Patent Application
20220259852
Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference in their entirety.
The disclosure generally relates to fire-rated building structures. In particular, the disclosure relates to fire-rated joint systems, wall assemblies, and other building structures that incorporate the fire-rated joint systems.
Fire-rated construction components and assemblies are commonly used in the construction industry. These components and assemblies are aimed at inhibiting or preventing fire, heat, or smoke from leaving one room or other portion of a building and entering another room or portion of a building. The fire, heat or smoke usually moves between rooms through vents, joints in walls, or other openings. The fire-rated components often incorporate fire-retardant materials which substantially block the path of the fire, heat or smoke for at least some period of time. Intumescent materials work well for this purpose, because they swell and char when exposed to flames helping to create a barrier to the fire, heat, and/or smoke.
One particular wall joint with a high potential for allowing fire, heat or smoke to pass from one room to another is the joint between the top of a wall and the ceiling, which can be referred to as a head-of-wall joint. In modern multi-story or multi-level buildings, the head-of-wall joint is often a dynamic joint in which relative movement between the ceiling and the wall is permitted. This relative movement is configured to accommodate deflection in the building due to loading of the ceiling or seismic forces. The conventional method for creating a fire-rated head-of-wall joint is to stuff a fire-resistant mineral wool material into the head-of-wall joint and then spray an elastomeric material over the joint to retain the mineral wool in place. This conventional construction of a fire-rated head-of-wall joint is time-consuming, expensive and has other disadvantages.
A wall assembly commonly used in the construction industry includes a header track, bottom track, a plurality of wall studs and a plurality of wall board members, possibly among other components. A typical header track resembles a generally U-shaped (or some other similarly shaped) elongated channel capable of receiving or covering the ends of wall studs and holding the wall studs in place. The header track also permits the wall assembly to be coupled to an upper horizontal support structure, such as a ceiling or floor of a higher level floor of a multi-level building.
Header tracks generally have a web and a pair of flanges, which extend in the same direction from opposing edges of the web. The header track can be a slotted header track, which includes a plurality of slots spaced along the length of the track and extending in a vertical direction. When the wall studs are placed into the slotted track, each of the plurality of slots aligned with a wall stud accommodates a fastener used to connect the wall stud to the slotted track. The slots allow the wall studs to move generally orthogonally relative to the track, creating a variable deflection gap between the wallboard and the upper horizontal support structure. In those areas of the world where earthquakes are common, movement of the wall studs is important. If the wall studs are rigidly attached to the slotted track and not allowed to move freely in at least one direction, the stability of the wall and the building might be compromised. With the plurality of slots, the wall studs are free to move. Even in locations in which earthquakes are not common, movement between the studs and the header track can be desirable to accommodate movement of the building structure due to other loads, such as stationary or moving overhead loads.
Recently, improvements to fire-rated head-of-wall joints have been developed. One example is the use a metal profile having a layer of intumescent material in a head-of-wall joint, such as the fire-rated angle manufactured and sold by the Applicant under the trade name Deflection Drift Angle (DDA™). The DDA™ angle is further described in U.S. Pat. No. 8,595,999, the entirety of which is hereby incorporated by reference. The DDA™ angle can be installed along with the installation of the header track or can be installed after the installation of the header track. Such an arrangement avoids the need to have the framers return after the installation of the wall board to install fire sealant in the deflection gap between the edge of the wall board and the overhead structure. When temperatures rise (e.g., due to a fire), the intumescent material on the DDA™ fire block product expands. This expansion creates a barrier which fills the deflection gap and inhibits or at least substantially prevents fire, heat and smoke from moving through the head-of-wall joint and entering an adjacent room for at least some period of time.
Although the DDA™ fire block represents an improvement over the conventional method of stuffing mineral wool material into the head-of-wall joint and applying the elastomeric spray material over the mineral wool, there still exists room for improved or alternative products, materials and methods for efficiently and cost-effectively creating fire-rated wall joints. The systems, methods and devices described herein have innovative aspects, no single one of which is indispensable or solely responsible for their desirable attributes. Without limiting the scope of the claims, some of the advantageous features will now be summarized.
According to one aspect, a fire-rated component for sealing a head-of-wall gap, the component includes a fire-rated angle of a first material including an upper flange and a lower flange. The upper flange connects with the lower flange at a corner. A gasket profile of a second material includes an upper flange and a lower flange, the lower flange connected with the upper flange at a corner. A fire-blocking strip connects with the lower flange. The fire-rated angle is coupled with the gasket profile.
