---

Register or Login To Download This Patent As A PDF

United States Patent Application	20090183456
Kind Code	A1
Shaw; Alan	July 23, 2009

---

---

---

Claims

---

1. A fire-barrier system, comprising:an impermeable fire-barrier system for use in an expansion-joint space formed by spaced building units, comprising:a fluid and gas impermeable fire-barrier made of at least one layer of fire-resistant material and at least one adjacent layer of fluid impermeable material, said fire-barrier having a length comprising a first long side edge, a spaced and an opposing second long side edge, andan attachment apparatus for attaching said fire-barrier to the spaced building units defining the expansion-joint space.

2. The fire-barrier system, as recited in claim 1, wherein said attachment apparatus for attaching said fire-barrier to the building units further comprises a screw, bolt, nail, or fire resistant adhesive.

3. The fire-barrier system, as recited in claim 1, wherein said attachment apparatus for attaching said fire-barrier to building units further comprises a first attachment apparatus for attaching said first long edge of said fire-barrier to one building unit and a second attachment apparatus for attaching said opposing second long edge of said fire-barrier to a second opposing building unit, where the first and second building units define an expansion-joint space.

4. The fire-barrier system, as recited in claim 1, further comprising wherein said fluid and gas impermeable barrier is fitted with a drain aperture.

5. The fire-barrier system, as recited in claim 1, further comprising wherein said fluid and gas impermeable barrier is fitted with a drain aperture and a drainage hose emanating from said drain aperture.

6. The fire-barrier system, as recited in claim 1, wherein said attachment apparatus for attaching said fire-barrier to the building units further comprises a multi-part fire-resistant retainer system including a first part for attachment to said first long edge and a second part for attachment to said spaced, opposing second long edge of said fire-barrier providing a fire-barrier retainer system.

7. The fire-barrier system, as recited in claim 7, wherein said fire-barrier retainer system is fixedly attached to said fire-barrier.

8. The fire-barrier system, as recited in claim 7, further comprising an installation tool for installing said fire-barrier comprising:a width-adjustable frame, consisting ofat least two horizontally oriented, parallel, spaced tracks that are connected to each other byat least two slidably attached, horizontally oriented, parallel, spaced sliding plates each of which is positioned at a ninety degree angle to one of the tracks, providing for the installation tool to be width adjustable,through each sliding plate there are at least two horizontally oriented, parallel base plates, each affixed to and connecting the ends of a set of opposing spaced tracks,at least two spaced vertical rails fixedly attached and protruding therethrough to extend above and below each sliding plate forming a ninety degree angle with said sliding plate, anda holding bracket fixedly attached to each of said extending lower ends of said vertical rails providing for securely supporting flanged retainer plates of said fire-barrier retainer to said spaced building-units for attachment.

9. The fire-barrier system, as recited in claim 7, wherein said multi-part fire-barrier retainer system is further defined by each of said parts having at least one attachment plate arranged for bottom-mounting attachment of said fire-barrier/retainer system to the building units.

10. The fire-barrier system, as recited in claim 7, wherein said multi-part fire-barrier retainer system is further defined by each of said parts having at least one attachment plate arranged for top-mounting attachment of said fire-barrier retainer system to the building units.

11. The fire-barrier system, as recited in claim 7, wherein said multi-part fire-barrier retainer system is further defined by each of said parts having at least one attachment plate arranged for side-mounting attachment of said fire-barrier/retainer system to the building units.

12. The fire-barrier system, as recited in claim 1, wherein said fluid impermeable fire-barrier layer comprises a layer of fluid-impermeable silicone material.

13. The fire-barrier system, as recited in claim 1, wherein said fire-barrier further comprises two short ends being butt short ends for butt end joining of abutting fire-barrier sections.

14. The fire-barrier system, as recited in claim 13, wherein said fire-barrier system further comprises a fire-resistant splice connector cover to cover the splice seam of abutting fire-barrier sections.

15. The fire-barrier system, as recited in claim 1, wherein said fire-barrier further comprises two short ends where one end is formed into a male connector and the other end is formed into a female connector for male/female joining of adjacent fire-barriers.

16. The fire-barrier system, as recited in claim 5, wherein said drainage hose is plastic tubing that is positioned into and through a flexible metal fire-resistant tubing providing protection for said plastic tubing.

17. The fire-barrier system, as recited in claim 16, wherein the impermeability of said fluid and gas impermeable barrier is maintained by caulking the join between the aperture and the plastic tubing with impermeable caulk material.

18. The fire-barrier system, as recited in claim 15, wherein the join between an outer surface of the barrier and the tubing is sealed using a fire-resistant caulk material.

