Modular Fire-Rated Duct Assembly Without Gypsum Enclosures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fire-rated exhaust duct systems face challenges in containing flammable or hazardous gases and vapors, as they often require additional gypsum enclosures and have limitations in air volume and space compatibility due to their round profile, leading to inefficiencies and rework in installations.
Innovation Solution
A modular fire-rated duct assembly with a rectangular cross-section, featuring an inner duct liner and outer casing with a void for insulation, thermal spacers to maintain spacing, and flange connectors for field assembly, allowing for efficient and secure connection of duct sections without on-site welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional fire-rated exhaust duct systems are used with round profile, then fire containment is achieved, but air volume capacity is limited and space compatibility is reduced
Solution Approach 1:
The patent transitions from a conventional round duct profile to a rectangular cross-section design. This asymmetric change allows the duct to better utilize building space, fit into conventional ceiling spaces, and increase air volume capacity while maintaining fire containment capabilities through the modular construction with insulation layer.
2Reliability
If conventional fire-rated duct sections are welded together on-site, then continuous conduits are formed, but installation complexity increases and rework is required due to poor weld quality
Solution Approach 1:
The duct system is divided into modular sections that can be pre-fabricated with factory-controlled welding or mechanical connections. These standardized modules are designed to connect via simple field assembly methods such as flange connections or interlocking mechanisms, eliminating the need for complex on-site welding while ensuring consistent seal quality through precision manufacturing of the connection interfaces.
Solution Approach 2:
The duct sections are pre-assembled and pre-tested in the factory before delivery to the installation site. This preliminary action ensures that welding quality and seal integrity are verified under controlled conditions, eliminating the need for expensive rework and re-welding during field installation. The modules arrive ready for final assembly, reducing both installation complexity and potential quality issues.
3Reliability
If additional gypsum fire-rated enclosure is installed around the duct, then fire protection is enhanced, but installation time and device complexity increase
Solution Approach 1:
The fire protection function is merged into the duct assembly itself by integrating an insulation layer between the inner duct wall and outer casing. This combined design eliminates the need for separate gypsum enclosures, as the insulated modular duct inherently provides fire resistance. The integration reduces installation time by removing additional construction steps and simplifies the overall system while maintaining or enhancing fire protection capabilities.
4Ease of manufacture
If duct sections are fabricated in sections and shipped to installation location, then transportation is facilitated, but welding quality deteriorates due to field conditions
Solution Approach 1:
The duct system is segmented into standardized modules that are small enough for efficient transportation but large enough to minimize the number of connections required. Each module is pre-fabricated with high-quality connections in the factory. The segmentation allows for practical shipping while the standardized design ensures that field assembly requires minimal welding or joining operations, thereby maintaining connection quality despite field conditions.
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 modular design enhances fire containment and air volume capacity while reducing installation complexities and rework, providing a more efficient and effective solution for handling flammable or hazardous materials in commercial and industrial settings.
Implementation Method 1
a void being formed between at least a portion of space between said inner duct liner and said outer casing, said void being configured for receiving an insulation material
Data Source
AI summary
A fire-rated exhaust duct system comprising a modular configuration or structure. The fire-rated exhaust duct system comprises a plurality of exhaust duct sections. Each of the exhaust duct sections is configured to be joined or connected with other exhaust duct sections in the field or at an installation site, e.g. in building housing a kitchen facility or a laboratory facility to form longer sections or runs for exhaust duct system.