According to another aspect, the lower flange of the gasket profile includes a slot. A lower end of the lower flange of the fire-rated angle disposed within the slot couples the fire-rated angle with the gasket profile.
According to another aspect, the upper flange of the fire-rated angle includes a planar section.
According to another aspect, the lower flange of the fire-rated angle includes a planar section.
According to another aspect, the upper flange of the fire-rated angle is perpendicular with the lower flange of the fire-rated angle.
According to another aspect, the first material of the fire-rated angle is steel and the second material of the gasket profile is vinyl.
According to another aspect, the lower flange of the fire-rated angle includes a second fire-blocking strip.
According to another aspect, the upper flanges are generally aligned and the lower flanges are generally aligned.
According to another aspect, the upper flange of the gasket profile has a flare-out configured to seal against an overhead structure.
According to another aspect, the lower flange of the gasket profile includes an upper section and a lower section, the upper section offset from the lower section by a transition section.
According to another aspect, the upper section is aligned parallel with the lower section.
According to another aspect, an outer surface of the fire-blocking strip is aligned with the lower section of the lower flange of the gasket profile.
According to another aspect, the second material is a polymer.
According to another aspect, a fire-rated component for sealing a head-of-wall gap includes a fire-rated insert of a first material. A gasket profile or a second material includes an upper flange, a lower flange; and a fire-blocking strip coupled on an interior side of the lower flange. The fire-rated insert is coupled with an interior side of the gasket profile.
According to another aspect, the first material of the fire-rated insert comprises steel and the second material of the gasket profile comprises vinyl.
According to another aspect, an upper end of the fire-rated insert includes a second fire-blocking strip.
According to another aspect, the lower flange of the gasket profile includes an upper section and a lower section, the upper section offset from the lower section by a transition section.
According to another aspect, the upper section is aligned parallel with the lower section.
According to another aspect, the lower flange includes an inner flange, the inner flange enclosing a portion of the interior side to form a slot, a lower end of the fire-rated insert received within the slot.
According to another aspect, the fire-rated insert contacts the fire-blocking strip.
According to another aspect, a wall assembly includes a header track configured to be coupled to a surface of an overhead structure, the header track having a web and first and second flanges extending from the web in the same direction, wherein each of the first and second flanges is substantially planar such that the track defines a substantially U-shaped cross section. At least one stud couples to the header track, an upper end of the stud located between the first and second flanges. At least one wallboard couples to the stud, an upper end of the wallboard overlapping the first flange of the header track. A deflection gap is formed between the upper end of the wallboard and the surface of the overhead structure. The deflection gap is variable between a closed position and an open position. The upper flanges of the fire-rated angle and the gasket profile are positioned between the web and the overhead structure and the lower flanges of the fire-rated angle and the gasket profile are positioned at least partially within the deflection gap.
Various embodiments are depicted in the accompanying drawings for illustrative purposes, and should in no way be interpreted as limiting the scope of the embodiments. Various features of different disclosed embodiments can be combined to form additional embodiments, which are part of this disclosure.
The various features and advantages of the systems, devices, and methods of the technology described herein will become more fully apparent from the following description of the embodiments illustrated in the figures. These embodiments are intended to illustrate the principles of this disclosure, and this disclosure should not be limited to merely the illustrated examples. The features of the illustrated embodiments can be modified, combined, removed, and/or substituted as will be apparent to those of ordinary skill in the art upon consideration of the principles disclosed herein.
The following disclosure provides an elongate, fire-rated joint component or fire-blocking assembly, which is configured to provide fire protection and pass the relevant UL fire rating tests, or other relevant fire rating tests or standards. The fire-rated assembly may be installed in a deflection gap of a wall assembly that allows dynamic movement according to the requirements of UL-2079.
In one embodiment, the two piece fire-rated assembly can include one piece made of steel and one piece made of vinyl. One reason for this is that steel, generally, will not melt in a fire and will provide a continuous level of fire protection to the deflection joint. However, the steel profile by itself may not provide enough fire protection to pass a UL-2079 5th edition fire test and/or it may not provide adequate sound protection to the deflection gap. The second piece made from vinyl. The vinyl profile slides over the steel profile and locks them together so that the two can be assembled and installed as one piece.
The vinyl profile functions to provide sound protection. Unlike steel, the vinyl profile is very flexible and when the vinyl profile meets the overhead structure it can compress and seal off against uneven overhead structures to improve sound protection.
