away from each other and meet at what is referred to as “expansion joints”.
Expansion joints allow differential building movement to take place without risking damage to the whole structure. These joints represent gaps in the structure which can widen or narrow due to differential movement of adjacent structural units and/or can reduce the stress caused by shear motion of adjacent structural units. Dynamic moveable joints are often referred to in the trade as “construction joints,” “soft joints,” “dynamic voids”, “seismic joints,” and “expansion joints.” Expansion joints or voids often occur where two wall sections, a wall and a floor, or a wall and ceiling meet, for example.
While the presence of these joints improves the integrity of the structure as a whole, they present a major risk to the structure in the event of a fire. The gaps at the joints provide easy pathways for flame, heat, and smoke to spread rapidly throughout the structure by utilizing what is known as the “chimney effect,” that is the updraft created by heated air rising up through the structural gaps. Building codes for commercial structures generally require fire barriers capable of preventing flame and smoke from passing through building joints into adjoining areas. Various fire barrier means are available and include fire retardant and/or intumescent putties, caulks, wraps, and mats.
The fire barrier products mentioned above, although suitable for static joints, are generally not suitable for acting as fire barriers for dynamic joints. To reduce the risk created by the chimney effect due to dynamic joints, a number of attempts have been made to block the joints with fire resistant materials. A fire barrier for a dynamic joint generally needs to be capable of accommodating the complex differential movement of the building structural units and to retain its resiliency over an extended period of time under dynamic conditions. Further, during a fire event, the joint is likely to be subject to even greater movement, thereby making it essential that the fire barrier retains its integrity to prevent the migration of heat, flame, and smoke.
Commonly available are fire resistant materials, such as fire brick, which typically may be either rigid and/or brittle, or fire barrier blankets that are constructed of refractory fibers that are flexible but can be easily damaged.
Rigid and brittle materials have been adapted to sealing building joints while maintaining flexibility. This is accomplished by first creating hollowed out regions within the structural units that meet at a joint that is to be sealed with a fire resistant barrier. The fire resistant barrier, which consists of a thin layer of material of appropriate high-temperature properties, is then inserted into both hollowed gaps at the ends of the adjacent structural units. Thus, the widening or narrowing or shear motion of the adjacent plates is accommodated by the fire resistant barrier moving in a sliding fashion within the adjacent structural units. As long as the lateral dimensions of the barrier exceed the widest distance between the adjacent structural units during differential movement, the integrity of the barrier should remain. Similarly, when the structural units move together, the barrier should remain undamaged providing that the lateral dimension of the barrier is less than the distance between the bottoms of the hollowed out regions of the structural units. The major drawback of this approach is that the fire resistant material must be thin enough to fit within the hollowed out areas of the adjacent structural units. However, fabricating the hollowed out areas further complicates the construction of the building and increases the cost of the construction. Moreover, correct installation of such a barrier in a pre-existing building is difficult and expensive.
On the other hand, fire resistant materials can be fabricated into thin, flexible fibers which can be incorporated into flexible, fire resistant structures resembling a blanket. The advantages of such a material are that the fabrication is not very expensive, the draping of the blanket across a joint is readily accomplished and any differential movement of the adjacent structural units can be accommodated by incorporating an appropriate amount of slack in the blanket during installation. The blanket, however, 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. A number of attempts have been made to protect the blanket from such mechanical damage. These have generally relied on the fabrication of a composite blanket which incorporates the fire resistant material between layers of a stronger, protective material such as metal foils or metal screens. The fire resistant layer can freely move with respect to these protective layers or they may be attached together via threads or similar attaching means.
Given the wide variety of movements that may occur between structural elements in a building, particularly one situated in a seismically active region, there still remains the possibility of gaps appearing in the fire barrier. To reseal these gaps in the event of a fire, intumescent materials are frequently added to the barrier. These are materials that expand when rapidly heated and at the same time have fire resistant properties. Thus, these provide a second method of sealing the structural gap in a building.
