U.S. patent application number 14/673117 was filed with the patent office on 2015-10-01 for insulating sealing element for head-of-wall joints.
This patent application is currently assigned to Hilti Aktiengesellschaft. The applicant listed for this patent is Hilti Aktiengesellschaft. Invention is credited to Christian FOERG, Manfred KLEIN, Markus KOEGLER.
Application Number | 20150275506 14/673117 |
Document ID | / |
Family ID | 54189554 |
Filed Date | 2015-10-01 |
United States Patent
Application |
20150275506 |
Kind Code |
A1 |
KLEIN; Manfred ; et
al. |
October 1, 2015 |
INSULATING SEALING ELEMENT FOR HEAD-OF-WALL JOINTS
Abstract
A sealing element for sealing a gap between a support structure
and a track, where the track includes a web and legs that extend
vertically from the web. An embodiment of the sealing element has
an insulating strip that includes an insulating material strip and
a cover layer.
Inventors: |
KLEIN; Manfred; (Kaufering,
DE) ; FOERG; Christian; (Lamerdingen, DE) ;
KOEGLER; Markus; (Buchloe, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hilti Aktiengesellschaft |
Schaan |
|
LI |
|
|
Assignee: |
Hilti Aktiengesellschaft
Schaan
LI
|
Family ID: |
54189554 |
Appl. No.: |
14/673117 |
Filed: |
March 30, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61972956 |
Mar 31, 2014 |
|
|
|
Current U.S.
Class: |
277/628 |
Current CPC
Class: |
E04B 1/68 20130101; E04B
1/88 20130101; E04B 2/7409 20130101 |
International
Class: |
E04B 1/68 20060101
E04B001/68; E04B 1/88 20060101 E04B001/88 |
Claims
1. A sealing element for sealing a gap between a support structure
and a track, wherein the track includes a web and legs that extend
vertically from the web, comprising: an insulating strip including
an insulating material strip and a cover layer adhesively attached
to the insulating material strip; wherein the cover layer has a
first portion that extends beyond the insulating material strip;
and wherein the insulating material strip is disposed at a first
end of a leg of the track, wherein the first end of the leg is
disposed away from the web.
2. The sealing element according to claim 1, wherein the first
portion of the cover layer is adhesively attached to the support
structure, wherein the first portion of the cover layer extends
away from the leg, and wherein the insulating material strip is
adhesively attached to the leg.
3. The sealing element according to claim 1, wherein the insulating
strip further includes a second insulating material strip, wherein
the second insulating material strip is disposed at a second end of
the leg, and wherein the second end of the leg is disposed near the
support structure.
4. The sealing element according to claim 1, wherein the first
portion of the cover layer is adhesively attached to the leg.
5. The sealing element according to claim 1, wherein the first
portion of the cover layer is adhesively attached to the web.
6. The sealing element according to claim 1, wherein the cover
layer has a second portion that extends beyond the insulating
material strip, wherein the first portion of the cover layer is
adhesively attached to the leg, and wherein the second portion is
disposed around an end of the insulating material strip.
7. The sealing element according to claim 4, wherein a thickness of
the insulating material strip corresponds to a height of a head of
a screw, wherein the screw is disposed in the leg, and wherein the
insulating material strip does not cover the head.
8. The sealing element according to claim 2, wherein a thickness of
the insulating material strip is larger than a height of a head of
a screw, wherein the screw is disposed in the leg, and wherein the
head is disposed in a recess defined by the insulating material
strip.
9. A sealing element for sealing a gap between a support structure
and a track, wherein the track includes a web and legs that extend
vertically from the web, comprising: an insulating strip including
a first insulating material strip, a second insulating material
strip, and a cover layer adhesively attached to the first
insulating material strip and the second insulating material strip;
wherein the first insulating material strip is disposed on a first
leg of the track, wherein the second insulating material strip is
disposed on a second leg of the track, and wherein the cover layer
extends around the web.
10. The sealing element according to claim 9: wherein the first
insulating material strip is disposed at a first end of the first
leg and wherein the first end of the first leg is disposed away
from the web; and wherein the second insulating material strip is
disposed at a first end of the second leg and wherein the first end
of the second leg is disposed away from the web.
11. The sealing element according to claim 9: wherein the
insulating strip includes a third insulating material strip and a
fourth insulating material strip; wherein the cover layer is
adhesively attached to the third insulating material strip and the
fourth insulating material strip; and wherein the third insulating
material strip and the fourth insulating material strip are
disposed between the web and the support structure.
12. The sealing element according to claim 11, wherein the third
insulating material strip and the fourth insulating material strip
are disposed between the cover layer and the web.
13. The sealing element according to claim 11, wherein the third
insulating material strip and the fourth insulating material strip
are disposed between the cover layer and the support structure.
14. The sealing element according to claim 9: wherein the
insulating strip includes a third insulating material strip;
wherein the cover layer is adhesively attached to the third
insulating material strip; and wherein the third insulating
material strip is disposed between the web and the support
structure.
15. The sealing element according to claim 14, wherein the third
insulating material strip is disposed between the cover layer and
the web.
16. The sealing element according to claim 14, wherein the third
insulating material strip is disposed between the cover layer and
the support structure.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/972,956, filed Mar. 31, 2014, the disclosure of
which is expressly incorporated by reference herein.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention deals generally with the field of
acoustical or firestopping insulation for head-of-wall joints,
including, possibly, intumescent components.
[0003] In the building construction trade, a head-of-wall joint/gap
(also sometimes referred to as a top-of-wall joint/gap) refers to
the linear junction or interface existing between a top section of
a framing or wallboard wall assembly and the ceiling, where the
ceiling may be a next-level floor or corrugated/fluted pan roof
deck, for example. A head-of-wall assembly is comprised of and
defined by the following elements of overhead structure, top of
wall framing deflection system, fill, void, or cavity materials
protecting any joints. Corrugated/fluted deck includes either floor
or roof pan deck assemblies varying in flute size, height, and
configuration. Concrete decks include post-tension slabs, poured in
place concrete, and precast concrete units. Gypsum drywall ceilings
are common fire rated assemblies.
[0004] Head-of-wall joints often present a serious challenge in
terms of reducing or preventing the spread of smoke and fire during
a building fire. In this regard and in common practice, a wall to
ceiling connection of many newly constructed buildings consists
essentially of metal framing assemblies. These metal framing
assemblies are generally constructed from a plurality of metal
framing members including studs, joints, trusses, and other metal
posts and beams formed from sheet metal and frequently fabricated
to have the same general cross-sectional dimensions as standard
members used for similar purposes. Typical head-of-wall deflection
systems include the following: "single long leg track", which is a
U-shaped track having typically longer legs, typically free
floating studs, some type of bracing (CRC, flatstrap) to prevent
rotation of studs; "double track", which is a nested track
configured of two U-shaped profiles, designed for screw attachment
to brace studs without need for other bracing materials; "slotted
track", which is a U-shaped track having vertical slots located in
the legs allowing for faster attachment thought the slots, whereas
screws keep the studs in place; and "slotted clips", which are
u-shaped tracks having pre-installed slotted clips that allow for
attachment of fasteners through the slots, another way to attach
the studs to eliminate dislodging. Although many cross-sectional
shapes are available, the primary shapes used in building
construction are C-shaped studs and U-shaped tracks. These C-shaped
studs and U-Shaped tracks may vary in their size, which, however,
are standardized. The steel track (or channel) is configured to
receive steel studs between the legs of the shaped channel. A
wallboard is generally attached to at least one side of the studs.
The studs and wallboard are in many instances spaced apart from the
ceiling a short gap distance in order to allow for ceiling
deflections caused by seismic activity or moving overhead loads.
Track and stud assemblies that allow for ceiling deflections are
commonly referred to as dynamic head-of-wall systems. Exemplary
steel stud wall constructions may be found in U.S. Pat. Nos.
4,854,096 and 4,805,364 both to Smolik, and U.S. Pat. No. 5,127,203
to Paquette. Exemplary dynamic head-of-wall systems having steel
stud wall constructions may be found in U.S. Pat. No. 5,127,760 to
Brady and U.S. Pat. No. 6,748,705 to Orszulak et al.