19. A fire-barrier system, comprising:an impermeable fire-barrier system for use in expansion-joint spaces formed by spaced building units, comprising:a fluid and gas impermeable fire-barrier made of at least one layer of fire-resistant material having an outer surface overlain by at least one layer of fluid and gas impermeable material having an upper surface, said fire-barrier having a length comprising one long edge, a spaced, opposing second long edge, and two short end edges;at least two-part attachment apparatus for attaching said fire-barrier to building units defining the expansion-joint space, where a first attachment apparatus is attachable to said one long edge providing for attaching said one long edge of said fire-barrier to a building unit and another attachment apparatus is attachable to said opposing long edge providing for attaching said opposing long edge of said fire-barrier to an opposing building unit, anda drain aperture on the upper surface of said fire-barrier and a drainage hose emanating from said drain aperture penetrating through and extending from the outer surface of said barrier providing for a drainage system, said drainage system for draining fluid from the upper surface of said fire-barrier.

20. A fire-barrier system, comprising:a gas and moisture impermeable fire-barrier system for use in expansion-joint spaces defined by spaced building units, comprising:a fire-barrier, comprisinga composite outer layer comprising an outermost protective cloth layer overlain by a layer of insulation blanket that is overlain by a sheet of stainless steel foil, andan attached composite inner layer comprising a layer of insulation blanket overlain by a layer of impermeable silicon cloth that is overlain by a layer of intumescent material,said fire-barrier having a length comprising an upper inner surface, a lower outer surface, a first long edge, a spaced, opposing second long edge, and two short end edges, anda drain aperture on the upper inner surface of said fire-barrier and a drainage hose penetrating through said fire-barrier to extend from the lower outer surface of said barrier providing for draining fluid from the upper surface of said fire-barrier,an at least two-part fire-barrier retainer system for attaching said fire-barrier to the spaced building units that define an expansion-joint space, said fire-barrier retainer system including a first part for attachment to said first long edge providing for attachment of said first long edge of said fire-barrier to a building unit and a second part for attachment to said spaced, opposing second long edge of said fire-barrier providing for attachment of said opposing second long edge of said fire-barrier to an opposing building unit, andan installation tool for installing said fire-barrier comprising:a width-adjustable frame, consisting ofat least two horizontally oriented, parallel, spaced tracks that are connected to each other byat least two slidably attached, horizontally oriented, parallel, spaced sliding plates each of which is positioned at a ninety degree angle to one of the tracks, providing for the installation tool to be width adjustable,through each sliding plate there are at least two horizontally oriented, parallel base plates, each affixed to and connecting the ends of a set of opposing spaced tracks,at least two spaced vertical rails fixedly attached and protruding therethrough to extend above and below each sliding plate forming a ninety degree angle with said sliding plate, anda holding bracket fixedly attached to each of said extending lower ends of said vertical rails providing for securely supporting flanged retainer plates of said fire-barrier retainer to said spaced building-units for attachment.

---

Description

---

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]This application claims benefit to Provisional Application No. 60/953,703, filed Aug. 3, 2007.

REFERENCE TO SEQUENCE LISTING, A TABLE OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX

[0002]Not Applicable

BACKGROUND OF THE INVENTION

[0003]The present invention relates generally to fire-barriers and more particularly to moisture impermeable fire-barriers that are installed into expansion spaces in between and from above and beneath the floor sections that are creating the expansion space.

[0004]The background information discussed below is presented to better illustrate the novelty and usefulness of the present invention. This background information is not admitted prior art. The particular versions of the invention as described below are provided, in part, as illustrative and exemplary, thus, the described versions should not be taken as limiting.

[0005]Modern building codes require stresses experienced by buildings from extreme and/or repetitive changes in temperature, the force of high winds impinging on the building, multi-directional forces due to seismic events, settling of subsoil, building remodels, and excavation on or near the site, for example, must be taken into account in the building design. To accommodate these stresses, buildings must be constructed with a code-mandated space between adjacent wall, floor, and/or ceiling structures. These spaces, referred to as "expansion-joint spaces," allow differential building motions to take place without risking damage to the whole structure.

[0006]While expansion-joint spaces improve the life-time integrity of the structure, they also present a major risk to the structure in the event of a fire because it is likely that the mandated spaces will act as chimney flues providing pathways for gases, flame, and smoke to spread rapidly throughout a structure. To counter the chimney flue effect, building codes for commercial structures require fire-barriers to be installed in the expansion-joints to prevent or to reduce the rate of flames and smoke passing through the joints into adjoining areas. Fire-barriers sometimes referred to as "fire-stops," protect both the building and the inhabitants of the building to extend the time available for inhabitants to leave the building and for fire fighters to get to the fire.

[0007]During their lifetime, fire-barriers undergo stresses from a variety of sources. Every time a structure is subjected to movement, whether from earthquake activity, ground settling, wind, or temperature contraction or expansion the fire-barriers installed in the expansion-joint spaces are stressed. During a fire, building joints and their associated fire-barriers are likely to be subjected to even greater stress than usual, making it essential that the fire-barriers retain their integrity to prevent the migration of gases, flame, and smoke. Accordingly, fire-barriers are legally mandated to be tested, rated, and certified. There are two currently mandated tests. One measures the ability of a fire-barrier to maintain its structural integrity under compressional and tensional motion. This test is referred to as the "cycle" test and its parameters are specified by ASTM 1399. The other test is referred to as the "fire" or "burn" test and its parameters are specified by UL 2079. The two tests are conducted in sequence. A fire-barrier is first cycled between forces of compression and tension 500 times and then, if the barrier passes that test, it is placed into a furnace where it is tested for its ability to resist and prevents flame, heat, and gases from passing through the barrier.