During a fire, a portion of the vinyl profile can flap downward and expose the intumescent material to the fire and heat which may cause the intumescent to expand upward and seal off the deflection gap. This whole process can take up to 20 minutes before the deflection is sealed off. During this time the steel profile will remain in place over the leg of the header track and continue to offer a level of fire protection. Without the steel profile, the fire and heat would be able to pass through the deflection gap while the intumescent tape of vinyl profile was still expanding.
The fire-rated angle 15 can include an upper flange 19. The upper flange 19 can include one or more planar, curvilinear and/or stepped regions. The upper flange 19 can connect with a lower flange 21 at a corner 23. The lower flange 21 can include one or more planar, curvilinear and/or stepped regions. In the implementation shown in
The lower flange 21 can include a fire blocking strip 24. The fire blocking strip 24 can include an intumescent material that expands upon being heated. The fire blocking strip 24 can be attached by an adhesive with the lower flange 21. The fire blocking strip 24 can be attached on an interior side of the lower flange 27 (e.g., on the side of the upper flange 19 relative to the corner 23). The fire blocking strip 24 can be located adjacent to and/or in contact with the upper flange 19. The fire blocking strip 24 can extend along the interior surface of the lower flange 21 between the corner 23 and the lower end 22. Optionally, the fire blocking strip 24 can extend all the way from the corner 23 or the upper flange 19 to the lower end 22.
The fire-rated angle 15 can comprise a steel or other metal material. The steel can be generally resistant to deformation when exposed to heat or fire for at least a limited amount of time. The steel material can facilitate the fire-rated profile assembly 10 retaining its shape at least partially or temporarily when exposed to heat or fire.
The gasket profile 16 can include an upper flange 25. The upper flange 25 can include one or more planar, curvilinear and/or stepped regions. The upper flange 25 can include a flare out for forming a corner 29. The corner 29 can be form a compressible seal. The gasket profile 16 can include a lower flange 27. The lower flange 27 can include one or more planar, curvilinear and/or stepped regions. The lower flange 27 can connect with the upper flange 25 at the corner 29. The lower flange 27 can extend from the corner 29 to a hem or hook portion 37.
The lower flange 27 can include an upper section 31. The upper section 31 can be planar. The lower flange 27 can include a lower section 33. The lower section 33 can be an offset leg. The lower section 33 can be planar. The lower section 33 can attach with the upper section 31 through a transition section 35. The transition section 35 can offset the planar portions of the upper section 31 from the lower section 33. The direction of offset of the transition 35 can be in the same direction of the upper flange 25 extending from the corner 29. The offset of the transition can be the same width as a common framing screw. This will this will help maintain a tight seal when a drywall or wallboard is installed over the lower section 33. It will also allow the fire rated assembly 10 to be pre-attached to a header track, as described further below.
The lower section 33 can include the hook portion 37. The hook portion 37 can include a portion of the lower flange 27 that is bent backwards on itself to extend generally upwardly. The hook portion 37 can form a slot. The slot can be sized to receive the lower end 22 of the fire-rated angle 15.
The lower flange 27 can include a fire blocking strip 34. The fire blocking strip 34 can be adhesively attached with the lower flange 27. The fire blocking strip 34 can be attached on an interior side of the lower flange 27. The fire blocking strip 34 can be attached with the upper section 31. The fire blocking strip 34 can be adjacent to the corner 29 and/or the upper flange 25. The fire blocking strip 34 can extend from the corner 29 towards the transition 35. An outer surface of the fire blocking strip 34 can be aligned with the lower section 33, as shown by the dotted line in
The gasket profile 16 can be formed of a vinyl or other polymer material. The material of the gasket profile 16 can be sensitive to heat such that it deforms when heated at temperatures associated with fires.
The fire-rated profile assembly 10 can be assembled within the deflection gap 160. The upper flanges 19, 25 can be installed between the web 136 and the overhead structure 120. The lower flanges 21, 27 can be installed along the length of the second flange 134. The lower flanges 21, 27 can be installed between the second flange 134 and the wall board 150. The fire blocking strip 24 can be in contact with the second flange 134. The upper section 31 can be in slidable contact with an inner face of the wall board 150, as the wall board 150 cycles between open and closed configurations of the head-of-wall assembly 100. The corner 29 can be compressed against the overhead structure 120 to form a seal therewith.
The fire-rated profile assembly 10 can be maintained within the deflection gap 160 through mechanical engagement between the overhead structure 120 and the web 136. The wall board 150 installed over the lower flanges 21, 27 can also maintain the position of the fire-rated profile assembly 10 within the deflection gap 160. Advantageously, this arrangement can be faster and easier to install than using mechanical fasteners or traditional stuff-and-spray techniques.