[0005] Firestops are thermal barrier materials or combinations of
materials used for filling gaps and openings such as in the joints
between fire-rated walls and/or floors of buildings. For example,
firestops can be used in walls or floors to prevent fire and smoke
from passing through the gaps or openings required for cables,
pipes, ducts, or other conduits. Firestops are also used to fill
joint gaps that occur between walls, between a ceiling and the
head-of-wall joints.
[0006] So-called head-of-wall joints pose a number of challenges
for the fireproofing industry. Walls are increasingly being made of
gypsum wallboard affixed to a framework of metal studs capped by a
horizontally extending track. Ceilings are increasingly being made
by pouring concrete onto fluted steel. Although the distance
between the horizontally extending tracks at the top of the wall is
often fixed in relationship to the ceiling, the gypsum wallboards
are subject to expansion and contraction due to motion of other
building components, ground settling, or other causes. The joint,
based on amount of deflection required, is designed and constructed
to allow for vertical movement, allowing the wall to move
independent of the structure, due to forces such as Live/Dead
loading, thermal expansion/contraction, wind sway, or seismic
movements. The head-of-wall joints allow vertical movement without
damaging the wall or drywall. The drywall is the fire protection
component and it's key that it's not damaged/cracked.
[0007] In order to contain the spread of smoke and fire, a fire
resistant material such as, for example, mineral wool is often
times stuffed into the gaps between the ceiling and wallboard (see,
e.g., U.S. Pat. No. 5,913,788 to Herren). For example, mineral wool
is often stuffed between a steel header track (e.g., an elongated
U-shaped channel) and a corrugated steel roof deck (used in many
types of steel and concrete building constructions); a fire
resistant and generally elastomeric spray coating is then applied
onto the exposed mineral wool to thereby form a fire resistant
joint seal (see, e.g., U.S. Pat. No. 7,240,905 to Stahl). In
certain situations where the ceiling to wallboard gap is relatively
small, a fire resistant and elastomeric caulk is commonly applied
so as to fill any small gaps. In still another approach and as
disclosed in U.S. Pat. Nos. 5,471,805 and 5,755,066 both to Becker,
a slidable non-combustible secondary wall member is fastened to an
especially configured steel header track and immediately adjacent
to the wallboard. In this configuration, the secondary wall member
provides a fire barrier that is able to accommodate ceiling
deflections. All of these approaches, however, are relatively labor
intensive and thus expensive.
[0008] Intumescent materials have long been used to seal certain
types of construction gaps such as, for example, conduit
through-holes. In this regard, intumescent and fire barrier
materials (often referred to as firestop materials or fire
retardant materials) have been used to reduce or eliminate the
passage of smoke and fire through openings between walls and floors
and the openings caused by through-penetrations (i.e., an opening
in a floor or wall which passes all the way through from one room
to another) in buildings, such as the voids left by burning or
melting cable insulation caused by a fire in a modern office
building. Characteristics of fire barrier materials suitable for
typical commercial fire protection use include flexibility prior to
exposure to heat, the ability to insulate and/or expand, and the
ability to harden in place upon exposure to fire (i.e., to char
sufficiently to deter the passage of heat, smoke, flames, and/or
gases). Although many such materials are available, the industry
has long sought better and more effective uses of these materials
and novel approaches for better fire protection, especially in the
context of dynamic head-of-wall construction joints and gaps.
[0009] Thus, and although construction joints and gaps are
generally sealed in some manner (e.g., mineral wool and/or
elastomeric coatings; see also, U.S. Patent Application No.
2006/0137293 to Klein), there are relatively few products and
methods available that effectively and efficiently seal
head-of-wall construction joints and gaps to thereby significantly
enhance the ability of such joints and gaps to withstand smoke and
fire penetration. In particular, there are very few products and
methods available that address the needs for adequate fire
protection and sealing of dynamic head-of-wall systems associated
with steel stud wall constructions.
[0010] Recently more advanced head-of-wall fire block arrangements
have been developed based on fire block header tracks. These fire
block header tracks utilize an expandable fire-resistant material,
such as an intumescent material, applied along a length of the
header track of a wall assembly. The intumescent material is either
positioned on the web of the header track, on the legs (hereinafter
also referred to as flange) of the header track or alternatively
wraps around a corner of the header track, extending both along a
portion of a web of the header track and a flange of the header
track. The intumescent material advantageously is held in place
between the web of the header track and the floor or ceiling above
the wall. When exposed to a sufficient temperature, the intumescent
material expands to fill gaps at the head-of-wall. The portion of
the intumescent trapped between the header track and the floor or
ceiling ensures that the intumescent stays in place as it expands
and does not become dislodged as a result of the expansion.
[0011] With the use of such fire-resistant material, the metal
tracks often require a unique construction on the exterior surface
of the metal track which can have a predefined area such as a
recess or the like which identifies the specific location required
for placement of such an intumescent and/or acoustic layer of
insulation material. In particular, as the joint moves responsive
to normal expansion and contraction of the building components, the
insulating tape and/or the coatings of insulating material which is
attached directly to the surfaces of flanges can become dislodged
from components of the head-of-wall area, that is, particularly
dislodging from the surfaces of the downwardly extending side
sections of the track or runner. Also these systems do not
specifically address variations in the contour or profile of the
ceiling or roof area which comes into direct abutment with the
upper portion of the metal track. Such variations in the
configuration of the building construction in this area can form
gaps between the track and the adjacent roof or ceiling area which
are not adequately addressed for insulation by the above described
prior art systems.
[0012] One of the advantages of the sealing element of the present
invention is that it is usable with conventionally OEM metal track
construction and does not require any customized design for the
ceiling runner.
[0013] It is an object of the sealing element for insulating
head-of-wall joints of the present invention to effectively seal
between conventionally designed metal track sections and the
immediately adjacent roof or ceiling area for firestopping and
optionally acoustic insulating thereof.
[0014] It is an object of the sealing element for insulating
head-of-wall joints of the present invention to be usable with any
joints and gaps between construction elements, preferably
conventional steel framing and gypsum board wall constructions.
[0015] It is an object of the sealing element for insulating
head-of-wall joints of the present invention to be usable with
floor or roof constructions of any conventional construction
including solid concrete or a composite material installed atop a
corrugated steel deck.
[0016] It is an object of the sealing element for insulating
head-of-wall joints of the present invention to prevent the spread
of sound, noise, fire, super-heated gases, flames and/or smoke in
these areas.
[0017] It is an object of the sealing element for firestop
insulating head-of-wall joints of the present invention to provide
more effective insulating by providing the insulating material just
before the joint between the top of the metal track and the bottom
of the support structure, e.g., overhead structure in case of a
ceiling, to assure sealing against cold gases and smoke before the
material provides a firestop at elevated temperatures.
[0018] It is an object of the sealing element for insulating
head-of-wall joints of the present invention to minimize costs and
maintenance requirements.
[0019] It is an object of the sealing element for insulating
head-of-wall joints of the present invention to expedite
installation and minimize labor costs.
[0020] Many patents have been applied or granted for various
constructions for insulating head-of-wall joints as described above
such as shown in U.S. Patent Application Publication No.
2011/247281 A1 published Oct. 13, 2011 to Don A. Pilz et al.
assigned to California Expanded Metal Products Company on a
"FIRE-RATED WALL CONSTRUCTION PRODUCT"; U.S. Patent Application
Publication No. 2013/031856 Al published Feb. 7, 2013 to Don A.
Pilz et al. assigned to California Expanded Metal Products Company
on a "FIRE-RATED WALL CONSTRUCTION PRODUCT"; U.S. Pat. No.
8,281,552 B2 patented Oct. 9, 2012 to Don A. Pilz et al. assigned
to California Expanded Metal Products Company on a "EXTERIOR WALL
CONSTRUCTION PRODUCT"; U.S. Pat. No. 8,499,512 B2 patented Aug. 6,
2013 to Don A. Pilz et al. assigned to California Expanded Metal
Products Company on a "EXTERIOR WALL CONSTRUCTION PRODUCT"; U.S.
Patent Application Publication No. 2013/0086859 A1 published Apr.
