U.S. patent application number 14/673093 was filed with the patent office on 2015-10-01 for intumescent 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 | 20150275510 14/673093 |
Document ID | / |
Family ID | 54189556 |
Filed Date | 2015-10-01 |
United States Patent
Application |
20150275510 |
Kind Code |
A1 |
KLEIN; Manfred ; et
al. |
October 1, 2015 |
INTUMESCENT 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 horizontal main track
section and track side sections that extend vertically from the
main track section, is disclosed. The sealing element includes an
insulating material strip which at least partially contains an
intumescent material. The insulating material strip abuts the
horizontal main track section of the track and is disposed between
the track and the support structure.
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: |
54189556 |
Appl. No.: |
14/673093 |
Filed: |
March 30, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61972969 |
Mar 31, 2014 |
|
|
|
Current U.S.
Class: |
52/232 ;
52/741.4 |
Current CPC
Class: |
E04B 2/7457 20130101;
E04B 2/7411 20130101; E04B 1/948 20130101 |
International
Class: |
E04B 1/94 20060101
E04B001/94; E04B 1/68 20060101 E04B001/68 |
Claims
1. A sealing element for sealing a gap between a support structure
and a track, wherein the track includes a horizontal main track
section and track side sections that extend vertically from the
main track section, comprising: an insulating material strip which
at least partially contains an intumescent material; wherein the
insulating material strip abuts the horizontal main track section
of the track and is disposed between the track and the support
structure.
2. The sealing element according to claim 1, further comprising an
adhesive layer disposed on the insulating material strip.
3. The sealing element according to claim 1, wherein a width of the
insulating material strip corresponds to a width of the track.
4. The sealing element according to claim 1, wherein a width of the
insulating material strip is broader than a width of the track.
5. The sealing element according to claim 1, wherein the insulating
material strip at least partially contains a compressible
material.
6. The sealing element according to claim 1, wherein the insulating
material strip at least partially contains an acoustically
insulating material.
7. The sealing element according to claim 1, further comprising a
sealing layer disposed between the insulating material strip and
the horizontal main track section of the track.
8. The sealing element according to claim 7, wherein the sealing
layer is an acoustically insulating material and/or a material that
seals against cold gases and smoke.
9. The sealing element according to claim 1, further comprising a
sealing layer disposed between the insulating material strip and
the support structure.
10. The sealing element according to claim 9, wherein the sealing
layer is an acoustically insulating material and/or a material that
seals against cold gases and smoke.
11. The sealing element according to claim 1, further comprising: a
sealing layer disposed between the insulating material strip and
the support structure; and a support layer disposed between the
insulating material strip and the horizontal main track section of
the track.
12. The sealing element according to claim 11, wherein the sealing
layer is a first strip and a second strip and wherein the first
strip and the second strip are disposed at respective ends of the
insulating material strip.
13. The sealing element according to claim 12, wherein a total
width of the first strip and the second strip is smaller than a
width of the track.
14. A method for attaching a sealing element to a support structure
for sealing a gap between the support structure and a track,
wherein the track includes a horizontal main track section and
track side sections that extend vertically from the main track
section, comprising the steps of: positioning the sealing element
on the track; and after positioning the sealing element on the
track, fixing the track and the sealing element to the support
structure by penetrating a fastener through the track and the
sealing element and into the support structure.
15. The method according to claim 14, wherein the sealing element
is an insulating material strip which at least partially contains
an intumescent material.
16. The method according to claim 14, wherein a width of the
sealing element strip corresponds to a width of the track.
17. The sealing element according to claim 14, wherein a width of
the sealing element is broader than a width of the track.
18. The method according to claim 14, wherein a sealing layer is
disposed on a side of the sealing element.
19. The method according to claim 18, wherein the sealing layer is
an acoustically insulating material and/or a material that seals
against cold gases and smoke.
20. The method according to claim 18, wherein a support layer is
disposed of a second side of the sealing element.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/972,969, 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
firestopping and acoustical insulation, in particular firestopping
for head-of-wall joints, including, 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 an
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 stud 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 intumescent 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 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 in
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 A1 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.
9, 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 A1 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
"DEFLECTION 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 MEANS 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 Dec. 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] In general, the present invention is directed 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.
[0023] The present invention is directed to an intumescent sealing
element for sealing a head-of-wall area between an overhead
structure, e.g., a ceiling, thereabove and a wall assembly
therebelow which includes a track, e.g., header track, having a
generally oriented main track with a first track side section
extending downwardly therefrom and a second side track section
extend downwardly therefrom at a position spatially disposed from
the first track section where the main track, the first track side
section defining a first lowermost edge thereof and the second side
track section defining a second lowermost edge thereof, the first
track section and the second track section defining therebetween a
frame receiving area which is C-shaped and oriented facing
downwardly therefrom to be adapted to receive the wall assembly
mounted therewithin, the intumescent sealing element including: an
insulating material strip which is at least partially made of
intumescent material and a support layer; which intumescent sealing
element extends generally horizontally and is positioned in direct
abutment with respect to the main track of the ceiling track and
extending thereabove.
