CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit of U.S. Provisional Application No. 62294582 filed February 12, 2016, U.S. Provisional Application No. 62372141 filed August 8, 2016, and PCT application PCT/US17/13501 filed January 13, 2017.

FIELD OF THE INVENTION

[0002] This invention relates generally to fire and smoke protection, and in particular, to a fabric coiling door product used as a rated passive fire protection and smoke barrier assembly.

BACKGROUND OF THE INVENTION

[0003] By code, buildings such as industrial, school and public buildings require fire and smoke barrier opening protectives. Due to the simplistic operation and known designs of swing door exit hardware, side-hinged swinging doors are commonly used.

[0004] However, code rated side-hinged swinging doors are not always the desired design choice to meet code requirements. For structures needing higher occupancy fire/smoke protection requirements, multiple swing doors and/or banks of swing doors and their associated frame assemblies are used. The framing requirements of multiple doors and/or banks of doors present architectural challenges for building designers. [0005] In an attempt to overcome these challenges, a variety of door designs have been developed. One known design uses up to two swinging fire door and frame assemblies that store in pockets perpendicular to the opening. A second known design includes a bank of swinging fire door and frame assemblies that are attached to the bottom of a coiling door. Although these designs include commonly accepted side-hinge swinging doors, they require significantly more head or side room clearances and cost more to manufacture than earlier designs.

[0006] Another known design uses commonly accepted side-hinge swinging doors in an accordion folding fire door configuration. However, this design requires side stack space for the folded accordion door and non-folding side-hinge swinging door(s). Because occupancy load determines the amount of door opening/number of required doors, each required side-hinge swinging door mandates additional side stack space, thereby reducing the overall free space and presenting construction challenges.

[0007] Accordingly, there remains a continuing need for improved combined emergency egress and fire/smoke barrier designs. The present invention fulfills this need and further provides related advantages.

BRIEF SUMMARY OF THE INVENTION

[0008] Described below is an electrically operated, vertically deployed, UL10D tested fabric coiling door product that may be used as a rated passive fire protection and smoke barrier assembly. It targets, for example, atrium closures to project smoke layers to lower floors, form protected atrium evacuation pathways and provide an alternative basis to lower or eliminate smoke evacuation system requirements.

[0009] The door utilizes a fire resistant fabric curtain, for example, a fiberglass based fabric curtain with thermal coating. In a preferred embodiment the curtain is stitched together with strip steel bands sewn in to each end for end lock attachment. End locks can be, for example, L-shape brackets or segments of curved spring steel. A third steel band is sewn in across the top for attachment of the curtain to the shaft. Brackets are riveted to the top band and the brackets are then bolted to the shaft, or alternatively, the band is slotted for side to side adjustment and bolted directly to the shaft. Curtains can be attached to the shaft in overlapping segments for easy installation. The overlapping segments are sealed to each other, for example, with a fire rated hook and loop material that is sewn to the curtains.

[0010] The tubular steel shaft is driven by an internal tube motor which provides governing to maintain consistent closing speeds. In a fire/smoke event or loss of power, the door will automatically close via gravity. The shaft can be segmented for easier installation. Segments have male/female ends and bolt together. Single/segmented shafts can extend to approximately 50 feet and are driven by a tube motor at each end. The shaft is supported approximately every 6 feet to minimize deflection. Support brackets are designed to attach to the header and employ rollers for the shaft to ride on during operation. Single door shafts can also be joined together with a coupler shaft to create infinitely wide doors. The coupler shaft is spring loaded to act as a take up reel for the coupling curtain which will overlap each adjacent single door shaft. All curtains are attached to the same bottom bar.

[0011] A sheet metal hood covers the shaft, curtain, and the supports that run across the width of the door. The curtain travels over these horizontal supports as it drops down through the hood opening. The horizontal supports keep the curtain in position for proper seal during fire/smoke event.

[0012] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The accompanying drawings are included to provide a further understanding of the present invention. These drawings are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the present invention, and together with the description, serve to explain the principles of the present invention.