11, 2013 to Donald A. Pilz et al. assigned to California Expanded
Metal Products Company on a "FIRE-RATED WALL AND CEILING SYSTEM";
U.S. Pat. No. 7,617,643 B2 patented Nov. 17, 2009 to Donald A. Pilz
et al. assigned to California Expanded Metal Products Company on a
"FIRE-RATED WALL AND CEILING SYSTEM"; U.S. Pat. No. 7,950,198 B2
patented May 31, 2011 to Donald A. Pilz et al. assigned to
California Expanded Metal Products Company on a "FIRE-RATED WALL
AND CEILING SYSTEM"; U.S. Pat. No. 8,087,205 B2 patented Jan. 3,
2012 to Don A. Pilz et al. assigned to California Expanded Metal
Products Company on a "FIRE-RATED WALL AND CEILING SYSTEM"; U.S.
Pat. No. 8,322,094 B2 patented Dec. 4, 2012 to Don A. Pilz et al.
assigned to California Expanded Metal Products Company on a
"FIRE-RATED WALL AND CEILING SYSTEM"; U.S. Pat. No. 7,752,817 B2
patented Jul. 13, 2010 to Don A. Pilz et al. assigned to California
Expanded Metal Products Company on a "TWO-PIECE TRACK SYSTEM"; U.S.
Pat. No. 8,132,376 B2 patented Mar. 13, 2012 to Don A. Pilz et al.
assigned to California Expanded Metal Products Company on a
"TWO-PIECE TRACK SYSTEM"; U.S. Pat. No. 8,413,394 B2 patented Apr.
09, 2013 to Don A. Pilz et al. assigned to California Expanded
Metal Products Company on a "TWO-PIECE TRACK SYSTEM"; U.S. Pat. No.
8,555,566 B2 patented Oct. 15, 2013 to Don A. Pilz et al. assigned
to California Expanded Metal Products Company on a "TWO-PIECE TRACK
SYSTEM"; U.S. Patent Application Publication No. 2011/214371 A1
published Sep. 8, 2011 to James A. Klein assigned to Blazeframe
Ind. Ltd. on an "OFFSET LEG FRAMING ELEMENT FOR FIRE STOP
APPLICATIONS"; U.S. Pat. No. 8,468,759 B1 patented Jun. 25, 2013 to
James A. Klein assigned to Blazeframe Ind. Ltd. on an "FIRE
RETARDANT COVER FOR FLUTED ROOF DECK"; U.S. Patent Application
Publication No. 2011/146180 Al published Jun. 23, 2011 to James A.
Klein assigned to Blazeframe Ind. Ltd. on an "ACOUSTICAL AND
FIRESTOP RATED TRACK FOR WALL ASSEMBLIES HAVING RESILIENT CHANNEL
MEMBERS"; U.S. Patent Application Publication No. 2011/167742 A1
published Jul. 14, 2011 to James A. Klein assigned to Blazeframe
Ind. Ltd. on "HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL
ASSEMBLIES"; U.S. Pat. No. 7,681,365 B2 patented Mar. 23, 2010 to
James A. Klein on "HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL
ASSEMBLIES"; U.S. Pat. No. 7,814,718 B2 patented Oct. 19, 2010 to
James A. Klein on "HEAD-OF-WALL FIREBLOCKS"; U.S. Pat. No.
7,866,108 B2 patented Jan. 11, 2011 to James A. Klein on
"HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES"; U.S.
Pat. No. 8,056,293 B2 patented Nov. 15, 2011 to James A. Klein on
"HEAD-OF-WALL FIREBLOCK SYSTEMS AND RELATED WALL ASSEMBLIES"; U.S.
Pat. No. 8,136,314 B2 patented Mar. 20, 2012 to James A. Klein on
"HEAD-OF-WALL FIREBLOCKS"; U.S. Pat. No. 8,151,526 B2 patented Apr.
10, 2012 to James A. Klein on "HEAD-OF-WALL FIREBLOCK SYSTEMS AND
RELATED WALL ASSEMBLIES"; U.S. Patent Application Publication No.
2012/0297710 A1 published Nov. 29, 2012 to James A. Klein on
"CONTROL JOINT BACKER AND SUPPORT MEMBER ASSOCIATED WITH STRUCTURAL
ASSEMBLIES"; U.S. Patent Application Publication No. 2011/0099928
A1 published May 5, 2011 to James A. Klein and Alastair Malcolm on
"DEFELCTION AND DRIFT STRUCTURAL WALL ASSEMBLIES"; CA Patent
Application Publication No. 2550201 A1 published Dec. 15, 2007 to
James A. Klein on "HEAD-OF-WALL FIREBLOCKS AND RELATED WALL
ASSEMBLIES"; U.S. Pat. No. 8,181,404 B2 patented May 22, 2012 to
James A. Klein on "HEAD-OF-WALL FIREBLOCKS AND RELATED WALL
ASSEMBLIES"; U.S. Patent Application Publication No. 2013/0186020
A1 published Jul. 25, 2013 to Don A. Pilz assigned to California
Expanded Metal Products Company on a "FIRE-RATED JOINT SYSTEM";
U.S. Pat. No. 8,353,139 B2 patented Jan. 15, 2013 to Don A. Pilz et
al. assigned to California Expanded Metal Products Company on a
"WALL GAP FIRE BLOCK DEVICE, SYSTEM AND METHOD"; U.S. Patent
Application Publication No. 2013/118102 A1 published May 19, 2011
to Don A. Pilz et al. assigned to California Expanded Metal
Products Company on a "WALL GAP FIRE BLOCK DEVICE; SYSTEM AND
METHOD"; U.S. Patent Application Publication No. 2013/205694 A1
published Aug. 15, 2013 to James P. Stahl assigned to Specified
Technologies Inc. on "INSULATING GASKET CONSTRUCTION FOR
HEAD-OF-WALL JOINTS"; U.S. Pat. No. 8,375,666 B2 patented Feb. 19,
2013 to James P. Stahl et al assigned to Specified Technologies
Inc. on "FIRESTOPPING SEALING MENAS FOR USE WITH GYPSUM WALLBOARD
IN HEAD-OF-WALL CONSTRUCTION"; U.S. Patent Application Publication
No. 2013/091790 A1 published Apr. 18, 2013 to James P. Stahl et al.
assigned to Specified Technologies Inc. on "FIRESTOPPING MEANS FOR
USE WITH GYPSUM WALLBOARD IN HEAD-OF-WALL CONSTRUCTION"; U.S. Pat.
No. 7,240,905 B2 patented Jul. 10, 2007 to James P. Stahl on
"METHOD AND APPARATUS FOR SEALING A JOINT GAP BETWEEN TWO
INDEPENDENTLY MOVABLE STRUCTURAL SUBSTRATES"; U.S. Pat. No.
6,698,146 B2 patented Mar. 2, 2004 to Michael D. Morgan et al.
assigned to W.R. Grace & Co.-Conn. on "IN SITU MOLDED THERMAL
BARRIERS"; U.S. Pat. No. 6,783,345 B2 patented Aug. 31, 2004 to
Michael D. Morgan et al. assigned to W. R. Grace & Co.-Conn. on
"IN SITU MOLDED THERMAL BARRIERS"; U.S. Pat. No. 7,043,880 B2
patented May 16, 2006 to Michael D. Morgan et al. assigned to W.R.
Grace & Co.-Conn. on "IN SITU MOLDED THERMAL BARRIERS"; U.S.
Pat. No. 7,152,385 B2 patented December 26, 2006 to Michael D.
Morgan et al. assigned to W.R. Grace & Co.-Conn. on "IN SITU
MOLDED THERMAL BARRIERS"; U.S. Pat. No. 5,010,702 patented Apr. 30,
1991 to T. L. Daw et al and assigned to Daw Technologies, Inc. on a
"Modular Wall System"; and U.S. Pat. No. 5,127,203 patented Jul. 7,
1992 to R. F. Paquette on a "Seismic/Fire Resistant Wall Structure
and Method"; and U.S. Pat. No. 5,755,066 patented May 26, 1998 to
D. W. Becker on a "Slip Track Assembly; and U.S. Pat. No. 5,913,788
patented Jun. 22, 1999 to T. R. Herren on a "Fire Blocking And
Seismic Resistant Wall Structure"; and U.S. Pat. No. 5,921,041
patented Jul. 13, 1999 to J. D. Egri, II on a "Bottom Track For
Wall Assembly"; and U.S. Pat. No. 5,950,385 patented Sep. 14, 1999
to T. R. Herren on an "Interior Shaft Wall Construction"; and U.S.
