Patent Description:
Intumescent-based passive vents are simple and effective firestop products. When ordinary intumescent-based vents are to stop fire within <NUM>, or also to stop radiation or smoke from fire, they must be replaced by other types of fire dampers that are expensive, large or by specially manufactured intumescent vents that require straight contact surfaces and are less flexible to movements and require accurate fitting.

Intumescent-based vents that are used for linear firestops in air cavities in facades, roof projections and roofs are prone to failure if the cladding or other construction parts bend or are consumed in a fire that create an opening for fire spread. The way that they are mounted is prone to error during fitting on site. Standard intumescent vents have a thick layer that takes a long time to close gaps of up to <NUM>. When the intumescent expands it can fall out. New requirements are to prevent large fires as a consequence of ordinary cavity vents failing. A requirement is that the products must retain firestopping performance even if the constructions move in fire or in wind and that they must stop fires that spread at speeds of around <NUM>/min or pass a <NUM> high vent within <NUM>.

<CIT> describes various forms for fire and smoke protection systems. The document describes a flexible fire protection which is rolled up on a roll and which is attached to a wall in front of an opening in a building. The flexible fire protection is in the form of a fire curtain which is rolled out to close the opening in the event of a fire. Furthermore, the flexible fire protection comprises a flexible woven material which is flame-resistant. The woven material has an interwoven fabric which provides improved resistance to the influence of external forces, such as from a powerful jet of water. The use of an intumescent is also mentioned, and it appears that the element is self-supporting. However, the solution is a closed construction that does not provide ventilation.

<CIT> shows a self-closing and plate-shaped vent which has a surrounding frame with a honeycomb-shaped structure coated with an intumescent. When the vent is attached to a wall with an opening, the vent is normally open and allows flow of air through the opening. When exposed to heat from a fire, the intumescent material expands and closes the vent.

Further reference is given to <CIT>, which corresponds to <CIT>, and which describes a ventilating fire filter in a building construction comprising a three-dimensional structure of wickerwork-shaped strings covered by an intumescent. The three-dimensional structure is in the form of a cut-out self-supporting, frame-free piece of the structure that can be cut and flexible. The frame-free pieces of structure are fitted by being adapted and pushed into place in a cavity gap and are self-locking under the influence of heat.

A common feature in known techniques is that fire insulation is not achieved until a volume is completely filled with an intumescent. Typical volumes are typically not filled until after <NUM> and up to <NUM>, depending on the size of the air opening. It requires extensive use of elements for quenching gap and heat sink to prevent fire from passing in the period.

It is an object to provide a firestop device that is normally ventilating and that transforms into a full reactive firestop within a very short time when exposed to heat of fire.

A common solution in a first step is a fire gap element which stops flames before the air vent opening in a second stage is closed by an expanding intumescent which fills the entire vent and insulates the fire. With the invention it is possible to introduce extra steps between the two mentioned, and which quickly shall form a thin shell of the first heat stress in the fire to shorten the time within which, for example, the quenching gap element is required to perform.

The invention is further based on as much of the first heat as possible being absorbed in the intumescent material that forms shells. Heat that finds its way to another intumescent at the same time and thereby reduces heat uptake in the shell will delay the formation of the shell. This can happen if the intumescent for volume filling is close to that for the shell. Heat transfer by both flame radiation and convection shall not be lost to an "unnecessary" intumescent near the shell in the shell-forming phase, according to the invention.

A further object is to provide a firestop of a spring-loaded mesh and with intumescent stripes which rapidly expands and forms a fire-insulating shell against the fire, especially in the attacking phase of the fire.

The firestop can be used alone. Alternatively, it can have a quenching gap element for flame blocking in the open condition of the vent or a further intumescent for filling the dimensioned volume for a sufficiently long fire resistance time. A three-stage firestop can combine techniques where the typical step sequence is flame blocking, fire-insulating shells and a fire-insulating filled volume. Flame blocking in the open state and shell formation takes place in the attacking phase of the fire.

A firestop vent according to the invention can be frame free, open to being cut, malleable and which, at the site of use or in the factory, can be fitted in one or more layers in hollow spaces, slits, sheets, canals built in a box or a frame.

