DEFLECTION AND DRIFT STRUCTURAL WALL ASSEMBLIES

Abstract

Metal framing system composed of stud and track profiles having preformed slots which allow system to accommodate for vertical deflection and horizontal drift/adjustment. Embodiment of the system also used to create protection of fire rated joints in rated wall partitions.

Description

TECHNICAL FIELD

The present invention relates generally to structural wall assemblies and, more particularly, to metal flaming structural wall assemblies configured to accommodate vertical deflections and horizontal drifts.

BACKGROUND OF THE INVENTION

Metal framing assemblies are commonly used to construct commercial and residential buildings in the building construction industry Such metal framing assemblies are generally constructed from a plurality of metal framing members including studs, joist, trusses, and other metal posts and beams formed horn sheet metal and frequently fabricated to have the same general cross-sectional dimensions as standard wood members used for similar purposes. Metal framing members are typically constructed by roll-forming 12 to 24 gauge galvanized sheet steel Although many cross-sectional shapes are available, the primary shapes used in building construction are C-shaped studs and U-shaped tracks.

In the building construction trade, a head-of-wall joint (also sometimes referred to as a top-of-wall joint) refers to the linear junction or interface existing between a top section of a framing/wallboard wall assembly and the ceiling (where the ceiling may be a next-level floor or corrugated pan roof deck, for example). In common practice, a wall to ceiling connection of many newly constructed buildings consists essentially of an inverted U-shaped elongated steel channel (or track) configured to receive steel studs between the legs (also sometimes referred to as sidewalls or flanges) of the shaped channel. A wallboard is generally attached to at least one side of the studs. The studs and wallboard are in many instances spaced apart from the ceiling a short gap distance in order to allow for ceiling deflections caused by seismic activity or moving overhead loads. Channel and stud assemblies that allow for ceiling deflections are commonly referred to as dynamic head-of-wall systems. Exemplary steel stud wall constructions may be found in U.S. Pat. Nos. 4,854,096 and 4,805,364 both to Smolik, and U.S. Pat. No. 5,127,203 to Paquette Exemplary dynamic head-of-wall systems having steel stud wall constructions may be found in U.S. Pat. No. 5,127,760 to Brady, and U.S. Pat. No. 6,748,705 to Orszulak et al.

Although some advances have been made with respect to structural wall assemblies, there is still a need in the art for new and improved structural wall assemblies that can accommodate both vertical deflections and horizontal drifts. The present invention fulfills these needs and provides for further related advantages

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a structural wall assembly in accordance with an embodiment of the present invention

FIG. 1B is a perspective view of a structural wall assembly in accordance with an embodiment of the present invention (embodiment having intumescent strips affixed lengthwise on the top portion of a generally U-shaped header track)

FIG. 1C is a perspective view of a structural wall assembly in accordance with an embodiment of the present invention (embodiment having intumescent strips affixed lengthwise on the top portion of a generally U-shaped header track and wherein the header track also includes an outwardly extending elongated protrusion or groove).

FIG. 2A is a side view of a structural wall assembly in accordance with an embodiment of the present invention

FIG. 2A is a side view of a structural wall assembly in accordance with an embodiment of the present invention wherein the wall assembly is attached to a floor and ceiling.

FIG. 3A is a perspective view of a portion of a structural wall assembly in accordance with an embodiment of the present invention.

FIG. 3B is a perspective view of a portion of a structural wall assembly in accordance with an embodiment of the present invention and showing an upward deflection of the header track

FIG. 4 is an exploded perspective view of a portion of a structural wall assembly in accordance with an embodiment of the present invention and showing the relation among the slots, fasteners, and wallboard

FIG. 5 is a side view of a portion of a structural wall assembly in accordance with an embodiment of the present invention.

FIG. 6 is an end view of a portion of a structural wall assembly in accordance with an embodiment of the present invention

FIGS. 7A-D are various end views of a portion of a structural wall assembly in accordance with different embodiments of the present invention

FIGS. 8-10 are various views of the fastening aspect of the present invention.

FIGS. 11A-C illustrates different embodiments of the present invention

FIGS. 12-13 illustrates different embodiments of the present invention.

DISCLOSURE OF THE INVENTION

The present invention provides for structural wall assemblies configured to accommodate vertical deflections and horizontal drifts. In an embodiment, the present invention is directed to a metal framing structural wall assembly that uses a simple fastener connection through preformed slots on both the U-shaped track and C-shaped studs. The present invention also allows an installer to “adjust” stud flaming in a horizontal direction without having to remove and reinstall fasteners when wall sheathing joints don't match up to the installed studs

For example, in current construction methods (accommodating the “growing or shrinking” of wall sheathing during application due to inconsistent wall sheathing widths or installed joints) the labor to unfasten, move and refasten studs is both labor intense and time consuming. The alternative of “adding” an additional stud in the cavity to create a backing element for wall sheathing edges which don't line up with attached framing is also labor intense and typically requires the “added stud” to be additionally field modified (cut out) to accommodate existing cavity obstructions such as pipes and wires installed horizontally within the wall Such “cut” studs not only don't meet code requirements but are also costly in both labor and material to install.

The present invention incorporates preformed slots of selected sizes and positioned at specific locations such as (1) a horizontal slot positioned on top and bottom tracks (allowing for horizontal movement of the stud and fastener) and (2) a vertical slot positioned on the studs (allowing for vertical deflection) with a fastener extending though both slots. The present invention thus provides a simple and cost effective means of reducing labor and materials.