Advantageously, the fire-rated profile assembly 10 can be pre-installed on the header track 130. The header track 130 can then be assembled against the overhead structure 120 such as through additional mechanical fasteners through the web 136. The pre-installation can dramatically reduce the amount of time required for attaching the fire-rated profile assembly 10 within the head-of-wall assembly 100. It can be much easier to pre-install the fire-rated profile assembly 10 than inserting the upper flanges 19, 25 between the overhead structure 120 and the web 136. The transition section 135 can be sized to accommodate the head of the fastener 170 so that the wall board 150 can be engaged with the upper section 131 and/or the head of the fastener 170.
The upper flange 225 can include or be coupled with a corner 229. The corner 229 can be a curved or bent section of the material of the gasket profile 216. A lower flange 227 can extend from the corner 229. The lower flange 227 can include an upper section 231 and a lower section 233. The upper section 231 can include straight, curvilinear or stepped regions. The upper section 231 can be coupled with the lower section 233 by a transition section 235. The transition section 235 can be orthogonal to the flat portion or straight portion of the upper section 231. The lower section 233 can include straight, curvilinear or stepped regions. The lower section 233 can couple on an upper end with the transition section 235. The lower section 233 and/or the upper section 231 can include a planar section that is perpendicular to the transition section 235.
The lower section 233 can include a kick out 237. The kick out 237 can comprise a planar section that is at an angle with respect to a planar section of the lower section 233. The kick out 237 can be angled towards an exterior side of the gasket profile 216 (e.g., opposite the extension of the upper flange 225).
The transition section 235 can include an inner flange 236. The inner flange 236 can extend from an upper end of the lower section 233. The inner flange 236 can at least partially form an interior region of the gasket profile 216 between the upper section 231 and the inner flange 236. The upper section 231 can include a fire blocking strip 234. The fire blocking strip 234 can be located between the corner 229 and the transition section 235 along the upper section 231. The fire blocking strip 234 can be located within the interior section of the gasket profile 216.
The fire-rated assembly 200 can further include a fire-rated insert 215. The fire-rated insert 215 can comprise a steel plate. The steel plate can include planar, straight, curvilinear or stepped regions. The insert 215 can include a straight section 221. The straight section 221 can extend between an upper end 223 and a lower end 222. The upper end 223 can include a fire blocking strip 224. The fire blocking strip 224 can extend between the upper end 223 and the lower end 222.
As shown in
A head-of-wall assembly 300 can include an overhead structure 320, a header track 330 attached with the overhead surface 320. The header track 330 can include a first flange 332, a second flange 334, and a web 336. A stud 340 can be assembled between the first flange 332 and the second flange 334 and coupled therewith by a first mechanical fastener 374. A wall board 350 can be attached with the stud 340. A deflection gap 360 can be formed between the upper end of the wall board 350 and the overhead structure 320. The stud 340 and the wallboard 350 can be movable vertically to open and close the deflection gap 360.
The fire-rated assembly 200 can be installed alongside of the second flange 334 within the deflection gap 360. A second mechanical fastener 372 can be installed through the lower section 233 of the lower flange 227. The second fastener 372 can attach the assembly 200 with the second flange 334. In certain implementations, the fire-rated assembly 200 can be preinstalled on the header track 330. The corner 229 can be compressed against the overhead structure 320 to form a seal therewith. The interior side of the fire-rated assembly 200 can face the second flange 334. The downwardly extending flange 226, the lower section 233, and/or the inner flange 236 can be flush against the second flange 334. The insert 215 can be located within the interior portion of the gasket profile 216 facing the second flange 334.
The first fastener 374 can be offset from the second fastener 372 (e.g., into and out of the page as shown in
When the fire-rated assembly 200 is exposed to heat or fire, the fire blocking strips 224 and/or 234 can expand to fill the deflection gap 360, the formable material of the gasket profile 216 can be at least partially maintained in its position by the insert 215. The insert 215 along with the upper section 231 and the upper flange 225 can fold outwardly across the top of the wall board 350 when exposed to heat or fire. The insert 215 can maintain structural integrity of the upper section 231 and thereby direct the expansion of the fire blocking strips 224, 234 towards the overhead structure 320 to close the deflection gap 360.
