Structural Barrier With Intumescent Core for Fire Gap Sealing
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Solution Overview
Problem
Existing methods for sealing gaps between building structures, such as walls and ceilings, are inefficient and cumbersome, often requiring large applicators for fire and soundproofing materials that can drip, waste material, and require extensive cleanup, while not effectively preventing fire and sound transmission.
Innovation Solution
An elongated structural barrier with flexible panels and wedges that can compress or expand to fit varying gap dimensions, containing a fire-resistant core that expands under heat to maintain sealing, and is easily installed in difficult-to-reach areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid or sprayed foam fire retardant material is applied using a large applicator tube or caulk gun, then the opening can be filled with fireproof and sound deadening material, but the applicator becomes large, bulky and unwieldy particularly when installing in overhead openings or along very long walls
Solution Approach 1:
The fire barrier system is divided into modular panels (e.g., 2x4 foot panels) that can be easily handled and installed without requiring large applicators. Each panel is a self-contained unit with integrated fire-resistant core material, allowing installers to work with manageable sections rather than bulk material requiring large tubes or guns.
Solution Approach 2:
The fire-resistant core material is pre-installed within rigid panels during manufacturing, rather than being applied on-site as liquid or foam. This preliminary preparation eliminates the need for large applicators during installation, as panels are simply positioned and secured in place.
2Reliability
If liquid or semi-liquid fire retardant material is hand applied, then the opening can be filled, but the material often drips or runs down walls and can coat or fill gaps intended for wiring, plumbing and HVAC ducting
Solution Approach 1:
The fire-resistant core is enclosed within rigid panel structures with defined edges and surfaces. This containment prevents the material from dripping or running down walls, and the solid panel form ensures material cannot inadvertently enter wiring, plumbing, or HVAC gaps.
Solution Approach 2:
The system uses composite panel construction combining rigid structural elements with integrated fire-resistant core material. This composite approach maintains the fireproofing function while eliminating the harmful dripping and contamination issues associated with liquid or semi-liquid applications.
3Reliability
If excess fire retardant material is applied to ensure complete filling, then the opening is adequately sealed, but extensive cleanup is required to remove excess material and provide a finished appearance
Solution Approach 1:
The panels are pre-manufactured with precise dimensions and integrated core material, ensuring proper fit and complete gap sealing before installation. This eliminates the need for on-site material application and subsequent cleanup, as panels arrive ready-to-install with exact specifications.
Solution Approach 2:
The rigid panels function as complete, self-contained units that provide fire barrier protection without requiring removal of excess material. The panels themselves are the final finished product, eliminating the cleanup process entirely.
4Ease of operation
If walls are constructed slightly shorter than the distance between floor and ceiling to facilitate raising, then the wall can be easily installed, but an opening is produced above the wall that requires fire retardant filling
Solution Approach 1:
The fire barrier panels are designed to integrate with the wall-ceiling assembly, combining the fire protection function with the structural closing of the gap. The panels can be installed as part of the wall system or as a coordinated component, merging multiple functions into a unified assembly rather than adding a separate complex system.
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 structural barrier efficiently seals gaps, provides fire and soundproofing, and is easily installed, reducing material waste and cleanup time, while effectively preventing fire and sound transmission.
Implementation Method 1
containing a fire-resistant core that expands under heat to maintain sealing
Data Source
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AI summary
An elongated structural barrier is provided including a base, a first panel extending upward from the base, a first sealer wall extending downward and transversely to the base, a second panel joined with the first panel and extending upwardly, a lower wedge extending upward from the base adjacent the first sealer wall, and a core compartment bounded by the lower wedge and the panels, with an open face defined above the lower wedge and offering a view into the core compartment. The lower wedge can include a flange to produce a first cavity of the compartment, in which an intumescent core can be positioned and configured to expand into a second cavity of the compartment when it swells. A second flange can oppose the first flange to further secure the core in the first cavity, and can form a bloom gap therebetween. A related method of use also is provided.