Firewall Insert Box Sealing Gaps for ASTM E-119 Compliance
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Solution Overview
Problem
Existing electrical boxes in firewalls often fail to meet the ASTM E-119 fire test standards due to gaps that allow heat, smoke, and gases to penetrate, posing a challenge in ensuring fire safety in commercial buildings.
Innovation Solution
A firewall box insert with a flanged open end that nests within existing electrical boxes, sealing gaps between the box and the wall, constructed from sheet metal or intumescent plastic to block heat and gases, and featuring wire harnesses to eliminate wire penetrations, enhancing fire protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrical boxes are installed in firewalls, then electrical functionality is provided, but gaps allow heat and smoke penetration failing fire tests
Solution Approach 1:
The firewall is segmented into two separate compartments by the firebox insert, creating distinct fire-rated zones that prevent heat and smoke transmission while accommodating electrical components within the insert structure
Solution Approach 2:
The firebox insert acts as an intermediary barrier between the electrical box and the firewall opening, providing fire protection while allowing electrical functionality to operate within the protected compartment
2Reliability
If fire protection is added to electrical boxes in firewalls, then fire test compliance is achieved, but installation complexity increases
Solution Approach 1:
The firebox insert is designed to nest within the existing electrical box structure, allowing fire protection to be added without requiring complete redesign or complex assembly procedures
Solution Approach 2:
The firebox insert is pre-assembled with fire-resistant materials and sealing components before installation, reducing on-site assembly complexity and ensuring fire test compliance is built-in rather than added 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 insert effectively divides the electrical box into sections, maintaining structural integrity at high temperatures and preventing heat and smoke penetration, thereby ensuring compliance with ASTM E-119 fire tests and enhancing fire safety.
Implementation Method 1
If the flange is metallic it blocks the direct path for heat and gases
Implementation Method 2
If the flange is partially or entirely of intumescent material it swells into the gap, which also seals the gap from heat or gases and smoke
Implementation Method 3
The insert box is constructed entirely of sheet metal capable of maintaining its structural integrity in the presence of at least 2000 degrees F. of direct heat
Data Source
AI summary
The invention described herein is a fire protection device in the form of an insert designed to be quickly installed in new or existing electrical boxes located in firewalls. This insert is comprised of a material designed to withstand high direct heat and serve as a barrier to the passage of direct heat or smoke and gases through firewalls rated under ASTM E-119. The insert features a flanged open end which overlaps any gaps between the existing electrical box and the wall. The back wall of the insert box may have either openings to permit wires to pass through to the electrical device or a plug-harness assembly which obviates the use of holes in the back of the insert box.