Fire-Rated Plumbing Supply Box With Thermoset Housing
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Solution Overview
Problem
Thermoplastic plumbing supply boxes used in fire-rated walls face high costs and poor structural integrity when attempting to maintain fire rating through thicker walls and large intumescent pads.
Innovation Solution
The use of thermoset plastic materials for the supply boxes, combined with adjustable support brackets and a minimal amount of intumescent material near the drain adaptor, ensures the boxes do not melt and collapse, while allowing for easy alignment and cost-effective fire rating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermoplastic supply boxes use thicker walls and large intumescent pads to achieve fire rating, then fire rating is maintained, but cost increases and structural integrity at high temperatures deteriorates
Solution Approach 1:
The patent changes the material parameter from thermoplastic to thermoset plastic, which fundamentally alters the material's thermal response. Thermoset plastics undergo chemical cross-linking during curing that creates a three-dimensional network structure, preventing melting and collapse at high temperatures. This parameter change eliminates the need for excessive wall thickness and large intumescent pads, thereby reducing cost while maintaining fire rating.
Solution Approach 2:
The patent employs composite construction by combining thermoset plastic material with strategically placed intumescent pads. The thermoset plastic provides inherent fire resistance and structural stability, while the intumescent pads provide additional fire protection where needed. This composite approach optimizes the balance between fire rating, cost, and structural integrity.
2Reliability
If thermoplastic supply boxes use thicker walls and large intumescent pads to achieve fire rating, then fire rating is maintained, but structural integrity at high temperatures deteriorates
Solution Approach 1:
The patent changes the material parameter from thermoplastic to thermoset plastic, which fundamentally alters the material's thermal response. Thermoset plastics undergo chemical cross-linking during curing that creates a three-dimensional network structure, preventing melting and collapse at high temperatures. This parameter change eliminates the need for excessive wall thickness and large intumescent pads, thereby reducing cost while maintaining fire rating.
Solution Approach 2:
The patent employs composite construction by combining thermoset plastic material with strategically placed intumescent pads. The thermoset plastic provides inherent fire resistance and structural stability, while the intumescent pads provide additional fire protection where needed. This composite approach optimizes the balance between fire rating, cost, and structural integrity.
3Ease of manufacture
If fixed mounting positions are used for supply boxes, then manufacturing is simplified, but adaptability to different stud bay spacings and plumbing alignments deteriorates
Solution Approach 1:
The patent introduces adjustable mounting brackets that can be positioned at different locations along the supply box. These brackets allow the box to be mounted in various positions within the wall cavity, accommodating different stud bay spacings (e.g., 16 inches vs. 24 inches on center). The mounting system transitions from fixed to adjustable, providing dynamic adaptability while maintaining manufacturing simplicity through standardized bracket designs.
Solution Approach 2:
The mounting brackets are designed as universal components that can accommodate multiple mounting scenarios and stud spacings. A single bracket design serves multiple functions across different installation configurations, eliminating the need for custom-manufactured boxes for each spacing requirement.
4Ease of manufacture
If fixed mounting positions are used for supply boxes, then manufacturing is simplified, but ease of alignment with in-wall plumbing deteriorates
Solution Approach 1:
The patent introduces adjustable mounting brackets that can be positioned at different locations along the supply box. These brackets allow the box to be mounted in various positions within the wall cavity, accommodating different stud bay spacings (e.g., 16 inches vs. 24 inches on center). The mounting system transitions from fixed to adjustable, providing dynamic adaptability while maintaining manufacturing simplicity through standardized bracket designs.
Solution Approach 2:
The adjustable mounting brackets are pre-installed on the supply box during manufacturing, but their positions can be adjusted during installation to facilitate alignment with in-wall plumbing. This preliminary preparation combined with field adjustability simplifies both manufacturing and installation processes.
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 provides fire-rated plumbing supply boxes with improved structural integrity at high temperatures and reduced costs, allowing for flexible mounting and alignment with in-wall plumbing, while maintaining the fire rating of the wall.
Implementation Method 1
the boxes may be made of a thermoset plastic fire rated material that will not melt or collapse inside a fire rated wall when subjected to flames or high temperatures caused by a fire
Implementation Method 2
the heat will also cause the intumescent material to expand sufficiently to form a hard char to seal off the wall opening previously occupied by the boxes
Implementation Method 3
if the boxes are exposed to enough heat to cause the drain adaptor to melt, the intumescent material will expand and form an insulating char that seals off the associated drain opening
Data Source
AI summary
Plumbing supply boxes may be made of a thermoset plastic material that will not melt or permit the boxes to collapse inside a wall if subjected to flames or high temperatures resulting from a fire. If the thermoset plastic boxes have a drain opening, a thermoplastic tubular drain adaptor may be connected thereto that can be solvent welded. Relatively small intumescent pads may be installed in close proximity to the drain opening which, if subjected to flames or high temperature caused by a fire, will expand and form an insulating char that seals off the drain opening. The boxes may be slidable in opposite directions along adjustable support brackets to permit the boxes to be mounted in any desired position in stud bays having different spacings between the stud walls for ease of alignment of one or more openings in the box with in-wall plumbing.