[0014] FIG. 1 is a view of an atrium opening.

[0015] FIG. 2 is a perspective view of an unrolled curtain.

[0016] FIG. 3 is a perspective view of a hood. [0017] FIGS. 4a and 4b are perspective views of a curtain bottom corner.

[0018] FIG. 5 is another perspective view of an end plate.

[0019] FIGS. 6 and 7 are a perspective views of a bracket.

[0020] FIG. 8 is a perspective view of two shafts.

[0021] FIGS. 9 and 10 are perspective views of a coupling curtain.

[0022] FIG. 11 is a front view of a door with coupling curtain.

[0023] FIG. 12 is a perspective view of curtain overlap.

[0024] FIGS. 13 - 18 are perspective views of a bottom bar assembly.

[0025] FIG. 19 is a perspective view of one form of a curtain side geometry.

[0026] FIG. 20 is a top view of the curtain side geometry of FIG. 19.

[0027] FIG. 21 is a perspective view of a second form of curtain side geometry.

[0028] FIG. 22 is a top view of the curtain side geometry of FIG. 21.

[0029] FIG. 23 is perspective view of the tool cutout of the curtain side geometry of FIG. 21.

[0030] FIG. 24 is a perspective view of a curved end lock. [0031] FIG. 25 is a perspective view of curved end locks on a curtain.

[0032] FIGS. 26 and 27 are perspective views of end locks rolled-up.

[0033] FIG. 28 is an end view of end locks rolled-up.

[0034] FIG. 29 is an exploded perspective view of a shaft stop mechanism.

[0035] FIG. 30 is a perspective view of a curtain stop assembly.

[0036] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0037] As required, detailed embodiments of the present invention are disclosed; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. The figures are not necessary to scale, and some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. Where possible, like reference numerals have been used to refer to like parts in the several alternative embodiments of the present invention described herein. [0038] For purposes of this disclosure, a smoke protective state is meant to be when the curtain(s) are closed to create a fire and smoke barrier during a fire/smoke event.

[0039] Turning now to the figures, the fabric fire rated door system is a vertically coiling fire and smoke containment system that is comprised of a fire resistant curtain or curtains, for example operational assembly curtains 4 and a coupling curtain 40, vertically oriented side members 6, for example, a guide, a counterbalance assembly 8 and an operational assembly 10. The counterbalance assembly 8 and operational assembly 10 are preferably contained within an overhead hood 12.

[0040] The counterbalance assembly 8 comprises a counterbalance barrel, for example, a shaft 14, which is supported above the opening and secured by horizontal support members, for example, brackets 16 and end plates 18. The curtain 4 directly attaches to the shaft 14 and rolls onto and off of the shaft 14 as the shaft 14 is rotated by the operational assembly 10. The operational assembly curtain 4 travels within the vertically oriented side members 6, within which the outer edges 20 of the operational assembly curtain 4 are contained and guided. In a preferred embodiment, the operational assembly curtain outer edges 20 comprise side geometries 22 (FIGS. 19 and 21) which are mechanically locked within the vertically oriented side members 6.

[0041] The operational assembly 10 comprises a drive motor assembly 11 and a releasing device 46, for example, a tube motor with internal brake. Optionally a controller and a continuously charged battery backup power supply (shown collectively as 47, FIG. 11) is included. In a preferred embodiment the shaft 14 is a tubular shaft driven by an internal tube motor 11 which provides governing to maintain consistent closing speeds. During a predetermined condition such as a fire/smoke event or loss of power, the door will automatically close via gravity upon activation of the releasing device 46, for example, release of the brake.

[0042] In the preferred embodiment the tube motor 11 is fully constrained at the end plate 18 and the shaft 14 is allowed to deflect as the curtain unrolls and the diameter decreases. In this embodiment a horizontal support member, for example, roller brackets 16 consistently support the shaft 14 across the door opening, and in particular, at elevated temperatures, for example, during a fire.