A firestop vent with a filling intumescent according to the invention can be designed to achieve a fixed expansion volume, self-locking by application of an expansion pocket, quenching gap, spark arrestor net, catch net for flammable droplets and, combined with a tight screen, it can stop flame radiation and smoke.

The invention relates to a solution for ventilating firestop elements, such as air transfer grilles with fire resistance for use in buildings, where they are normally ventilated by air and block in the event of fire. A ventilating firestop can thus also be called a completely ventilatable firestop or fire damper.

The invention is based on ventilating firestops with or without a quenching gap element, including an element of a self-supporting mesh applied with a semi-open intumescent pattern that forms a shell or a crust very quickly in fire heat. The shell-forming element is placed in the firestop so that it receives the heat as directly as possible. The intumescent pattern is fine meshed to provide a maximum surface area to take up the heat and provide a short distance so that an expanding intumescent mass from a thread in the pattern meets an expanding intumescent mass from the nearest thread early. The pattern is hereinafter also referred to as a stripe pattern. Pattern stripes may be angled arbitrary, cross each other or be in parallel to each other. The stripe pattern is attached to a reinforcing self-supporting mesh, typically of metal, made as a quenching gap element where it is required.

An intumescent-based or other reactive or ablative materials that are used in the invention can, for example, be based on graphite, sodium silicate or ammonium phosphate and be characterised in that they expand at exposure to heat. Heat exposure will typically be <NUM> -<NUM>, but high temperature activation can alternatively occur later, for example, from <NUM> upwards.

The ventilating firestop according to the invention is preferably dimensioned so that a large and good contact surface between flames and an endothermic intumescent helps to prevent flame passage while the ventilating firestop is open, especially by extending the duration of the "quenching gap" effect when quenching gap element are used up to the time intumescent material has expanded and sealed the firestop element. For example, one layer of quenching gap mesh can replace several quenching gap elements.

With quenching gap mesh that can be used in the invention is meant a mesh with openings smaller than a specific quenching gap for the combustible gas fire in intended use will be nourished.

With self-supporting and able to be cut is meant that the ventilating firestop does not need to be fitted in any kind of frame or the like, and that the size can be adapted to the actual ventilation opening by cutting and/or cutting out to the desired dimension.

A ventilating and yielding firestop according to the invention which, for example, is cut out of a plate will be self-supporting, i.e., it can be used as it is without a bracing or a frame to hold the intumescent material and can be attached by pressing or clamping in place by hand and/or by using clamps, screws, pins, glue, gaskets, etc. in openings. Furthermore, the yielding mesh will be able to follow the shape and/or movement of the structure and thus contribute to a more efficient firestop.

A firestop according to the invention can be bent double or in several layers to achieve extended fire resistance time. Cut out flat firestops can be folded and adapted in layers fitted in entire building elements or in frames at the factory and can take up, for example, linear or rectangular shapes.

The above-mentioned objects are achieved with a ventilating firestop according to claim <NUM>.

Tests show that with a shield according to the invention, full fire insulation within <NUM> against a typical <NUM> for conventional vents is obtained in the same opening.

The fine meshed stripes of intumescent readily have a surface and short mutual distance which, under the influence of heat, are enough for the stripes to quickly become expanded towards each other during the attacking phase of the fire for the formation of the shield.

An intumescent located inside or outside the shield can form a coarse grid that slowly expands and fills the volume, giving fire insulation for extended time of fire resistance.

Furthermore, the mesh can be formed as a flame-stopping mesh with mesh-openings of rectangular shape closing gaps.

Said intumescent can in a first embodiment be applied to the mesh in a stripe pattern of parallel intumescent stripes. Alternatively, the intumescent can in a second embodiment be applied to the mesh in a check pattern of intumescent stripes.

Said intumescent can be added on to the mesh as a stripe pattern carried out completely or partially in the form of close and evenly distributed dots or raised pegs or in the form of threads distributed in an air volume adjacent to the mesh.

Mesh can be provided in a sheet form with longitudinal side edges where one or both of the longitudinally running side edges comprises a reinforcing flange.

