Intumescent Backer Rod Fire Stop for Fast Wall Joint Sealing
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Solution Overview
Problem
Existing fire-rated wall construction components for expansion joints are inefficient, costly, and labor-intensive, failing to meet building codes for fire resistance and smoke containment, while posing environmental and safety hazards during installation.
Innovation Solution
A fire-rated system comprising a durable foam backer rod with integrated intumescent strips that expand up to 33 times its size upon exposure to heat, providing a comprehensive seal for expansion joints in walls, reducing installation complexity and eliminating the need for mineral wool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fire-rated wall construction components are used for expansion joints, then fire resistance and smoke containment are achieved, but installation is time-consuming and expensive
Solution Approach 1:
The patent combines multiple fire-rated components (backer rod, intumescent material, and sealant) into a single integrated fire stop system. The backer rod and intumescent material are pre-assembled as one unit, eliminating the need for separate installation steps and reducing labor time while maintaining fire resistance ratings.
Solution Approach 2:
The intumescent material is pre-positioned within the backer rod structure before installation. This preliminary arrangement ensures that when fire occurs, the intumescent material is already in the correct position to expand and seal the expansion joint, eliminating the need for complex on-site assembly during emergency conditions.
2Reliability
If intumescent materials are mechanically attached or compressed into the opening, then fire test requirements are met, but installation complexity increases
Solution Approach 1:
The backer rod is designed with self-supporting characteristics that allow it to hold the intumescent material in place without requiring additional mechanical attachment devices. The structural design of the backer rod itself provides the necessary support, eliminating complex attachment mechanisms while ensuring the intumescent material remains positioned to meet fire test requirements.
3Reliability
If mineral wool is used for fire stopping, then fire resistance is achieved, but environmental and safety hazards are created during installation
Solution Approach 1:
The patent employs synthetic foam backer rod material that serves the fire stopping function effectively but can be easily disposed of after use. This disposable approach eliminates the environmental persistence issues associated with mineral wool, allowing the material to fulfill its fire protection purpose and then be removed without long-term environmental impact concerns.
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 system simplifies installation, reduces labor, meets or exceeds fire safety standards, avoids environmental and safety concerns, and allows for easy disposal, while effectively preventing the spread of fire and smoke.
Implementation Method 1
an intumescent strip that when exposed to high temperatures expands up to 33 times its size, preventing the passage of flames, hot gasses, and smoke
Data Source
AI summary
A device that is an improved rapid expansion fire stop and system for wall openings. The fire stop is made of a backer rod comprised of a durable foam material in a pre-determined size and cross-sectional configuration, the backer rod has a slot that accepts an intumescent strip with expansion characteristics of expanding up to thirty-three (33) times its size and volume when exposed to high heat or flame. The firestop is placed into the wall opening or crack of the wall system and then the wall system is completed with an architectural sealant across the remaining crack. The improved expanding rapid expansion fire stop serves to prevent fire, smoke and heat by expanding and fully sealing the wall opening and crack from any intrusion or passage of the heat, smoke or flame through the opening.