Fire Barrier System for Expansion Joints Using Composite Materials
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Solution Overview
Problem
Existing fire barriers fail to meet the 3-hour rating requirement of UL 2079 and are difficult to install due to complex geometry, lacking adequate fire protection and ease of installation.
Innovation Solution
A fire barrier system comprising ceramic fiber blankets with metal foil, intumescent sheets, and a flame retardant element, affixed using pressure-sensitive adhesives, which forms a robust and easy-to-install solution for expansion joints, capable of meeting the 3-hour fire-rating standard.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing fire barriers are used, then fire protection is provided, but they fail to meet the 3-hour rating requirement and have complex geometry making installation difficult
Solution Approach 1:
The fire barrier is divided into multiple modular components including fire blankets, intumescent sheets, and adhesive layers that can be separately manufactured and assembled. This segmentation simplifies installation while maintaining the required 3-hour fire rating through the coordinated function of each component.
Solution Approach 2:
The invention uses composite material structures combining ceramic fiber blankets with metal foil encasements, intumescent sheets, and adhesive layers. This composite approach achieves the 3-hour fire rating requirement while creating a more installation-friendly structure compared to monolithic existing barriers.
2Reliability
If complex geometry fire barriers are used, then fire protection is achieved, but installation becomes difficult and time-consuming
Solution Approach 1:
By segmenting the fire barrier into standardized modules (fire blankets, intumescent sheets, adhesives), the invention reduces geometric complexity while maintaining protective function. Each module has simple geometry that can be easily handled and installed.
Solution Approach 2:
The invention changes the physical and chemical parameters of the materials used (e.g., using flexible ceramic fiber blankets with metal foil, intumescent sheets with specific expansion properties) to achieve fire protection without requiring complex geometric configurations.
3Reliability
If traditional fire barriers are used, then some fire protection is provided, but they cannot meet the 3-hour rating standard of UL 2079
Solution Approach 1:
The invention achieves the 3-hour fire rating by combining multiple materials with complementary fire-resistant properties: ceramic fiber blankets for thermal insulation, metal foil for structural integrity and flame resistance, and intumescent sheets for expansion-based fire blocking. This composite material strategy meets the stringent UL 2079 standard while using commercially available components that are relatively easy to manufacture.
Solution Approach 2:
The intumescent sheets are pre-formed with specific geometric configurations and adhesive properties that enable them to expand and seal gaps during fire exposure. This preliminary preparation of the materials ensures the 3-hour rating is achieved without complex manufacturing processes during installation.
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
The solution effectively meets the 3-hour fire-rating requirement, provides excellent fire protection, and is easier to install compared to existing systems, while maintaining structural integrity under stress conditions.
Implementation Method 1
a first intumescent sheet (40) having a first surface (41) and a second surface (42), said first intumescent sheet (40) affixed to a first structure (300), and a second intumescent sheet (50) having a first surface (51) and a second surface (52), said second intumescent sheet (50) affixed to a second structure (400)
Implementation Method 2
a first fire blanket (10) having a top side (11), a bottom side (12), a first lateral side (13) and a second lateral side (14), said first fire blanket (10) comprising a ceramic fiber blanket surrounded with a metal foil
Implementation Method 3
a first fire blanket (10) having a top side (11), a bottom side (12), a first lateral side (13) and a second lateral side (14), said first fire blanket (10) comprising a ceramic fiber blanket surrounded with a metal foil
Implementation Method 4
a first lateral side (13) of the first fire blanket (10) and the first lateral side (23) of the second fire blanket (20) are affixed to a portion of the first surface (41) of the first intumescent sheet (40) and the second lateral side (14) of the first fire blanket (10) and the second lateral side (24) of the second fire blanket (20) are affixed to a portion of the first surface (51) of the second intumescent sheet (50)
Data Source
AI summary
The presently claimed invention relates to a fire barrier, a method for installing the same, an expansion joint system and a fire barrier assembly.