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.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

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 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 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.

SUMMARY

The 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;

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;

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 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. 1 is a plan view illustrating a template used in the cutting and sewing of protective cloth used in the construction of the multi-dimension fire barrier in accordance with the teachings of this invention so as to produce a cloth to accommodate an expansion joint that comprises a corner junction without having excess cloth bulk or causing tearing of the cloth.

FIG. 2 is a plan view looking down on one part of a multi-dimension fire barrier that is to be fitted into protective cloth that has been folded and seamed for installation into a 90 degree expansion joint.

FIG. 3 is a perspective view looking down on and into a multi-dimension fire barrier ready for installation in a 90 degree expansion joint as shown in FIG. 2.

FIG. 4 is a cross-sectional view of a multi-dimension fire barrier installed in a 90 degree expansion joint as illustrated in FIG. 3 to show how stitching may be used to connect the layers.

FIG. 5 is a plan view looking down onto unfolded Part 1 (i.e., the base-part) of a multi-dimension fire barrier to be installed in a “T” shaped expansion joint.

FIG. 6 is a perspective view of folded Part 1 as shown in FIG. 5.

FIG. 7 is a perspective view of unfolded Part 2 of the multi-dimension fire barrier to be installed in a “T” shaped expansion joint.

FIG. 7a is a perspective view of the “T” shaped expansion fire barrier ready for installation.

FIG. 8 is a plan view looking down onto the unfolded base-part of a multi-dimension fire barrier to be installed in a 4-way expansion joint.

FIG. 9 is a perspective view of the folded base-part as shown in FIG. 8.

FIG. 10 is a plan view looking down onto an unfolded second part of a 4-way fire barrier.

FIG. 11 is a plan view illustrating a template used in the cutting and sewing of the protective cloth used in the construction of a vertical/horizontal 90 degree fire barrier so as to produce a cloth to fit around an expansion joint that comprises a vertical/horizontal 90 junction without having excess cloth bulk or causing tearing of the cloth.

FIG. 12 is a plan view looking down onto a vertical/horizontal 90 degree fire barrier before it has been cut, folded, or stitched.

FIG. 13 is a perspective view of the vertical/horizontal 90 degree fire barrier, as shown in FIG. 12, prepared for installation.

FIG. 13a is a perspective view of the vertical/horizontal 90 degree fire barrier, as shown in FIG. 12, seamed by the use of pins and bolts.

FIG. 14 is a plan view of a template used in the cutting and sewing of the protective cloth used in the construction of a horizontal 45 degree fire barrier so as to produce a cloth to fit around an expansion joint that comprises a horizontal 45 junction without having excess cloth bulk or causing tearing of the cloth.

FIG. 15 is a plan view looking down onto a horizontal 45 degree fire barrier prepared for installation.

FIG. 16 is a perspective view of the horizontal 45 degree fire barrier, as shown in FIG. 15, ready to be installed.

FIG. 17 is a plan view of a template used in the cutting and sewing of the protective cloth used in the construction of a horizontal T-joint/vertical fire barrier so as to produce a cloth to fit around a horizontal T-joint/vertical expansion joint without having excess cloth bulk or causing tearing of the cloth.

FIG. 18 is a plan view looking down onto an unfolded insulation blanket with intumescent material positioned on the insulation blanket ready for fitting into a protective cloth cut and sewn to fit into a horizontal T-joint/vertical expansion joint fire barrier.

FIG. 18a is a perspective view of the cut, folded, and seamed fire barrier sized and shaped to fit a horizontal T-joint/vertical expansion joint with the insulation blanket and intumescent material, as shown in FIG. 18 positioned in the cut, folded, and seamed fire barrier.

FIG. 18b is a plan view of the template that is used to cut the protective cloth that is to be positioned under and about the T-shaped extension arms as illustrated in FIG. 18a.

FIG. 19 is a perspective view of the four additional insulation blanket/intumescent material parts that will complete the side walls for that part of the horizontal T-joint/vertical expansion joint fire barrier. These pieces are to be inserted inside of the protective cloth coverings (i.e., shown as a template in FIG. 18b. The T-shaped structure (as is shown in FIG. 18.) is in the figure only as a guide for the placement of the insulation blanket/intumescent material parts. This step will complete the assembly of the horizontal T-joint/vertical expansion joint fire.