Attempts have been made to provide for sealing the dynamic joints that occur between structural units in a building. All of these solutions only provide for a fire barrier that is designed to obstruct air flow through a gap that occurs only between two building structures, such as the gap that occurs at the join of two walls. Many expansion joints, however, occur at the juncture of more than two building structures, such as where four walls meet to create a cross-wise gap, or where two exterior walls and an interior wall meet creating a “T”-shaped gap. Presently, there is no system which is capable of sealing a gap between more than two structural units in a building. None of the previously described fire barrier assemblies is capable of bridging the kind of multi-dimensional gap that occurs at the convergence of a plurality of structural units.
Thus, it is clear that what is sorely lacking in the art is a fire barrier that can accommodate that important safety need. It would be a significant improvement in the art to provide a fire barrier that is designed to provide a multi-pathway air flow obstacle. Ideally, the novel multi-dimensional fire barrier would ideally be constructed as a one piece, ready to install, unit to better ensures the integrity of the barrier when stressed and to allow for quicker and easier installation than would a multi-piece multi-dimensional fire barrier.
Accordingly, the invention described herein addresses this heretofore unmet need.
SUMMARYThe present invention satisfies the pressing need for means to prevent the rapid spread of flames, heat, and smoke throughout a structure caused by the “chimney effect,” that is, the updraft created by multi-dimensional structural gaps.
The unique fire barrier structures as described herein offer fire barriers sized and designed to fit into multi-dimensional expansion joints occurring at the junction of more than two structures. The barriers made be provide ready to assemble or ready to install. One preferred version of the invention comprises a barrier made using a three layer construction that includes a layer of protective cloth, an insulating material layer (insulation blanket), and an intumescent material layer. The three layers are affixed together to form a fundamental layer using high-temperature resistant means. This barrier is not, however, the typical strip-type barrier that consists of one or more fire resistant layers simply superimposed one over the other.
The fire barrier of the present invention is unique in several ways. One point of novelty is the variety of three-dimensional configurations that can be accomplished using the fundamental layer regardless of the number or kinds of layers used to construct the fundamental layer. For example, in one aspect, the fundamental layer of the barrier is shaped into a unitary multi-dimensional barrier that is to be inserted directly into a corner expansion joint. Another aspect is a multi-dimensional barrier that fits into a “T” shaped space created by the convergence of three building structures, such as three walls, for example. In yet another aspect, a unitary multi-dimensional fire barrier is functionally designed to be fitted into the cross-wise or 4-way shaped expansion joints that are created by the confluence of four building structures, such as when four walls meet, for example. An additional aspect is a multi-dimensional fire barrier that fits into a vertical/horizontal 90 degree expansion joint. Another alternative is a multi-dimensional fire barrier that is operative for use in an expansion joint comprising a 45 degree angle. Yet another alternative multi-dimensional fire barrier is designed for use in a T-shaped joint having an additional joint that comes in at a right angle to the T-shaped expansion joint.
Yet another unique feature of the present invention is that regardless of the type of multi-dimensional expansion joint system that the fire barrier is intended to fit, all of the barriers are designed to have movement and expansion capabilities. Additionally, each of the materials used in the construction of the fire barriers meet Underwriters Laboratory, Inc. required specifications for materials used in a joint system.
Thus, the invention as described make available the above described advantages by providing for multi-dimensional fire barriers for use in multi-dimensional architectural expansion joints, wherein the fire barriers may comprise a plurality of fire resistant material layers. The fire resistant material layers may be connected together by stitching, stapling, using pins and bolts, using adhesive, or by any other bonding or connection method.
The multi-dimensional fire barriers, as taught may be operatively manufacture for use in a corner junction expansion joint, a “T’-shaped expansion joint, or in a 4-way expansion joint, a vertical/horizontal 90 degree expansion joint, an expansion joint comprising a 45 degree angle, and a T-shaped joint having an additional joint that comes in at a right angle to the T-shaped expansion joint, for example.
The multi-dimensional fire resistant barriers, according to the principles of the present invention may further comprise a plurality of fire resistant material layers including at least one mechanical support layer, at least one insulating layer, and at least one layer of intumescent material, wherein the insulating layer is disposed between the mechanical support layer and the one intumescent layer; and where the layers are bonded together substantially continuously along their to provide for multi-dimensional fire barriers operatively adapted for fitting into multi-dimensional architectural expansion joints.
The mechanical support and protective layer may be made from continuous filament amorphous silica yarns, polymeric material, fiber reinforced polymeric material, metallized fiber reinforced polymeric material, metallized, fiberglass cloth material, or inorganic fiber cloth material. The inorganic fibers may be selected from glass or ceramic fibers.
