Patent Grant
11306476
The present invention relates to a structural gap filler, and more particularly to a gap filler that is disposed between adjacent structures to inhibit the spread of sound, fire, smoke and other things through a gap between the adjacent structures.
In the construction of buildings, walls typically extend between a floor and a ceiling in a room or other space. In many construction projects, where a wall, floor or ceiling abuts another wall, floor or ceiling, a joint or gap sometimes is created. This is many times the case in commercial construction, where a building shell or a number of structural floors are first constructed. After construction of the shell or floors, walls are built to subdivide the shell or each floor into multiple rooms. The walls typically include a bottom plate that is fastened to the floor. The walls extend upward toward a ceiling. The walls also include a top plate or top that is placed close to the ceiling. To facilitate raising or tilting of a built wall into place under the ceiling, walls are constructed slightly shorter than the distance between the floor and ceiling so that the top plate does not engage the ceiling as a wall is raised to a vertical configuration.
Due to the shortness of the walls relative to the distance between the floor and ceiling, an opening is produced above the wall, below the ceiling. Most fire and other building codes require this opening to be filled with a fire retardant, fireproof and/or sound deadening material. Frequently, these materials are applied in liquid, semi-liquid or sprayed foam form. An installer usually manipulates a large applicator tube or caulk gun filled with a tube of the material, and aims a nozzle into the opening. The installer activates the tube or gun to squirt or spray a bead or amount of the material into the opening as the installer advances along the opening. The installer must perfectly time and move the nozzle at a constant rate to ensure the bead is of a uniform size so material is not wasted, and so enough material fills the opening to seal it between the wall and ceiling.
In most cases, the materials are applied with a large tube or caulk gun, as mentioned above. These applicators are large, bulky and unwieldy, particularly when the installer installs the material in an opening overhead, along a very long wall, or along multiple walls for multiple times during a workday. Further, after the materials set, the excess applied material must be removed to provide a finished appearance of the filler and adjacent walls. For example, the material may need to be cut and sometimes sanded away to smooth it flush with the adjacent wall or ceiling so that wall coverings or flooring can be applied. In addition, when the material is hand applied and is semi-flowable upon application, the material often drips or runs down walls. It also can coat or otherwise fill gaps intended for wiring, plumbing and/or HVAC ducting. This can create a lot of extra work to remove the extra material.
Accordingly, there remains room for improvement in the field of fillers to seal or fill the openings between adjacent walls, ceilings or panels in construction projects.
An elongated gap filler is provided including a first panel and a second panel in an angled or curved configuration joined at an apex, a first extension wall extending from the first panel, a first sealer wall extending transversely to the first extension wall, and a second extension wall extending from the second panel. The first sealer wall can engage a surface of a wall and set a depth of insertion of the first and second panels and first extension wall into a gap between building surfaces, e.g., a wall and a ceiling or roof or another wall. The elongated gap filler can be easily and precisely installed between a variety of building structures to seal a respective gap therebetween.
In one embodiment, the second extension wall can be arcuate and can bend against a ceiling or roof. The second extension wall and second panel can yield or move relative to the first extension wall to accommodate a variety of different sized gaps so that the gap filler can be used in many applications.
In another embodiment, the apex can include a U-shaped groove to enhance articulation of the panels and/or compression of the gap filler. The U-shaped groove can be defined by an apex projection that extends from the first and second panels opposite a V-shaped or other shaped void defined between those panels. In some cases, this groove can provide extra expansion or compression of the first and second panels relative to one another to adequately fill a gap.
In still another embodiment, the first sealer wall can extend downward from a distal end of the first extension wall. The first sealer wall can include a first sealer wall inner surface that can face and/or engage a building wall outer surface. In some applications, the first sealer wall can be curved or arcuate in shape so it can resiliently deform upon engagement with the building wall outer surface and seal a distal end of the first sealer wall against the building wall outer surface.
In even another embodiment, the second extension wall can be arcuate in shape, extending upward from a second panel distal end. In some applications, the second extension wall can resiliently deform upon engagement with a building horizontal surface spaced adjacent the gap. The second extension wall can seal a distal end of the second extension wall against the building horizontal surface.