[0008]Another stress that fire-barriers experience is exposure to moisture. Keeping fire-barriers dry is important, however, it is difficult, if not impossible, to prevent moisture from reaching some barriers. For example, a daily stress that fire-barriers may be subjected to, especially fire-barriers that are installed between adjacent floor units, is stress from exposure to moisture, especially from water and cleaning chemicals used for floor washing. Repeated exposure to moisture could result in deterioration of the barrier. Moreover, the weight of the water provides for a stress. Often, one or more of the multiple layers of materials in a typical fire-barrier is a metal layer adding to the weight of each barrier. Because of their weight, fire-barriers are often secured to building units using heavy duty screws, bolts, tacks, and the like. The number of these used is calculated by the strength of the attachment means, the strength of the barrier material, and the weight of the barrier. Any moisture or water taken on by a barrier greatly increases its weight, thus, compromises the integrity of the attachments and of the barrier. Failed barriers, regardless of the reason for the failure, pose life-threatening consequences. Fire-barriers are typically used in hospitals, schools, sports facilities, hotels, air ports, and high-rise buildings. In many of these uses, copious amounts of water are used for cleaning purposes, especially for floor cleaning, on a daily or even more frequent basis. In some instances, parts of these facilities are open to the outdoors, where rain and melted snow can collect on the floors. Public facilities such as open stadiums are regularly subjected to the effects of rain and snow. Fire-barrier failure in any of these facilities is likely to result in unnecessary hazard to life and to facility.

[0009]The importance of correctly installed, tested, and maintained fire-barriers is increasingly recognized by building officials, owners, insurance companies, contractors, and the public. As explained above, fire-barriers are designed to fit into the spaces mandated between building units. Today, such building units are frequently constructed from 41/2 inches thick pre-cast concrete slabs, or the like. Thus, for example, two adjacent floor sections of pre-cast concrete provide a 41/2 fire-barrier installation depth. Installing a fire-barrier in such a confined space would be difficult under any circumstances as the thickness of the barrier alone is often greater than 41/2 inches. Because of the observed injurious effects of moisture on fire-barriers, fire regulations now require a moisture impermeable cover to be placed over the barrier, to protect it from damage due to water or other fluids or chemicals.

[0010]Moisture impermeable fire-barrier covers (referred to in the industry as "boots") are usually about 4 inches thick. The moisture impermeable covers fill, or nearly fill, the space between the pre-cast floor units, leaving little or no room for the fire-barrier or for installation of the fire-barrier. Moreover, when used to protect a fire-barrier installed between adjacent floor units, it is imperative that the boot does not protrude above the floor surface, as it would create a tripping hazard and, additionally, would expose itself to damage. Furthermore, top or outer surface mount installation cannot be used because attachment hardware cannot protrude above the floor surface. The boot and the minimal thickness of the pre-cast floor sections act to eliminate both top and side-mounting of fire-barrier into floor joint spaces.

SUMMARY

[0011]The present invention provides for a gas and water impermeable fire-barrier system. The fire-barriers contemplated by the invention include gas and water impermeable fire-barriers for installation into wall to wall, wall to ceiling, wall to floor, floor to floor, and ceiling to ceiling expansion-joint spaces. The barriers may be fitted with a drain and a drainage hose providing for drainage of any water that does collects within the barrier, especially for when the barriers are to be used in floor to floor or floor to ceiling expansion-joint spaces, or any other joint spaces that could be a likely repository for water and or other liquids. The rubber boots covering the barriers are meant to protect the barriers from moisture, however if the boots are damaged are moved by, for example, machines that are used to maintain or repair a floor, it is likely that moisture will reach the barriers. Thus, the barriers are provided with drains and drainage hoses.

[0012]The fire-barrier systems of the present invention include various styles of gas and moisture impermeable fire-barriers and their mounting means. The various styles of fire-barrier systems are designed for top, side, or bottom mounting of the barrier, depending on the type of joint space in which they are to be installed, For example, if a gas and water impermeable fire-barriers are required for installation in floor to floor expansion-joint spaces of an open-air baseball stadium, where the floors are heavily trod and are exposed to rain and melting snow and ice, the barriers would be bottom mount to provide ample room for the installation of a rubber boot, to avoid any tripping hazards, and so that the mounting hardware is not exposed to the elements. Such a barrier would also be fitted with drainage hoses to prevent the build-up of any fluid. The prefabricated fire-barriers of the present invention are produced in various lengths as desired. However, because of the weight of the barriers and the difficulty in handling very long barriers, the length of the barriers is usually limited, to for example, 10 feet. Therefore, when the expansion is longer than 10 feet, two barriers must be installed end to end. The barriers of the present invention are pre-assembled and delivered to the site ready for one-step, easy, rapid installation by one or at most two installers. The barriers are pre-assembled to have male and female butt-end connections that prevent any possible leaking from end to end seams. For male/female connecting seams, as well as for seams made up of butt-end to butt-end connections, a butt-cover is provided to ensure that there is no leakage of any collected fluids except through the drainage system. The seam-butt cover also ensures that there in no penetration of smoke or fire into the barrier from below the barrier.