[0024] According to a first embodiment of present invention the
intumescent sealing element includes an elongated intumescent
material strip and optionally an adhesive strip. The intumescent
material strip is intended for sealing against hot gases and fire
and additionally for sealing against sound. Therefore, the
intumescent material strip includes a material which is able to
expand when the temperature rises and which at the same time
provides sealing against sound transmission.
[0025] One effect of the present invention is comprehensive sealing
against undesirable influences, e.g., smoke, cold and hot gases,
fire, and sound, which can be obtained by a simple element which is
easy to install.
[0026] The intumescent material strip includes 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.
When the temperature rises the intumescent material will expand
quickly and block air pathways. In this manner, the entire gap or
joint between a construction element and the top of a 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.
[0027] In this embodiment it is preferred that the intumescent
material strip is constructed partially or entirely from a
compressible material such as plasticines, for example putty, or
foam-like or felt-like material to better adapt to an uneven
contour of the horizontal support structure and provide good sound,
acoustic and smoke sealing. 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
include 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. The intumescent
material strip may also be constructed partially or entirely from a
felt like material which by itself does not expand when the
temperature rises. In this case an additional intumescent material
is integrated in the felt like material. The felt-like material may
consist of any material that provides sound insulation known to the
person skilled in the art. If the expansion by the material itself
is too small when the temperature raises compounds which provide
sufficient expansion, such as intumescent materials, may be
incorporated in the compressible material.
[0028] To fix the intumescent sealing element of the present
invention on the drywall assembly, i.e., in particular a track, the
intumescent material strip may either be self-adhesive or is
provided with an adhesive strip/layer.
[0029] A removable protective layer may cover the underneath
surface of the self-adhesive intumescent material strip or the
adhesive strip/layer until the insulating strip is ready to be
applied.
[0030] In case the intumescent material strip only has intumescent
properties and has no sealing properties against sound transmission
and transmission against cold gases and smoke, an additional
sealing element is necessary to provide sealing properties against
sound and acoustic transfer as well as sealing against cold gases
and smoke.
[0031] Therefore, according to another, second embodiment of the
invention, the intumescent sealing element includes an intumescent
material strip, optionally an adhesive layer, and an additional
sealing element.
[0032] The sealing element shall provide sound or acoustic sealing
and sealing against cold gases and smoke until the temperature
reaches the on-set temperature of the intumescent material strip,
i.e., until the intumescent material expands and seals any joint or
gap. Therefore, the sealing element is allowed to burn away because
the intumescent material after its expansion closes any gap and
provides sufficient sealing.
[0033] The sealing element may be any material that provides sound
or acoustic sealing and/or sealing against cold gases and smoke.
This material may include a firestopping material or a material
which burns away in the event of fire. Preferably, the sealing
element includes a compressible material, for example putty,
foamed, foam-like, felt, or felt-like material to better adapt to
an uneven contour of the horizontal support structure.
[0034] To provide sufficient (mechanical) support for the
intumescent material strip or the separate sealing element of the
insulating material strip the intumescent sealing element may also
include an additional support layer.
[0035] Therefore, in still another, third embodiment of the present
invention the intumescent sealing element includes an intumescent
material strip, optionally an adhesive layer, a sealing element,
and a support layer.
[0036] The support layer may be formed of a fabric (woven or
non-woven) of fibers, like glass fibers or any other suitable
material.
[0037] In any of the afore-mentioned embodiments the intumescent
sealing element will be positioned between a building structure of
a wall, floor or roof and a wall assembly therebelow which shall be
fire-rated and has a need for acoustical insulation. Such wall
assemblies usually include steel framing members or studs with
gypsum board or sheetrock mounted thereupon and extending
vertically therewith. As exemplified by the drawings the
intumescent sealing element is usually positioned between an
overhead structure, i.e., a ceiling, and the header track of the
wall assembly. In more detail, the intumescent sealing element will
be positioned on top of the header track and will be attached to
the web of the track.
[0038] The elongated intumescent sealing element extends along the
length of the track. Its width corresponds to the width of the web
so that the intumescent sealing element exactly covers the web and
does not extend beyond the web. In an alternative embodiment,
however, the elongated intumescent sealing element may extend
beyond the side edges of the web to intrude into the deflection gap
between the wallboard and the overhead structure so that the
intumescent sealing element is visible from the outside to
improve/facilitate inspection.
[0039] In case the intumescent sealing element includes an
additional adhesive layer, the adhesive layer will preferably be
attached to the web of the track. It, however, will also be
possible that the adhesive layer will face towards the overhead
structure.
[0040] According to the second embodiment the intumescent sealing
element includes an intumescent material strip, optionally an
adhesive layer, and a sealing element. In case the intumescent
material strip is self-adhesive, the intumescent sealing element
can be attached to the header track either by the intumescent
material strip facing towards the web of the track and the sealing
element facing towards the overhead structure or vice versa. In
case the intumescent sealing element includes an additional
adhesive layer, the additional adhesive layer can be positioned on
one surface of the intumescent material strip whereas the sealing
element is positioned on the other (opposed) surface of the
intumescent material strip. In an alternative, the adhesive layer
can be attached to one surface of the sealing element, whereas the
insulating material strip is attached to the opposing surface of
the sealing element.