Pat. No. 6,058,668 patented May 9, 2000 to T. R. Herren on a
"Seismic And Fire-Resistant Head-of-Wall Structure"; and U.S. Pat.
No. 6,176,053 patented Jan. 23, 2001 to Roger C. A. St. Germain and
assigned to Robert C. A. St. Germain on a "Wall Track Assembly And
Method For Installing The Same".
[0021] Although the known fire block header tracks provide
exceptional performance, there still exists a need for fire block
arrangements that can be applied to any desired structure, such as
the wall, floor or ceiling of a building construction or to the
stud wall assembly and to header tracks. Furthermore, as described
herein, alternative embodiments of the wall gap fire blocks can be
applied to a wall bottom track to protect a foot-of-wall gap or a
(vertical or horizontal) gap in a location other than the head or
foot of a wall. The present fire blocks are well-suited to
application on the job site.
[0022] Preferred embodiments of the present invention provide an
optional adhesive insulating material strip that can be applied to
a header track or other head-of-wall structure to create a
head-of-wall insulation block, including, fire block. The adhesive
insulation strip may include strip portions of another material,
among other material portions, if desired.
[0023] In brief, the present invention is directed in general to a
fire retardant head-of-wall assembly configured to seal a linear
head-of-wall or similar construction joint or gap when exposed to a
heat source, such as in the event of fire. In more detail the
present invention is directed to a firestopping sealing for use
with dry wallboard, i.e., gypsum wallboard, in a head-of-wall or
similar construction including an insulating strip, in particular
an elongated insulating material strip, and a cover layer. The
insulating strip being positioned on at least one portion of the
leg of the track, whereas the insulating material strip only in
some embodiments will be affixed on the leg of the track.
[0024] The insulating material strip having an outer strip surface
offset from the outer leg surface an insulating material strip
offset distance and an inner strip surface directed towards the leg
surface. In other words, one strip surface faces away from the leg
surface towards the wallboard and the other strip surface is
directed towards the leg surface. In some embodiments the strip
surface which is directed towards the leg surface comes in direct
contact with the leg surface. In some embodiments no adhesive is
provided between the strip and the leg. In other embodiments an
adhesive will be provided between the strip and the leg, in
particular when the insulating strip consists of a sticky material
and therefore provides stickiness by itself, or alternatively, when
an additional adhesive layer is provided on the strip.
[0025] The insulating strip includes an insulating material strip
and a cover layer that covers the insulating material strip whereas
the cover layer secures the insulating strip to the construction
element (hereinafter also referred to as support structure), such
as a wall, floor or an overhead structure, i.e., a ceiling.
[0026] The insulating material strip may comprise non-intumescent
and/or intumescent materials, but will preferably include
intumescent materials to provide enhanced sealing in the event of
fire. These intumescent materials may be constructed partially or
entirely from an intumescent material such as CP 646 from Hilti,
for example. It is also possible for the insulating material of the
present invention to have components of both intumescent and
acoustical sealing therewithin. It is particularly preferred that
the insulating material includes an intumescent material only. The
acoustical insulating material is intended for applications where
sealing against sound transmissions is found to be desirable in
addition to firestop. Such acoustical insulating configurations can
preferably be formed of a felt acoustical insulating material.
Alternatively, it can be formed of a foamed insulating material
which can easily be provided with intumescent properties by
including intumescent additives.
[0027] When the temperature rises the intumescent material will
expand quickly and block air pathways. In this manner, the entire
gap or joint between the construction element, and the top of the
drywall assembly, in particular the wallboard and/or track will be
sealed, substantially preventing fire, heat, and smoke from
reaching other rooms or parts of the building for at least some
period of time.
[0028] In one embodiment the insulating material may be constructed
partially or entirely from a compressible material such as
plasticines, fabric (non-woven or woven) or a felt, e.g., glass
fiber braid, glass fiber fabric or glass fiber mat. Plasticines,
which are also referred to as putties, are frequently used for this
application. They generally consist of a liquid polymer such as
butyl rubber, plasticizers (paraffin oil, phthalates, adipates,
etc.) and fillers, with a filler content of up to 80 percent. In
particular the plasticine contains, as liquid polymer, at least one
representative of the group comprising polyurethanes, polyvinyl
acetates, polyvinyl ethers, polyvinyl propionates, polystyrenes,
natural or synthetic rubbers, poly((meth)acrylates) and
homopolymers and copolymers based on (meth)acrylates,
acrylonitrile, vinyl esters, vinyl ethers, vinyl chloride and/or
styrene, preferably poly(alkyl methacrylate), poly(alkyl acrylate),
poly(aryl methacrylate), poly(aryl acrylate) and/or copolymers
thereof with n-butyl acrylate and/or styrene. The plasticine may
comprise fire-protection additives. In this regard reference is
made to the U.S. patent application No. 2005/032934 A1 which is
incorporated in its entirety herein by reference.
[0029] In another, preferred embodiment, the insulating material
may be constructed partially or entirely from a pressure-resistant
material such as acrylate based polymer or a hard putty such as
rubber, e.g., polyisobutylene based rubber. These materials may
include a reinforcing member such as glass fibers or a glass fiber
fabric to enhance strength of the material. The term
"pressure-resistant" means that while installing the wallboard, the
material shall be deformed only slightly so that in case of
vertical movement of the wallboard tilting and entanglement of the
insulating material are always avoided.
[0030] More preferably the insulating material is also
abrasive-resistant to resist abrasion caused by the wall member
rubbing against the insulating material when moving up and down to
due movement of the building.
[0031] If sound insulation is desired, the intumescent strip may
include an additional sound proofing material. If sound insulation
is desired without using an additional sound proofing material, the
insulating material is made of a material that provides both
firestopping, in particular intumescent properties, as well as
sound or acoustic insulation properties, e.g., plasticines or foams
having intumescent properties.
[0032] Intumescent materials include standard fire protection
additives known to a person skilled in the art which foam in the
event of fire, i.e., with exposure to heat, and in doing so form a
foam that inhibits flame propagation, such as an intumescent
material based on an acidifier, a compound supplying a carbon and a
gas former. The intumescent material preferably includes, as the
acidifier, a salt or ester of an inorganic non-volatile acid
selected from sulfuric acid, phosphoric acid, and boric acid; as
the compound supplying carbon, a polyhydroxy compound and/or a
thermoplastic or thermosetting polymer resin binding agent; and as
the gas former, a chlorinated paraffin, melamine, a melamine
compound, in particular melamine cyanurate, melamine phosphate,
melamine polyphosphate, tris(hydroxyethyl)-cyanurate, cyanamide,
dicyanamide, dicyandiamide, biguanidine and/or a guanidine salt, in
particular guaninide phosphate or guanidine sulfate.
[0033] It is particularly preferred that the insulating strip
includes an insulating material strip which is pressure-resistant
and which has intumescent properties and which additionally is
abrasion-resistant.
[0034] The insulating material strip also includes a cover layer.
The cover layer has two main functions. On the one hand it enables
mounting the insulating material strip on the wall or ceiling. On
the other hand it provides sufficient sealing of the joint or gap
between the dry wall assembly, in particular header track or bottom
(floor) track and the construction element, i.e., a wall, floor or
ceiling. A further function depending on the material used for the
insulating material strip is to provide abrasive-resistance to the
insulating material strip.
[0035] Therefore, the cover layer is made of an airtight material.
Preferably, the cover layer is made of both an airtight and an
abrasion-resistant material to provide a sealing against cold
gases, like smoke or other harmful gases, and to provide resistance
against abrasion resulting in loss of the insulating material
caused by repeatedly rubbing of the wallboard over the insulating
material. The cover layer can be a film material, preferably a
synthetic film like plastic or poly-type material such as polyvinyl
chloride or polyalkylene material, for example polyethylene
material. Alternatively the cover layer can be an inorganic
material, like metal films or any other suitable material. The
cover layer provides protection in the event that the wall is
designed to accommodate vertical movement, which could result in
the wallboard rubbing against the insulating material. However, the
cover layer still permits the insulating material to expand in case
it comprises an intumescent material. In one embodiment the cover
layer has a printable surface.