In yet another embodiment, the apex, first panel, first extension wall, second panel and second extension wall can be configured to fit within the gap between adjacent building structures and fill that gap. In some cases, these elements fit within a gap between a wall upper end adjacent a ceiling or roof (referred to interchangeably as ceiling herein). In other cases, these elements fit within a gap between adjacent walls. In yet other cases, these elements can fit between a vertical building structure and a horizontal building structure.
In a further embodiment, the first extension wall can extend a first distance from the first panel distal end, and the second extension wall can extend a second distance from the second panel distal end. The ratio of the second distance to the first distance can be at least 2:1. The second extension wall can be configured to engage a generally horizontal surface that extends above an upper portion of a wall, well beyond a vertical surface of the wall that is engaged by the first sealer wall.
In still a further embodiment, the second extension wall can be placed above the first extension wall when the gap filler is placed in a gap. The second extension wall can extend a greater distance from the second panel than the first extension wall extends from the first panel so that the second extension wall is longer than the first extension wall relative to a reference line taken through the apex.
In still yet a further embodiment, the gap filler can include an elongated filler strip disposed between the first extension wall and the second extension wall. This filler strip can be constructed from a fire retardant, fire proof and/or sound deadening material to further enhance the isolation functionality of the gap filler placed in a gap.
In still yet a further embodiment, a method of installing an elongated gap filler is provided. The method can include placing an elongated gap filler in a gap between a first surface and a second surface of a building structure such that a first panel and a second panel in a V configuration are within the gap, and such that a first extension wall extending at an obtuse angle from a distal end of the first panel is adjacent the first surface and such that a second extension wall extending from a distal end of the second panel is adjacent the second surface; placing a first sealer wall extending transversely from the first extension wall against a third surface of the building that is substantially perpendicular to the first surface with the first sealer wall at least impairing the first and second panels from being inserted too far into the gap between the first and second surfaces; and moving the first and second panels relative to one another so that the first and second panels at least one of move toward one another and move away from one another to fit within the gap between the first surface and the second surface. The method can further include applying a wall covering to the first sealer wall so that the first sealer wall melds into the third surface.
In even a further embodiment, the method can be used where the first surface is an upper portion of a vertical wall, where the second surface is a horizontal surface above the vertical wall, spaced from the upper portion of the vertical wall by the gap, and where the third surface is a vertical surface of the vertical wall. The applying step can include applying a filler material over a lower edge of the first sealer wall and over the vertical surface. The second extension wall can be arcuate and can bend when the second extension wall is placed adjacent the horizontal surface.
The current embodiments of the gap filler and related method of installation provide benefits in sealing or filling gaps between adjacent building structures that previously have been unachievable. For example, the elongated gap filler can be rapidly installed within gaps overhead, down low, or in difficult to reach locations in a building. The elongated gap filler can include the V configuration and/or the supplemental bead at the apex to allow the filler to compress or expand within a gap and adequately seal against the adjacent surfaces. Where the extension or sealer walls are arcuate or include a radius, these elements can be resiliently deformed and/or sealed against surfaces adjacent the gap to enhance such sealing or engagement. Where the volume between the panels and/or extension walls is filled with an additional material filler, the gap filler can further reduce sound transfer.
These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.
A current embodiment of the gap filler is illustrated in
As shown in
The gap filler 10 can be constructed from a variety of materials such as polymers, composites, metals and combinations thereof. In the embodiment illustrated, the gap filler can be extruded piece of polymeric material. This polymeric material can be a fire resistant or fire retardant thermoplastic urethane (TPU). Of course, other types of polymeric materials can be used. These polymeric materials can be resistant to fire and/or thermal degradation or generally can burn at very slow rates. These polymeric materials can include polar monomers and/or hydrogen bonding between polymer chains to enhance fire resistance. The polymers optionally can incorporate aromatic cycles or heterocycles, polyimides, polybenzoxazoles, polybenzimidazoles, and polybenzthiazoles are some examples of polymers suitable for the gap filler. The polymeric material can be a ladder polymer, which links to polymer chains with periodic covalent bonds, or can be a single chain that is double-stranded. Further optionally, the polymeric material can include an inorganic and/or semi-organic polymer having silicon-nitrogen, boron-nitrogen and/or phosphorus-nitrogen monomers. Further optionally, the polymeric material can include a flame retardant additive filler. Examples of such an additive can include aluminum, phosphorus, nitrogen, antimony, chlorine, bromine, and in some cases magnesium, zinc and/or carbon. In some cases, where the gap filler is constructed from a comp that composite can include natural fibers that are fire retardant. In other cases, the gap filler can be constructed from nano composites, carbon fibers another carbon based materials. In yet other cases organic modified clays, titanium dioxide, nanoparticles, silica nanoparticles, layered double hydroxides, carbon nanotubes and polyhedral silsesquioxanes can be incorporated into and/or form the gap filler.