[0013]Having silicone cloth as the final upper layer, is one example of how to make the barrier moisture impermeable from the top layer down. It should be understood that a fire-barrier must be gas and flame impermeable in order to be a functional fire-barrier. The materials used to construct each barrier are fire resistant to degrees that are defined by the tests that the barriers are required to pass before they can be used. These materials are of exceptional strength and are firmly and sturdily attached to the attachment frame which is used in conjunction with the fire-barrier materials to attach the barrier to building units.

[0014]The barriers that are supplied with a drainage system have a drainage opening through the thickness of the barrier. The drain is kept separated from the fire-barrier material by an impermeable caulking that ensures that any moisture that does collect on the surface of the moisture impermeable layer does not come into contact with the other material of the barrier or leak through the fire-barrier. Moisture that does collect on the surface of the moisture impermeable layer gravity drains through a drainage tube. The drainage tube is constructed so the if there is a fire the drainage opening is automatically plugged. The heat of the fire destroys the tube but at the same time melts the tube material so that it functionally plugs the drain opening.

[0015]Fire-barriers that present all of the above benefits are made possible by providing for:

[0016]a fire-barrier system, comprising:

[0017]an impermeable fire-barrier system for use in the expansion-joint spaces that are formed by spaced building units, such spaced building units including wall to wall, wall to floor, wall to ceiling, ceiling to ceiling, and floor to floor building units, where the system comprises: [0018]a fluid and gas impermeable fire-barrier made of at least one layer of fire-resistant material and by at least one adjacent layer of fluid impermeable material, the fire-barrier having a length comprising a first long side edge, a spaced, an opposing second long side edge, and two short end edges, and [0019]an attachment apparatus for attaching the fire-barrier to the spaced building units defining the expansion-joint space.

[0020]The attachment apparatus for attaching the fire-barrier to the building units may further comprises a screw, bolt, or nail, or a fire resistant adhesive.

[0021]The attachment apparatus for attaching the fire-barrier to building units may further comprise a first attachment apparatus for attaching the first long edge of the fire-barrier to one building unit and a second attachment apparatus for attaching the opposing second long edge of the fire-barrier to a second opposing building unit, where the first and second building units define an expansion-joint space.

[0022]Furthermore the fluid and gas impermeable barrier may further comprise being fitted with a drain aperture providing for drainage of any liquids that find there way into the fire-barrier. Yet furthermore, the fluid and gas impermeable barrier is fitted with a drain aperture and a drainage hose emanating from the drain aperture.

[0023]The attachment apparatus for attaching the fire-barrier to the building units may further comprises a two part fire-resistant retainer system, one of the parts for attachment to the first long edge and another of the parts for attachment to the spaced, opposing second long edge of the fire-barrier providing for a fire-barrier retainer system. wherein the fire-barrier retainer system is fixedly attachable to the fire-barrier.

[0024]The fire-barrier system is routinely preassembled for immediate on-site installation, but exceptions may be made for at least partial on-site manufacture of the fire-barrier system when unique construction requirements are present.

[0025]The fire-barrier retainer system may be further defined by each of the attachment parts having attachment plates arranged for bottom-mounting attachment of the fire-barrier/retainer system to the building units.

[0026]The fire-barrier retainer system may be further defined by each of the parts having attachment plates arranged for top-mounting attachment of the fire-barrier retainer system to the building units.

[0027]The fire-barrier retainer system may be further defined by each of the parts having attachment plates arranged for side-mounting attachment of the fire-barrier/retainer system to the building units.

[0028]The retainer system may further comprise a stainless steel fire-barrier retainer.

[0029]The fluid impermeable fire-barrier layer may further comprise a layer of fluid-impermeable silicone material.

[0030]The fire-barrier system may further be made to have butt short ends for butt end joining of abutting fire-barrier sections.

[0031]If desired, there may also be a fire-resistant splice connector cover to attachedly cover the splice seam of abutting fire-barrier sections

[0032]Alternatively, the fire-barrier system further may be constructed to have male and female connecting short end edges for male/female joining of two fire-barriers.

[0033]The drainage system further includes a drainage hose emanating from the drain aperture, which may be a plastic tubing, to pass through the fire-barrier to a fluid collection device.

