U.S. patent application number 13/662314 was filed with the patent office on 2013-05-02 for fire rated radius wall structure.
The applicant listed for this patent is James Alan Klein. Invention is credited to James Alan Klein.
Application Number | 20130104474 13/662314 |
Document ID | / |
Family ID | 48170952 |
Filed Date | 2013-05-02 |
United States Patent
Application |
20130104474 |
Kind Code |
A1 |
Klein; James Alan |
May 2, 2013 |
FIRE RATED RADIUS WALL STRUCTURE
Abstract
A curved wall structure is disclosed herein that comprises a
curved footer track; a curved header track confronting and
vertically spaced apart from the curved footer track; a plurality
of studs having upper and lower end portions (wherein the studs are
vertically positioned between the spaced apart and confronting
header and footer tracks such that the lower end portions are
received into the footer track and the upper end portions are
received into the curved header track); and a corrugated curved
wall panel having a plurality of vertically spaced apart grooves.
Mineral wool (or other suitable insulation material) may be
positioned between the plurality of studs and adjacent to the
corrugated curved wall panel. In addition, a heat-expandable
intumescent material strip may be positioned along a top portion of
at least one of the downwardly extending sidewalls of the curved
header track and adjacent to the first curved wallboard.
Inventors: |
Klein; James Alan;
(Bellevue, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Klein; James Alan |
Bellevue |
WA |
US |
|
|
Family ID: |
48170952 |
Appl. No.: |
13/662314 |
Filed: |
October 26, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61628184 |
Oct 26, 2011 |
|
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|
Current U.S.
Class: |
52/232 ;
52/245 |
Current CPC
Class: |
E04B 2/7411 20130101;
E04B 2002/7481 20130101; E04C 2/36 20130101; E04C 2/08 20130101;
E04C 2/328 20130101; E04B 2/7457 20130101; E04C 2/322 20130101 |
Class at
Publication: |
52/232 ;
52/245 |
International
Class: |
E04B 1/78 20060101
E04B001/78; E04B 2/00 20060101 E04B002/00 |
Claims
1. A curved wall structure, comprising: a curved footer track
defined by a pair of upwardly extending curved sidewalls connected
to a curved footer web; a curved header track confronting and
vertically spaced apart from the curved footer track, the curved
header track being defined by a pair of downwardly extending curved
sidewalls connected to a curved header web; a plurality of studs
having upper and lower end portions, the studs being vertically
positioned between the spaced apart and confronting header and
footer tracks such that the lower end portions are received into
the footer track and the upper end portions are received into the
header track; a corrugated curved wall panel having a plurality of
vertically spaced apart grooves, the corrugated curved wall panel
being positioned along the curved header track and the curved
footer track and adjacent to the plurality of studs; and a
plurality of fasteners connecting the corrugated curved wall panel
to the plurality of studs, the plurality of fasteners being
positioned within the plurality of grooves and penetrating into the
plurality of studs to thereby define the curved wall structure.
2. The curved wall structure of claim 1, further comprising a
curved first wallboard positioned adjacent and conforming to the
corrugated curved wall panel.
3. The curved wall structure of claim 2, further comprising a
curved second wallboard positioned adjacent and conforming to the
first curved wallboard.
4. The curved wall structure of claim 3 wherein the curved footer
track, the curved header track, the plurality of studs, and the
corrugated curved wall panel are all made of sheet-metal.
5. The curved wall structure of claim 4 wherein the first and
second curved wallboard each contain gypsum.
6. The curved wall structure of claim 5, further comprising mineral
wool positioned between the plurality of studs and adjacent to the
corrugated curved wall panel.
7. The curved wall structure of claim 1 or 6 wherein the plurality
of fasteners is a plurality of screws with each screw having a
screw head connected to a ridged cylinder, and wherein the screw
heads are within the plurality of grooves and the ridged cylinders
are penetrating into the plurality of studs.
8. The curved wall structure of claim 7, further comprising a first
heat-expandable intumescent material strip positioned along a top
portion of at least one of the downwardly extending sidewalls of
the curved header track and adjacent to the first curved
wallboard.
9. The curved wall structure of claim 7, further comprising a
second heat-expandable intumescent material strip positioned along
a bottom portion of at least one of the upwardly extending
sidewalls of the curved footer track and adjacent to the first
curved wallboard.
10. The curved wall structure of claim 8 wherein the curved wall
structure is fire retardant.