The insulating layer may be made from refractory ceramic fiber that may consist of alumina-silica, polycrystalline mullite, or glass mat materials.
The intumescent layer of the multi-dimensional fire barriers, may be selected from the group consisting of unexpanded vermiculite, hydrobiotite, water-swelling tetrasilicic fluorine mica, expandable graphite, or mixtures thereof. The intumescent layer may comprise a blend of fibers, wherein said fibers are selected from the group consisting of refractory ceramic fibers, high-temperature resistant glass fibers, or unexpanded vermiculite.
The method for making the multi-dimensional fire barriers comprises the steps of:
-
- a) providing for at least one mechanical support layer;
- b) providing for at least one insulating layer, and
- c) providing for at least one layer of intumescent material,
- d) disposing the insulating layer between the mechanical support layer and the intumescent layer; and
- e) bonding the layers together substantially continuously along their lengths to provide for multi-dimensional fire barriers operatively adapted for fitting into multi-dimensional architectural expansion joints.
Further preferred embodiments, include fire barriers for installation into spaces formed by the intersection of architectural expansion joints comprising approximately right-angled, acute-angled, and obtuse-angled intersections of at least two architectural expansion joints, comprising fire barriers for installation into flue-like fire, heat, and smoke funneling spaces formed by the angled intersections of at least two architectural expansion joints, comprising:
fire resistant barriers comprising a plurality of fire resistant material layers including:
-
- a first layer comprising:
- a fire resistant protective cloth sheet having a first and second surface, and
- a first fire resistant insulation blanket sheet having a first and second surface, the second surface of said protective cloth sheet positioned under and contiguous to the first surface of the first insulation blanket sheet providing protection and mechanical support for the fire barrier;
- at least one layer of a first fire resistant intumescent material sheet arranged on the second surface of the first insulation blanket sheet;
- a first fire resistant resilient mechanical support sheet having a first and second surface, the first surface of said first resilient mechanical support sheet positioned over the second surface of the first insulation blanket having a layer of the intumescent sheet, and
- a second layer comprising:
- a second fire resistant insulation blanket sheet having a first and second surface,
- at least one layer of a second fire resistant intumescent material sheet arranged on the second surface of the second insulation blanket sheet, and
- a second fire resistant resilient mechanical support sheet having a first and second surface, the first surface of the second resilient mechanical support sheet positioned over the second surface of the second insulation blanket having a layer of the second intumescent sheet;
- a first layer comprising:
the second layer positioned over the first layer so that the first surface of the second insulation blanket is positioned over the second surface of the first resilient mechanical support sheet,
the layers locally bonded together forming a unitary layered fire barrier ready for installation within the spaces formed by the expansion joints intersecting at angles for affixation to the building structural units forming said expansion joints providing for a barrier against the travel of fire, heat, or smoke through the flue-like expansion joints of a structure.
In still furthermore preferred embodiments, the protective cloth of the fire barriers further includes mounting means for affixing the layered fire barrier to the building structural units, wherein the mounting means comprise flanges attached to the side edge portions of the protective cloth, and wherein the mounting means further comprise a plurality of fasteners used in conjunction with the flanges providing for the fire barrier to be affixed to the building structural units, and further comprising wherein the plurality of fasteners further comprises a plurality of pins and washers.
The invention as described further comprises a reusable mounting tool for depositing said fire barrier within said expansion joints for affixation to said building structural units; said at least one reusable mounting tool comprising a rigid frame that is reversibly attachable to each of said fire barriers using reversible attachment means, such as, but not limited to pins and washers, and where each frame has at least one grasping means, such as a handle on the frame providing for easy lifting and positioning of the frame along with the fire barrier that is reversibly attached to the frame into said expansion joints. The width of the mounting tool is adjustable to accommodate the width of the fire barrier, which accommodates the width of the expansion joints that are intersecting at 90 degrees. Moreover, the reusable mounting tools are available in a kit of mounting tools containing installation tool frames for installation of various sized and shaped fire barriers into various sized and shaped spaces formed by the intersection of architectural expansion joints comprising angled intersections of at least two architectural expansion joints.