Likewise, mesh can be produced in a sheet form or is cut into a sheet form with longitudinal side edges, where one or more side edges are folded to, or mounted on, a mounting flange.

Mounting flanges on said side edges can be arranged for locking engagement with each other.

In one variant, the mesh can have longitudinally running side edges where a first side edge is formed with a S-shape and a second side edge is formed into a half ball shape, as the half ball shape is arranged in a locking arrangement by the insertion under the S-shape when this is fastened to a base.

The mesh can be a malleable and spring-loaded mesh produced with spring wires for the formation of a spring-loaded effect.

Furthermore, the malleable and spring-loaded mesh can be produced with braided steel wires equipped with transverse spring wires for the formation of a spring-loaded effect.

The malleable and spring-loaded mesh can also be produced with knitting steel wires equipped with transverse spring wires for the formation of a spring-loaded effect.

The transverse spring wires can be arranged mutually spaced apart in the longitudinal direction of the mesh which is larger than a quenching gap and smaller than the maximum mesh size to prevent wastage of the expanded intumescent.

Furthermore, the firestop can be comprising an expansion pocket, the expansion pocket comprises an expandable intumescent interposed between several meshes, which pocket under expansion unfolds and become pressed against surrounding structure and edges.

One or more of said spring wires and/or steel wires can be coated with an intumescent and be connected to a power source, said wires are arranged to be activated as heating wire(s).

In one embodiment, said intumescent stripes may be powder/electrode lacquered with metal, or have nano-fibred surfaces.

Furthermore, said stripes of an intumescent can be extruded, glued or sprayed onto the mesh in parallel or in transverse with ventilating mesh openings between, in one or more layers.

Said pattern of an intumescent can be attached with seams to the mesh, such as a seam of sacrificial-based polyester or cotton.

The firestop can be cut or folded to comprise several mesh layers with inlaid, intermediate intumescent stripes between respective mesh layers with quenching gap.

Preferred embodiments of the invention shall, in the following, be described in more detail with reference to the enclosed figures, in which:.

As can be seen from the figures, in an embodiment example, the present invention comprises a ventilating firestop which comprises a malleable and preferably spring-loaded mesh <NUM> with a fine mesh stripe pattern <NUM> of an intumescent which forms an insulating shell in the earliest phase of fire. The mesh <NUM> also includes stripes or bands of an intumescent for subsequent volume filling and fire insolation. The mesh <NUM> can be bent or rolled into a completely or approximate tubular shape so that an inner volume <NUM> is formed. The tube form can be circular, square or other shapes.

The firestop according to the invention has a mesh with a mesh size that provides quenching gap, however, the firestop can be made with a mesh <NUM> without a quenching gap. However, the term "quenching gap mesh" is generally used in the description in connection with the figures, while the more generic term "mesh" is generally used in the patent claims. An intumescent <NUM> can be applied to the mesh <NUM> in the same way whether the mesh has a quenching gap or not.

The quenching gap mesh <NUM>, when this is used, has a mesh size which gives quenching gap, for example, a mesh size of between <NUM> and <NUM>. The mesh size, i.e., the size of the openings <NUM> between the wires in the quenching gap net, must be less than or equal to the maximum size of the quenching gap in the particular application as determined by the gas mixture which is developed by the fire, in order to quench.

A pattern of thin stripes, dots, pins or wires <NUM> of an intumescent can be applied to the mesh <NUM> and which can have a large surface area and a short mutual distance between them with open meshes or openings <NUM> between them in the plane in which the fire first strikes. Said intumescent can in a first embodiment be applied to the mesh in a stripe pattern of parallel intumescent stripes. Alternatively, the intumescent can in a second embodiment be applied to the mesh in a check pattern of intumescent stripes. In <FIG>, <FIG>, <FIG> and <FIG> the intended fire direction is upwards, and the fire is thus first noted in the lower part of the firestop <NUM>. The effect which the fire applies is described in more detail in connection with <FIG>.

To produce a spring-loaded effect in the quenching gap, mesh <NUM>, the quenching gap mesh <NUM> can be made of braided or knitted spring threads <NUM>, or the quenching gap mesh <NUM> can be made of braided or knitted steel threads <NUM> equipped with preferably spring threads <NUM> running in the transverse direction. The spring threads <NUM> can have a size of, for example, <NUM>. The steel wires <NUM> can also be yielding.

