Modular Fire-Rated Duct Assembly With Rectangular Leak-Safe Joints
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Solution Overview
Problem
Existing fire-rated exhaust duct systems face challenges in preventing the spread of flammable or hazardous gases and vapors, require costly rework due to poor welding quality, and have a round profile that limits air volume and fits poorly in conventional building spaces.
Innovation Solution
A modular fire-rated duct system with a rectangular cross-section, comprising inner and outer ducts with insulation, flange connectors for field assembly, and a joint encasement to form a continuous duct run, reducing the need for on-site welding and improving fitment in building spaces.
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 protection is provided, but the volume of air that can be carried is significantly limited and fitment in conventional building spaces is poor
Solution Approach 1:
The patent applies asymmetry by changing the duct cross-section from a conventional round profile to a rectangular profile. This asymmetric shape change allows the duct to better fit into conventional building spaces and significantly increases the air volume capacity while maintaining fire protection capabilities through the modular construction with insulation layers.
2Reliability
If field welding is used to assemble duct sections, then continuous conduits can be formed, but poor welding quality results in leaks requiring expensive rework and re-welding
Solution Approach 1:
The patent merges the sealing function into the modular duct connection system itself, rather than relying on separate welding operations. The modular sections are designed with integrated sealing mechanisms that ensure leak-free connections during field assembly, eliminating the need for post-assembly welding and rework while maintaining reliable seal integrity.
3Reliability
If additional gypsum fire-rated enclosure is installed around the duct, then fire rating is enhanced, but installation complexity increases and requires coordination with another trade
Solution Approach 1:
The patent combines the fire protection function directly into the duct assembly itself through modular sections with integrated insulation layers, rather than requiring a separate gypsum enclosure. This integration maintains the required fire rating while significantly reducing installation complexity and eliminating the need for coordination with additional trades.
4Reliability
If wall thickness is increased to prevent heat transfer, then fire protection is improved, but the duct becomes too large to fit in conventional building spaces
Solution Approach 1:
The patent uses composite material construction with multiple layers including insulation materials between the inner and outer duct walls. This composite structure provides effective heat transfer prevention and fire protection while maintaining a compact overall duct size that fits within conventional building spaces, avoiding the need for excessive wall thickness.
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 system effectively contains flammable materials, reduces rework costs, and fits within conventional building dimensions, enhancing safety and installation efficiency.
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.