Concealed Intumescent Fenestration Frames for Fire Gap Sealing

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Solution Overview

Problem

Existing fire-resistant fenestration units with visible intumescent materials are prone to degradation from environmental factors, and integrating intumescent materials within steel frames prevents them from filling gaps during fires.

Innovation Solution

Concealing intumescent members within cavities of thermally sacrificial frame materials that degrade during a fire, allowing the intumescent materials to expand and fill gaps between the frame and panel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If intumescent materials are applied directly to the exterior of the panel or frame, then they are visible and can be easily applied, but they are exposed to environmental conditions (water, water vapor, sunlight) that degrade the intumescent materials over time

Engineering Contradiction:

Improveease of applicationVSAvoidfire resistance reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The intumescent member is nested within a cavity formed in the frame member, with the intumescent material positioned inside the cavity rather than on the exterior surface. This nesting arrangement protects the intumescent material from environmental degradation while maintaining its fire-resistant function.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The cavity is constructed of thermally sacrificial material that is designed to degrade during a fire event. This sacrificial material serves as a temporary protective structure that allows the intumescent member to expand outward to fill gaps between the panel and frame during fire, after which the sacrificial material has served its purpose.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If intumescent materials are integrated within steel frames, then they are protected from environmental degradation, but the steel frame does not degrade during fire events so the intumescent material cannot expand to fill gaps

Engineering Contradiction:

Improveprotection from environmental degradationVSAvoidgap-filling capability during fire

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The cavity construction material is changed from non-degradable steel to thermally sacrificial material that undergoes parameter changes (degradation, melting, disintegration) when subjected to heat and flame during fire events. This parameter change enables the intumescent member to expand outward and fill gaps between the panel and frame during fire.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The frame member is constructed as a composite structure combining thermally sacrificial material for the cavity walls with structural material for overall support. This composite construction allows the cavity to degrade during fire while maintaining structural integrity, enabling the intumescent member to expand and seal gaps.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If strips of intumescent material are placed on exterior surfaces, then they can be applied directly, but careful alignment is required to ensure proper positioning

Engineering Contradiction:

Improveapplication simplicityVSAvoidalignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The intumescent member is nested within a pre-formed cavity in the frame member during manufacturing. This nesting approach eliminates the need for field alignment, as the intumescent material is positioned precisely within the cavity structure during fabrication rather than being applied to exterior surfaces where alignment would be critical.

Inventive Principle:

Principle #7Nested doll (Nesting)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances fire resistance by ensuring intumescent materials effectively occupy gaps between the frame and panel, maintaining fire protection without degrading from environmental exposure.

Implementation Method 1

the thermally sacrificial material of the cavity melts and/or disintegrates

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

Intumescent materials typically expand when exposed to sufficient heat and/or flame

Methodology Applied

Scientific EffectIntumescent expansion: Intumescent Materials

Data Source

PatentUS20250376892A1Fenestration unit frames and fenestration units with concealed intumescent members

Publication Date: 2025.12.11 ANDERSEN CORPORATION

AI summary

Fenestration unit frames and fenestration units with concealed intumescent members are described herein along with related methods. The fenestration unit frames and fenestration units incorporating the fenestration unit frames described herein include one or more concealed intumescent members configured to expand to occupy gaps that may be found between one or more edges of a fire-rated panel and the fenestration unit frame in which the panel is located during a fire event.