Fire barrier component

Abstract

A fire barrier component has an outer sleeve retaining and protecting a fire stop material therein which is preferably compressed. The outer sleeve when exposed to a fire condition partially fails and the fire stop material forms the fire stop barrier. The fire stop material if compressed expands and can cooperate with adjacent components to form an effective fire stop barrier. The firestop barrier component can be factory made and used in complete fire barrier systems, or the component can be used as part of a specific field application. The component may be sold in longer lengths and cut as required to meet a particular application. Conventional saws work satisfactorily in cutting of the component while maintaining the performance of the component when exposed to a fire condition.

Description

FIELD OF THE INVENTION

The present invention relates to a factory manufactured prefabricated fire barrier component where a firestop insulation product such as mineral wool is preinstalled into a sleeve or frame and is designed to release and seal the opening in the event of a fire. The product can be used on its own or in groups, and can be installed with or without a framing assembly.

BACKGROUND OF THE INVENTION

Fire stop assemblies are required to prevent the spread of fire through openings in a wall, floor or other structural barrier of a building structure. The openings are typically provided through fire rated assemblies to allow conduits, piping and other penetrating members to pass through the barrier. These fire stop assemblies often provide some protection about the access port during a non-fire condition and in the event of a fire are designed to stop the fire from progressing through the port. Many fire stops are field fabricated at the building site by installers using methods that make it difficult to ensure the appropriate material compression and depth of material installation. They can also be very difficult to install.

Many of these fire stop assemblies use intumescent materials which foam and greatly expand when exposed to a fire condition. For fire stop assemblies of a large size for example for providing a fire stop for a port having a longitudinal direction in excess of two feet, some additional structural components may be required when using intumescent materials to keep it from separating or falling out during a fire condition. In addition, the use of intumescent material increases the cost of the fire stop assembly and the intumescent material on its own may not meet certain fire codes which require the barrier to withstand a restricted temperature transmission requirement or remain intact after an exposure to a pressurized stream of water.

There remains a need to provide an effective fire stop assembly that can be properly installed on a job site with minimal installer effort, training, or skill level and allows quick installation of additional penetrants without major effort or rework.

SUMMARY OF THE PRESENT INVENTION

A fire barrier component according to the present invention comprises an elongated outer sleeve of a molded material and generally fixed cross section and a compressed fire stop material retained and protected interior to the outer sleeve.

According to an aspect of the invention the outer sleeve is of a material that is consumable in a fire.

According to an aspect of the invention the outer sleeve is of an extruded plastic material.

In yet a different aspect of the invention the fire barrier component has a rated fire stop application and the compressed fire stop material is a non-combustible material for the rated fire stop application.

In yet a further aspect of the invention the compressed fire stop material is compressed mineral wool.

In a further aspect of the invention the compressed fire stop material is a compressed glass fiber material.

In a preferred aspect of the invention the outer sleeve is of a rectangular cross-section.

In a preferred aspect of the invention the outer sleeve is a one-piece extruded tube designed to release the compressed insulation material upon exposure to heat or fire.

The fire barrier component according to an aspect of the present invention, has an outer sleeve of a profile to retain a compressed fire stop material therein. The outer sleeve is partially consumed and/or fails when exposed to a fire condition thereby releasing and/or exposing the compressed fire stop material. The sleeve may be of a plastic or other material capable of being consumed by flame or heat of a fire.

In a different aspect of the invention the outer sleeve is an elongate component of a single piece or multi-piece construction that is configurable to allow the insertion of the compressed fire stop material and to retain the compressed fire stop material therein. In one form, the elongate component includes a bottom channel and a top coverplate. In a different aspect of the elongate outer sleeve is a single extruded component with a live hinge running the length thereof with the sleeve being initially manufactured in the open condition. This single extruded component operates in a clamshell manner.

In a further embodiment of the invention the outer sleeve is manufactured of a single extrusion where this extrusion has a male connector and a female connector. The extrusion is reversible to define the outer sleeve basically the single extrusion is cut into two pieces with one reversed to collectively define the outer sleeve about the compressed fire stop material.

The fire barrier component when the outer sleeve is of a plastic material, is of significant structural integrity to protect the fire stop material from the normal day to day environment which may tend to deteriorate or expose the fire stop material to potential damage. In addition, the plastic outer sleeve can easily be cleaned as may be required over time. If desired end caps can be provided on the tubes to essentially close these members. In addition, the fire barrier component can be manufactured in relatively long lengths and then cut to appropriate size for insertion in a fire barrier assembly or for a customized configuration in the field. Basically this is a building component for defining a fire barrier.

