This application is a National Stage entry under § 371 of International Application No. PCT/EP2018/083327, filed on Dec. 3, 2018, and which claims the benefit of European Application No. 18150169.3, filed on Jan. 3, 2018. The contents of each of these applications are hereby incorporated by reference in their entirety.
The present disclosure relates generally to the field of construction, and more particularly to systems and methods for forming a filler element for sealing a metal deck against environmental factors.
In contemporary building constructions, different structural components (solid walls, floors, ceilings, etc.) contact one another at various intersections. For example, one such intersection within a contemporary building construction is the area between a top track and the ceilings. In certain situations, it may be helpful to seal the spaces (e.g., gap) around these intersections so that various environmental factors (e.g., noise, smoke, fire, etc.) are not transmitted through the gap. For example, sealant compounds such as mineral wool may be installed to seal the gap from such environmental factors. However, these and other typical sealant compounds may not be form fitted to the contours of the ceiling, thereby resulting in gaps remaining within these intersections. Furthermore, these and other typical sealant compounds utilized to seal the gap may be costly and time consuming to install. For example, the sealant compound may be installed after the top track is installed—resulting in a cumbersome installation where the sealant compound is pressed into the gap to seal the opening.
Accordingly, there is a need for an element for sealing the gaps between a top track and a ceiling so that various environmental factors (e.g., noise, smoke, fire, etc.) are not transmitted through the gap. In particular, there is a need for a sealing element that is both cost effective to manufacture and efficient to install.
Certain embodiments commensurate in scope with the originally claimed subject matter are summarized below. These embodiments are not intended to limit the scope of the claimed subject matter, but rather these embodiments are intended only to provide a brief summary of possible forms of the subject matter. Indeed, the subject matter may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
In a first embodiment, a system is provided. The system includes a metal deck having alternating valley regions and peak regions. The alternating valley regions and peak regions form one or more flutes, and each flute of the one or more flutes includes a geometry having one or more geometrical features. The system also includes a pre-formed sealant element configured to conform to the geometry of each flute. The pre-formed sealant element includes one or more integrated features that conform to the geometrical features of each flute of the metal deck. The pre-formed sealant element is configured to seal each flute against a potential environmental source.
In a second embodiment, a method is provided. The method includes activating an adhesion component of a pre-formed sealant element, where the pre-formed sealant element includes one or more integrated features. The method also includes inserting the pre-formed sealant element into a flute of a metal deck. The flute of the metal deck is formed of alternating valley regions and peak regions, and the flute includes a geometry having one or more geometrical features. The method also includes conforming the one or more integrated features of the pre-formed sealant element to the one or more geometrical features of the flute of the metal deck. The method also includes affixing the pre-formed sealant element to the flute of the metal deck to seal the metal deck from a potential environmental source.
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
Present embodiments are directed to systems and methods for a sealant or filler element utilized for sealing gaps (e.g., spaces or voids) around and between various structural components (e.g., ceilings, walls, floors, etc.) in contemporary building constructions. Specifically, the filler element of the present embodiments may be described in relation to spaces or gaps between a ceiling component and a top track component. For example, in certain situations, the profile element of the present embodiments may be utilized to seal one or more flutes of a metal deck in dry wall configurations, such that various environmental factors (e.g., noise, smoke, fire, etc.) are not transmitted through the gaps. However, it should be noted that the present embodiments are not limited to the spaces between the ceiling component and an associated top track, but may be applicable and utilized to seal any spaces within a building, such as any spaces between any structural component (e.g., floors, ceilings, walls, etc.) of a building.
As noted above, typical sealant or filler compounds utilized to seal the gap may be costly and time consuming to install. For example, in typical construction situations, the sealant compound may be installed after the top track is installed—resulting in a cumbersome installation where the sealant compound is pressed into the gap to seal the opening. In the present embodiments, the sealant compound may be fixed to the top track before the top track is mounted and installed. In this manner, a customer may not need to engage in a cumbersome installation process where the sealant compound is pressed into gaps.