[0034]The plastic tubing emanating from the drain aperture may be positioned for its protection into and therethrough a flexible protective metal fire-resistant tubing. The impermeability of the fluid and gas impermeable barrier is maintained by caulking the join between the aperture and the plastic tubing with impermeable caulk material and wherein the join between an outer surface of the barrier and the tubing is sealed using a fire-resistant caulk material.

[0035]A preferred example of a fire-barrier system, includes an impermeable fire-barrier system for use in expansion-joint spaces defined by spaced building units, comprising: [0036]a fire-barrier, comprising [0037]a composite outer layer comprising an outermost protective cloth layer overlain by a layer of insulation blanket overlain by a sheet of stainless steel foil, and [0038]an attached composite inner layer comprising a layer of insulation blanket overlain by a layer of impermeable silicon cloth, overlain by a layer of intumescent material, [0039]where the fire-barrier has a length comprising a first long edge, a spaced, opposing second long edge, and two short end edges, and [0040]an at least two-part attachment apparatus for attaching the fire-barrier to the spaced building units defining an expansion-joint space, where a first attachment apparatus provides for attaching the first long edge of the fire-barrier to a building unit and a second attachment apparatus provides for attaching the opposing second long edge of the fire-barrier to an opposing building unit, where the first and second building units define an expansion-joint space, and where [0041]the fluid and gas impermeable barrier is fitted with a drain aperture and a drainage hose protected from the heat of a fire emanating from said drain aperture.

BRIEF DESCRIPTION OF THE DRAWINGS

[0042]In order that these and other objects, features, and advantages of the present invention may be more fully comprehended, the invention will now be described, by way of example, with reference to the accompanying drawings, wherein like reference characters indicate like parts throughout the several figures, and in which:

[0043]FIG. 1 is a cross-sectional view of a straight-line top-mount moisture impermeable fire-barrier of the present invention installed in an expansion-joint.

[0044]FIG. 2 is a diagrammatic perspective side-view of a moisture impermeable fire-barrier, as illustrated in FIG. 1.

[0045]FIG. 3a is a diagrammatic perspective view of partial sections of two top-mount straight-line fire-barrier of the present invention butt joining each other and a butt cover to protect the seam from moisture leaking through and to assure that no fire, heat, or smoke can enter the barrier from fire activity below the barrier.

[0046]FIG. 3b is a diagrammatic perspective view of partial sections of two top-mount straight-line fire-barrier of the present invention joining each other using a male/female connection.

[0047]FIG. 4 is a cross-sectional view of a bottom-mount moisture impermeable fire-barrier of the present invention installed in an expansion-joint.

[0048]FIG. 5a is a diagrammatic perspective view of a straight-line barrier being mounting between two spaced floor units using the installation tool specific for this barrier and this installation.

[0049]FIG. 5b is an elevation view of the barrier and installation tool as illustrated in FIG. 5a.

DEFINITIONS

[0050]Building units, as used herein, refers to structures such as walls, floors, ceilings, and the like, and may be referred to as structural units.

[0051]High-temperature thread, as used herein, refers to any thread that is fire-resistant or any thread that will not support combustion, such as a ceramic thread.

[0052]Impermeable membrane, as used herein, refers to a material that does not allow the passage of a fluid, such as water, other liquids, and/or gases. The impermeable material disclosed herein includes a flexible, fluid-impermeable, sealing layer that is used for waterproofing by applying one or more layers of the membrane material onto a surface and/or object to be protected. Such impermeable blanket layers are made of a variety of materials, such as, but not limited to, silicone, fiberglass fabric coated with silicone rubber, coal tar, bitumen and synthetic polymers that are formed as sheet-like substances of desired sealing properties. Material and substance properties of impermeable membranes used herein meet the requirements of any particular structure, building, authority, climate, chemical and physical environment, required durability, cost effectiveness and the like.

[0053]Intumescent as used herein, refers to those materials having properties that cause them to expand (or intumesce) to several times their original size when activated by high temperatures to prevent the spread of flames and smoke to other parts of a building, for example passive fire-seals contain intumescent compounds. The intumescent occurs in many forms and may be, for example an intumescent layer, strip, or paste, such as a caulking material.

[0054]Insulation blanket, as used herein, refers to any number of insulation materials, including fiber blankets made from alumina, zirconia, and silica spun ceramic fibers, fiberglass, and the like.

[0055]Interdigitate as used herein, refers to the verb interlock, to be interwoven or to commingle.

[0056]Interdigitation as used herein, refers to the act of interlocking or the condition being interlocked or interpenetrated. As example of interdigitated coupling is a couple formed using a male/female connection system.

[0057]Metallic backing layer, as used herein, refers to fire-resistant metal or metallicized foil, such as stainless steel, or the like.

[0058]Multi-directional and/or multi-dimensional architectural expansion join or joint, as used herein refers to any joint that is formed by the convergence of more than two structural units, such as the convergence of three wall units or two walls and a floor unit. These joints create spaces between building units that act like chimney flues carrying gases, hot air, flame, and smoke throughout a structure.

