Pre-Formed Metal Deck Flute Seal for Fire and Sound Blocking
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Solution Overview
Problem
Existing sealant compounds for sealing gaps between structural components in building constructions are costly and time-consuming to install, and do not conform well to the contours of the ceiling, leaving gaps that allow environmental factors like noise, smoke, and fire to transmit through.
Innovation Solution
A pre-formed sealant element with integrated features that conform to the geometry of metal deck flutes, made of heat-resistant materials, which can be installed before the top track is mounted, and includes adhesion components and extensions to ensure a secure fit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional foam board or spray foam insulation is used in metal deck voids, then thermal insulation is provided, but fire safety is compromised due to flammability
Solution Approach 1:
The patent changes the material composition from organic foam (flammable) to inorganic blown-in insulation material (non-combustible), maintaining thermal insulation properties while eliminating fire hazards. The material achieves a fire rating of ASTM E84 Class A or UL 723 Class 1 through compositional change.
Solution Approach 2:
The insulation material is a composite consisting of inorganic particles (glass beads, sand, or slag) bound with cementitious binder, creating a material that combines thermal insulation properties with fire resistance. This composite structure provides both R-value and fire safety.
2Ease of manufacture
If metal deck voids are left empty or filled with traditional materials, then installation is simple, but acoustic performance is insufficient for sound transmission control
Solution Approach 1:
The patent modifies the acoustic properties by using the air voids within the blown-in insulation material and the metal deck geometry to create sound transmission control. The material's porous structure and the cavity design work together to achieve STC 50 or higher while maintaining easy installation through a single pour process.
3Reliability
If metal deck voids are filled with insulation material, then thermal and acoustic performance improve, but the material must navigate complex void geometries and reach all areas effectively
Solution Approach 1:
The blown-in insulation material is delivered through a hose and automatically distributes itself throughout the complex void spaces using air pressure. The material flows into and fills all accessible areas of the irregular geometry without requiring manual placement or complex delivery mechanisms, achieving complete coverage of the metal deck voids.
4Object-affected harmful factors
If fire blocking is added to prevent fire spread, then fire safety improves, but the complexity of the insulation system increases
Solution Approach 1:
The blown-in insulation material serves multiple functions simultaneously: thermal insulation, acoustic control, and fire blocking. The material fills the metal deck voids and creates fire barriers at floor line intersections, eliminating the need for separate fire blocking components and reducing overall system complexity.
Data Source
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AI summary
A system includes a metal deck having alternating valley regions and peak regions. The alternating valley regions and peak regions form one or more flutes, and each flute of the one or more flutes includes a geometry having one or more geometrical features. The system also includes a pre-formed sealant element configured to conform to the geometry of each flute. The pre-formed sealant element includes one or more integrated features that conform to the geometrical features of each flute of the metal deck. The pre-formed sealant element is configured to seal each flute against a potential environmental source.