FIG. 19a is a perspective view of a horizontal T-joint/vertical expansion joint fire barrier installed in a model horizontal T-joint/vertical expansion joint structure. In this illustration the intumescent strip layer is about to be positioned on the insulation blanket. The barrier is shown temporarily attached to the model structure with clamps.

FIG. 20 is a plan view of four schematic multi-dimensional expansion joints.

FIG. 21 is a perspective view of the novel work form that is required for the seaming of a fire barrier that is shaped and sized to fit into a 90° expansion joint structure.

FIG. 21a is another perspective view of the novel work form that is required for the seaming of a fire barrier that is shaped and sized to fit into a 90° expansion joint structure.

FIG. 22a is an exploded view of a layered fire barrier comprising one vertical arm and one horizontal arm, which arms provide for the barrier to fit into an expansion joint space defined by the angled intersection of a vertically oriented expansion joint and a horizontally oriented expansion joint.

FIG. 22b is a perspective view of the exploded layers illustrated in FIG. 22a positioned within one another.

FIG. 23a is a perspective view illustrating the structural relationship between the fire barrier, the support/attachment strips that may be used to attach an installation tool to the barrier as shown in FIG. 22b, and the installation tool.

FIG. 23b is a perspective view illustrating the positioning of pins through the barrier and the stripping so that the pins along with washer act to reversibly affix the installation tool to the barrier.

FIG. 23c is perspective view illustrating the installation tool reversibly affixed to the fire barrier which is now ready for a one-step drop-in installation into an expansion joint.

FIG. 23d is a perspective view of the fire barrier installed into the space formed by a vertical/horizontal expansion joint with its installation tool remaining attached to the barrier until the barrier is fixedly attached to the building units that define the vertical/horizontal expansion joint.

FIG. 23e is a perspective view of the fire barrier as illustrated in FIG. 23d illustrating the attachment means used to fixedly attach the barrier to the building units.

FIG. 23f is a perspective view of the fire barrier as illustrated in FIG. 23e illustrating the barrier fixedly attached to the building units with its installation tool removed.

FIG. 24a is a perspective view illustrating a cross-shaped fire barrier.

FIG. 24b is a perspective view illustrating a cross-shaped fire barrier with its unique installation tool attached.

FIG. 25a is a perspective view illustrating a T-shaped fire barrier.

FIG. 25b is a perspective view illustrating a T-shaped fire barrier with its unique installation tool attached.

FIG. 26a is a perspective view illustrating an L-shaped fire.

FIG. 26b is a perspective view illustrating an L-shaped fire barrier with its unique installation tool attached.

FIG. 27 is a cross-sectional view of a fire barrier and its installation tool in place illustrating how the barrier layers are attached to each other and how the barrier's installation tool is attached to the barrier.

FIG. 28 is a perspective view of a kit containing all of the installation tools required for the installation of all of the barriers of the present invention and the spacers that provide for each tool to be used with fire barriers made to fit into expansion joints of various widths.

DEFINITIONS

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 DESCRIPTION

Referring 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. FIG. 20 illustrates the basic one-dimensional, straight expansion joint and three multi-dimensional expansion joints. An example of one preferred version of the multi-dimensional fire barriers taught herein is an L-shaped fire barrier that fits into corner expansion joints. To construct the three-layered L-shaped fire barrier, protective cloth, which is one of the three-layers, is cut according to the template illustrated in FIG. 1 and then stitched along the “sew line.” This assembly method produces a protective cloth jacket that fits neatly into a 90 degree junction expansion joint with tearing. Protective cloth, although strong and somewhat flexible, is often rigid enough to be prone to tearing when stressed by bending, such as by being forced to achieve a corner shape. Additionally, if the relatively thick protective cloth is folded to fit a corner without first shaping the cloth, as taught herein, an unacceptable bulky product will be produced. However, when the protective cloth is cut, folded, and seamed according to the pattern provided by the principles of this invention a custom-shaped multi-dimension L-shaped fire barrier without excess bulk is produced. Moreover, this unique method of shaping the protective cloth of the barrier eliminates the stresses on and potential for tearing of the protective cloth. The protective cloth may be seamed by stitching using a high-temperature thread, such as filamentous fused silica, for example. The L-shaped protective cloth cut, folded, and sewn according to this method is now ready to be used in the construction of a 90 degree expansion joint fire barrier unit. The protective cloth part, thus shaped, will be referred to as the first part of the L-shaped barrier.