In certain embodiments, the sealant or filler element may be formed of any heat resistant materials or foams that are configured to protect against a threshold amount of heat. For example, in certain embodiments, the sealant element may be formed of a fire-resistant material, a fire-resistant foam, mineral wool, an ash crust creating foam, or any combination thereof. In certain embodiments, the sealant element may be formed of an intumescent material or foam that is configured to expand when triggered by a threshold amount of heat.
In certain embodiments, the filler element of the present disclosure may be manufactured as a pre-formed product having a specific geometry that is configured to conform to a flute of a metal deck. For example, in certain embodiments, the filler element may be pre-formed in a trapezoidal shape that is configured to conform to a trapezoid flute of a metal deck. In certain embodiments, the filler element may incorporate one or more features (e.g., indentations, valleys, ridges, protrusions, etc.) that are shaped to conform to one or more features of the metal deck (e.g., indentations, valley, ridges, protrusions, etc.). As a further example, in certain embodiments, the filler element may include an extension or flange that is configured to conform to additional surfaces areas of the metal deck. Further still, in certain embodiments, one or more filler elements may be arranged in a series to form a filler strip, such that the filler strip may be conformed to one or more adjacent flutes of a metal deck. Indeed, it should be noted that the filler element may be pre-formed and configured in any cross-section type, shape, or form. For example, the sealing regions of the filler element may be configured as a substantially trapezoidal shape, round shape, oval shape, polygonal shape, square shape, rectangular shape, parallelogram shape, triangular shape, or any combination thereof. Further, the filler element may include one or more features that help facilitate the installation of the filler element into the flute of the metal deck, such as, for example, an adhesion component, a sealing strip, a mineral wool, plastic film, coating to facilitate sealant properties, and so forth. These and other features are described in detail with respect to
With the forgoing in mind,
In particular, the gaps 114 (e.g., spaces or voids) within the one or more flutes 104 may be filled with a sealant component that seals the gaps 114 so that various environmental factors, (e.g., noise, smoke, fire, etc.) are not transmitted through the metal deck 106 and other components of the construction system 100. Indeed, preventing such environmental factors from being transmitted through the illustrated components of the construction system 100 may help isolate certain areas of a finished construction site (e.g., building) from environmental factors. In the disclosed embodiments, the gaps 114 may be sealed with one or more filler elements 102 that are installed into the gaps 114, as further described with respect to
As noted above, the filler element 102 may be a pre-formed material that is configured to conform to the geometry of the flutes 104. For example, an inner surface 116 of each flute 104 may include one or more features 118 that protrude from and/or indent into the inner surface 116. For example, the features 118 may be ridges, valleys, depressions, protrusions, grooves, embossments, cavities, contours, etc. Furthermore, the filler element 102 may be pre-formed to conform to the one or more features 118 of each flute 104. In certain embodiments, the filler element 102 may include one or more extensions 120 (e.g., flanges) that extend the amount of surface area sealed by the filler element 102. For example, the extension 120 of the filler element 102 may be utilized to seal one or more valley regions 122 of the metal deck 106, which may be positioned adjacent to one or more peak regions 124 of the metal deck 106. It should be noted that the filler element 102 may be pre-formed to conform to any geometry of the flutes 104 and/or to any geometry of the metal deck 106. Furthermore, various components of the filler element 102 may be utilized to facilitate the installation of the filler element 102 against the metal deck 106. These and other features are described with respect to
In certain embodiments, the adhesion component 130 may be configured to affix the filler element 102 to any surface of the metal deck 106. The adhesion component 130 may be in shape (e.g., rectangle, square, strip, circle, etc.) or size, and may encompass any portion or region of the filler element 102. For example, the adhesion component 130 may be disposed on a top surface 136, one or more side surfaces 138, and/or a bottom surface 140 of the filler element 102. In certain embodiments, the top surface 136 of the filler element 102 may be configured to contact the inner surface 118 of the flute 114 of the metal deck 106. In certain embodiments, the adhesion component 130 may be covered by a disposable strip of wax paper (or similar material), and maybe removed prior to installing the filler element 102 to the metal deck 106.