A preferred embodiment includes wherein the fire resistant barrier is contoured in the form of a cross for fitting into a planar intersection of four architectural expansion joints, a T-shape for fitting into a planar angled intersection of three architectural expansion joints architectural expansion joints, an L-shape for fitting into a planar angled intersection of two architectural expansion joints, and an L-shape for fitting into a non-planar angled intersection of two architectural expansion joints, wherein the non-planar angled intersection of two architectural expansion joints, comprises an intersection of an vertically oriented expansion joint with a horizontally oriented expansion joint.
Also included in the preferred embodiment are methods for installing fire barriers into fire, heat, and smoke funneling spaces formed by essentially angled intersections of at least two architectural expansion joints, comprising the steps of:
providing for fire resistant barriers comprising a plurality of fire resistant material layers including:
-
- a first layer comprising:
- a fire resistant protective cloth sheet having a first and second surface, and
- a first fire resistant insulation blanket sheet having a first and second surface, the second surface of the protective cloth sheet positioned under and contiguous to the first surface of the first insulation blanket sheet providing protection and mechanical support for the fire barrier;
- at least one layer of a first fire resistant intumescent material sheet arranged on the second surface of the first insulation blanket sheet;
- a first fire resistant resilient mechanical support sheet having a first and second surface, the first surface of the first resilient mechanical support sheet positioned over the second surface of the first insulation blanket having a layer of the intumescent sheet, and
- a second layer comprising:
- a second fire resistant insulation blanket sheet having a first and second surface,
- at least one layer of a second fire resistant intumescent material sheet arranged on the second surface of the second insulation blanket sheet, and
- a second fire resistant resilient mechanical support sheet having a first and second surface, the first surface of said second resilient mechanical support sheet positioned over the second surface of said second insulation blanket having a layer of the second intumescent sheet;
- a first layer comprising:
positioning said second layer over said first layer so that the first surface of the second insulation blanket is positioned over said second surface of the first resilient mechanical support sheet,
bonding said layers locally together forming a unitary layered fire barrier ready for installation within the spaces formed by said expansion joints intersecting at angles for affixation to the building structural units forming the expansion joints intersecting at angles providing a barrier against the travel of fire, heat, or smoke through the expansion joints of a structure.
Still other benefits and advantages of this invention will become apparent to those skilled in the art upon reading and understanding the following detailed specification and related drawings.
BRIEF DESCRIPTION OF THE DRAWINGSIn 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:
Angled, as used herein, refers to acute, obtuse, right-angled, and nearly, or approximately right-angled. The term “angled” is used herein mostly to refer to the configuration formed when architectural expansion joints (which may be referred to as spaces), building units, or extensions (or as referred to as “arms”) of fire barriers intersect or meet at a common place.
Intumescent as used herein refers to those materials having properties that cause that material to expand when heated.
Insulation blanket as used herein refers to any number of insulator 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.
Multi-dimensional architectural expansion join” as used herein refers to any joint that is formed by the convergence of more than two structural units, such as the convergence of three wall units or two walls and a floor unit.
Multi-dimensional fire resistant barrier as used herein refers to any fire barrier that is functionally shaped to functionally fit into a multi-dimensional architectural expansion joint.
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. Metalized cloth may include fibers of stainless steel, aluminum, or copper, for example. Protective materials may also include metal foils or metal screens.
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.
Stripping, as used herein, refers to off-the-shelf non-flammable stripping used in construction and fabrication for holding, binding, and/or attaching.
Structural unit as used herein refers to such constructs as a wall, floor, ceiling, or the like.
Tri-dimensional as used herein refers to either an expansion joint that has three member 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.
Tetra-dimensional as used herein, refers to either an expansion joint that has four member parts, such as a cross-shaped expansion joint where the cross-joint is made up of four co-joint-arms or to a fire barrier that is functionally shaped to accommodate a cross-shaped joint.
Vertical/horizontal fire barrier, as used herein, refers to a unitary structure fire barrier comprising one vertical arm and one horizontal arm, which structure provides for the barrier to fit, as a one-piece drop-in unit, into an expansion joint space defined by the 90° intersection of two expansion joints, one vertical joint and one horizontal joint.
A LIST OF THE REFERENCE NUMBERS AND RELATED PARTS OF THE INVENTION
- 20 Intumescent strip material.