It has been found that by providing a compressed fire stop material within the outer sleeve certain advantages are possible. Basically, the sleeve forms a restraining member and the compressed fire stop material may be compressed from 10% to 200%. A compression range of 30% to 80% is satisfactory for most applications. In the event of a fire the outer sleeve may be partially consumed or at least will be weakened and the barrier thereof will allow the expansion of the compressible fire stop material. The failed outer sleeve allows the expanded fire stop material to form a positive fire stop layer and it will also serve to protect the remaining portion of the sleeve as an insulating layer. It has been found during testing that the sleeve can be completely consumed on one side while the two side edges of the sleeve and the back-face of the sleeve remain generally intact throughout the fire test. Any consumed portion of the sleeve is immediately compensated by the expanding compressed fire stop material. As can be appreciated the compressed fire stop material would also expand against any wires or pipe which are immediately adjacent thereto.

In a preferred aspect of the invention the elongate outer sleeve includes a series of knockout ports in the length thereof to allow a wire or pipe to pass through the barrier. This provides a simple arrangement for easy retrofit in the future for a specific application. Generally these fire stop assemblies do allow removal of an elongate fire stop component however the use of the knockout port allows a wire to pass therethrough at a convenient location or where removal of the entire component is not necessary or desired as the amount of expansion needed is relatively small. At a future point in time if this barrier component needs to be removed it is easily cut.

In yet a further aspect of the invention the barrier component can be manufactured in long lengths and cut to the appropriate size either for shipping or for the specific application.

BRIEF DESCRIPTION OF THE DRAWINGS

The above as well as other advantages and features of the present invention will be described in greater detail according to the preferred embodiments of the present invention in which;

FIG. 1 is a partial perspective view of three fire barrier components placed in side by side relationship;

FIG. 2 is a plan view of a series of fire barrier components secured in a circular frame to close a passage through a building structure;

FIG. 3 is a cross section through a two-piece fire barrier component;

FIG. 4 is a schematic view of the outer sleeve manufactured by a single extrusion component; and

FIG. 5 is a sectional view through a fire a barrier component which is manufactured with a live hinge to allow closure thereof.

DETAILED DESCRIPTION ACCORDING TO THE PREFERRED EMBODIMENTS OF THE PRESENT INVENTION IN WHICH

The fire barrier components 2 shown in FIG. 1 have an elongate outer sleeve 4 of a generally rectangular configuration which retains and protects the compressed fire stop material 6. The compressed fire stop material 6 is preferably a mineral wool or other fire barrier material and the outer sleeve 4 is preferably a thin walled PVC enclosure. Other cross sections of the outer sleeve 4 can be used.

As can be appreciated from FIG. 1 these rectangular fire barrier components can be manufactured in long lengths and can be placed side by side for forming the fabricated barrier 10.

FIG. 2 shows a circular retaining frame 20 securing the barrier components 22 within the frame. As can be appreciated the components 22 can be field cut to different lengths and the ends of these components can be cut to generally form to the shape of the circular retaining frame 20. The factory made components 22 can be used as part of a factory manufactured fire barrier assembly or these components can be used as a fire retardant building component that can be cut and/or used in combination to suit a particular onsite requirement.

It is preferred that each of the fire barrier components 2 be of a generally rectangular section where the compressed fire stop material 6 is compressed between the two opposed sidewalls of the outer sleeve identified as 6a and 6b. Typically, the fire barrier components 2 are installed in the orientation shown in FIG. 1 for a horizontal access port. The bottom surface 12 is the surface that is likely to be exposed to a fire condition. It is this portion of the outer sleeves that is first to fail in a fire condition and the failure of this portion allows the compressed fire block material to be exposed to the fire condition from below and to expand. Somewhat surprisingly, it is not necessary that the outer sleeve be of a non-combustible material. It may be desired to make it of a non-combustible material or a material which burns or fails in a particular manner. For example, this could be of a PVDF material of an appropriate firing rating. The outer sleeve could also be of a co-extruded material and have an outer protective surface.