The second part of the L-shaped barrier as shown in FIG. 2, comprises the other two layers of the three-layer construction. In this example, a layer of intumescent material 20 strip-layers are positioned on insulation blanket layer 40, as shown. The two layers may be connected by stitching using high-temperature thread 22 at this point or they may be stitched together with the protective cloth after the following step.

FIG. 3 is a perspective view looking down on and into a multi-dimension fire barrier preformed and ready to be installed in a 90 degree expansion joint. As can be seen, the insulation blanket and the intumescent strips, as shown in FIG. 2 have been placed into the L-shaped protective blanket. The three-layers are affixed together at this point by sewing or by any other desired fixation means, such as by stapling or by using pins and washers as illustrated in FIG. 3. As can be seen, the more easily damaged insulation blanket and the intumescent strips are supported and protected by the shaped layer of protective cloth. The intumescent material, which expands when a certain high-temperature is reached, is functionally positioned to provide the maximum amount of protection against the penetration of heat, flame, or smoke. The intumescent expansion prevents the passage of heat, flame, or smoke though openings that may have existed before being blocked by the swollen intumescent.

As is shown in FIG. 4, the stitching that attaches the intumescent material to the blanket goes through the intumescent strips, the blanket, and the protective cloth, so that all three-layers are attached together to provide a unitary functional unit. Once the L-shaped fire barrier is situated in a 90 degree expansion joint it may be attached to the structural unit in a variety of ways, such as by riveting the fold-out portions of the protective blanket (as shown in FIG. 3) to the top of the structure.

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. FIG. 5 shows the base part of a custom sized and styled T-shaped fire barrier. Also illustrated in FIG. 5 is the three-layer construction that was also used in the L-shaped fire barrier. It must again be pointed out, however, that other materials and other constructions may be used in the manufacture of a fire barrier. The novelty of this invention resides mainly in providing multi-dimensional fire barrier structures regardless of the materials used to make the structures, and in teaching the methods of making the custom-fit and custom-sized multi-dimensional fire barriers, where the fire barriers are produced as ready to install one-piece units, or if desired, may be provided unassembled to be assembled on-site. As shown in FIG. 5, strips of intumescent material 20 are functionally positioned on the surface of insulation blanket 40, which in turn is functionally positioned on protective cloth 30. Intumescent layer 20, insulation blanket 40, and protective cloth 30 are fixedly attached together to form an integral unit. In this example, the fixation is accomplished by stitching, as was shown in FIG. 4, using a high-temperature thread, although the fixation may be accomplished by any other fixation means, including staples and adhesive, for example. To prepare unfolded Part 1 (i.e., the base of the barrier), as illustrated in FIG. 5, for its union with Part 2 (i.e., the attachment part) as illustrated in FIG. 7, the top and bottom end of Part 1 (the base) are folded toward each other about the two fold lines shown in FIG. 5. Shown situated on each side of the “T” flap of the base, FIG. 5, 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 (i.e., cut loose from the “T” flap) so that the “T” flap can be maintained in its folded out position while the two insulator blanket extensions along with the protective cloth extensions (denoted PC) are folded up, as is shown in FIG. 6.

FIG. 7 is a plan view looking down onto an unfolded second part (the attachment part) of a T-shaped multi-dimension fire barrier. To prepare Part 2 (the attachment part) for connection to Part 1 (the base section), the two side walls of Part 2 are folded up towards each other at the fold lines shown in the figure. Once this is accomplished, Part 2 is positioned so that the “T” flap support part of the base part is placed under the “T” flap of the attachment part. With Part 2 (the attachment part) so positioned, the folded-up side walls of Part 2 (the base part) provide side walls for the “T” flap extension of the T-shaped fire barrier. Finally, the fold-out portions are folded out to be used for attaching the fire barrier to the structure parts of the expansion joint.

FIG. 7a, a perspective view of the “T” shaped expansion fire barrier ready for installation, illustrates the completely fabricated fire barrier with the addition of protective metal screening, which can be shipped directly to the construction site to be positioned in place. The barrier is permanently attached to the joint structure by any effective attachment means, such as by the use of rivets. The figure shows the use of clamps as the means to attach the barrier to the model expansion structure.

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 FIGS. 8-10.