[0059]Multi-directional and/or multi-dimensional fire-resistant barrier, as used herein, refers to any fire-barrier that is shaped to functionally fit into a multi-directional and/or multi-dimensional architectural expansion-joint.

[0060]Protective cloth, as used herein, refers to a flexible, strong, protective, fire-resistant material that is designed to mechanically support the insulation material and to protect the insulation material from mechanical damage, as the insulation is mechanically weak and can be easily damaged by tearing or ripping either accidentally or intentionally during or after installation thus largely compromising the integrity of the fire-resistant barrier. The fire-resistant layers, such as a layer of insulation material together with a layer of intumescent material, can freely move with respect to the one or more protective layers or they may be attached together via threads or other attaching means. Protective cloths may be manufactured from continuous filament amorphous silica yarns, polymeric material, fiber reinforced polymeric material, high-temperature resistant woven textiles, or a metalized, fiberglass cloth, among others. Metalized cloth may include fibers of stainless steel, aluminum, or copper, for example. Protective materials may also include metal foils or metal screens. Protective cloths also include cloths that are woven to provide for shear, including lateral, motion.

[0061]Retainer, as used herein, refers to a means used to attach fire-barriers to building units. For example one top-mount system uses "L" brackets that are first attached to the barrier and then attached to a building unit. Similar, but more complex, brackets are used for mounting bottom-mount systems.

[0062]Seaming, as used herein, refers to connecting one part to another part, for example where a cloth is folded and the two parts of the cloth that have been brought together by the folding are subsequently "seamed" together along a predetermined line. The seaming may utilize stitching, using an adhesive, stapling, pinning, or any other means that will connect the two parts to each other.

[0063]Structural unit, as used herein, refers to such building unit constructs as a wall, floor, ceiling, or the like and may be referred to as building units. These units are often pre-constructed concrete, or of a like material, slabs or panels and can be about 4 inches thick which poses a challenge for the installation of a fire-barrier and the, recently, mandated rubber protective boot.

[0064]Tri-dimensional, as used herein, refers to either an expansion-joint that has three member parts, such as a T-shaped expansion-joint where the T-joint is made up of three co-joint-arms or to a fire-barrier that is functionally shaped to accommodate a T-shaped joint.

TESTS:

[0065]Fire testing per UL 20 79Cycle test ASTME 1399 (expansion, compression test)

A LIST OF THE REFERENCE NUMBERS AND RELATED PARTS OF THE INVENTION

[0066]10 Fluid and moisture impermeable fire-barrier. [0067]11 Attachment means. [0068]12 Impermeable membrane. [0069]14 Insulation blanket. [0070]15 Intumescent strip material. [0071]16 Attachment means. [0072]17 Metal foil. [0073]18 Protective cloth. [0074]19 Weld pins. [0075]20 Drain mechanism. [0076]21 Inner aperture. [0077]22 Impermeable caulk material. [0078]23 Outer aperture. [0079]24 Plastic tubing. [0080]26 Impermeable fire-resistant caulk material. [0081]28 Flexible metal fire-resistant tubing. [0082]29 Attachment means, such as washers and nuts. [0083]30 Fluid. [0084]32 One fire-barrier section impermeable to fluid and moisture. [0085]34 Another fire-barrier section impermeable to fluid and moisture. [0086]35 Attachment means, such as nuts and washer. [0087]42 Attachment means, such as weld pins. [0088]44 Retainer. [0089]46 Retainer arms. [0090]50 Intumescent caulking. [0091]60 A join or butt between two fluid and moisture impermeable fire-barriers. [0092]70 A butt or splice cover connector. [0093]80 Fluid catchment means. [0094]90 A building unit. [0095]94 Nailer. [0096]100 Attachment tool. [0097]200 Male connection end. [0098]203 Female connection end. [0099]300 Installation tool specific for this system. [0100]302 Base plate. [0101]304 Track. [0102]306 Vertical rail. [0103]308 Horizontal sliding plate. [0104]310 Rollar assembly. [0105]312 Holding bracket.

DETAILED DESCRIPTION

[0106]To provide an understanding of the basic structure of the moisture and gas impermeable barriers contemplated herein, we refer now to the drawings to illustrate exemplary versions of the invention. It should be noted that the disclosed invention is disposed to versions in various sizes, such as lengths, widths, depths to accommodate the variety of expansion-joint spaces that require fire-barriers, in addition to variation in shapes, contents, number and composition of layers, materials, and attachment means. Therefore, the versions described herein are provided with the understanding that the present disclosure is intended as illustrative and is not intended to limit the invention to the versions described.

[0107]FIG. 1 is a cross-sectional diagrammatic view of a straight-line top-mount moisture-impermeable fire-barrier of the present invention installed in an expansion-joint of a desired width. It is to be understood that the invention is available is multi-directional fire-barrier systems, as well as in straight-line versions. In this example, gas, fluid, and moisture impermeable fire-barrier 10 includes an outer multi-layer and an inner multi-layer. The outer multi-layer of the fire-barrier, as illustrated, comprises outermost protective cloth 18, such as fire-resistant fiberglass material, overlain by a layer of insulation blanket 14, which is overlain by a sheet of stainless steel foil 17. The inner multi-layer of the moisture-impermeable fire-barrier, as illustrated, comprises another layer of insulation blanket 14 overlain by a layer of impermeable material 12, an example of which is silicon cloth, where the top surface edges of the inner multi-layer are overlaid by intumescent material 15.