The design having the slot located in the stud flange formed in a manner which provides a connection that holds the fastener in place during installation and also allows said fastener to be moved (vertically) with increased pressure on the fastener (without damaging stud) and having fastener held in “permanent” vertical plane or position by the track solves accommodating vertical deflection and permanent positive connection of the stud and track profiles.

The embodiments of the invention having an adhered or affixed intumescent as thick or thicker than a fastener head profile also provides similar solutions for fire rated walls while providing sealing of joints from air, sound, smoke, fire, and thermal transfer between the wall sheathing and substrates as well.

Having horizontal slots in the track improves the short comings of typical slotted track (multiple slots running vertically) by allowing studs and fasteners positively attached via a fastener through a slot to be adjusted horizontally during wall sheathing installation and also accommodate horizontal drift movement. Slots formed in the stud profiles receiving the shank portion of the fastener extending through the slot of the track and formed in a manner which creates a connection between the stud and fastener supports the fastener from “pull out” while still allowing and directing vertical deflection of the stud or substrate when additional pressure is applied from external forces with the fastener being held in “stationary vertical position” by the u-shaped track profile.

In the embodiments including an affixed materials such as intumescent positioned on the U-shaped track provides an air, smoke, sound, fire, and thermal seal or barrier for both non-rated and fire rated joints between wall sheathing and substrates.

Claims

1. A U-shaped profile having a web surface and two leg surfaces affixed and extending in a perpendicular fashion with a minimum of one slot located through a minimum of one of the leg surfaces such that the lengthwise dimension is parallel the web surface and the width of the slot is less than the diameter of a fastener head having it's shank extending through the slot, preventing said fastener from passing through the slot, while allowing said fastener to move in either direction parallel to the profile web.

2. An embodiment of the invention with multiple slots or rows of slots located in one leg or both legs.

3. An embodiment of claim 1 having a minimum of one additional slot located in the web in which the lengthwise dimensions is perpendicular to the web and leg intersection.

4. An embodiment of claim 3 having multiple slots in the web.

5. Said profile of claims 2 and 3 having opposing slots in opposing legs spaced apart and offset intermittently so that opposing slots don't line up with one another but a slot is opposed by at least a portion of the solid surface spacing between two slots on the opposing leg.

6. An embodiment of claim 1-5 having a material including intumescent being as thick or thicker or thinner than a fastener head profile providing sealing of joints from one or a combination of air, sound, smoke, fire, and thermal transfer between the wall sheathing and substrates affixed to the at least the outer surface of a minimum of one leg with an adhesive, positioned between a minimum of one of the web and leg intersections and said slot(s) in the leg(s) for both non-rated and fire rated joints or walls

7. Said material or intumescent of claim 6 being similar or thicker than a fastener and creating an offset surface a distance similar or thicker than said fastener beyond the leg outer surface.

8. Said material and or intumescent of claim 7 having a polyester coating on the outer surface

9. Said material and or intumescent of claim 7 or 8 wrapping around the web and leg intersection onto a portion of an outer web surface.

10. Said embodiments of claims 1-9 having a minimum of one additional corrugation in a minimum of one leg surface or having one leg “hemmed” at the end creating an offset surface distance from the outer leg surface that is the same or thicket than a fastener

11. Said embodiment of claim 10 having a minimum of one corrugation in both leg surfaces or having both legs “hemmed” at the end creating an offset surface distance from the outer leg surface that is the same or thicker than a fastener.

12. A C-Shaped profile having a web with flanges extending perpendicular to the web and return flanges which extend perpendicular to the flanges and parallel to the web and a minimum of one slot formed in a flange located proximate and end of a minimum of one of said flanges with said slot being of a width that is equal to or narrower than the outer dimensions of a smooth or threaded fastener shank such that when said fastener shank extends through said slot at least the lengthwise edges of the flange which define said slot engage said fastener via contact with the outer edges of the fastener shank or threaded surfaces of a threaded shank creating a connection securing said fastener from a “pull out” while still allowing the fastener to move in a liner direction defined by the slot when increased pressure is applied to the fastener.

13. An embodiment of claim 12 with said slot having “flared” edges directed inward towards the opposing flange such that the inward protruding longitudinal edges are spaced a distance apart that is equal to or narrower than the outer dimensions of a smooth or threaded

14. Said profile of claims 12 and 13 having single or multiple slots located in a single or multiple flanges near a single or multiple ends.

15. Said profile of claims 12 and 13 having a minimum of one corrugation in a minimum of one flange and said slot located within a portion or exclusively through the corrugation surface.

16. Said profiles of 12 and 13 having an embossed pattern in the flange or web surface areas.

17. A wall assembly comprised of an embodiment of the U-shaped profile and an embodiment of the C-shaped profile with a minimum of one end of a C-shaped profile located between the legs of a minimum of one of the embodiments of the U-shaped profile, having a mechanical or friction fit fastener located through a minimum of one slot of a minimum of one U-shaped profile with the head of the fastener proximate to the outer surface of the U-shaped profile leg outer surface and said fastener shank extending into a minimum of one said slot of a minimum of one C-shaped profile with the lengthwise edges of said slot in the C-shaped profile in contact with the outer or threaded surface of the fastener shank creating a connection with the shank or threaded shank of the fastener, said connection firmly connecting the fastener not allowing it to “pull out” from installed position, with C-shaped profile and fastener able to be move in a lateral (horizontal) direction defined by the slot in the connected U-Shaped profile, with C-shaped profile able to move in an up and down (vertical) direction defined by the slot in the connected C-shaped profile with the fastener held in place (from vertical movement) by the U-shaped profile.