Fire-rated modular duct assembly suitable for exhausting flammable or hazardous gases, vapours and other materials

Abstract

A fire-rated exhaust duct system comprising a modular configuration or structure. The fire-rated exhaust duct system comprises a plurality of exhaust duct sections. Each of the exhaust duct sections is configured to be joined or connected with other exhaust duct sections in the field or at an installation site, e.g. in building housing a kitchen facility or a laboratory facility to form longer sections or runs for exhaust duct system.

What is claimed is: 
     
       1. A modular fire-rated exhaust duct assembly comprising:
 two or more exhaust duct modules;   each of said exhaust duct modules having an inner duct liner and an outer casing, and a void being formed between at least a portion of space between said inner duct liner and said outer casing, said void being configured for receiving an insulation material, and including one or more insulation encapsulation sections configured to connect to said inner duct liner and said outer casing to contain said insulation material in said void;   a first exterior flange connector, and one end of each of said exhaust duct modules being configured for receiving said first exterior flange connector;   a second exterior flange connector, and another end of each of said exhaust duct modules being configured for receiving said second exterior flange connector;   said inner duct liner comprising a flange configured to be affixed to said first exterior flange connector and a flange configured to be affixed to said second exterior flange connector;   said first and said second exterior flange connectors being configured to form a field assembly junction for coupling respective ends of said exhaust duct modules to form a single exhaust duct run; and   a joint encasement section configured to be field connectable to each of said exhaust duct modules and encase said junction.   
     
     
       2. The modular fire-rated exhaust duct assembly as claimed in  claim 1 , wherein said exhaust duct modules have a generally rectangular cross-section. 
     
     
       3. The modular fire-rated exhaust duct assembly as claimed in  claim 1 , wherein said inner duct liner and said outer casing are formed from a metallic material, and each having a thickness to provide a specified fire rating. 
     
     
       4. The modular fire-rated exhaust duct assembly as claimed in  claim 1 , wherein said insulation capsulation sections have a profile comprising one of a flat profile, a step profile, a sawtooth profile and an accordion profile. 
     
     
       5. The modular fire-rated exhaust duct assembly as claimed in  claim 1 , wherein said joint encasement section comprises a plurality of joint encasement sections, each of said joint encasement sections comprising an outer layer and an inner layer, and said outer layer having a flange on each longitudinal edge for affixing said encasement section to respective ends of said adjacent exhaust duct modules. 
     
     
       6. The modular fire-rated exhaust duct assembly as claimed in  claim 5 , wherein said outer casing is formed from a metallic material having a thickness sufficient to provide a specified fire rating and said outer layer of said joint encasement section comprises the same metallic material. 
     
     
       7. The modular fire-rated exhaust duct assembly as claimed in  claim 6 , wherein said joint encasement sections are configured to be field attachable to said respective surfaces of the said exhaust duct modules. 
     
     
       8. An exhaust duct module configured to be assembled in the field to form a fire-rated exhaust duct assembly, said exhaust duct module comprising:
 an inner duct liner formed with a generally rectangular cross-section, said inner duct liner having a flange at one end and a flange at another end;   an outer casing formed with a generally rectangular cross-section and being sized to substantially surround said inner duct liner;   a first flange connector configured to be attached to said flange at one end of said inner duct liner and one end of said outer casing, and couple said inner duct liner to said outer casing;   a second flange connector configured to be attached to said flange at the other end of said inner duct liner and one end of said outer casing, and couple said inner duct liner to said outer casing; and   said first flange connector and said second flange connector being configured to be field attachable to couple another exhaust duct assembly.   
     
     
       9. The exhaust duct module as claimed in  claim 8 , wherein a void is formed in at least a portion of a space separating said inner duct liner from said outer casing. 
     
     
       10. The exhaust duct module as claimed in  claim 9 , further including a plurality of insulation encapsulation sections configured to connect to said inner duct liner and said outer casing to close in said void space. 
     
     
       11. The exhaust duct module as claimed in  claim 10 , further including a thermal insulation material substantially filling said void space between said inner duct liner and said outer casing. 
     
     
       12. The exhaust duct module as claimed in  claim 11 , wherein said inner duct liner and said outer casing are formed from a metallic material, and each having a thickness to provide a specified fire rating. 
     
     
       13. A modular fire-rated exhaust duct assembly comprising:
 two or more exhaust duct modules;   each of said exhaust duct modules having an inner duct liner and an outer casing, and a void being formed between at least a portion of space between said inner duct liner and said outer casing, said void being configured for receiving an insulation material, and including one or more insulation encapsulation sections configured to connect to said inner duct liner and said outer casing to contain said insulation material in said void;   a first exterior flange connector, and one end of each of said exhaust duct modules being configured for receiving said first exterior flange connector;   a second exterior flange connector, and another end of each of said exhaust duct modules modules being configured for receiving said second exterior flange connector;   said inner duct liner comprising a flange configured to be affixed to said first exterior flange connector and a flange configured to be affixed to said second exterior flange connector;   said first and said second exterior flange connectors being configured to form a field assembly junction for coupling respective ends of said exhaust duct modules to form a single exhaust duct run; and   at least one joint encasement section configured to be field connectable to each of said exhaust duct modules and encase said junction;   wherein said at least one joint encasement section comprises a plurality of low-profile joint encasement sections, each of said low profile joint encasement sections having a flange formed on a longitudinal edge to form a longitudinal attachment surface, and said flange for each of said low-profile joint encasement sections comprising a low profile configuration for accommodating one or more low profile fasteners, and said longitudinal attachment surface for each of said low-profile joint encasement sections being configured to affix said encasement section to respective ends of adjacent said exhaust duct modules.   
     
     
       14. The modular fire-rated exhaust duct assembly as claimed in  claim 13 , wherein said exhaust duct modules have a generally rectangular cross-section. 
     
     
       15. The modular fire-rated exhaust duct assembly as claimed in  claim 13 , wherein said inner duct liner and said outer casing are formed from a metallic material, and each having a thickness to provide a specified fire rating. 
     
     
       16. The modular fire-rated exhaust duct assembly as claimed in  claim 13 , wherein said insulation encapsulation sections have a profile comprising one of a flat profile, a step profile, a sawtooth profile and an accordian profile. 
     
     
       17. The modular fire-rated exhaust duct assembly as claimed in  claim 13 , wherein each of the said low-profile joint encasement sections comprises a hat configuration with a channel having an outwardly facing return formed on a longitudinal edge of said channel and each of said outwardly facing returns providing a respective attachment surface for affixing said low-profile joint encasement section to respective ends of said adjacent exhaust duct modules. 
     
     
       18. The modular fire-rated exhaust duct assembly as claimed in  claim 17 , wherein said outer casing is formed from a metallic material having a thickness sufficient to provide a specified fire rating and an outer layer of said joint encasement section comprises the same metallic material. 
     
     
       19. The modular fire-rated exhaust duct assembly as claimed in  claim 18 , wherein said joint encasement sections are configured to be field attachable to said respective attachment surfaces of the said exhaust duct modules.