[0036] The cover layer is abrasive-resistant to resist abrasion
caused by the wall member rubbing against the insulating material
when moving up and down due to movement of the building. This is
particularly important in case the insulating material will not
follow the movement of the wall member and will maintain its
position towards the header track, especially when an adhesive
power acts between the insulating material strip and the leg of the
header track.
[0037] After the insulating material is being brought into its
desired positioned near the track the cover layer will constitute
the outer surface of the material. The cover layer will come into
contact with the wallboard or similar construction element. The
side portion of the cover layer with which the insulating material
strip is fixed on the construction element will then point away
from the track.
[0038] In each of the various embodiments the cover layer includes
at least one side portion that extends outwardly from the
insulating material strip and therefore has a greater dimension
than the insulating material. The dimension of the cover layer
shall be selected such that sufficient adhesion to the construction
element, like a wall, floor or overhead structure, i.e., ceiling,
can be achieved by the side portion. The cover layer must not
affect movement of the wallboard member. Thus, the cover layer
shall be as thin as possible.
[0039] In a preferred embodiment the insulating material strip is
an elongated strip to be positioned lengthwise at the leg of the
header track such that the insulating strip has a great length in
one direction and a smaller width to cover only part of the leg of
the track. Preferably, the insulating strip is designed as an
endless strip. The cover layer then shows a greater width than the
insulating material. The insulating material is positioned on the
cover layer such that both have a joint edge and the cover layer
only extends beyond one side.
[0040] The insulating material strip is adapted to extend along a
length of the track having a first surface and a second surface.
The first surface faces the track and the second surface faces and
contacts the wallboard, where each surface defines a length and a
width. The width is less than a width of the leg of the track to
not cover the leg entirely. With this, the insulating material
strip can be positioned on the leg of the track such that the
insulating material portion of the strip is positioned either in a
middle part, an upper part or a bottom part (lower part) of the
leg. Preferably, the insulation material strip is positioned on the
leg such that the insulating material portion thereof is positioned
in the middle or more preferably lower part of the leg.
[0041] The underneath surface of the cover layer includes an
adhesive or adhesive layer (herein both referred to as adhesive).
The adhesive has two functions. On the one hand the adhesive is to
affix the insulating material to the cover layer. On the other
hand, the adhesive is to affix the insulating material strip to the
wall, floor or ceiling of the construction. The adhesive must
provide sufficient adhesion to construction elements made of
various materials, like concrete, brick, wood and the like.
Suitable adhesives are for example acrylic adhesives, butyl rubber
adhesives, and bitumen.
[0042] Preferably a removable protective layer covers that part of
the underneath surface of the cover layer which extends beyond the
insulating material until the insulating strip is ready to be
applied.
[0043] In one (first) aspect of the invention the insulating strip
comprises a cover layer and an insulating material strip. The cover
layer not only covers the insulating material strip but also
includes a side portion that extends outwardly from the insulating
material strip and therefore has a greater dimension than the
insulating material. The dimension of the cover layer shall be
selected for sufficient adhesion to the element the insulating
strip shall be attached. But, for improved appearance the
insulating material strip, in particular the cover layer shall not
extend beyond the joint, i.e., when mounted on the construction
element, e.g., ceiling, the cover layer shall not extend beyond the
wallboard member and thus shall not be visible after the wallboard
member is mounted.
[0044] With the side portion of the cover layer the insulating
strip of the first aspect of the invention will be fixed to the
support structure, like a wall, floor or overhead structure, i.e.,
ceiling, on the leg or on the web of the track. For this an
adhesive layer can be used which will preferably be applied on that
part of the side portion of the cover layer, which contacts the
support structure or the track. Additionally the insulating
material strip may also be provided with an additional adhesive
layer to fix the insulating material strip on the track.
[0045] The advantage of the insulating strip according to the first
aspect of the invention is that the width of the insulating
material strip is independent from the maximal size of the gap
between the wallboard and the support structure.
[0046] After the insulating material is being brought into its
desired positioned near the track the cover layer will constitute
the outer surface of the material. The cover layer will come into
contact with the wallboard or similar construction element. The
side portion of the cover layer with which the insulating material
strip is fixed on the construction element will then point away
from the track.
[0047] The insulating strip according to the various embodiments of
the first aspect of the invention can be used with solid and with
slotted tracks. If it is intended to use the insulating strip with
slotted tracks the thickness of the insulating material strips
located on the first and second side portion of the cover layer and
after its installation on the track will be positioned on the legs
of the track corresponding to the size, in particular height, of
the screw heads used for securing the studs to the track. The
insulating material strips are positioned on the leg below the
screws so that the screws are covered by the cover layer of the
insulating strip. The screws can freely move between the track and
cover layer. The slots are sealed against cold gases and smoke. Hot
gas and fire sealing will be provided by the intumescent properties
of the insulating material.
[0048] In another embodiment the intumescent effect of the
insulating material, if an intumescent material is used, can be
enhanced so that the intumescent material is directed towards the
gap between the wallboard and the structure element. To achieve
this, the cover layer has an additional side portion that extends
beyond the insulating material strip. The additional side portion
will be wrapped around one edge of the insulating material strip.
After installation of the insulating strip, the enveloped edge of
the insulating material strip will constituted the end of the
insulating strip which is positioned on the lower part of the
leg.
[0049] In still another embodiment the insulating strip includes an
additional insulating material strip, whereas both material strips
are arranged side by side in direct abutment with each other.
Preferably, the insulating material strips consist of different
materials, whereas one of them comprises an intumescent material
and the other a non-intumescent material. In a preferred
embodiment, the intumescent material strip is positioned at one
edge of the cover layer, whereas the non-intumescent material is
positioned next to it, preferably in direct abutment with the
intumescent material strip. The cover layer extends beyond the free
end of the non-intumescent material strip to still constitute a
side portion. The non-intumescent material preferably comprises a
material which provides sound and acoustic insulation, like a glass
fiber fabric, or a foamed material.
[0050] In another (second) aspect of the invention the insulating
strip includes a cover layer and two insulating material
strips.
[0051] The cover layer, which is an elongated layer, is designed as
a continuous strip defining two faces, an upper and a bottom face.
This holds for all aspects and embodiments of the present
invention. The width of the continuous strip is selected depending
on the size of the header track or other construction product to
which the insulating strip shall be attached. The continuous strip
defines a middle section which extends generally horizontally and
which will be positioned on the web of, for example, a header track
and defines side sections (hereinafter also referred to as first
and second side sections), so that the total width of the tape is
larger than the width of the web. While installing the insulating
strip the side sections shall cover both flanges of the header
track or other head-of-wall structure.
[0052] The two insulating material strips are arranged side-by-side
on the same face of the cover layer. The strips are elongated
strips and extend along each leg of the track when the insulating
strip is positioned on the header track, i.e., in a length
direction. The insulating material strips are positioned at a
certain distance between each material strip to define separated
material strips and to define sections without any insulating
material therebetween.
[0053] Preferably one insulating material strip is positioned on
each of the side sections so that one insulating material strip is
positioned on the first side section and another insulating
material strip is positioned on the second side section of the
cover layer. The middle section of the cover layer will be free of
any additional insulating material. After installing the insulating
strip, the insulating material strips are facing towards the header
track or other construction product. In this embodiment the cover
layer serves as a protective layer to protect the insulating strips
as discussed further below.
[0054] The insulating strip will be mounted on the track such that
the insulating material strips on the first and second side
sections will face towards the leg of the track and will be
positioned in the lower part of the leg. With this the upper part
of the legs and the web is free of any insulating material and will
only be covered by the cover layer. Preferably, the two insulating
material strips are located near the lower edges of the leg distal
from the web to have a maximum distance between each other.
[0055] The overall width of the elongated insulating strip from one
outside edge of the insulating strip to the other outside edge
varies depending on the size of the header track or other
construction product on which the insulating strip shall be
installed. The width of the middle section depends on the width of
the web of the header track or other construction product. The
width of the side sections depend on the desired application, e.g.,
normal and slotted tracks, and/or the desired deflection
requirement of the insulating strip. The width of the side sections
again depends on the size of the legs or the type of the leg.
[0056] The insulating strip can be applied to a header track or
other construction product, such as a bottom track, metal stud,
metal flat strap or any other framing member that needs an open gap
between the wallboard and a perimeter structure, in particular for
movement (deflection or drift) but not restricted thereto. In other
words, the elongated insulating strip can be used for sealing any
open gap between the wallboard and the construction product or
between the construction product and a perimeter structure, like
the support structure, for example, a floor, side walls or ceiling.