Optionally, the gap filler can be constructed via extrusion. This can enable the gap filler to be produced in elongated form and in a continuous, repeatable manner. Such extrusion also can facilitate manufacture of long pieces of the gap filler, which optionally can be cut to custom or standard lengths for a particular job. These long pieces of gap filler also can be rolled into rolls where the gap filler material is flexible. Of course, in other applications, the elongated gap filler can be constructed via injection molding, pour molding with other techniques.
With further reference to
The first panel 20 can include a first or proximal end 21 and a second or distal end 22. Likewise the second panel 30 can include a first or proximal end 31 and a second or distal end 32. The proximal end of the first panel 21 can be adjacent and/or directly or indirectly joined with the proximal or first end 31 of the second panel 30.
Optionally, the apex 20A can include a groove 20U defined at the apex 20A. In particular, this groove or channel 20U can be defined by an apex projection 20P that extends from the first and second channels, opposite the void V defined between the first 20 and second 30 panels. This apex projection 20P can be formed from extensions of the respective first and second panels at the proximal ends thereof. In some cases, the apex projection 20P can be in the form of a channel and have a C- or V- or U-shape such that a corresponding groove faces and opens to the void V defined between the first panel and the second panel. Optionally, the groove 20U can include a radius, which can be less than 0.1 inches, less than 0.08 inches, or about 0.063 inches.
As shown in
Each of the first and second panels also can extend to their respective distal ends 22 and 32 the same distance from the apex 20A. Optionally, these ends 22 and 32 can be separated from one another by a height H2. This height H2 can be less than, equal to or greater than the gap G within which the gap filler 10 is to be placed. In some cases, the height H2 can be slightly greater than the gap G so that the panels 20 and 30 are resiliently compressed such that the distal ends 22 and 32 engage the respective surfaces forming the gap G. The height H2 can be any height, depending on the gap to be filled, but can be optionally about ¼ inch, ½ inch, ⅔ inch, ¾ inch, 0.755 inch, 1 inch, 2, inches, 3 inches, 4 inches or other heights.
At the distal end of the first panel 20, the first panel can transition to the first extension wall 40. This first extension wall 40 can be joined at its proximal end 41 to the distal end 22 of the second panel 20, and can extend to a distal end 42. The first extension wall 40 can include an inner surface 401 and an exterior surface 40E. The inner surface 401 can face toward the reference line RL and toward the second extension wall 60. Optionally, the thickness T1 of the first extension wall, the first panel and the second panel can be substantially equal. In some cases, this thickness T1 can be optionally 0.01 inches to 0.25 inches, inclusive, about 0.05 inches, 0.10 inches to 0.2 inches, inclusive, or 0.05 inches to 0.125 inches.
As shown, the first extension wall 40 can extend a distance D1 parallel to the reference line RL away from the first panel 20. For this distance, the inner surface 401 and the first extension panel 40 can be generally parallel to the reference line RL. This distance D1 can optionally be at least ¼ inch, at least ½ inch, about 0.555 inch, at least 1 inch, at least 1.5 inch, at least 3 inches, at least 5 inches, or greater depending on the application. This first extension wall also can extend at an obtuse angle A2 relative to the first panel 20. This obtuse angle A2 can be optionally greater than 90°, between 91° and 170°, inclusive, between 90° and 150°, inclusive, between 110° and 145° inclusive, or about 145°. Of course, other angles can be selected as desired. Optionally, the inner surface 401 and the inner surface 601 can be spaced a distance D3 from one another at the proximal ends 41 and 61 respectively, where that distance is less than the height H2 as mentioned above. In some cases this height H2 can be equal to the thickness T1 times 2, plus the distance between the inner surface 401 and the inner surface 601.