FIG. 8 shows the base part of a 4-way fire barrier. As in the other examples, this example also employs three-layer construction, where the layers comprise an intumescent strip layer positioned on a layer of insulation material, which in turn is positioned on a layer of protective cloth. The three-layers are connected together by stitching (as shown in FIG. 4), where the stitching is accomplished using high-temperature thread. The design of the base part of the 4-way fire barrier uses the principals of the T-shaped fire barrier. In fact, the construct of the “T” flap end of the base part of the T-shaped fire barrier is simply followed on the two opposing ends of the base part of the 4-way fire barrier instead of on only one end of the base as is done in the T-shaped fire barrier.

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 FIG. 9. The protective cloth extensions are subsequently folded out to be used for attaching the fire barrier to the structure parts of the expansion joint.

Shown in FIG. 9 is the 4-way base folded up and out ready for the addition of the attachment parts. Note that in the case of the 4-way fire barrier there are two attachment parts. FIG. 10 illustrates one attachment part. Only one attachment part is shown in FIG. 10 as the two attachment parts required in the construction of a 4-way fire barrier are identical to each other and to the attachment part used in the T-shaped fire barrier. As in the T-shaped fire barrier, the “flap support” parts of the attachment parts (Part 2 in the T-shaped fire barrier) are each inserted beneath one of the two 4-way flaps. In this way, as in the previous example, insulator parts 20 then are in position to form the side barriers of the 4-way flap extensions. Once the two attachments are in position, as just described, the 4-way fire barrier is ready for installation in a 4-way extension joint.

FIG. 11 shows a plan view of a template used to cut and sew protective cloth to construct a vertical/horizontal 90 degree fire barrier to fit a vertical/horizontal 90 degree junction expansion joint without having excess cloth bulk or causing tearing of the cloth. The template teaches four cut lines. Once these cuts are made in the protective cloth shaped according to the template, the cloth is folded about the four fold-out lines and two fold-in lines. The cloth is also to be folded about the two pair of angled pattern lines and then seamed, such as by being sewn together, for example, using the pattern lines as a stitching guide. The cutting, folding, and sewing of the protective cloth, as just described, results in the cloth assuming a chair-like shape, where the chair has arm-like and wing-like extensions. These extensions will be used to attach the finalized fire barrier to the structures. As in the previous examples, if stitching is the connection means used, high temperature thread is employed.

FIG. 12 is a plan view looking down onto a protective cloth patterned for cutting, folding, and seaming according to the vertical/horizontal 90 degree fire barrier template as illustrated in FIG. 11. In the designated (see FIG. 11) mid-area an insulation blanket has been positioned. Positioned on the edge surface area of the insulation blanket is a layer of intumescent stripping material. As in the previous examples, the three layers are connected together by stitching with high temperature thread.

FIG. 13, a perspective view, shows the cut, folded, and sewn vertical/horizontal 90 degree fire barrier ready for installation in a vertical/horizontal 90 degree expansion joint. FIG. 13a shows the barrier seamed by the use of pins and bolts “installed” in a model vertical/horizontal 90 degree expansion joint. In this figure, the barrier is attached to the model expansion by clamps. In will be appreciated, that in an actual structure the barrier is permanently installed using any functional attachment means, such as rivets.

FIG. 14 is a plan view of a template used in the folding and seaming of protective cloth used in the construction of a horizontal 45 degree fire barrier so as to produce a cloth to fit around an expansion joint that comprises a horizontal 45 junction without having excess cloth bulk or causing tearing of the cloth. Cutting is not required to achieve the horizontal 45 degree fire barrier. In this example, the protective cloth, once cut to conform to the template, as shown, is folded and seamed along the fold and stitch lines and then folded up along the inner set of the fold lines and folded out along the outer set of fold lines. At this point, the protective blanket is ready for the addition of a layer of insulation blanket and a layer of intumescent material.

FIG. 15 is a plan view looking down onto a horizontal 45 degree fire barrier with attached layers of insulation blanket and intumescent material ready for installation in a the horizontal 45 degree expansion joint.

FIG. 16 is a perspective view of one end of the horizontal 45 degree fire barrier, as shown in FIG. 15, ready to be installed.