11. The curved wall structure of claim 1 wherein the plurality of
grooves each has a generally U-shaped profile.
12. The curved wall structure of claim 1 wherein the plurality of
grooves each has a generally V-shaped profile.
13. The curved wall structure of claim 1 wherein the plurality of
grooves are uniformly spaced apart from one another.
14. The curved wall structure of claim 1 wherein the curved header
track comprises a first inner header track section in a
side-by-side cooperative relation with a second outer header track
section.
15. The curved wall structure of claim 14 wherein the first inner
header track section comprises an inner curved header wall having a
plurality of outwardly extending first section header prongs, and
wherein the second outer header track section comprises an outer
curved header wall having a plurality of inwardly extending second
section header prongs, and wherein the first section header prongs
together with the second section header prongs define the curved
header web.
16. The curved wall structure of claim 15 wherein the curved header
track is selectively adjustable as to define a plurality of
different curvatures of the curved header track.
17. The curved wall structure of claim 1 wherein the curved footer
track comprises a first inner footer track section in a
side-by-side cooperative relation with a second outer footer track
section.
18. The curved wall structure of claim 17 wherein the first inner
footer track section comprises a footer curved wall having a
plurality of outwardly extending first section footer prongs, and
wherein the second outer footer track section comprises an outer
curved wall having a plurality of inwardly extending second section
footer prongs, and wherein the first section footer prongs together
with the second section footer prongs define the curved footer
web.
19. The curved wall structure of claim 18 wherein the curved footer
track is selectively adjustable as to define different curvatures
of the curved footer track.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S.
Provisional Application No. 61/628,184 filed on Oct. 26, 2011, all
of which application is incorporated herein by reference in its
entirety for all purposes.
TECHNICAL FIELD
[0002] The present invention relates generally to building
construction and, more particularly, to curved wall structures that
are easy to construct/install on-site within a building and that
may be fire rated to comply with ever stringent fire codes and
regulations.
BACKGROUND OF THE INVENTION
[0003] In the building construction industry, there is often a need
to build a curved wall structure within a building. For example, in
many hospitals and other like buildings, architects' designs
frequently call for one or more curved walls that are required to
comply with ever stringent fire codes. Builders, however, have few
options for constructing such curved walls.
[0004] One solution is a curved track product manufactured and
distributed by Priceless Steel Products Co. (Spokane, Wash.
U.S.A.). The curved track products available from Priceless Steel
Products are fabricated to have a specified curvature or radius and
when assembled together with studs and wallboard define a curved
wall structure. A problem with such curved wall products, however,
is that it is often difficult and cumbersome to attach wallboard to
the studs because the screw heads (associated with the sheet-metal
screws used to attach the studs to the curved header/footer tracks)
tend to protrude outwardly away from the exterior surface of the
curved header/footer tracks such that they interfere with smooth
attachment of the wallboard. Another problem is that such curved
wall products (when assembled together with studs and wallboard so
as to define a curved wall structure) are generally not
sufficiently fire retardant to comply with modern fire codes.
[0005] Accordingly, and although some curved wall structures are
known to exist, there is still a need in the art for new and
improved curved wall structures that are easy to construct/install
on-site within a building and that may be fire rated to comply with
ever stringent fire codes. The present invention fulfills these
needs and provides for further related advantages.
SUMMARY OF THE INVENTION
[0006] In brief, the present invention in one embodiment is
directed to a curved (radius) wall structure that is easy to
construct/install on-site within a building and that may be fire
rated to comply with fire codes and regulations. The curved wall
structure of the present invention comprises a curved footer track
defined by a pair of upwardly extending sidewalls connected to a
curved footer web; a curved header track confronting and vertically
spaced apart from the footer track, wherein the curved header track
is defined by a pair of downwardly extending sidewalls connected to
a curved header web; a plurality of studs having upper and lower
end portions, wherein the studs are vertically positioned between
the spaced apart and confronting header and footer tracks such that
the lower end portions are received into the footer track and the
upper end portions are received into the header track; a corrugated
curved wall panel having a plurality of vertically spaced apart
grooves, wherein the corrugated curved wall panel is positioned
along the curved header track and the curved footer track and
adjacent to the plurality of studs; and a plurality of fasteners
connecting the corrugated curved wall panel to the plurality of
studs, wherein the plurality of fasteners are positioned within the
plurality of grooves and penetrate into the plurality of studs to
thereby define the curved wall structure.