The first extension wall 40 can include a first extension wall exterior surface 40E configured to face toward a first surface 1 of a first building structure. For example, as shown in
As further shown in
Optionally, the second extension wall 60 can taper or curve or angle away from the reference line RL, while the first extension wall 40 can extend generally parallel to the reference line RL. As an example, the second extension wall 60 can include a radius of curvature R2 that is centered upon a center C2 of a circle. The center C2 can be disposed above the reference line RL, generally above the second panel 30 and the apex 20A. This radius R2 can be optionally between 1 inch and 8 inches, inclusive, between 1 inch and 5 inches, inclusive, between 2 inches and 4 inches, inclusive, or about 2.28 inches. Further optionally, the first sealer wall 50, as described below, can include a radius of curvature R1 that is centered on a center C1. That center C1 can be disposed below the reference line RL, generally below the apex 20A. This radius R1 can be greater than radius R2. This radius R1 can be optionally between 1 inch and 8 inches, inclusive, between 1 inch and 5 inches, inclusive, between 2 inches and 4 inches, inclusive, or about 3.026 inches. Of course, these centers can be moved above and/or below the reference line RL depending on the application and the radius of curvature of each of these elements. The second extension wall 60 can be arcuate, curved or arched generally upward, and away from the reference line RL. Generally, the wall 60 can be convex toward the reference line RL. In other embodiments, the second extension wall 60 can be angled at a variety of steps upward and away from the reference line, depending on the application. With this curvature or angling of the second extension wall 60 away from the reference line RL, this element can be somewhat resilient and bendable and flexible so that its distal end 62, when placed against a surface, such as a second surface 2, can bend toward the reference line RL, yet maintain the distal end 62 in contact with the horizontal surface 2 as described below. In some cases, the height H1 can be reduced to almost 0.
Optionally, the distal end 62 can be thinned to a second thickness T2 that is less than, greater than or equal to the first thickness T1 of the second panel 30, the first panel 20 and/or the first extension wall 40. The second thickness T2 can be very thin so that the structure at the distal end 62 melds into and cleanly transitions to an adjacent horizontal or other second surface 2. This can enable a wallcovering WC such as paint, coating, wallpaper, drywall, film or other material to be placed over the distal end 62 without forming a substantially noticeable line or edge at that location. Similarly, the first sealer wall 50 can include such a second thickness T2 that is tapered toward a distal end 52 of that first sealer wall 50 as described below. As an example of this tapering, the first sealer wall 50 can taper from a first thickness T1 to a lesser second thickness T2 generally from the proximal end 51 to the distal end 52 of the first sealer wall 50. The first extension wall 40 optionally can transition from a first thickness T1 to a lesser second thickness T2 of the first sealer wall 50, which thickness T2 can start at the proximal end 51 or near it. In other applications, the thickness T2 optionally can be greater than the thickness T1. For example, thickness T1 can be about 0.050 inches and thickness T2 can be about 0.060 inches. The sealer walls can be of that greater thickness T2 starting at the proximal ends 51, 61, and those sealer walls can be of a uniform thickness T2 from those ends to the respective distal ends.
As shown in
The first sealer wall 50 can be joined with the distal end 42 of the first extension wall 40. The first sealer wall 50 can extend generally perpendicular to the first extension wall 40 and downward, away from the reference line RL, which optionally can be in the form of a reference plane through which the reference line extends along the length L of the gap filler 10. As mentioned above, the first sealer wall 50 can be of an arcuate or curved shape as shown, extending downward, away from the reference line RL or plane and the first extension wall 40. The first sealer wall 50 can extend downward from the first extension wall 40 by a distance H3. This distance H3 can be greater than the height H2 of the first and second panels 30 and 40, and optionally greater than the height H1 of the second extension wall 60. In some cases, the height H2 can be taken between the exterior surface 60E at the proximal end 61 and the exterior surface of panel 40 at proximal end 41. The height H2 can be in a ratio to H3, the ratio H2:H3 optionally being about 3:4; 1:2, 2:3, 1:1 or other ratios. The height H3 can be optionally 0.25 inches to 2.00 inches, inclusive, 0.5 inches to 1.5 inches inclusive, 0.75 inches to 1.25 inches, 0.5 inches to 1.00 inches, inclusive, about 1.00 inches, about 1.03 inches, or other heights, depending on the application and the amount of overlap of an adjacent building surface 3, for example, a vertical surface of a wall W. This first sealer wall 50 can be arcuate as mentioned above. Optionally, it can be resilient and can bend when the distal end 52 engages a third surface 3, which can be substantially perpendicular to the first surface 1 as shown in
A method of installing gap filler will now be described with reference to
The gap filler 10 in
As shown in
With reference to
Optionally, a wallcovering WC can be applied to the respective surfaces 2 and 3 of the wall W and ceiling C. The wallcovering WC also can extend over portions of the second extension wall 60 as well as the first sealer wall 50. A filler material FM, optionally plaster, drywall, spackle or other material, can be installed between the first extension wall 40 and the second extension wall 60 to fill in that volume. The wallcovering WC also can extend over the filler material FM as shown. Of course, in other applications, the filler material FM might not be installed such that there is a small groove the top of the wall.