[0108]The moisture impermeability of the silicon cloth layer was tested by filling an installed fire-barrier having the silicon cloth layer with water. In this test water remained on the surface of the silicon layer for 120 days when the water finally evaporated.

[0109]The layers making up the barrier are attached to each other in various ways. In some embodiments the layers may be sewn together. In other embodiments the layers are attached to each other using attachment means, for example, as nuts and washers 11. The outer multi-layer is positioned on the outer side of the barrier, that is, on the side of the barrier that faces into the extension joint space created by building floor units 90. The inner multi-layer is positioned on the inside of the barrier, that is, on the inner side of the "U" shape formed by the barrier when attached to building floor units 90.

[0110]There are many attachment means that may be used to attach a fire-barrier to a building unit and all are contemplated for use with the present invention; one example of an attachment means used to attach a fire-barrier directly to a building unit are tack-weld pins 16. Other attachment means include screw, bolts, nails or a fire-resistant adhesive. One favored embodiment (FIG. 4) uses a retainer attachment apparatus to attach a fire-barrier to the building structures that define the expansion-joint space. The retainer attachment is generally fixedly attached to the fire-barrier at the time of manufacture, but need not be so if there are unique on-site requirements. It is to be understood that there may be some instances when unusually sized and shaped expansion-joint spaces may require on-site partial or full-construction of the barrier, but for all routinely used sizes and spaces, the fire-barriers are fully pre-assembled at the factory and are ready for on-site installation.

[0111]Water collecting in a fire-barrier may be anticipated for example, in systems installed in floor to floor joint spaces, where the floors are regularly washed with copious amount of water and cleaning chemicals. If moisture and/or water do collect in the lowest surface area of the U-shaped installed moisture impermeable fire-barrier, drain 20 provides drainage of any liquid. Any liquid that collects on the inner surface of the inner multi-layer, i.e., on the exposed surface of the impermeable layer, will gravity drain through the aperture that is functionally positioned through the surface of the impermeable layer at the lowest depression of the u-shaped fire-barrier. The liquid will drain through the aperture into and through plastic tubing 24, which emanates from the aperture, through the barrier, to hang out the lower outer surface of the barrier. Because this tubing is plastic that would quickly be affected by heat and other environmental conditions, it is protected by being positioned within an outer tubing flexible metal fire-resistant tubing 28. After passing through the length of the metal tubing, a length of the plastic tubing emanates out of metal fire-resistant tubing 28. Liquid traveling through the tubings will eventually be collected by fluid catchment means 80. Therefore, drain system 20 comprises plastic tubing 24 emanating from inner aperture 21 through the entire thickness of moisture impermeable fire-barrier 10 to extend out of outer aperture 23 to extend outside the outermost layer of the outer multi-layer fire-barrier. Impermeability is maintained by caulking the join between the inner surface of the barrier and the tubing with impermeable caulk material 22. Impermeable fire-resistant caulk material 26 is used to seal the join between the outer surface of the barrier and the tubing. Plastic tubing 24 extends from the outside of the barrier to be securely covered by flexible, fire-resistant, metal tubing 28. Intumescent caulking 50 is inserted into the space between the outer surface of plastic tubing 24 and the inner surface of metal tubing 28. In the event of a fire, intumescent caulking 50 will expand. Metal tubing 28 will force the expansion of the intumescent caulking toward the plastic tubing which will cause the tubing to collapse upon itself and, thus, create a seal preventing fire, smoke, and gases from getting through the barrier.

[0112]FIG. 2, a diagrammatic perspective side-view of a moisture impermeable fire-barrier, illustrates the positioning of drain system 20 in the fire-barrier equidistant from both open ends of the section of impermeable fire-barrier. The length of each impermeable fire-barrier section is, to some extent, dependent on the weight of the barrier, as well as the length of the joint space that requires a barrier. If the barrier is constructed with extra layers of material, for example to provide for a barrier having a higher fire-rating (in terms of hours the barrier can withstand the destructive forces of a full scale fire), then the barrier will weigh more and will have to be shorter than a barrier rated for fewer hours and made of a reduced thickness.

[0113]FIG. 3, a diagrammatic perspective view, illustrates the join of two top-mount straight-line fire-barrier partial sections. Section 32 is illustrated as butting up against section 34 at join line 60. Butt cover 70 is secured over join line 60 with all exposed joins caulked. FIG. 3b, a diagrammatic perspective view, illustrates partial sections of two top-mount straight-line fire-barrier of the present invention being joined to each other using male 200 and female 203 connection structures.