[0007] These and other aspects of the present invention will become
more evident upon reference to the following detailed description
and attached drawings. It is to be understood, however, that
various changes, alterations, and substitutions may be made to the
specific embodiments disclosed herein without departing from their
essential spirit and scope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] In the drawings like reference numerals are used to
designate like features throughout the several views of the
drawings.
[0009] FIG. 1 is a front perspective partial exploded view of a
curved wall structure in accordance with an embodiment of the
present invention.
[0010] FIG. 2 is a rear perspective partial exploded view of the
curved wall structure shown in FIG. 1.
[0011] FIG. 3 is a perspective view of a curved footer track in
accordance with an embodiment of the present invention (noting that
the curved header track of the present invention is of similar
shape and construction).
[0012] FIG. 4 is an end profile view of a corrugated wall panel
(before bending to shape) in accordance with an embodiment of the
present invention.
[0013] FIG. 5 is a perspective view of the corrugated wall panel
shown in FIG. 4.
[0014] FIG. 6 is an end profile view of a corrugated wall panel
(after bending to shape) in accordance with an embodiment of the
present invention.
[0015] FIG. 7 is a top (or bottom) partial view of a curved wall
structure in accordance with an embodiment of the present
invention.
[0016] FIG. 8 is another top (or bottom) partial curved view of a
wall structure in accordance with an embodiment of the present
invention.
[0017] FIG. 9 is a top (or bottom) partial view of the curved wall
structure shown in FIG. 8, but having wallboard (sheathing)
attached.
[0018] FIG. 10 is a top (or bottom) partial view a curved wall
structure in accordance with an embodiment of the present invention
that better details how a fastener (e.g., screw) connects the
corrugated wall panel to a stud.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring now to the drawings wherein like reference
numerals are used to designate like features and, more
particularly, to FIGS. 1-10, the present invention in one
embodiment is directed to a curved (radius) wall structure 10 that
is easy to construct/install on-site within a building (not shown)
and that may optionally be fire-rated to comply with applicable
fire codes. As shown in FIGS. 1 and 2, the curved wall structure 10
is an assembly that comprises a curved footer track 12; a curved
header track 14 confronting and vertically spaced apart from the
curved footer track 12; a plurality of studs 16 having upper and
lower end portions 18, 20, (wherein the studs 16 are vertically
positioned between the spaced apart and confronting header and
footer tracks 12, 14 such that the lower end portions 20 are
received into the footer track 12 and the upper end portions 18 are
received into the curved header track 14); and a corrugated curved
wall panel 22 having a plurality of vertically spaced apart grooves
24. As shown, the corrugated curved wall panel 22 is positioned
along the curved header track 14 and the curved footer track 12 (so
as to be adjacent to the plurality of studs 16). As further shown,
a plurality of fasteners 26 connect the corrugated curved wall
panel 22 to the plurality of studs 16. In this configuration, the
plurality of fasteners 26 are positioned within the plurality of
grooves 24 and penetrate into the plurality of studs 16 to thereby
define the curved wall structure 10 (noting that is desirable that
some of the vertical grooves 24 align with the studs 16).
[0020] The curved footer track 12, the curved header track 14, the
plurality of studs 16, and the corrugated curved wall panel 22 may
all made of sheet-metal. The plurality of grooves 24 may be
uniformly spaced apart from one another. In some embodiments, the
plurality of grooves 24 may each have a generally V-shaped profile,
while in other embodiments they may each have a generally U-shaped
profile. In either case, the plurality of grooves 24 facilitate the
bending of the resilient and corrugated curved wall panel 22 so
that it more readily conforms to the curvature of the curved wall
structure 10.
[0021] As best shown in FIG. 3, the curved footer track 12 is
defined by a pair of upwardly extending curved sidewalls 12a, 12b
connected to a curved footer web 12c. Similarly, the curved header
track 14 is defined by a pair of downwardly extending curved
sidewalls 14a, 14b connected to a curved header web 14c.
[0022] In some embodiments and as shown, the curved footer track 12
may comprise a first inner footer track section 12' in a
side-by-side cooperative relation with a second outer footer track
section 12''. The first inner footer track section 12' includes a
footer curved wall 12a having a plurality of outwardly extending
first section footer prongs 12x, and the second outer footer track
section 12'' includes an outer curved wall 12b having a plurality
of inwardly extending second section footer prongs 12y. The first
section footer prongs 12x together with the second section footer
prongs 12y define the curved footer web 12c. In this configuration,
the curved footer track 12 is selectively adjustable as to define
different curvatures of the curved footer track 12.