The transverse spring wires <NUM> are usually arranged at a distance apart in the longitudinal direction of the quenching gap mesh <NUM> and with a mesh size which is larger than the quenching gap and smaller than maximum meshes in order to prevent a loss of expanded intumescent. With maximum meshes is meant here the size of openings/meshes in which an expanded intumescent will be pushed through and fall down. The mesh size can vary with the type of intumescent.

<FIG> and <FIG> show a specific embodiment of the quenching gap mesh <NUM> as discussed above, while the remaining figures show the quenching gap mesh illustratively.

In <FIG>, one or more of the wires <NUM> or <NUM> are covered by the intumescent <NUM> and are connected via a wire <NUM> to a power source <NUM>. On the activation of the power source <NUM>, the wire(s) are heated up and said intumescent <NUM> will expand.

The quenching gap mesh12 is initially intended to be produced in a flat form, but which can be bent into an approximately semicircular shape or in accordance with the invention into a tubular shape with a spring effect to withstand compression and at the same time react with protrusions or depressions on the surface where it is mounted. <FIG> and <FIG> show, by way of example, that the transverse spring wires <NUM> substantially produce the spring effect while the longitudinal wires <NUM> are thinner and/or less rigid to provide a mesh which fills uneven surfaces.

The quenching gap mesh <NUM> can be produced in a sheet form with longitudinal side edges <NUM>, where one or both longitudinal side edges <NUM> comprises a mounting flange <NUM>. This can be done, either the quenching gap mesh <NUM> is produced in a sheet form or is cut into a sheet form, in that one or more of the side edges <NUM> are folded to, or mounted on, a mounting flange <NUM>.

The mounting flange <NUM> can be used to fasten the firestop <NUM> in a cavity <NUM> between two building parts <NUM> by means of a screw, pin <NUM> or similar fastening means. The mounting flanges <NUM> can also be glued to the surface. <FIG> shows such a fitting, where firstly the one mounting flange <NUM> on a first side edge <NUM> is attached to the base <NUM> by means of a screw or pin <NUM>, and in <FIG> wherein also the second mounting flange <NUM> on the second side edge <NUM> is attached to the base <NUM> by means of the screw or pin <NUM>.

<FIG> shows an example of a variant which is not formed into a closed tubular shape, and which is only attached to one side edge so that the other part is "free" to move.

Mounting flanges <NUM> on the side edges <NUM> of the quenching gap mesh <NUM> can also be arranged to have a locking integration with each other.

<FIG> show an alternative embodiment of a ventilating firestop in which the quenching gap mesh <NUM> correspondingly has longitudinally running side edges <NUM>, but where a first side edge is formed with an S-shape <NUM> and a second side edge is formed with a half ball shape <NUM>. The half ball shape <NUM> can enter into a locking engagement by the insertion under the S-shape <NUM> when it is attached to the surface <NUM>, as shown in <FIG>.

The <FIG> further show variants of the mounting flange <NUM>, where one or two vertical edges / folds can be folded by a folding and flange machine standing, for example, at right angles to the mesh. This makes the mounting flange <NUM> rigid enough to secure the quenching gap mesh <NUM> to hard or soft surfaces, such as wood or rock wool.

Locking of the side edges <NUM> of the firestop <NUM> results in a fixed expansion volume <NUM> (as shown in <FIG>). The fixed expansion volume being similar to said cavity <NUM> between two building parts <NUM>.

<FIG> show the difference between prior art and the invention, performed in a three-step function.

<FIG> shows an example of prior art where an intumescent <NUM> is placed in a mesh structure <NUM> between two building parts <NUM> to maximize air passage and such that the intumescent <NUM> can fill the entire void between the intumescent and opposite sides when all the intumescent is expanded in heat and in that it blocks against the fire (the figure to the right).