FIG. 17 is a plan view of a template used in the cutting, folding, and sewing of the protective cloth used in the construction of a horizontal T-joint/vertical fire barrier so as to produce a cloth to fit around a horizontal T-joint/vertical expansion joint without having excess cloth bulk or causing tearing of the cloth. The lines that are to be used as cutting guides, are Illustrated in FIG. 17, as the lines marked with circles, whereas the lines that to be used as the pattern for folding and seaming are the lines marked with “X”s. The plain lines are guides for folding only. As seen in the figure, the T-shaped area on which a suitable shaped insulation blanket is to be placed is marked according. Once the cloth has been cut, folded, and seamed according to the template as illustrated in FIG. 17,

FIG. 18 is a plan view looking down onto an unfolded, but T-shaped insulation blanket with an intumescent material layer positioned on the insulation blanket layer. These two layers are ready for fitting into a protective cloth cut and sewn following the horizontal T-joint/vertical fire barrier template as illustrated in FIG. 17.

FIG. 18a, a perspective view of the cut, folded, and seamed fire barrier sized and shaped to fit a horizontal T-joint/vertical expansion joint with the insulation blanket and intumescent material, as shown in FIG. 18 positioned in the cut, folded, and seamed fire barrier, shows the partially assembled barrier ready for the protective cloth, cut according to the template illustrated in FIG. 18b, to be positioned under and about the T-shaped extensions.

FIG. 18b is a plan view of the template that is used to cut the two pieces of protective cloth, where each piece is to be positioned under and about the extended T-shaped extension arms, as illustrated in FIG. 18a. This addition provides a protective and supportive layer to hold the insulation blanket/intumescent material layers that are to be installed next.

FIG. 19 is a perspective view of the four additional insulation blanket/intumescent material parts that will complete the layered side walls for the T-shaped extension arm part of the horizontal T-joint/vertical expansion joint fire barrier. The insulation blanket/intumescent material parts, as shown in FIG. 19, are to be inserted inside of the protective cloth coverings (i.e., shown as a template in FIG. 18b). The T-shaped structure (as is shown in FIG. 18.) is shown again in this figure only as a guide for the placement of the insulation blanket/intumescent material parts. This step will complete the assembly of the horizontal T-joint/vertical expansion joint fire.

FIG. 19a is a perspective view of a horizontal T-joint/vertical expansion joint fire barrier installed in a model horizontal T-joint/vertical expansion joint structure for seaming and for purposes of illustration. In this illustration the intumescent strip layer is about to be positioned on the insulation blanket side walls. The barrier is shown temporarily attached to the model structure with clamps.

FIG. 20 is a plan view illustrating four schematic multi-dimensional expansion joint structures. Of course, it is appreciated that there are many variation of multi-dimensional expansion joint structures.

FIG. 21 is a perspective view of the novel work form that has been designed to hold the barrier that is shaped and sized to fit into a 90 degree expansion joint structure for seaming.

FIG. 21a is another perspective view of the novel work form that is required for the seaming of a fire barrier that is shaped and sized to fit into a 90 degree expansion joint structure.

FIG. 22a is an exploded view to illustrate the various layers that are assembled one over another in a fire resistant layered fire barrier. The fire resistant barrier illustrated in FIGS. 22a through 22f, when fully assembled, comprises a structure that may be described as having a vertical arm that extends at an angle from one of its ends to form a horizontal arm, which arms provide for the barrier to be installed as a one-piece drop-in unit into an architectural expansion joint space defined by the approximately 90° intersection of vertical expansion joint 80 and horizontal expansion joint 82 (see expansion joints illustrated in FIGS. 23d-23f) referred to a vertical/horizontal joint. It is well known that expansion joints act like chimney flues in that they provide channels for fire, smoke, poisonous gases, and heat to travel through to spread the fire throughout a structure. Up until the present invention there was no way to stop the spread of the fire through extension joints that were not simply straight line extension joints. The fire resistant fire barriers of the present invention provide a solution for this problem in that they provide fire barriers for joints that are not straight line joints. One such joint is the vertical/horizontal joint. In particular FIG. 22a illustrates the material sheets that may be described as constituting two layers; a first layer comprises protective support cloth sheet 30 having a first and a second surface and flanges 32, first insulation blanket sheet 40 having a first and a second surface, with the second surface of protective cloth 30 positioned under and contiguous to the first surface of the first insulation blanket 40, which protective cloth provides protection and mechanical support for the fire barrier; on the second surface of first insulation blanket 40 is arranged intumescent material sheet 20; first resilient mechanical support sheet 50, here shown as a flexible, resilient screening having a first and second surface, which first surface of resilient screening 50 is arranged over the second surface of insulation blanket 40 with its layer of intumescent sheet 20. As shown in more detail in FIG. 4, the stitching that attaches the intumescent material to the blanket goes through the intumescent strips, the blankets, and the protective cloth, so that all of the sheets are bonded together to provide for a unitary, ready-to-use, drop-in unit. A second layer comprises second insulation blanket sheet 42 having a first and second surface and second resilient mechanical support sheet 52 having a first and second surface, with the first surface of support sheet 52 positioned over the second surface of second insulation blanket 42.