[0023] Similarly, the curved header track 14 may comprise a first
inner header track section 14' in a side-by-side cooperative
relation with a second outer header track section 14''. The first
inner header track section 14' includes an inner curved header wall
14a having a plurality of outwardly extending first section header
prongs 14x, and the second outer header track section 14'' includes
an outer curved header wall 14b having a plurality of inwardly
extending second section header prongs 14y. The first section
header prongs 14x together with the second section header prongs
14y define the curved header web 14c. In this configuration, the
curved header track 14 is selectively adjustable as to define
different curvatures of the curved header track 14.
[0024] As seen in FIG. 7-10, the plurality of fasteners 26 may be a
plurality of screws with each screw having a screw head 26a
connected to a ridged cylinder 26b. As best shown shown in FIG. 10,
the screw heads 26a are within the plurality of grooves 24 and the
ridged cylinders 26b are penetrating into the plurality of studs
16. In other words, the screw heads 26a reside within the plurality
of grooves 24 (regardless of whether or not the grooves 24 are
U-shaped or V-shaped) so as to not interfere with the attachment of
subsequent wallboard 28, 30 or other sheathing.
[0025] As best shown in FIG. 1 and in further embodiments, the
curved (radius) wall structure 10 of the present invention may
further comprise a curved first wallboard 28 positioned adjacent
and conforming to the corrugated curved wall panel 22. In addition,
the curved (radius) wall structure 10 may further comprise a curved
second wallboard 30 positioned adjacent and conforming to the first
curved wallboard 28. In this way, the first and second curved
wallboards 28, 30 (both which may contain gypsum) may be able to
better "match-up" with thicker fire rated gypsum wallboard sheets
positioned on the adjoining walls (not shown) (and that are
generally flat as opposed to being curved in nature).
[0026] In still further embodiments that are even more fire
retardant, mineral wool 32 (or other suitable insulation material)
may be positioned between the plurality of studs 16 and adjacent to
the corrugated curved wall panel 22. In addition, a heat-expandable
intumescent material strip 34 may be positioned along a top portion
of at least one of the downwardly extending sidewalls 14b of the
curved header track 14 and adjacent to the first curved wallboard
28. Similarly, a second heat-expandable intumescent material strip
36 may be positioned along a bottom portion of at least one of the
upwardly extending sidewalls 12b of the curved footer track 12 and
adjacent to the first curved wallboard 28. The intumescent strip 36
is commercially available (e.g., 3M Company or The Rectorseal
Corporation, U.S.A.) and preferably has an adhesive backing that
allows it to be readily affixed onto the downwardly extending
sidewalls 14b of the curved header track 14. Exemplary in this
regard are the heat expandable compositions disclosed in U.S. Pat.
No. 6,207,085 to Ackerman (incorporated herein by reference), which
discloses a composition that, when subjected to heat, expands to
form a heat-insulating barrier. A preferred composition contains
expandable graphite (.about.10-40 wt %), a fire retardant
(.about.10-40 wt %), and an optional inorganic intumescent filler
(<50 wt %), all of which are admixed together with a resinous
emulsion (.about.30-60 wt %). The expandable graphite is generally
manufactured by the oxidation of graphite flake in sulfuric acid
(with such intercalated graphite being swellable or expandable up
to about 100 times of its original volume when heated at high
temperature). The fire retardant generally includes
amine/phosphorous containing salts such as, for example, amine
salts of phosphoric acid or lower alkyl esters thereof. A preferred
fire retardant is a C.sub.2-C.sub.8 alkyl diamine phosphate.
Intumescent activation or expansion generally begins at about
392.degree. F. In order to ensure that the intumescent strip 36
stays in place when exposed to heat, it has been found that a
commercially available (e.g., 3M Company, U.S.A.) fire-retardant
epoxy adhesive may preferably also be used.
[0027] While the present invention has been described in the
context of the embodiments illustrated and described herein, the
invention may be embodied in other specific ways or in other
specific forms without departing from its spirit or essential
characteristics. Therefore, the described embodiments are to be
considered in all respects as illustrative and not restrictive. The
scope of the invention is, therefore, indicated by the appended
claims rather than by the foregoing description, and all changes
that come within the meaning and range of equivalency of the claims
are to be embraced within their scope.
* * * * *