In certain embodiments, the sealing strip 132 may be configured to further conform to the geometry (e.g., ridges, valleys, depressions, protrusions, grooves, embossments, cavities, contours, etc.) of the flutes 104. In particular, the sealing strip 132 may facilitate a precise seal against the metal deck 106, in order to seal uneven surfaces and/or other unique geometries along the surface of metal deck 106. In certain embodiments, the sealing strip 132 may be formed of a heat resistant material or foam to compensate for any shrinkage of the filler element 102 in the event that the filler element 102 is exposed to a heat source.
In certain embodiments, the filler element 102 may include a coating 142 and/or a plastic film 144 on exposed surfaces (e.g., side surfaces 138). The coating 142 may be applied to the filler element 102 during and/or after the manufacturing process where the filler element 102 is formed. In certain embodiments, the coating 142 may be utilized to seal the gaps 114 around the metal deck 106 from air, thereby giving the metal deck 106 an air tight sealant feature. The coating 142 may be spray applicated, printed acrylic, a silicone material, a film layer, and/or other airtight fabrics or materials. In certain embodiments, the plastic film 144 may additionally or alternatively be provided on the exposed surfaces (e.g., side surfaces 138) of the filler element 102. The plastic film 144 may be configured to improve handling properties of the filler element 102. For example, the plastic film 144 may be configured to minimize interaction between an operator (e.g., installer of the filler element 102) and fibers/textures of the heat resistant material (e.g., heat or fire resistant foam, ash crust creating foam, intumescent material or foam, mineral wool, etc.). Furthermore, the plastic film 144 may provide a smooth surface upon which to install the adhesive component 130.
In this manner, the filler element 102 may be configured to conform precisely to the geometries of the metal deck 106. Furthermore, such a pre-formed design may facilitate the installation process, since an installer may be able to view the shape of the filler element 102 and quickly understand the direction of the installation process, as further described with respect to
In certain embodiments, the method 170 includes activating the adhesion component 130 (step 172) by removing a film protecting the adhesion component 130. The method 170 further includes inserting the filler element 102 into a corresponding flute 104 of the metal deck 106 (step 173). In certain embodiments, the method 170 includes inserting the strip 160 into one or more corresponding flutes 104 of the metal deck 106 (step 174). Further, in certain embodiments, the method 170 includes fixing the filler element 102 to the metal deck 106 (step 176). After securely installing the filler element 102 to the one or more corresponding flutes 104 of the metal deck 106, additional components of the construction system 100 may be installed. For example, in certain embodiments, the method 170 includes installing the ceiling runner 108 to the metal deck 106 (step 178) and attaching the gypsum boards to the ceiling runner 108 (step 180).
Technical advantages of the present disclosure include a fast and simple installation process for seal the spaces (e.g., gap) around the spaces between the ceiling component and a top track component. Specifically, the present disclosure relates to a filler element 102 that is configured as a pre-formed sealant product for sealing the flutes 104 of a metal deck 106. In the present embodiments, the filler element 102 (otherwise known as the sealant element 102) may be fixed to the top track before the top track is mounted and installed. In this manner, a customer may not need to engage in a cumbersome installation process where the sealant compound is pressed into gaps after the top track is mounted and installed. In certain embodiments, the filler element 102 may be formed of heat resistant material (e.g., heat or fire resistant foam, ash crust creating foam, intumescent material or foam, mineral wool, etc.) that is configured to expand when triggered by a threshold amount of heat. In particular, advantages of this technique include reducing the need for special equipment or tools for cutting mineral wool or shaping heat resistant material for such spaces.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
Number | Date | Country | Kind |
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18150169 | Jan 2018 | EP | regional |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2018/083327 | 12/3/2018 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2019/134778 | 7/11/2019 | WO | A |
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Number | Date | Country | |
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20200362551 A1 | Nov 2020 | US |