The fire barrier components of FIG. 1 are each individual components however if desired it is possible to provide interior partitions to the barrier component. It may be desired to effectively have three channels within a barrier component and knockout ports 14 can be provided in the top and bottom surfaces of the fire barrier component as shown in FIG. 1. It may be desired that the knockout ports are only associated with the center channel of the three channels whereby the wire or pipe can be forced through the center channel. Some damage or dislocation of the compressible fire barrier material may occur but it would be limited to only a small portion and the component would continue to function in its intended manner. Fire stop sealants can be applied on top of the component about any penetrants if desired or necessary. By dividing the components into the channels the damage is limited, and the channels either side of the center channel serve to provide additional capacity when the fire condition occurs. As can be appreciated the failure of the bottom surface of the component would allow all of the compressed mineral wool material to expand laterally and correct for any small gaps or deficiencies resulting from the removed compressed fire stop material. Preferably any interior portions within the barrier component are thin walled.

A further advantage of the knockout ports is that only a limited surface of the outer sleeve is removed while allowing the worker a clear indication of how to use the factory made fire barriers component having a quality controlled known performance due to the compressed fill material.

Although the knockout ports are desirable it is also possible to merely drill through the outer sleeve as may be required using conventional tools commonly available. With this arrangement for certain applications where only a single wire or small pipe needs to additionally pass through the barrier, the installer can merely use one of the ports rather than removing an entire barrier component. As can be appreciated, the removal of an entire component creates a significant gap that can be avoided when the expansion requirements to accommodate a pipe or wire are quite minimal.

Various designs for the outer sleeve are shown with respect to FIGS. 3, 4 and 5. All of these designs have the common advantage of defining a structure where the insertion of the compressed fire stop material 6 is easily accomplished. Furthermore, each of these structures, once the material has been inserted allow the tube to be closed and locked. The specific designs show a snap fit lock type arrangement but other arrangements are possible. Furthermore, it may be desired to provide an overlap fit or provide for welding of the lock arrangement. The purpose of the open capabilities of the structures of FIGS. 3 through 5 is from a manufacturing point of view as it is desirable to manufacture this barrier component in long lengths or on a continuous basis.

As can be appreciated from a consideration of FIG. 5 it would be possible to allow the extrusion of the component and the subsequent insertion of the compressible fill material as part of a continuous manufacturing process. The continuous extruded component can then be cut to desired lengths for shipping or storage. As previously described it may be desirable to permanently close the sleeve as opening of the sleeve after the compressed material has been inserted is not normally required.

In the present design it is desirable that the fire stop material be compressed at least laterally. Preferably, this material is compressed to at least one third of its non-compressed state. Some compression in the longitudinal or top to bottom direction is possible and desired. The extent of this compression would be much less. For many applications it is desirable merely to provide the expansion in one direction for better control and it also simplifies the manufacturing process.

The outer sleeve cross section of FIG. 3 shows a two-piece outer sleeve 30, a clamp on cover 32 and a base channel 34. Snap locks 36 allow the cover to be secured and retained on the base channel 34. As can be appreciated compressible fire stop material may be easily loaded in the base channel 34 and the cover 32 may then be locked on the channel.

The two-piece extrusion of FIG. 4 has the two-piece one extrusion structure 40 made up of the first component 42 and the second component 44. These are the same component but merely reversed in orientation. At one end of the extrusion is the male connector 46 and on the opposite end of the extrusion is the female connector 48.

The embodiment of FIG. 5 shows a one-piece open outer sleeve 60. A live hinge 62 is provided between the first half component 64 and the second half component 66. Once the compressed fire material has been loaded in the one-piece open sleeve 60 the two halves may be brought into engagement with the male connector 68 inserted and locked in the female connector 70. Due to the flexibility of plastic the live hinge could be deleted and the sleeve merely forced open to insert the fire stop material. The sleeve can then be longitudinally secured in a suitable manner.

The fire barrier component as described with respect to the drawings simplifies the manufacture of factory produced fire stop assemblies where the barrier component is inserted preferably and retained within a structural frame or system. The component may be cut to the appropriate length and the user can easily modify the structure in the field as required to suit the different conduits or pipes that may have to pass through the assembly.

It is also possible to use the fire barrier component for the construction of customized barriers in the field or to protect particular surfaces. For example, in some applications it is desirable to provide additional fire stop insulation beneath the deck of a ship and the varying components could be installed to provide both the fire barrier and insulation properties. It is also possible that the fire barrier component can be used for closing of large ports in walls that may be present for future expansion. Basically the fire barrier component is easily cut on the jobsite using a circular saw or other cutting device and this allows the user to easily customize the structure. This flexibility increases the number of applications where the fire barrier component can be used.