The insulating strip allows the gap to stay open for movement and
provides fire and smoke protection and/or sound reduction.
[0057] For a better adhesion of the insulating material strips on
the track or support structure, an additional adhesion layer can be
used on the opposite surface of the insulating material strip which
is provided with the cover layer, i.e., on that surface which faces
the support structure or the track. Moreover, an adhesion layer can
be used for securing the cover layer on the web. This also helps to
install the insulating strip on site.
[0058] The insulating strip according to the various embodiments of
the second aspect of the invention can be used with solid and with
slotted tracks. If it is intended to use the insulating sealing
element with slotted tracks the insulating strips will be located
on the first and second side portions of the cover layer and after
the installation of the insulating sealing element on the track the
insulating strips will be positioned on the legs of the track. In
this case the thickness of the insulating material strips
corresponds to the size, in particular height, of the screw heads
used for securing the studs to the track. The insulating material
strips are positioned on the leg below the screws so that the
screws are covered by the cover layer of the insulating strip. The
screws can freely move between the track and cover layer. The slots
are sealed against cold gases and smoke. Hot gas and fire sealing
will be provided by the intumescent properties of the insulating
material.
[0059] In still another (third) aspect of the invention the
insulating strip includes a cover layer and four insulating
material strips.
[0060] The cover layer, which is an elongated layer, is designed as
a continuous strip defining two faces, an upper and a bottom face.
The width of the cover layer is selected depending on the size of
the header track or other construction product to which the
insulating strip shall be attached. The cover layer defines a
middle section which extends generally horizontally and which will
be positioned on the web of, for example, a header track and
defines side sections (hereinafter also referred to as first and
second side sections), so that the total width of the tape is
larger than the width of the web. While installing the insulating
strip the side sections shall cover both flanges of the header
track or other head-of-wall structure.
[0061] In a first embodiment the four insulating material strips
are arranged side-by-side on the same face of the cover layer. The
strips are elongated strips and extend along the web when the
insulating strip is positioned on the header track, i.e., in a
length direction. The insulating material strips are positioned at
a certain distance between each material strip to define separated
material strips and to define sections without any insulating
material therebetween.
[0062] Preferably one insulating material strip is positioned on
each of the side sections so that one insulating material strip is
positioned on the first side section and another insulating
material strip is positioned on the second side section of the
cover layer. The other two insulating material strips are
positioned in the middle section of the cover layer so that they
are positioned between the insulating material strip of the first
side section and the insulating material strip of the second side
section. After installing the insulating strip, the insulating
material strips are facing towards the header track or other
element of the drywall assembly. In this embodiment the cover layer
serves as a protective layer to protect the insulating strips
against abrasion as discussed further above.
[0063] The insulating strip will be mounted on the track such that
the insulating material strips on the first and second side
sections will face towards the leg of the track and will be
positioned in the lower part of the leg. With this the upper part
of the leg is free of any insulating material and will only be
covered by the cover layer. Preferably, the two insulating material
strips positioned on top of the web and facing towards the web will
be located near the edges of the web to have a maximum distance
between each other.
[0064] The insulating material strips will preferably include a
fire-resistant material and/or an acoustically insulating material.
The insulating material strips may be made from the same or
different material. A compressible or deformable material strip
portion is preferably positioned on the top of the header track or
other head-of-wall structure to provide enhanced smoke, air and
sound seal at the head-of-wall. A pressure-resistant material strip
portion is preferably positioned on a side flange of the header
track or side surface of the other head-of-wall structure so that
the pressure-resistant portion is positioned between the header
track, especially the leg, or other head-of-wall structure and the
wallboard. Preferably the two insulating material strips that are
to be positioned on the web of the track are arranged near the
edges of the track. For a fire-proof insulation it is sufficient
that the insulating material of the side portions are provided with
intumescent properties and that the portions of the insulating
material strip positioned on top of the track are provided with
sound insulating properties. To enhance the fire-proof properties
all insulating material strips are provided with intumescent
materials.
[0065] In a further embodiment the four insulating material strips
are arranged so that two of the insulating material strips are
arranged on one face of the cover layer and two of the insulating
material strips are arranged on the opposite face of the cover
layer. After installing the insulating strip two insulating
material strips are arranged on the bottom face and the other two
insulating material strips are arranged on the upper face of the
cover layer.
[0066] Preferably one insulating material strip is positioned on
each of the side sections so that one insulating material strip is
positioned on the first side section and another insulating
material strip is positioned on the second side section of the
cover layer. The other two insulating material strips are
positioned on the middle section of the cover layer so that they
are arranged between the insulating material strip of the first
side section and the insulating material strip of the second side
section. The insulating material strips are arranged at a certain
distance from each other. The two insulating material strips which
are positioned on the first and the second side sections are
arranged on the same face of the cover layer. The other two
insulating material strips which are positioned on the middle
section are arranged on an opposite face of the cover layer.
[0067] Similar to the embodiment described above, the insulating
strip will be mounted on the track such that the insulating
material strips on the first and second side sections will face
towards the leg of the track and will be positioned in the lower
part of the leg. With this the upper part of the leg is free of any
insulating material and will only be covered by the cover layer.
Preferably, the two insulating material strips positioned on top of
the web and facing towards the support structure will be located
near the edges of the web to have a maximum distance between each
other.
[0068] In alternative to the just described two embodiments, the
two insulating material strips positioned in the middle section of
the cover layer and located on top of the web can be replaced by a
single broad insulating material strip that covers the entire web.
With this the insulating strip includes a cover layer and three
insulating material strips. The singly broad insulating material
strip can either face the support structure or the web of the
track.
[0069] After having attached the insulating material strip of the
first embodiment (all insulating material strips positioned on the
same side of the cover layer) of the third aspect of the invention
to the track the cover layer will constitute the outer surface of
the material. The cover layer will be in contact with both the
support structure and the wallboard.
[0070] The overall width of the elongated insulating strip from one
outside edge of the insulating strip to the other outside edge
varies depending on the size of the header track or other
construction product on which the insulating strip shall be
installed. The width of the middle section depends on the width of
the web of the header track or other construction product. The
width of the side sections depend on the desired application, e.g.,
normal and slotted tracks, and/or the desired deflection
requirement of the insulating strip. The width of the side sections
again depends on the size of the legs or the type of the leg. In
any event, the insulating strips on the side sections and the
insulating strips on the middle section are only positioned on the
legs and on the web of the header track or other construction
product, respectively.
[0071] The insulating strip can be applied to a header track or
other construction product, such as a bottom track, metal stud,
metal flat strap or any other framing member that needs an open gap
between the wallboard and a perimeter structure, in particular for
movement (deflection or drift) but not restricted thereto. In other
words, the elongated insulating strip can be used for sealing any
open gap between the wallboard and the construction product or
between the construction product and a perimeter structure, like
the support structure, for example, a floor, side walls or ceiling.
The insulating strip allows the gap to stay open for movement and
provides fire and smoke protection and/or sound reduction.
[0072] In one arrangement two material strip portions may be
positioned on the top of the header track or other head-of-wall
structure facing away from the header track towards the ceiling or
wall to provide a smoke, air and sound seal at the head-of-wall.
The other two material strip portions may then be positioned on a
side flange of the header track or side face of the other
head-of-wall structure so that the other two material portion are
positioned between the header track or other head-of-wall structure
and the wallboard.
[0073] The insulating material strips will preferably include a
fire-resistant material and/or an acoustically insulating material.
The insulating material strips may be made from the same or
different material. A compressible or deformable material strip
portion is preferably positioned on the top of the header track or
other head-of-wall structure to provide enhanced smoke, air and
sound seal at the head-of-wall. A pressure-resistant material strip
portion is preferably positioned on a side flange of the header
track or side surface of the other head-of-wall structure so that
the pressure-resistant portion is positioned between the header
track, especially the leg, or other head-of-wall structure and the
wallboard. Preferably the two insulating material strips that are
to be positioned on the web of the track are arranged near the
edges of the track. Depending on the material used for the cover
layer, for a fire-proof insulation it is sufficient that the
insulating material of the side portions are provided with
fire-resistant properties, which do not include expansion of the
insulating material, especially for cover layers made of glass
fibers. These materials provide sufficient fire resistance so that
the insulating material need not necessarily be intumescent.
