Factory-Applied Modular Fire Barrier Assembly
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Solution Overview
Problem
Existing modular building systems require labor-intensive on-site installation of fire barrier assemblies, which can be challenging due to access issues and increases construction costs.
Innovation Solution
A modular fire barrier assembly is designed to be factory-applied, comprising an elongated fire barrier with a lower and upper foam core, an intumescent layer, and a fire-resistant fabric wrap, which can be easily attached to modular building units using fasteners or adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fire barrier assemblies are installed on-site by hand, then flexibility in installation is maintained, but labor costs increase and quality control deteriorates
Solution Approach 1:
The fire barrier assembly is pre-applied to the modular building unit in the factory before transport to the building site. This preliminary action eliminates the need for on-site installation labor while maintaining the same fire protection function, directly resolving the contradiction between ease of manufacture and device complexity.
2Productivity
If fire barrier assemblies are applied by hand on-site, then installation adaptability is maintained, but construction time increases and productivity decreases
Solution Approach 1:
The fire barrier is applied in the factory during manufacturing, so that when the modular unit arrives at the building site, the fire protection is already in place. This eliminates time-consuming on-site installation work and directly increases construction productivity without adding operational complexity.
Solution Approach 2:
The fire barrier assembly is integrated as a separate component that can be independently manufactured and then assembled to the modular building unit. This segmentation allows the fire barrier to be produced in a controlled factory environment and then quickly installed on-site, resolving the contradiction between productivity and ease of operation.
3Productivity
If modular components are assembled quickly on-site, then construction efficiency improves, but access for fire barrier installation becomes difficult
Solution Approach 1:
The fire barrier is applied to the modular unit in the factory before it is transported to the building site and assembled with other modules. This preliminary application ensures that fire protection is already in place when the modular units are quickly assembled on-site, eliminating the access problems that would arise from trying to install fire barriers between rapidly assembled components.
4Ease of manufacture
If factory-based assembly is increased, then construction cost decreases and quality improves, but fire barrier application complexity increases
Solution Approach 1:
The fire barrier assembly is pre-applied to the modular building unit in the factory during manufacturing. This approach moves the fire barrier application to the factory environment where quality control and manufacturing efficiency can be optimized, reducing overall construction cost and improving quality while managing the complexity through standardized factory processes.
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 factory-applied fire barrier assembly reduces labor costs, improves quality control, and ensures effective fire protection when modular components are assembled on-site, while also accommodating movement and installation variations.
Implementation Method 1
a lower foam core, the lower foam core comprising at least a first layer of foam and a second layer of foam with at least one intumescent layer sandwiched between the first and second foam layers
Implementation Method 2
an outer wrap of a fire resistant fabric surrounding the lower foam core and upper foam core and bridging the gap
Implementation Method 3
The strength of the fabric wrap and the compressibility of the foam allows the first modular unit to be dropped adjacent to the second modular unit without damaging the fire barrier
Data Source
AI summary
An improved fire barrier assembly is disclosed for use between two structures, either in a compressive mode or a combination compression/shear mode. The assembly includes at least a single foam core, or two foam cores separated by a gap. At least one foam core includes an intumescent layer. An outer wrap of a fire-resistant fabric surrounds the foam core. The assembly is fastened to one surface of one structure.