- 22 High-temperature thread.
- 30 Protective cloth.
- 32 Protective cloth flange.
- 40 First insulation blanket.
- 42 Second insulation blanket.
- (S) Stitching
- (PC) Protective cloth.
- 50 First non-flammable supporting mesh.
- 52 Second non-flammable supporting mesh.
- 60 Non-flammable strapping.
- 70 Friction-fit washer to attach fire barrier to building unit 90.
- 70B Friction-fit washer to attach fire barrier sheets to each other to form a layer.
- 70T Friction-fit washer to attach installation tool to related fire barrier.
- 72 Pin to attach fire barrier to building unit 90.
- 72B Pin to attach fire barrier sheets to each other to form a layer.
- 72T Pin to attach installation tool to related fire barrier.
- 73T Head of pin 72T.
- 74 Spacer.
- 76 Fasteners to attach fire barrier to building unit 90.
- 76B Fasteners to attach fire barrier sheets to each other to form a layer.
- 76T Fasteners to attach installation tool to related fire barrier.
- 80 A vertical expansion joint.
- 82 A horizontal expansion joint.
- 90 Building unit.
- 100 Installation tool.
- 110 Vertical/horizontal fire barrier.
- 200 Installation tool.
- 220 Two-way or L-shaped fire barrier.
- 300 Installation tool.
- 330 Three-way or T-shaped fire barrier.
- 400 Installation tool.
- 440 Four way or cross-shaped fire barrier.
- 102 Width determining exchangeable installation tool segments.
- 104 Tool frame
- 106 Tool grasping means.
- 500 Kit providing all of the basic parts required to construct a desired installation tool and the tools used in the tool construction and in reversibly attaching and detaching an installation tool from a fire barrier.
- 502 Storage compartments.
- 503 Allen wrenches for assembling and changing width of installation tools.
- 504 Installation tool frame segments.
- 505 A set of width determining exchangeable installation tool segments.
- 510 Joining means for joining segments 504 for assembling installation tools.
It should be understood that the drawings are not necessarily to scale. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not limited to the particular versions illustrated herein, but encompasses many embodiments, such as those that are discussed throughout the specification. Expansion joint intersections occur in many configurations, as all of those configurations entail various combinations of vertical, horizontal, and corner joints, it will be appreciated that all of the configurations are embodied by this invention.
DETAILED DESCRIPTIONReferring now particularly to the drawings which show views of exemplary versions of some of the templates that are contemplated by this invention. The drawings also illustrate how the above mentioned disadvantages have been overcome. It should be noted that the disclosed invention is disposed to versions in various sizes, shapes, contents, and forms. 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 herein.
Fire barriers are often, but not necessarily, constructed of three-layers; a thick insulation layer, an intumescent layer, and a protective cloth layer where the protective cloth is used to prevent the more susceptible insulation blanket from suffering physical damage, such as tearing. One preferred method of constructing the multi-dimensional fire barriers of this invention is to use the three-layer construction method, although it should be understood that many other methods and materials may also be used.
Many variations of structural multi-dimensional expansion joints exist.
The second part of the L-shaped barrier as shown in
As is shown in
Another expansion joint configuration that occurs frequently is the T-shaped expansion joint which occurs when three structures meet, such as the convergence of three walls.
Another common multi-dimensional expansion joint configuration is that of the 4-way or cross-shaped joint. This joint occurs where four structures converge, such as the convergence of four walls, for example. How to make a fire barrier custom styled and sized for any 4-way junction is shown in
Situated on each side of the two 4-way Flaps of the protective cloth base of the 4-way barrier are two extensions of insulator blanket 40. The inner edges of the two extensions of the insulator blanket, that is, the edges that border each side of the “T” flap, are constructed to be physically separate from the “T” flap, so that the “T” flap is kept open flat while the two insulator blanket extensions along with the protective cloth extensions (denoted PC) are folded up, as is shown in
Shown in
The
Thus, it can be seen from the above that the present invention provides the solution to the long felt and extremely important safety need for means to prevent the rapid spread of flames, heat, and smoke throughout multi-dimensional expansion joints of any type of structure by providing fire barriers styled and sized to fit multi-dimensional expansion joints, as well as the method of making the barriers, and the forms on which the barriers are seamed. Moreover, as the multi-dimensional fire barriers of the present invention may be constructed of presented available and permitted materials, the added cost to manufacture the barrier is minimal, thus making these essential safety features, affordable.