[0114]FIG. 4, a cross-sectional view, illustrates a bottom-mount moisture impermeable, draining, fire-barrier of the present invention installed in an expansion-joint. The bottom-mount fire-barrier system provides for installing the fire-barrier/retainer unit either from above the floor through the expansion-joint space, from beneath the floor, or from both. In this system, the fire-barrier is securely attached to retainer 44 by attachment means 19 whose size is exaggerated for ease of viewing. This attachment is only one way to attach a barrier to its supporting retainer. The barrier may be attached to the retainer by attachment means that extend through the outermost barrier layer, through the downwardly extending leg of the retainer, and through the innermost barrier layer, for example. The complete barrier/retainer system is fixedly mounted to the bottom of floor units 90 by any desired fixation attachment means, such as by use of a nail gun to insert nails 94. A nail gun or nailer is a type of tool used to drive fasteners into a material that is usually driven by electromagnetism, compressed air, or, for powder-actuated tools, a small explosive charge. One example of such a nail gun is a Hilti gun that inserts fasteners through the barrier/retainer into the pre-cast concrete floor in the present example. Note that by being mounted below the floor, there is adequate space in the expansion joint for a required rubber boot to be installed. All of the impermeable fire-barrier of the present invention are contemplated to be manufactured with retainer 44 as part of its structure and, thus, is provided from the manufacturing facility as a ready to install unit. However, if there should exist a need for an impermeable fire barrier without a retainer, that embodiment is also contemplated. As discussed, the elongate fire barrier illustrated has a length with two opposing long sides, which provide the attachment areas for attaching the fire barrier/retainer to building units, and a center portion or mid-section between. Note that there is a separate retainer structure for each long side of the fire-barrier. Each retainer illustrated comprises four retainer arms or plates, thus has a four arm cross-sectional profile. When installed, the downwardly extending part of the vertical arm of the retainer of the fire-barrier/retainer system is positioned to extend into the space between the innermost and outermost fire-barrier layers, while the vertical upwardly extending portion of the retainer arm is positioned against the sides of the building units that define the expansion joint space to provide a secure and close connection of the fire-barrier/retainer system to the building units by acting in concert with the other arms to keep the fire barrier is a correct position tight against the building unit surfaces. One part of the horizontal retainer arm is situated between the extending outermost fire-barrier layer and the bottom surface of the building unit providing addition support for the fire barrier and supports the function of the other arms, while the other part of the horizontal retainer arm extends into the joint space to cover the exposed end of the inner-most fire-barrier layer, as illustrated in FIG. 4 and to provide a lifting support for the installation tool, as explained below. It is to be understood that there are many variations on the shape and size of a retainer. The arms could be of a variety of widths and lengths, and some arms could be eliminated. Note that in the illustration, one retainer arm of a first retainer is affixed to the first long side of the fire barrier and one retainer arm of a second retainer is affixed to the opposing second long side of the fire barrier to form the fire barrier/retainer system for bottom mounting the system into an expansion joint space. Attaching the fairly rigid retainer to the flexible fire barrier provides for the barrier to be held tightly against the bottom surface of the floor unit providing for a tight and secure attachment (as illustrated).

[0115]FIG. 5a, a diagrammatic perspective view, illustrates a straight-line barrier being mounted between two spaced floor units using the installation tool 300 specific for this barrier and this installation. The frame of installation tool 300, as illustrated in the figure, consists of a pair of horizontally oriented spaced tracks 304, slidably attached at a ninety degree angle to each of tracks 304 is one of two horizontal sliding plates 308, protruding through and extending above and below each sliding plate 308 forming a ninety degree angle are two spaced vertical rails 306, a base plate 302 connects each end pair of each of the two spaced tracks 304. Roller assembly 310 provides for horizontal sliding plate 308 to be slidably adjusted, thus, providing for the installation tool to be width adjustable. Holding bracket 312 (as seen in FIG. 5b) attached to the lower end of each of spaced vertical rails 306. To prepare the impermeable fire-barrier retainer system for installation, one of the holding brackets 312 of the installation tool are attached to one long side of a fire-barrier and the other bracket is attached to the opposing long side of the fire-barrier. The entire system, installation tool and impermeable fire-barrier retainer system, can now be lifted holding the handles that are provided on the installation tool. Depending on the weight of the barrier, the installation tool and impermeable fire-barrier retainer system can be lifted and put into the expansion-joint by one or two installers. The width of the installation is adjusted so that base plates 302 rest on the surface of the to building unit 90 to support the barrier/retainer, while the retainer of the barrier retainer system is being fixedly attached to the side and or bottom of the building units 90. The use of the tool provides for rapid and easy installation by a minimum number of installers.

[0116]FIG. 5b, an elevation view illustrates how the installation tool supports the fire-barrier/retainer for secure attaching of the barrier to spaced building units. The installation, as shown, is used for bottom mounting of the barrier/retainer to spaced floor to floor building units and to spaced floor to wall building units.

* * * * *