According to the invention as shown in <FIG>, an intumescent <NUM> is placed in several thin stripes which forms a fine mesh stripe pattern, in at least one plane transverse to the air direction facing the actual fire load and so closed that ventilation is good enough. In that the stripes expand towards each other in heat, a shield or shell barrier <NUM> is formed which quickly closes the vent completely in the first minutes of the attack phase (as shown in the figure in the middle). After that, sustained heat from the fire will activate the rest of the intumescent in the vent to give a lasting volume sealing during the full filling phase (as shown in the figure to the right). This other intumescent can also be fine meshed, but preferably coarse meshed and with wider stripes or bands. The intumescent for the formation of the shield and volume filling are separated from each other.

The invention also works if the direction of the fire is opposite to that shown in <FIG>.

Thus, a firestop <NUM> according to the invention can be comprising many fine stripes <NUM> of an intumescent rather than conventional thick stripes and gratings and in that the stripes are coated directly on the quenching gap mesh <NUM> with optimized ventilation distances in between. The heat of the flame and the large contact surface with an intumescent make the stripes expand very quickly to a closed shield <NUM> which blocks flames for many minutes. In the exposure phase, the heat activates an endothermic chemical process (heat consuming) in the intumescent material that takes heat from the fire gas / flames, and in that there is such a large area of intumescent surface concentrated at the outermost mesh layer that meets the flames, the process will further effectively extend the quenching gap effect such that several layers of quenching gap mesh can be avoided (several layers required in prior art).

In the next phase of the fire resistance time, more intumescent <NUM> expands downstream from said shield <NUM>, but slowly due to the heat shield to the shield <NUM>, and it is beneficial for building up an even and compact volume of an expanded intumescent.

At the same time, it is a preferred application of the invention that it is rolled <NUM> degrees and into a tubular shape where the long sides are attached to each other. The effect of this is that expansion will always take place in a given volume <NUM>, either the environment forms the filter into an oval, into a flattened shape or into a square shape inside a suitable frame or otherwise. Because there are sealed stripes <NUM> with fine intumescent threads, also in the next layer the fire must pass, robust reliability is achieved. A fixed expansion volume further enables the use of an optimal amount of intumescent to ensure the longest possible fire resistance time, at the same time as any falling out of intumescent is virtually impossible. Intumescent that falls out / down leaves openings for fire and is known as one of the two biggest weaknesses with conventional solutions, where the passage of flames in the early phase is the other.

As an additional guarantee for rapid reaction also against smoke passage, the wires can be extruded with heating element wire before coating on the quenching gap mesh <NUM>, as shown in <FIG>. A short and adapted electrical current passage will cause the intumescent to expand and seal in a few seconds, while there is still only a little smoke in the room with the fire. Activation can happen from a smoke detector or manually, and a relatively small battery can be used.

As a further improvement of rapid expansion and less dust collection, metal powder/electrode-lacquered intumescent stripes (current) or "nano hair" coatings with high heat transfer performance can be used.

The firestop <NUM> can further be comprising an expansion pocket, for example, where the expansion pocket comprises an expandable intumescent interposed between several quenching gap meshes <NUM>.

As shown in <FIG>, a quenching gap mesh <NUM> with an intumescent stripe pattern <NUM> can be placed in the opening in a building structure as a strip or the like and attached as explained above. In addition, an externally perforated cover <NUM> can be used.

The expansion pocket <NUM> contributes to that the firestop <NUM>, under the influence of fire heat, can fill not only the ventilating empty space <NUM> in which it stands, but also fill in the expansion which can result from the building parts <NUM> bending in the fire and increasing the void space. The expansion pocket "inflates" with "limited space" for expansion. Whether the building parts are slightly compressed or give outwards, the expansion pocket will contribute to the firestop closing tightly against them when it is "inflated". The expansion pocket can be in a mesh and will normally be ventilating, but not letting through an intumescent which is activated to expand in fire. Parts of the expansion pocket can be held together by threads or the like fastened between parts of the expansion pocket's mesh, where the threads can be sacrificed.

<FIG> shows that a ventilating expansion pocket can attach itself to a single fire sheet when it expands. Even if it is attached only from the outside, it can neither push itself out of the opening outwards nor inwards when it expands. It does not have a gasket as in ordinary vents between the frame and sheet and is mounted quickly.