FIG. 22b, a perspective view, illustrates the layers, as illustrated in FIG. 22a, positioned and assembled one over another forming the basic structure of layered fire barrier 110. Attachment means 76B fixedly attaches the layers to each other. The sheets comprising each layer are fixedly attached to each other in the same manner, which is illustrated in FIG. 27. The sheets comprising each layer may be fixedly attached to each other using any known or yet to be known method for affixing such sheets. The technology of affixing sheets is well known and need not be discussed further here.

FIG. 23a, a perspective view, illustrates the structural relationships between fire barrier 110, as shown in FIG. 22b, support/attachment strips 60, and installation tool 100. Installation tool 100 is uniquely shaped for installing a 90° vertical/horizontal fire barrier into an expansion joint space defined by the approximately right-angled intersection of a vertically oriented expansion joint and a horizontally oriented expansion joint. Installation tool 100 is required for the one-step drop-in placement of the barrier. Having the ability of installing the barrier in a one-step drop-in placement using the specially made installment tool provides substantial cost savings in that the barriers are able to be installed easily, rapidly, and correctly by a single person with minimal, if any, risk of damage to the barrier. Non-flammable strapping 60 is shown positioned for attachment to and through the vertical portion and the horizontal flange portion of the barrier and attaches second resilient mechanical support 52, second insulation blanket 42, first resilient mechanical support sheet 50, first insulation blanket 40, and protective cloth 30 to each other and provides for the vertical section of the fire barrier to remain secure in a vertical position regardless of any physical stress that may be placed on the barrier, such as motion the fire barrier may experience due to the movement of the building structural units that is facilitated by the expansion joints. Non-flammable stripping material 60 is a common and inexpensive metal stripping material, often having apertures along its length. Positioned over barrier 110, stripping material 60 also serves as a means of reversibly attaching installation tool 100 to barrier 110 using attachment means 76.

FIG. 23b, a perspective view, illustrates support/attachment strips 60 affixed to barrier 110 using pins 72 in conjunction with friction fitting washer 70T. The reversible attachment of installation tool 100 to fire barrier 110 is accomplished in the examples provided using support/attachment strips 60 and a series of pins 72T that project beyond the upper surface of the flanges of the layered barrier along with friction fitting washers 70T (for more detail see FIG. 27). At the time of manufacture, pins 72T are inserted completely through the fire barrier from the first surface side of flange 32 of protective cloth 30. Each pin is positioned, relative to the fire barrier, so that pin head 73T is situated beneath and up against protective cloth 30 providing for the length of pin 72T to extend from pin head 73T up through flange 32 of protective cloth 30, first non-flammable supporting mesh 50, second non-flammable supporting mesh 52, and through non-flammable stripping 60. Once all of the pins are in place, friction fitting washers 70T are positioned over the extending ends of pins 72T and the fire barrier is ready to reversibly accept installation tool 100.

FIG. 23c, a perspective view, illustrates installation tool 100 reversibly affixed to fire barrier 110 which is now ready for a one-step drop-in installation into an expansion joint. After installation tool 100 is positioned on barrier 110 by fitting the apertures of fasteners 76T over the extending ends of pins 72T, a spacer 74 is placed over extending ends of pins 72T (spacer 74 is clearly illustrated in FIG. 27). The function of the spacer is to provide for easy removal of installation tool 100 from barrier 110 once the installation of barrier 110 an expansion joint is complete. Friction fit washers 72T (washers 72T are clearly illustrated in FIG. 27) are then positioned about each pin over each spacer. Installation tool 100 is now firmly, but reversibly, attached to barrier 110. The attachment of the tool onto the barrier, as described, provides for one person to be able to install the barrier into a receiving expansion joint. Grasping means, such as handle 106 allows one person to lift the barrier, carry it to the place of installation, and lift and drop the barrier into place.