[0043] In an alternate embodiment a slot 54 (FIG. 5) is added to the end plate 18 to allow the tube motor to slide up and down as the rolled / unrolled curtain 14 gets larger or smaller. Additionally, a roller bracket 16 may be added next to the end plate 18 to support a curtain rollup at its end. At the end plates 18 the shaft 14 will remain straight instead of deflecting as the curtain 14 unrolls.

[0044] The operational assembly 10 is designed to function under normal or test conditions with, for example, a secured or unsecured Open/Close/Stop station 49. The controller is programmed to automatically deploy the curtain upon entering an alarm condition, for example, receiving notification from a building fire alarm control panel, local fire and/or smoke detection appliances, or upon a pre-determined reduction of available power, for example, battery power.

[0045] The curtains 4, 40 comprise a fire resistant fabric, for example, a fiberglass based fabric curtain with thermal coating. In a preferred embodiment the operational assembly curtain 4 is stitched together with side strip steel bands 24 sewn in to each curtain outer edge 20 for attachment of an end lock 26, 78 (FIGS. 4a, 4b, 25). The end lock 26 can be, for example, L-shape brackets or segments of curved spring steel. The end lock 26 is fastened to the side strip steel band 24 with fasteners 25, for example, rivets.

[0046] Depicted in FIG. 12, a top strip steel band 28 is sewn into the curtain top 30 and used to attach the curtain 4, 40 to the shaft 14. In one form brackets are fastened to the top strip steel band 28 and the brackets are then bolted to the shaft 14. Curtains 4 can be attached to the shaft 14 in overlapping segments 32, for example, every 3 feet, for easy installation. The overlapping segments 32 are sealed to each other, for example, with a fire rated hook and loop material 44 that is sewn to the curtains 14.

[0047] Depicted in FIG. 8, the shaft 15 can be segmented for easier installation. The shaft segments 34 are joined. For example, the shaft segments 34 comprise male/female ends and bolt together. Preferably, single/segmented shafts 14 can extend to approximately 50 feet and may be driven by a tube motor 11 at each end. The shaft 14 requires support approximately every 8 feet to minimize deflection. Horizontal support members, for example, shaft support brackets 16 are designed to attach to the header and employ rollers 36 (FIG. 6) for the shaft 14 to ride on during operation.

[0048] As shown in FIGS. 9 - 11, door curtains can be joined together with a coupler shaft 38 comprising a hook and loop separator channel 102 and coupling curtain cross brace 104 to create infinitely wide doors. The coupler shaft 38 is not motor driven, but rather it is spring loaded to act as a take up reel for a coupling curtain 40 which will overlap each adjacent curtain 14 and its respective shaft 14 by about 3 feet.

[0049] Preferably, the coupler shaft 38 is a smaller, spring loaded shaft used together with its coupling curtain 40 to connect two adjacent operational assembly curtains 4. The coupler shaft 38 is spring loaded with enough force to separate the hook and loop material 44 as it winds and acts as take up reel for the coupling curtain 40 (depicted as rolled-up in FIG. 10). In this configuration all operational assembly curtains 4 and coupling curtains 40 are attached to the same bottom bar assembly 42, described in detail below.

[0050] The hood 12 is preferably a sheet metal hood which covers the shaft 14, curtain 4, 40, and support brackets 16. Inside of the hood 12 are the horizontal supports that run across the width of the door opening. They comprise the end plates 18 and the support brackets 16. The operational assembly curtain 4 travels over these horizontal supports as it drops down through the hood opening. The horizontal supports keep the curtain in position to maintain an effective seal during a smoke protective state. [0051] Turning to FIGS. 13-18, the bottom bar assembly 42, comprises, for example, a first angle bottom bar 48 and a second angle bottom bar 50 with a bottom bar center flat section 52 therebetween. The operational assembly curtain 4 and coupling curtain 40 are secured to the bottom bar flat section 52, for example, by inserting the bottom bar flat section 52 into a curtain bottom hem pocket 108. The bottom bar flat section 52 is fixed, for example, pinned, to the first and second angle bottom bars 48, 50 at each end. Preferably, the first and second angle bottom bars 48, 50 remain outside of the curtain bottom hem pocket 108.