The fire barrier component has been described with respect to its ability to expand laterally when exposed to a fire condition. This lateral expansion against other like components provides a cooperative effect. There are applications where the component can be installed in the opposite orientation to provide higher insulation properties when the component is exposed to a fire condition. Basically rather than the components expanding against one another the compressed fill material expands downwardly. This expansion increases the amount of insulation due to the expansion of the fire stop material. Therefore in applications where space may be limited this pre-compressed state effectively provides more clearance until such time as a fire condition occurs.

The fire barrier component has been described for providing a single layer fire stop barrier. It is also possible in certain applications to greatly improve the fire barrier capability by providing a second layer of fire barrier components above a first layer. Furthermore, the orientation of this second layer can be changed. For example, the first layer and the second layer could be effectively rotated 90 degrees to each other. Therefore it is possible to use this fire barrier component in alternate manners and this again increases the number of applications that component can be used.

Although various preferred embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that variations may be made without departing from the spirit of the invention or the scope of the appended claims.

Claims

1. A fire barrier component comprising an elongate outer sleeve of a moldable material of a generally fixed cross section and a compressed fire stop material retained and protected interior to said outer sleeve.

2. A fire barrier component as claimed in claim 1 wherein said outer sleeve is of an extruded plastic material.

3. A fire barrier component as claimed in claim 2 wherein said fire barrier component has a rated fire stop application and said compressed fire stop material is a non combustible material for the rated fire stop application.

4. A fire barrier component as claimed in claim 3 wherein said compressed fire stop material is compressed mineral wool.

5. A fire barrier component as claimed in claim 3 wherein said compressed fire stop material is compressed glass fiber material.

6. A fire barrier component as claimed in claim 3 wherein said outer sleeve is of a rectangular cross section.

7. A fire barrier component as claimed in claim 6 wherein said outer sleeve is a one piece extruded tube.

8. A fire barrier component as claimed in claim 6 wherein said outer sleeve is defined by at least two elongate components that cooperate to engage and retain said compressed fire stop material therein.

9. A fire barrier component as claimed in claim 8 wherein said at least two elongate components define in an unlocked condition an open channel for locating said compressed fire stop material therein and in a locked condition retain said compressed fire stop material in said outer sleeve.

10. A fire barrier component as claimed in claim 3 wherein said compressed fire stop material is compressed in at least a lateral direction across said outer sleeve.

11. A fire barrier component as claimed in claim 10 wherein said fire stop material is compressed in at least one direction to at least a third of its non-compressed state.

12. A fire barrier component as claimed in claim 11 wherein said component is manufactured in a length exceeding six feet.

13. A fire barrier component as claimed in claim 11 wherein said component can be cross cut by a user using a saw.

14. A fire barrier component as claimed in claim 13 wherein said component is of a length of at least eight feet.

15. A fire barrier component as claimed in claim 3 wherein said outer sleeve includes a series of knockout ports along the length of the component through which electrical wires, pipes or conduits can pass.

16. A fire barrier component as claimed in claim 15 wherein said outer sleeve includes at least one internal partition running the length thereof with said compressed fire stop material either side thereof.

17. A fire barrier component as claimed in claim 15 wherein said outer sleeve has at least two internal longitudinally extending partitions defining three channels within said outer sleeve, and wherein said knockout ports are associated with a center channel of said three channels.

18. A fire barrier component as claimed in claim 17 wherein said component is of a generally rectangular cross section.

19. A fire barrier component as claimed in claim 18 wherein said outer sleeve is of a material to be at least partially consumed when exposed to a fire condition and at least partial fail thereby allowing said compressed fire stop material to expand and at least partially protect a portion of the outer sleeve that remains.

20. A fire barrier comprising a series of elongate fire barrier components held in a side by side configuration wherein each component comprises an elongate outer sleeve of a plastic material and a compressed fire stop material retained and protected interior to said outer sleeve, said outer sleeve being at least semi-rigid.

21. A fire barrier as claimed in claim 20 wherein said fire barrier components have a rated fire stop application and said compressed fire stop material is a non combustible material for the rated fire stop application.

22. A fire barrier as claimed in claim 21 wherein said compressed fire stop material is compressed mineral wool.

23. A fire barrier component comprising an outer sleeve of a material that will at least partially fail when exposed to a fire condition, and a compressed fire stop material retained within said outer sleeve; said compressed fire stop material expanding to form a fire stop barrier upon said at least partial failure of said outer sleeve.

24. A fire barrier component as claimed in claim 23 wherein said outer sleeve is of a material that is combustible when exposed to a fire condition.