FIG. 23d, a perspective view, illustrates fire resistant barrier 110 installed into the space formed by the intersection of vertical expansion joint 80 with horizontal expansion joint 82 with installation tool 100 still attached to the barrier. Installation tool 100 will be removed when barrier 110 is fixedly attached to the building units that define the vertical/horizontal expansion joint. Also pointed out in the figure are those tool segments 102 that may be removed from tool frame 104 and replaced with longer or shorter segments providing for use of the installation tool with 4-way fire barriers that occur in a number of widths, such as four, six, eight, ten, and twelve inch wide expansion joints. All of the installation tools, according to the principles of the present invention may be adjusted for width in a similar manner.

FIG. 23e, a perspective view, illustrates fire resistant barrier 110 in the process of being fixedly attached to building units 90 using pins 72T and friction fit washers 70T functionally inserted through apertures that are commonly found in stripping 60. It is to be understood that the attachment means used to fixedly attach the barrier to the building units may be any known or yet to be known attachment means, such as bolts, screws, nails, staples, and adhesive to name a few.

FIG. 23f, a perspective view, illustrates the barrier fixedly attached to building units 90 by attachment means comprising pins 72T and friction fit washers 70T securely and tightly positioned to and through stripping 60 and its installation tool 100 removed. Once the barrier is in place, the installation tool is easily and rapidly removed, ready for use in emplacing another barrier into another expansion joint. To remove the installation tool from the barrier, a simple leverage type tool, such as a screw driver or a pair of pliers is used to remove each spacer 74 and friction-fit washer 70T that had been positioned over the spacer. Once all of the spacers and washers are lifter off of the pins, the tool may easily be raised and removed from the barrier. At this point, if desired, the protruding pins may be simply and rapidly removed by snipping off their protruding length with a pair of wire snips. Installation tool 100 is easily and rapidly removed by prying up on washers 72 that were positioned over spacers 74 enabling the easy removal of both washer and spacer.

The FIGS. 22-23 series illustrate a multi-planar, i.e., vertical/horizontal layered fire barrier. However, the layered fire barriers according to the principles of the present invention also provide barriers for use in planar angled expansion joints. Three commonly occurring planar expansion joints are those formed by the planar approximately right-angled intersection of two, three, and four expansion joints resulting in L-shaped, T-shaped, and cross-shaped planar expansion joints, such as those illustrated schematically in FIG. 20.

FIG. 24a, a perspective view, illustrates 4-way fire barrier 440 that may be described to be in the form of a cross, which form fits into the cross-shaped planar space defined by the right-angled intersection of four architectural expansion joints that constitute the space between building units 90. The planar cross-shaped fire barrier is constructed in the same double layered manner as the vertical/horizontal fire barrier described above and is attached to building units 90 using the same attachment means, or similar means that provide for the same function, including the use of the non-flammable stripping material, as was described above for the vertical/horizontal barrier. It is to be appreciated that the angle of intersection of the expansion joints, building units and barrier arms may be any acute, obtuse, or right angle.

FIG. 24b, a perspective view, illustrates 4-way fire barrier 440 with its uniquely shaped installation tool 400 firmly attached for one-step drop-in installation of planar 4-way fire barrier 440 into a planar 4-way planar expansion joint. Installation tool 400 is attached to barrier 440 in the same manner as was described above for the vertical/horizontal barrier using the same attachment means, or similar means that provide for the same function

FIG. 25a, a perspective view, illustrates T-shaped fire barrier 330, which is simply a 4-way barrier with one arm removed, thus a T-shaped barrier comprises three arms all in the same horizontal plane for fitting into an expansion joint space defined by the intersection of three planar approximately right-angled expansion joints. The layered T-shaped barrier, as the barriers described above, is constructed of the two layers where each layer comprises a resilient mechanical support sheet over and attached to an insulation blanket having a layer of intumescent material over the blanket, where one layer is positioned over the other layer to form a layered fire barrier, and where the double layer is underlain by a protective cloth having flanges that coincide with flanges that extend from the resilient mechanical support sheet. The layered flanges and the stripping provide attachment means for the attachment of an installation tool to its related fire barrier and for the attachment of the fire barrier to the building units 90 as was described above. Tool 400 has the width adjustable properties that are available on all of the installation tools of the present invention.

FIG. 25b, a perspective view, illustrates T-shaped fire barrier 330 with its uniquely shaped installation tool 300 firmly attached to the barrier for one-step drop-in installation of planar T-shaped fire barrier 330 into a three-way planar expansion joint, as described above. The layered flanges and the stripping provide attachment means for the attachment of an installation tool to its related fire barrier and for the attachment of the fire barrier to the building units 90 as was described above. Tool 300 has the width adjustable properties that are available on all of the installation tools of the present invention. The width adjustments, as described above, are made easily and rapidly using the set of width adjusting segments that are provided with each tool.

