Pre-manufactured Isolation Block for Fluted Metal Deck Sealing

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Solution Overview

Problem

Existing methods for sealing fluted metal decks and movement joints between metal decks and adjacent walls are cumbersome, involve hazardous materials like mineral wool, and result in variable sealing quality, especially for fire-rated walls.

Innovation Solution

A pre-manufactured isolation block with specific geometric portions to snugly fit into flutes, seal movement joints, and fill corrugations, made from materials like polyurethane foam, which can be easily inserted and provides a high-quality seal with minimal manual effort, suitable for fire-rated walls.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mineral wool is stuffed into the gaps and spray coating is applied, then fire resistance and smoke proofing are achieved, but the process becomes cumbersome and requires multiple working steps

Engineering Contradiction:

Improvefire resistanceVSAvoidsealing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple sealing functions (fire stopping, smoke sealing, airtightness, sound attenuation) into a single integrated isolation block that seals the flute, movement joint, and corrugation simultaneously. This eliminates the need for separate mineral wool stuffing and spray coating steps, resolving the contradiction between achieving reliable fire resistance and reducing process complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The isolation block is pre-manufactured with the exact geometry needed to seal all gaps and joints before installation. This preliminary preparation of the sealing component eliminates on-site complex operations, allowing workers to simply insert the pre-configured block into the flute space between the metal deck and gypsum boards

Inventive Principle:

Principle #10Preliminary action

2Reliability

If mineral wool is used for sealing, then fire resistance is provided, but skin irritation occurs and protective clothing is required

Engineering Contradiction:

Improvefire resistanceVSAvoidskin irritation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter from mineral wool to foam material (such as polyurethane foam or other resilient foams). This material substitution maintains the fire resistance function while eliminating the skin irritation problem, as the foam material does not cause contact dermatitis and does not require protective clothing during installation

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If mineral wool is stuffed and spray coating is applied, then sealing quality is improved, but the quantity and quality of sealing are heavily dependent on the worker

Engineering Contradiction:

Improvesealing qualityVSAvoidworker dependency

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The isolation block is pre-manufactured with precise dimensions and geometry that exactly match the flute profile. This preliminary fabrication of the sealing component with built-in compliance features ensures consistent sealing quality regardless of worker skill level, as the block is designed to naturally conform to the flute shape upon insertion

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The isolation block is designed to self-adjust and self-seal within the flute space. The resilient foam material automatically conforms to the flute geometry and seals all gaps (flute walls, movement joints, corrugations) through its own elastic properties, eliminating the need for worker skill in stuffing and coating operations

Inventive Principle:

Principle #25Self-service

4Reliability

If spray coating is applied from both sides of the wall, then smoke proofing is achieved, but the process becomes time consuming

Engineering Contradiction:

Improvesmoke proofingVSAvoidsealing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines smoke sealing functionality into the isolation block itself through the use of foam material that provides both airtightness and smoke proofing in a single component. This eliminates the need for separate spray coating operations from both sides of the wall, significantly improving productivity while maintaining smoke proofing reliability

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10472819B2Isolation block, method for sealing a flute of a fluted metal deck, and wall and deck configuration

Publication Date: 2019.11.12 HILTI AG

AI summary

An isolation block is useful for sealing a flute of a fluted metal deck and a movement joint between the metal deck and an adjacent wall configuration. The isolation block includes a flute sealing portion adapted to snugly fit into one of the flutes of the fluted metal deck, a joint sealing portion for sealing a movement joint, and a corrugation sealing portion for sealing a corrugation between adjacent fluted deck elements or in one of the fluted deck elements.