Terms of orientation used herein, such as “top,” “bottom,” “proximal,” “distal,” “longitudinal,” “lateral,” and “end,” are used in the context of the illustrated embodiment. However, the present disclosure should not be limited to the illustrated orientation. Indeed, other orientations are possible and are within the scope of this disclosure. Terms relating to circular shapes as used herein, such as diameter or radius, should be understood not to require perfect circular structures, but rather should be applied to any suitable structure with a cross-sectional region that can be measured from side-to-side. Terms relating to shapes generally, such as “circular,” “cylindrical,” “semi-circular,” or “semi-cylindrical” or any related or similar terms, are not required to conform strictly to the mathematical definitions of circles or cylinders or other structures, but can encompass structures that are reasonably close approximations.
Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include or do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.
Conjunctive language, such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.
The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, in some embodiments, as the context may dictate, the terms “approximately,” “about,” and “substantially,” may refer to an amount that is within less than or equal to 10% of the stated amount. The term “generally” as used herein represents a value, amount, or characteristic that predominantly includes or tends toward a particular value, amount, or characteristic. As an example, in certain embodiments, as the context may dictate, the term “generally parallel” can refer to something that departs from exactly parallel by less than or equal to 20 degrees. Ranges given are inclusive of endpoints.
Several illustrative embodiments of head-of-wall assemblies and components such as sound-blocking and/or fire-blocking gasket profiles have been disclosed. Although this disclosure has been described in terms of certain illustrative embodiments and uses, other embodiments and other uses, including embodiments and uses which do not provide all of the features and advantages set forth herein, are also within the scope of this disclosure. Components, elements, features, acts, or steps can be arranged or performed differently than described and components, elements, features, acts, or steps can be combined, merged, added, or left out in various embodiments. All possible combinations and subcombinations of elements and components described herein are intended to be included in this disclosure. No single feature or group of features is necessary or indispensable.
Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation also can be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can in some cases be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.
Any portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in one embodiment or example in this disclosure can be combined or used with (or instead of) any other portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in a different embodiment, flowchart, or example. The embodiments and examples described herein are not intended to be discrete and separate from each other. Combinations, variations, and some implementations of the disclosed features are within the scope of this disclosure.
While operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Additionally, the operations may be rearranged or reordered in some implementations. Also, the separation of various components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. Additionally, some implementations are within the scope of this disclosure.
Further, while illustrative embodiments have been described, any embodiments having equivalent elements, modifications, omissions, and/or combinations are also within the scope of this disclosure. Moreover, although certain aspects, advantages, and novel features are described herein, not necessarily all such advantages may be achieved in accordance with any particular embodiment. For example, some embodiments within the scope of this disclosure achieve one advantage, or a group of advantages, as taught herein without necessarily achieving other advantages taught or suggested herein. Further, some embodiments may achieve different advantages than those taught or suggested herein.
Some embodiments have been described in connection with the accompanying drawings. The figures are drawn and/or shown to scale, but such scale should not be limiting, since dimensions and proportions other than what are shown are contemplated and are within the scope of the disclosed invention. Distances, angles, etc. are merely illustrative and do not necessarily bear an exact relationship to actual dimensions and layout of the devices illustrated. Components can be added, removed, and/or rearranged. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with various embodiments can be used in all other embodiments set forth herein. Additionally, any methods described herein may be practiced using any device suitable for performing the recited steps.
For purposes of summarizing the disclosure, certain aspects, advantages and features of the inventions have been described herein. Not all, or any such advantages are necessarily achieved in accordance with any particular embodiment of the inventions disclosed herein. No aspects of this disclosure are essential or indispensable. In many embodiments, the devices, systems, and methods may be configured differently than illustrated in the figures or description herein. For example, various functionalities provided by the illustrated modules can be combined, rearranged, added, or deleted. In some embodiments, additional or different processors or modules may perform some or all of the functionalities described with reference to the example embodiment described and illustrated in the figures. Many implementation variations are possible. Any of the features, structures, steps, or processes disclosed in this specification can be included in any embodiment.
In summary, various embodiments and examples of head-of-wall assemblies and fire blocking tracks and related methods have been disclosed. This disclosure extends beyond the specifically disclosed embodiments and examples to other alternative embodiments and/or other uses of the embodiments, as well as to certain modifications and equivalents thereof. Moreover, this disclosure expressly contemplates that various features and aspects of the disclosed embodiments can be combined with, or substituted for, one another. Accordingly, the scope of this disclosure should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims.
| Number | Date | Country | |
|---|---|---|---|
| 62813472 | Mar 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16809401 | Mar 2020 | US |
| Child | 17653771 | US |
