Mechanically Fastened Firestop Flute Plug for Head-of-Wall Assemblies
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Solution Overview
Problem
Conventional fire block arrangements for head-of-wall assemblies are time-consuming to install and prone to degradation, leading to reduced effectiveness over time due to the use of flexible coatings that crack and flake, compromising the seal against fire, smoke, and sound.
Innovation Solution
The flute plug assembly, which includes a support with an attachment portion and retention portions to secure a fire-blocking material plug within a flute void, providing a durable and effective seal by compressing the fire-blocking material against the concave perimeter of the flute void, eliminating the need for external sealants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flexible coating is sprayed on head-of-wall to secure fire block material, then fire block material is secured in place, but coating degrades over time causing cracks and flaking that compromise the seal
Solution Approach 1:
The patent removes the flexible coating component from the fire block assembly, replacing it with a mechanical retention system using clips or interlocking structures that physically secure the fire block material without requiring degradable coating materials
Solution Approach 2:
The patent replaces the chemical/adhesive-based flexible coating system with a mechanical retention system using clips, interlocking structures, or physical fastening mechanisms that provide durable, long-term security without degradation
2Reliability
If conventional fire block arrangement is installed, then fire blocking is achieved, but installation requires significant time and expertise
Solution Approach 1:
The fire block material and retention structures are pre-assembled into integrated units or modules before installation, allowing for rapid deployment without requiring complex on-site assembly or specialized installation expertise
Solution Approach 2:
The fire block assembly is divided into modular segments or standardized components that can be quickly installed using simple, repeatable procedures, reducing both installation time and the need for specialized expertise
3Reliability
If fire block material is positioned within gaps, then fire resistance is achieved, but material may become dislodged over time reducing effectiveness
Solution Approach 1:
The patent removes the dependency on flexible coating for material retention, using instead dedicated mechanical retention structures such as clips, tabs, or interlocking features that provide stable, long-term positioning without degradation
Solution Approach 2:
The patent employs friction-fit or compression-based retention mechanisms where curved or contoured surfaces create stable positioning through geometric interlocking, preventing material dislodgement through mechanical rather than chemical means
Data Source
AI summary
An improved flute plug for a head-of-wall assembly for fire rated wall construction beneath a fluted deck or ceiling. The improved flute plug can be friction fit within individual flute voids that run over the top of the header track. The improved flute plug can include a single piece pre-bent steel profile with fire stopping material attached thereto or contained therein. The fire stopping material can be oversized so that it will compress into the flute void over the top of the header track. The compressed fire stopping material can provide a seal against fire, smoke and/or noise through the fluted deck voids.