FIG. 26a, a perspective view, illustrates two-way or L-shaped fire barrier 220, which is simply a 3-way barrier with one arm removed. Barrier 220 comprises two arms approximately 90° to each other with their bases in the same horizontal plane, which barrier fits into a two-way expansion joint space defined by the approximately right-angled intersection of one expansion joint with a second expansion joint

FIG. 26b, a perspective view, illustrates two-way or L-shaped fire barrier 220, with its uniquely shaped installation tool 200 firmly attached to the barrier for one-step drop-in installation of planar T-shaped fire barrier 220 into a two-way right-angled expansion joint. The layered flanges and the stripping of the barrier, as with the barriers previously described, provide attachment means for the attachment of installation tool 200 to fire barrier 220 and for the attachment of the fire barrier to building units 90, as described above. Tool 200 has the width adjustable properties that are available on all of the installation tools of the present invention. The width adjustments, as described above, are made easily and rapidly using the set of width adjusting segments that are provided in the tool kit for use with each tool.

FIG. 27 provides a cross-section view, taken along line FIG. 27-FIG. 27 of FIG. 23d, of the vertical/horizontal fire illustrated in FIG. 23d, to illustrate one of the many methods and means that is used to attach the vertically oriented portions of the individual barrier sheets to each other to form a layer. In this example, pin. 72B is shown extending through the sheets 30, 40, and 50, of a first layer and is also shown being held in place by a first friction-fit washer 70B positioned about one of its ends and by a second friction-fit washer 70B positioned about a second end. A second layer, comprising sheets 42 and 52, is formed in an analogous manner, as shown. Additionally, FIG. 27 illustrates one way that installation tool may be attached to a fire barrier, which in this illustration is a vertical/horizontal barrier, for installation of the barrier into an expansion joint. All of the installation tools are reversibly attached to their respective barriers in analogous manners. The means and method illustrated include the use of friction-fit washers 70T, spacers 74, and pins 72T with pin heads 73T (see discussion of FIG. 23d for more detail).

FIG. 28, a perspective view, illustrates an example of a kit that contains the parts needed to assemble one or all of installation tools of the present invention, as desired. Kit 500, offering a variety of storage compartment 502, may provide all of the basic parts required for the construction of a desired installation tool and the tools that are used in the tool's construction, such as the set of Allen wrenches 503 for assembling and changing width of installation tools, as well as the tools that are used for reversibly attaching and detaching the tool from its related fire barrier, or optionally, may provide all of the parts and tools needed to assemble the entire suite of the fire barriers of the present invention. As illustrated, the kit is a kit of parts that are commonly referred to as 80/20. This product in a general sense is well known by those of ordinary skill in the art and does not need further discussion here. It is to be understood, however, that the installation tools of the present invention may be made any suitable material, which can include parts of wood, plastic, and the like. Also illustrated in FIG. 28 are installation tool extension parts 505 that provide for the tool to be used with fire barriers designed to fit joint spaces of varying widths. The installation tools according to the principles of the present invention are unique to this invention. They are made to be used solely with the fire barriers of the present invention and because each tool is shaped to fit with a particularly shaped fire barrier, the tools cannot be used for any other function with any other device. Each particular style of fire barrier has a mating installation tool. As the tools are reusable, providing for only one tool per style of fire barrier being required. For example, if an installer is ready to install a plurality of the vertical/horizontal fire barriers, the installer starts the installation process by simply placing the installation tool over the surface of the fire barrier for the tool and firmly attaching the tool to the barrier. Because dynamic expansion joints occur in a variety of widths, the most common being four, six, eight, ten, and twelve inches, each of the installation tools comprises a basic frame with width determining exchangeable installation tool segments 504. Each installation tool is supplied with a set 505 of width determining exchangeable installation tool segments providing for each tool to be used in any of the basic joint widths by making an easy and rapid switch of width determining exchangeable installation tool segments.

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.
Patent History
Publication number: 20060090411
Type: Application
Filed: Dec 7, 2005
Publication Date: May 4, 2006
Inventor: Alan Shaw (Lockport, NY)
Application Number: 11/295,910
Classifications
Current U.S. Class: 52/233.000
International Classification: E04B 1/10 (20060101);