Improved fire-resistance can be achieved by the insulating material
being provided with intumescent properties and that the portions of
the insulating material strip positioned on top of the track are
provided with sound insulating properties. In case the insulating
material will expand when the temperature raises, the insulating
material cover layers need not be made of a fire-resistant
material. To enhance the fire-proof properties all insulating
material strips are provided with intumescent materials. To even
better enhance the fire-proof properties all insulating material
strips are provided with intumescent material and the cover layers
are made of a fire-resistant material.
[0074] For a better adhesion of the insulating material strips on
the track or support structure, an additional adhesion layer can be
used on the opposite surface of the insulating material strip which
is provided with the cover layer, i.e., on that surface which faces
the support structure or the track. This also helps to install the
insulating strip on site.
[0075] Since the gap or joint between the support structure and the
track in general is very small compared to the gap between the
wallboard and the support structure, the thickness of the
insulating material used may also be small, or alternatively, the
intumescence of the material when exposed to elevated temperatures
can be selected to be small. Reduced intumescence can be achieved
for example by using only a small amount of intumescent compounds
which makes the insulating material cheaper.
[0076] The insulating strip according to the various embodiments of
the third and fourth aspect of the invention can be used with solid
and with slotted tracks. If it is intended to use the insulating
strip with slotted tracks the thickness of the insulating material
strips located on the first and second side portions of the cover
layer and after its installation on the track will be positioned on
the legs of the track corresponds to the size, in particular
height, of the screw heads used for securing the studs to the
track. The insulating material strips are positioned on the leg
below the screws so that the screws are covered by the cover layer
of the insulating strip. The screws can freely move between the
track and cover layer. The slots are sealed against cold gases and
smoke. Hot gas and fire sealing will be provided by the intumescent
properties of the insulating material.
[0077] In a still another (fifth) aspect of the invention intended
for use with slotted tracks the insulating strip includes a cover
layer and an insulating material strip, whereas the insulating
material strip is adapted to cover screws with which the studs are
fixed to the track. After the insulating material is being brought
into its desired positioned near the track the cover layer will
constitute the outer surface of the material. The cover layer will
come into contact with the wallboard or similar construction
element. In this embodiment the insulating material strip will
neither hinder movement of the screws nor will the screws injure
the insulating material strip. For this, the insulating material
strip is provided with a recess to accommodate the screw head.
Accordingly, the insulating material strip has two portions with a
bigger thickness (also referred to as protruding portions). After
installation of the insulating material strip one of the protruding
portions will be positioned on the leg of the track below the slot
and the other portion will be positioned above the slot. The
thickness of the insulating material strip shall be selected such
that the protruding portions have a thickness which is bigger than
the height of the screw heads to ensure that the screws will be
covered--also on top--by the insulating material. It is preferred
that the height of the recess is slightly bigger than the height of
the screw heads to ensure that the insulating material will not be
injured when the screws will move. The protrusions and the recess
will form a channel, the channel covers the screws and the slot
when the insulating strip is mounted on the leg of the track.
[0078] The dimension of the insulating material strip shall be
selected such that--depending on the length of the slots--one
protruding portion can be positioned above the slot and the other
protruding portion will be positioned below the slot. Preferably
the protruding portion positioned above the slots will be designed
to contact the bottom of the support structure to which the track
will be fixed and to cover the gap or joint between the track and
the support structure, e.g., between the header track and the
overhead structure.
[0079] The cover layer not only covers the insulating material
strip but also includes a side portion that extends outwardly from
the insulating material strip and therefore has a greater dimension
than the insulating material. The dimension of the cover layer
shall be selected for sufficient adhesion to the element the
insulating strip shall be attached. But, for improved appearance
the insulating material strip, in particular the cover layer, shall
not extend beyond the joint, i.e., when mounted on the construction
element, e.g., a ceiling, and the cover layer shall not extend
beyond the wallboard member and thus shall not be visible after the
wallboard member is mounted. The insulating strip can be fixed
either to the track or to the support structure in any way as
described above for the other aspects of the invention.
[0080] As to the materials which can be used for the insulating
material strip and the cover layer reference is made to the above
descriptions.
[0081] The insulating strip of the fifth aspect may be designed as
a single strip to be positioned on one side of the track, whereby a
separate second insulating strip can be positioned on the other
side of the track. As to this, the insulating material strip
includes a cover layer and one insulating material strip.
Alternatively, the insulating strip of the fifth aspect may be
designed as a strip including one broad cover layer and two
insulating material strips analogous to the insulating strip of the
second aspect of the invention. Therefore, the description of the
second aspect also holds for the fifth aspect.
[0082] The above-described and other features, aspects and
advantages of the present invention are described below with
reference to drawings of preferred embodiments, which are intended
to illustrate, but not to limit, the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0083] FIG. 1 is a cross-sectional view of a portion of a stud wall
assembly with an insulating strip assembly installed at the
head-of-wall according to one embodiment of the first aspect of the
invention;
[0084] FIG. 2 is a cross-sectional view of a portion of a stud wall
assembly with an insulating strip assembly installed at the
head-of-wall according to another embodiment of the first aspect of
the invention;
[0085] FIG. 3 is a cross-sectional view of a portion of a stud wall
assembly with an insulating strip assembly installed at the
head-of-wall according to another embodiment of the first aspect of
the invention;
[0086] FIG. 4 is a cross-sectional view of a portion of a stud wall
assembly with an insulating strip assembly installed at the
head-of-wall according to another embodiment of the first aspect of
the invention;
[0087] FIG. 5 is a cross-sectional view of a portion of a stud wall
assembly with an insulating strip assembly installed at the
head-of-wall according to another embodiment of the first aspect of
the invention;
[0088] FIG. 6 is a cross-sectional view of a portion of a stud wall
assembly with an insulating strip assembly installed at the
head-of-wall according to one embodiment of the second aspect of
the invention;
[0089] FIG. 7 is a cross-sectional view of a portion of a stud wall
assembly with an insulating strip assembly installed at the
head-of-wall according to one embodiment of the third aspect of the
invention;
[0090] FIG. 8 is a cross-sectional view of a portion of a stud wall
assembly with an insulating strip assembly installed at the
head-of-wall according to another embodiment of the third aspect of
the invention;
[0091] FIG. 9 is a cross-sectional view of a portion of a stud wall
assembly with an insulating strip assembly installed at the
head-of-wall according to one embodiment of the fourth aspect of
the invention;
[0092] FIG. 10 is a cross-sectional view of a portion of a stud
wall assembly with an insulating strip assembly installed at the
head-of-wall according to another embodiment of the fourth aspect
of the invention;
[0093] FIG. 11 is a cross-sectional view of a portion of a stud
wall assembly having a slotted track with an insulating strip
assembly installed at the head-of-wall according to one embodiment
of the first aspect of the present invention; and
[0094] FIG. 12 is a cross-sectional view of a portion of a stud
wall assembly having a slotted track with an insulating strip
assembly installed at the head-of-wall according to an embodiment
of the fifth aspect of the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0095] FIGS. 1, 3 and 5 illustrate various possibilities to fix the
insulating strip 1 of the first aspect of the invention to the dry
wall assembly. The dry wall assembly includes a header track 7 with
a web 8, legs 9, wallboards 11 and studs (not shown). The header
track is a U-shaped channel that is attached to an upper horizontal
support structure 10 (also referred to as overhead structure 10).
Wall studs (not shown) are received in the header track 7 and may
be configured for vertical movement relative to the header track 7.
A wallboard 11 is attached to the studs such as by a plurality of
suitable fasteners.
[0096] The insulating strip 1, in particular an elongated strip,
according to the first aspect of the invention includes an
insulating material strip and a cover layer which extends on one
side beyond the insulating material strip. The insulating material
strip is positioned on the cover layer so that one long edge of the
elongated material strip aligns with one long edge of the elongated
cover layer.