A firestop according to the invention can be produced in that an intumescent is applied in stripes <NUM> by extrusion.

The stripe pattern <NUM> of an intumescent can alternatively be glued or sprayed on the quenching gap mesh <NUM> in parallel or transversely with the ventilating mesh openings <NUM> in between, in one or more layers. This also applies to extrusion.

Furthermore, said stripes <NUM> of an intumescent can be fastened with seams to the quenching gap mesh <NUM>, such as seams of sacrificial-based polyester or cotton.

A firestop according to the invention can also be produced with several quenching gap meshes <NUM> with inlaid, intermediate intumescent stripes <NUM> between respective quenching gap meshes <NUM>.

In use, the flat-produced firestops can be folded or rolled into one or more short rollers which are fitted together with, for example, two or more continuous steel wires which are cut and bent at the ends. This then constitutes an element for use in an air transfer grille, eaves vent, outer wall vent etc., where an intumescent will not glide over time. Transverse locks are secured without a throughgoing connection in the direction of fire spread and vents will be packed tightly and accurately and not bulge out in the middle.

An example of optimal application in an air gap can be a <NUM> quenching gap mesh, but this is primarily needed only at the bottom where the fire hits. Other mesh can be in a spring thread of a coarser mesh, e.g., <NUM>. <NUM> is enough to hold most of the intumescent in place, but can push a suitably small amount through which seals against the connections.

<FIG> shows in more detail a cross-section of intumescent threads <NUM> at a distance a apart and with a diameter b in a fine meshed intumescent pattern on the load-bearing mesh <NUM>. In the event of a fire, as shown, an expanding intumescent mass <NUM>' meets between two wires <NUM> when the expanded thickness, for example, is ½ a for the formation of the shield <NUM>. In a preferred embodiment, but not limited to, a can be larger than <NUM>b and less than <NUM>b, when the wire diameter b is <NUM>-<NUM>.

The load-bearing mesh can be in metal, glass fiber or other poorly combustible material with a preferred wire diameter of <NUM>-<NUM> but not limited to this.

Nearly finished expanding intumescent mass <NUM> 'is shown in dashed lines. An early-activated fire shield <NUM>, including a load-bearing mesh <NUM>, achieves at least thickness c. Shell thickness c can vary according to how long it shall insulate. A preferred thickness is <NUM>-<NUM> without listed articles. With listed articles in the form of a fixed quenching gap mesh, the thickness c can be less than <NUM>. In tests of fire shells according to the invention, a fire insulation time of <NUM>-<NUM> minutes has been achieved, but the shell according to the invention can be dimensioned to function for a longer time period. Additional fire insulation time can be achieved with the last step where more expanded intumescent fills the entire firestop.

In a practical embodiment, the fine mesh stripe pattern which forms the shield <NUM> and which expands rapidly can be very thin stripes, for example <NUM>×<NUM>, and be a short distance from each other and in all have a very large surface area per unit mass.

Claim 1:
Ventilating firestop (<NUM>), comprising
a self-supporting mesh (<NUM>) fitted with an intumescent (<NUM>),
whereby
the mesh (<NUM>) is malleable and is formed into a tubular shape forming an inner volume (<NUM>),
wherein said mesh (<NUM>) is designed as a flame-stopping mesh with a mesh size that provides quenching gap,
characterized in that
the mesh (<NUM>) comprises first and second intumescent (<NUM>) applied to the mesh forming a stripe pattern of intumescent with spacing and ventilating openings (<NUM>) between the stripes,
whereby
said first intumescent (<NUM>) is on a fire load facing plane of the mesh (<NUM>) and has a fine meshed and a rapidly expandable pattern of stripes which, during a fire attack phase, expands towards each other to close said ventilating openings (<NUM>) and form a fire-insulating shield (<NUM>), and
said second intumescent (<NUM>) is located on the mesh (<NUM>) separate from the first intumescent (<NUM>), and has a coarse meshed pattern of stripes expandable slower than those of the first intumescent (<NUM>) which, after formation of the fire-insulating shield (<NUM>), are expandable to subsequent fill up a remaining volume (<NUM>) of the firestop (<NUM>).