With the gap filler 10 installed in the gap G, it can provide sound deadening between the different spaces S1 and S2 on opposite sides of the building structure W. The gap filler 10 also can inhibit, prevent or impair spread of fire between those spaces S1 and S2. Further, the gap filler can prevent debris, materials, matter or other things from being transmitted or transferred from the first space S1 to the second space S2.
A first alternative embodiment of the gap filler 10 is shown in
This embodiment can optionally include an elongated filler strip 190. The strip 190 can be in the form of a fire retardant, sound deadening, sound reducing, and/or cushion element. In some cases, the elongated filler strip 190 can extend along the entire length L of the gap filler 110. It can extend generally between the first extension wall 140 and the second extension wall 160. The strip can be of a rectangular cross shape as shown, or can be sprayed or otherwise filled within the void V between the first 120 and second 130 panels, as well as the first extension wall 140 and the second extension wall 160. This filler strip can be of other cross-sections, for example, it can be polygonal, circular, elliptical, triangular or of other shapes depending on the amount of compressibility and/or expansion suitable for the gap filler 110. The filler strip 190 can be compressible, such that when the first and second panels move relative to one another, for example, toward one another, and/or the first and second extension walls move relative to one another, for example, closer to one another, the filler strip 190 can compress. In some cases, the filler strip 190 can be constructed from a foam, a polymer, natural fibers, a gel, a viscous material, or combinations of any of the foregoing.
A second alternative embodiment of the gap filler is shown in
The gap filler 210 can be configured to be placed between adjacent first and second building structures, such as a first wall W1 and a second wall W2. The first and second walls can form a vertical gap G1. The first wall W1 and second wall W2 can be parallel to one another and can include associated surfaces 4 and 5 which form vertical surfaces of the walls. The walls can include surfaces 6 and 7, which are generally parallel to one another and optionally can be vertically oriented as well. The gap filler 210 can be inserted within the gap G1 and pushed between the surfaces 6 and 7. When this occurs, the first 220 and second 230 panels can compress toward one another, as can the first 240 and second 260 extension walls, to fill in the gap G1, with the extension walls engaging the respective surfaces 6 and 7. In so doing, the gap filler 210 can continue to be pushed into the gap G1. Where the sealer walls 250 and 269 are of an arcuate shape, they can resiliently flex or bend in directions R until the sealer walls are flush with respective outer surfaces 4 and 5 of the walls W1 and W2. Optionally, the first and second sealer walls can be coated with an adhesive to engage the surfaces 4 and 5 to secure those sealer walls against the surfaces 4 and 5. The gap filler 210 can be held in place by the adhesive or other fastener. Of course, adhesive can be applied to other parts of the gap filler, for example, to the extension walls and/or the panels, to secure them in place. Afterward, the wallcovering can be applied over the gap filler and its respective components so that the gap is covered.
The various components and features of the embodiments herein, for example, the gap filler and its components, can take on a variety of aesthetic forms, shapes and sizes. Although a particular component or feature can have a function, that feature can be expressed in different aesthetic manners to form an artistic design and/or a purely ornamental design.
Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).
In addition, when a component, part or layer is referred to as being “joined with,” “on,” “engaged with,” “adhered to,” “secured to,” or “coupled to” another component, part or layer, it may be directly joined with, on, engaged with, adhered to, secured to, or coupled to the other component, part or layer, or any number of intervening components, parts or layers may be present. In contrast, when an element is referred to as being “directly joined with,” “directly on,” “directly engaged with,” “directly adhered to,” “directly secured to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between components, layers and parts should be interpreted in a like manner, such as “adjacent” versus “directly adjacent” and similar words. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z, and/or any other possible combination together or alone of those elements, noting that the same is open ended and can include other elements.
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