[0052] This configuration allows the bottom bar center flat section 52 to deflect vertically in the center of the door between the first and second angle bottom bars 48, 50. This will allow the operational assembly curtain 4 and coupling curtain 40 to move during a smoke protective state without breaching the fire and smoke barrier when pressure is applied from air temperature change during a fire. The configuration prevents the bottom bar center flat section 52 to which the operational assembly curtain 4 and coupling curtain 40 are attached from deflecting far enough to "pop out" of or no longer be contained within the first and second angle bottom bars, thereby preventing creation of an opening which would allow smoke to pass. Containment of smoke is critical for a fire rated product.

[0053] If necessary to meet larger width openings, multiple angle bottom bars are joined with an angle bottom bar connector 106 (FIGS. 11 and 14). If multiple bottom bar center flat sections 52 are required they are overlapped inside of the curtain bottom hem pocket 108. FIG. 17 depicts the bottom bar assembly 42 attachment and FIG. 18 depicts the bottom bar assembly 42 attachment when a coupling curtain 40 is utilized. In both figures the curtains are depicted as transparent.

[0054] Turning now to FIGS. 19-20, one form of operational assembly curtain side geometry 22 comprises a three piece guide used for L-shaped end retention. A fascia fastener 56 attaches a fascia guide 58 and an inner guide 60 to a wall. An outer guide fastener 62 attaches an outer guide 64 to the inner guide 60, for example, with a screw to an inner guide weld stud or threaded hole.

[0055] Alternatively, as shown in FIGS. 21-25, a two piece guide utilizing press in studs for a "no fastener" appearance is used with a curved band retention system. The outer guide 66 with a press in stud 68 slides onto inner guide slots 70 with washer 72 and a nut 74 loosely attached. The installer can then use a nut driver to tighten the fasteners. A cutout 76 at the bottom of the guide assembly allows insertion of the tool.

[0056] Curved end locks 78 are attached to the curtain 4, for example, in about 5 inch segments. Depicted in FIGS. 26-28, as the curtain 14 rolls up, the curved end locks 78 flatten out to roll up similar to a tape measure. End lock slots 100 allow circumferential movement to account for different diameters in material as the curtain 14 rolls up. For example, when the curtain 14 is about 1/8 inch thick and rolls on top of the end locks 78, the end locks 78 roll up on a tighter diameter than the curtain 14, and therefore, the end locks 78 have to move independent of the curtain 14. This allows for a tighter roll-up on the shaft 14 and less chance for the end locks 78 to catch on something thereby preventing the curtain 14 from closing.

[0057] A curtain stop assembly 80 is shown in FIGS. 29-30. A spring loaded pin 82 is installed inside of the shaft 14 and can extend out from the shaft 14 when the door is closed and the curtain 14 unwraps, thereby uncovering the pin 82. The pin 82 will then stop the shaft 14 from rotating when it hits a shaft stop mechanism 84 mounted directly or indirectly to the building structure 116.

[0058] Preferably, the shaft stop mechanism 84 is also spring-loaded 120 to absorb impact. In one form a threaded tube 86 accepts shoulder bolts 88 and threads into larger tubes 90 that rotate on a main pivot bolt 92. The shoulder bolts 88 can be used to rotate the tube and adjust the shaft stop plate 112 in and out to modify curtain tension.

[0059] Optionally, when it is desirable that the curtain 14 not fully unwind, one or more curtain slots 94 (FIG. 2) are fabricated into the curtain 14 at a predetermined location(s) to allow the spring loaded pin 82 to extend through the curtain 14 before the curtain 14 fully unwinds.

[0060] Although the present invention has been described in connection with specific examples and embodiments, those skilled in the art will recognize that the present invention is capable of other variations and modifications within its scope. These examples and embodiments are intended as typical of, rather than in any way limiting on, the scope of the present invention as presented in the appended claims.