The foregoing description, for purposes of explanation, used specific and defined nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. The disclosed descriptions and illustrations are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Those skilled in the art will recognize that many changes may be made to the features, embodiments, and methods of making the versions of the invention described herein without departing from the spirit and scope of the invention, such as adjusting the template patterns shown in the drawings and described above to fit the variety of other similar, but different, multi-dimensional expansion joints, as well as to fit the various sizes of multi-dimensional joints that require fire barriers. Furthermore, the present invention is not limited to the described methods, embodiments, features or combinations of features but include all the variation, methods, modifications, and combinations of features within the scope of the appended claims. The invention is limited only by the claims.
Claims
1. Fire resistant barriers for installation into fire, heat, and smoke funneling flue-like spaces formed by the angled intersection of at least two architectural expansion joints, comprising:
- fire barriers comprising a plurality of fire resistant material layers including: a first layer comprising: a fire resistant protective cloth sheet having a first and second surface, and a first fire resistant insulation blanket sheet having a first and second surface, said second surface of said protective cloth sheet positioned under and contiguous to said first surface of said first insulation blanket sheet providing protection and mechanical support for the fire barrier; at least one layer of a first fire resistant intumescent material sheet arranged on said second surface of said first insulation blanket sheet; a first fire resistant resilient mechanical support sheet having a first and second surface, said first surface of said first resilient mechanical support sheet positioned over said second surface of said first insulation blanket having a layer of said intumescent sheet, and a second layer comprising: a second fire resistant insulation blanket sheet having a first and second surface, and a second fire resistant resilient mechanical support sheet having a first and second surface, said first surface of said second resilient mechanical support sheet positioned over said second surface of said second insulation blanket; said second layer positioned over said first layer so that said first surface of said second insulation blanket is positioned over said second surface of said first resilient mechanical support sheet, said layers locally bonded together forming a unitary layered fire barrier ready for installation within said expansion joints spaces, and mounting means for fixedly mounting said barrier to building structural units defining said expansion joints providing for a barrier against the travel of fire, heat, or smoke through flue-like channels created by the expansion joints of a structure.
2. The fire barriers, as recited in claim 1, wherein said protective cloth further includes mounting means for affixing said layered fire barrier to said building structural units.
3. The fire barriers, as recited in claim 2, wherein said mounting means further comprise mounting flanges comprising the side edge portions of the protective cloth.
4. The fire barriers, as recited in claim 2, wherein said mounting means further comprise a plurality of fasteners used in conjunction with said flanges providing for said fire barrier to be affixed to said building structural units.
5. The fire barriers, as recited in claim 4, further comprising wherein said plurality of fasteners further comprises a plurality of pins and washers used in conjunction with said flanges providing for said fire barrier to be affixed to said building structural units.
6. The fire barriers, as recited in claim 1, wherein said mounting means further comprises at least one reusable mounting tool for depositing said fire barrier within said expansion joints for affixation to said building structural units;
- said at least one reusable mounting tool comprising: a sturdy frame reversibly attachable to said fire barrier using reversible attachment means, and at least one grasping means on said frame, said grasping means providing for easy lifting and positioning of the frame and the reversibly attached fire barrier into said expansion joints.
7. The fire barriers, as recited in claim 6, further comprising wherein said frame of said mounting tool is width adjustable to accommodate the varying widths of the fire barriers.
8. The fire barriers, as recited in claim 6, further comprising wherein said at least one reusable mounting tool further comprises a kit of mounting tools for installation of said fire barriers into the spaces formed by the angled intersection of architectural expansion joints.
9. The fire barriers, as recited in claim 1, further comprising wherein said fire resistant barrier is contoured in the form of a cross for fitting into a planar intersection of four architectural expansion joints.
10. The fire barriers, as recited in claim 1, further comprising wherein said fire resistant barrier is contoured to form a T-shape for fitting into a planar approximately right-angled intersection of three architectural expansion joints architectural expansion joints.