[0097] As shown in FIG. 1 an insulating strip 1 including an
insulating material strip and a cover layer is affixed on the
support structure, e.g., overhead structure, with the portion of
the cover layer extending beyond the insulating material strip. The
insulating material strip is positioned lengthwise in abutment with
at least one, preferably both legs 9 of the header track 7, and
preferably comes in contact therewith. The cover layer supports
movement of the wallboard 11 and protects the insulating material
strip against abrasion due to the movement of the wallboard 11. The
insulating material strip can be additionally attached to the leg 9
either by an adhesive (not shown) or by using a self-adhesive
material as insulating material. Thus, the insulating strip will
stay in place and will not follow the movement of the wallboard
11.
[0098] The insulating strip may additionally include a further
insulating material strip to enhance sound and acoustic insulation
as best shown in FIG. 2. With reference to FIG. 2, the further
insulating material strip 3, which preferably is a sound insulating
material, is located side-by-side to the insulating material strip
2, which preferably is an intumescent material. It is preferred
that both material strips 2 and 3 are made of an abrasive-resistant
material. The further insulating material strip is positioned on
the upper portion of the leg 9 and is located near the support
structure 10.
[0099] As shown in FIGS. 3 and 5 an insulating strip 1 including an
insulating material strip and a cover layer is affixed on the track
7, whereas in FIG. 3 the strip 1 is affixed on the leg 9 and in
FIG. 5 the strip 1 is affixed on the web 8. In the embodiments
shown, the insulating strip 1 differs from the one shown in FIG. 1
in that a portion of the cover layer is attached to the leg (FIG.
3) or web (FIG. 5) near the corner between the web 8 and the leg 9
by use of an adhesive (not shown).
[0100] FIG. 4 illustrates another embodiment of the insulating
strip 1 according to the first aspect, showing the strip directed
towards the support structure, e.g., overhead structure, in the
event of fire. As shown, the insulating material strip 1 includes a
cover layer with two side portions, whereas one side portion of the
cover layer is wrapped around the corner of the insulating material
strip, which preferably includes an intumescent material. As a
result thereof, when the intumescent material expands due to
elevated temperatures, the expansion will be directed towards the
support structure, since the second side portion of the cover layer
provides a barrier of the expanding material.
[0101] FIG. 6 illustrates an insulating strip 1 having two
insulating material strips and a cover layer connecting and
covering both insulating material strips applied to a head-of-wall
structure, in particular to a header track 7, according to one
embodiment of the third aspect of the invention. The insulating
strip 1 is attached to the header track 7 so that the insulating
material strips are positioned between the legs 9 and the wallboard
11. Each insulating material strip is positioned in the lower part
of the leg 9 near its end. The cover layer extends from one edge of
the first insulating material strip to the other insulating
material strip thereby covering each insulating material strip and
the web. In this embodiment the insulating material strip can
either be installed at the construction site or on the job side
before mounting the track to the support structure.
[0102] FIGS. 7 and 8 illustrate the insulating strip 1 of the third
aspect of the invention applied to a head-of-wall structure, in
particular to a header track 7. The insulating strip 1 includes two
first insulating material strip portions 20 and two second
insulating material strip portions 30. The insulating strip 1 is
attached to the header track 7 so that a portion, i.e., the middle
section with the second material strip portions 30, is positioned
between the header track 7 and the overhead structure 10 and
another portion, i.e., the side sections with the first material
strip portions 20, is positioned between the legs 9 and the
wallboard 11. With reference to FIG. 7, preferably the insulating
material strip portions 20 are positioned between the legs 9 of the
header track 7 and the wallboard 11 and the insulating material
strip portions 30 are positioned between the web 8 and the overhead
structure 10. In the shown arrangement, the cover layer in the side
sections constitutes the face of the insulating strip 1 that faces
towards the wallboards 11 and comes in direct contact with the
wallboards 11. And in the middle section constitutes the face of
the insulating strip 1 that faces towards the overhead structure
10, i.e., the insulating material strip portions 30 are positioned
between the cover layer and the web 8.
[0103] The insulating material strip portions 20 are fixed on the
legs 9 of the header track 7 either by their inherent adhesion or
by an optional adhesive layer on its surface (not shown), the
surface facing towards the leg of the header track 7. Preferably,
the transition between the side sections and the middle section of
the insulating strip 1 is aligned with the corner between the web 8
and the legs 9 of the header track 7 (also referred to as edge of
the header track). The insulating material strip portions 30 are
secured on the header track 7 by their inherent adhesion or by an
optional adhesive layer. Either of the two insulating material
strip portions 20 or 30 can be self-adhesive or provided with an
adhesive layer (not shown) on both insulating material strip
portions. In one embodiment only the two insulating material strip
portions 30 are self-adhesive or are provided with an adhesive
layer (not shown). It is preferred that the two insulating material
strip portions 20 are made of a pressure-resistant and
abrasive-resistant material, which more preferably also has
intumescent properties, and the two insulating material strip
portions 30 are made of a compressible material which, however,
does not has intumescent properties or is only slightly
intumescent.
[0104] Alternatively, the two intumescent material strip portions
30 may be positioned such that they directly contact the overhead
structure 10, i.e., are positioned between the cover layer and the
overhead structure 10 as best shown in FIG. 8.
[0105] FIGS. 9 and 10 illustrate the insulating strip 1 of the
fourth aspect of the invention applied to a head-of-wall structure,
in particular to a header track 7. The insulating strip 1 includes
two first insulating material strip portions 20 and one second
insulating material strip portion 30. The insulating strip 1 is
attached to the header track 7 so that a portion, i.e., the middle
section with the second material strip portion 30, is positioned
between the header track 7 and the overhead structure 10 and
another portion, i.e., the side sections with the first material
strip portions 20, is positioned between the legs 9 and the
wallboard 11. With reference to FIG. 9, preferably the insulating
material strip portions 20 are positioned between the legs 9 of the
header track 7 and the wallboard 11 and the insulating material
strip portion 30 is positioned between the web 8 and the overhead
structure 10. In the shown arrangement, the cover layer in the side
sections constitutes the face of the insulating strip 1 that faces
towards the wallboards 11 and comes in direct contact with the
wallboards 11. And in the middle section constitutes the face of
the insulating strip 1 that faces towards the overhead structure
10, i.e., the insulating material strip portion 30 is positioned
between the cover layer and the web 8.
[0106] In alternative to the insulating material strip portion 30
positioned between the web 8 and the cover layer as shown in FIG.
9, the insulating material strip portion 30 is positioned between
the cover layer and the overhead structure as best shown in FIG.
10.
[0107] FIG. 11 illustrates the insulating strip 1 of the first
aspect of the invention applied to a dry wall assembly with slotted
tracks. The thickness of the insulating material strip corresponds
to the size, in particular height, of the screw heads used for
securing the studs to the track. The insulating material strip is
positioned on the leg below the screws so that the screws are
covered by the cover layer of the insulating strip. The screws can
freely move between the track and cover layer. The slots are sealed
against cold gases and smoke by the cover layer.
[0108] This arrangement also holds for all embodiments or the other
aspects of the invention, when these are applied to slotted
tracks.
[0109] FIG. 12 illustrates the insulating strip 1 of the fifth
aspect of the invention applied to a dry wall assembly with slotted
tracks, whereas the insulating strip includes a cover layer and an
insulating material strip. The insulating material strip has two
protruding portions, one of which is positioned below the screws
and the slots and the other portion is positioned above the screws
and the slots. The recess portion covers the screw heads and
enables movement of the screws within the slots without injuring
the insulating material strip. The thickness of the insulating
material strip corresponds to the size, in particular height, of
the screw heads used for securing the studs to the track or is
slightly bigger. The slots are sealed against cold gases and smoke
by the cover layer. The width of the intumescent material strip
corresponds to the width of the leg 9. With this, the insulating
material strip will connect the overhead structure 10 and covers
the gap/joint between the overhead structure 10 and the header
track 7.
[0110] While particular embodiments of this invention have been
shown in the drawings and described above, it will be apparent that
many changes may be made in the form, arrangement and positioning
of the various elements of the combination. In consideration
thereof, it should be understood that preferred embodiments of this
invention disclosed herein are intended to be illustrative only and
not intended to limit the scope of the invention.
[0111] The foregoing disclosure has been set forth merely to
illustrate the invention and is not intended to be limiting. Since
modifications of the disclosed embodiments incorporating the spirit
and substance of the invention may occur to persons skilled in the
art, the invention should be constructed to include everything
within the scope of the appended claims and equivalents
thereof.
* * * * *