11. The fire barriers, as recited in claim 1, further comprising wherein said fire resistant barrier is contoured to form an L-shape for fitting into a planar approximately right-angled intersection of two architectural expansion joints.
12. The fire barriers, as recited in claim 1, further comprising wherein said fire resistant barrier is contoured to form an L-shape for fitting into a non-planar approximately right-angled intersection of two architectural expansion joints.
13. The fire barriers, as recited in claim 1, wherein said non-planar approximately right-angled intersection of two architectural expansion joints further comprises an intersection of a vertically oriented expansion joint with a horizontally oriented expansion joint.
14. A method for installing fire resistant barriers into fire, heat, and smoke funneling flue-like spaces formed by the angled intersections of at least two architectural expansion joints, comprising the steps of:
- providing for fire barriers comprising a plurality of fire resistant material layers including: a first layer comprising: a fire resistant protective cloth sheet having a first and second surface, and a first fire resistant insulation blanket sheet having a first and second surface, said second surface of said protective cloth sheet positioned under and contiguous to said first surface of said first insulation blanket sheet providing protection and mechanical support for the fire barrier; at least one layer of a first fire resistant intumescent material sheet arranged on said second surface of said first insulation blanket sheet; a first fire resistant resilient mechanical support sheet having a first and second surface, said first surface of said first resilient mechanical support sheet positioned over said second surface of said first insulation blanket having a layer of said intumescent sheet, and a second layer comprising: a second fire resistant insulation blanket sheet having a first and second surface, and a second fire resistant resilient mechanical support sheet having a first and second surface, said first surface of said second resilient mechanical support sheet positioned over said second surface of said second insulation blanket;
- positioning said second layer over said first layer so that said first surface of said second insulation blanket is positioned over said second surface of said first resilient mechanical support sheet,
- bonding said layers locally together forming a unitary layered fire barrier ready for installation within said expansion joints spaces, and
- fixedly mounting said barrier using mounting means to building structural units defining said expansion joints providing a barrier against the travel of fire, heat, or smoke through flue-like channels created by the expansion joints of a structure.
15. The method, as recited in claim 14, further comprising wherein said fire resistant barrier is contoured in the form of a cross for fitting into a planar intersection of four architectural expansion joints.
16. The method, as recited in claim 14, further comprising wherein said fire resistant barrier is contoured to form a T-shape for fitting into a planar approximately right-angled intersection of three architectural expansion joints architectural expansion joints.
17. The method, as recited in claim 14, further comprising wherein said fire resistant barrier is contoured to form an L-shape for fitting into a planar approximately right-angled intersection of two architectural expansion joints.
18. The method, as recited in claim 14, further comprising wherein said fire resistant barrier is contoured to form an L-shape for fitting into a non-planar approximately right-angled intersection of two architectural expansion joints.
19. The fire barriers, as recited in claim 14, wherein said non-planar approximately right-angled intersection of two architectural expansion joints further comprises an intersection of a vertically oriented expansion joint with a horizontally oriented expansion joint.
20. Fire barriers for installation into fire, heat, and smoke funneling spaces formed by the approximately right-angled intersections of at least two architectural expansion joints, comprising:
- fire resistant barriers comprising a plurality of fire resistant material layers including: at least one fire resistant insulation blanket sheet having a first and a second surface; at least one layer of fire resistant intumescent material sheet; at least one fire resistant resilient mechanical support sheet having a first and a second surface;
- said at least one layer of said intumescent material is disposed between said second surface of said at least one insulation blanket sheet and said first surface of at least one resilient mechanical support sheet,
- at least one fire resistant protective cloth sheet positioned beneath and contiguous to said first surface of said at least one insulation blanket sheet, said protective cloth providing protection and mechanical support,
- said at least one protective cloth sheet, said at least one insulation blanket sheet, said at least one layer of intumescent material sheet, and said at least one resilient mechanical support sheet are locally bonded together forming a layered fire barrier ready for installation within said spaces formed by said expansion joints intersecting at angles therein providing a barrier against the travel of fire, heat, or smoke through the flue-like channels created by the expansion joints of a structure.
Type: Application
Filed: Dec 7, 2005
Publication Date: May 4, 2006
Inventor: Alan Shaw (Lockport, NY)
Application Number: 11/295,910
International Classification: E04B 1/10 (20060101);