[0041] The sealing element can either be a layer which covers any
of the other layers of the intumescent sealing element to which the
sealing element is attached to (herein also referred to as sealing
layer) or can be formed of one or more single elongated strip(s)
(herein also referred to as sealing strip(s)). The overall width of
the sealing strips is smaller than the width of the cover layers
(elements) of the intumescent sealing element. From a viewpoint of
sound and acoustic sealing as well as sealing against smoke and
cold gases small, i.e., narrow, sealing strips are sufficient. In
most cases only one narrow sealing strip is sufficient. The
position of the sealing strip(s) has no influence on the sealing
properties and can freely be selected. It is preferable to use two
sealing elements each of which are positioned near the side edge of
the other layers of the intumescent sealing element so that after
having installed the intumescent sealing element on the track, the
sealing strips are positioned in abutment with the gap between the
wallboard and the overhead structure. From a viewpoint of
construction it is preferred that the additional sealing element is
designed as a layer.
[0042] According to the third embodiment the intumescent sealing
element includes an intumescent material strip, optionally an
adhesive layer, a sealing element, and a support layer.
[0043] In this arrangement, the intumescent sealing element is
positioned between the overhead structure and the header track such
that either the intumescent material strip or the support layer or
the additional sealing layer faces towards the overhead structure
depending on the materials used for each layer. Preferably, the
layer including a compressible material faces towards the overhead
structure to better adapt to an uneven contour of the overhead
structure.
[0044] Since the joint or gap between the overhead structure and
the header track is very small, the thickness of the intumescent
sealing element must not be very big and/or the expansion rate of
the intumescent material must not be very high. The expansion rate
of the intumescent material strip can be adjusted by the amount of
the intumescent additives added.
[0045] 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
[0046] FIG. 1 is a cross-sectional view of a portion of a stud wall
assembly with an intumescent sealing element installed at the
head-of-wall according to a first embodiment of the invention;
[0047] FIG. 2 is a cross-sectional view of a portion of a stud wall
assembly with an intumescent sealing element installed at the
head-of-wall according to the first embodiment of the
invention;
[0048] FIG. 3 is a cross-sectional view of a portion of a stud wall
assembly with an intumescent sealing element installed at the
head-of-wall according to a second embodiment of the invention;
[0049] FIG. 4 is a cross-sectional view of a portion of a stud wall
assembly with an intumescent sealing element installed at the
head-of-wall according to the second embodiment of the
invention;
[0050] FIG. 5 is a cross-sectional view of a portion of a stud wall
assembly with an intumescent sealing element installed at the
head-of-wall according to a third embodiment of the invention;
and
[0051] FIG. 6 is a cross-sectional view of a portion of a stud wall
assembly with an intumescent sealing element installed at the
head-of-wall according to the third embodiment of the
invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0052] The intumescent sealing element will be positioned between a
building structure of a wall, floor or roof and a wall assembly
therebelow which shall be fire-rated and has a need for acoustical
insulation. Such wall assemblies usually include steel framing
members or studs with gypsum board or sheetrock mounted thereupon
and extending vertically therewith.
[0053] A header track 10 is secured to the bottom area of the
overhead structure 1, e.g., floor or roof, conventionally such that
it is adapted to receive the framing members (not shown) positioned
therewithin for maintaining attachment therebetween. The header
track 10 preferably includes a main track section 11, i.e., the web
11, which normally extends approximately horizontally and track
side sections 12, i.e., the legs 12, extending approximately
vertically downwardly therefrom. In this manner a framing receiving
area is defined between the first leg and the second leg into which
the upper portion of the steel framing studs extend.
[0054] The intumescent sealing element 20 of the present invention
will preferably be formed as a flat endless-type product and will
include at least one layer which provides the intumescent
firestopping and acoustic insulation to minimize sound
transmissions therethrough. For example, as shown for the
intumescent sealing element 20 as shown in FIG. 1, the element 20
includes the intumescent material strip 21 and optionally an
adhesive layer (not shown), with the adhesive layer either facing
the web 11 of the header track 10 or the bottom of the overhead
structure 1. The width of the intumescent sealing element 20
corresponds to the width of the header track 10, in particular of
the web 11 thereof. No portion of the intumescent sealing element
20 will extend beyond the edges of the web 11.
[0055] With reference to FIG. 2, the intumescent sealing element 20
may also have a width that is broader than the width of the header
track 10 to extend beyond the edges of the web 11. In this
arrangement, the intumescent sealing element 20 intrudes into the
deflection gap between the wallboard 13 and the overhead structure
1 so that the intumescent sealing element is visible from the
outside to improve/facilitate inspection.
[0056] The intumescent sealing element 20 shown in FIG. 3 includes
the intumescent material strip 21 facing towards the bottom of the
overhead structure 1, and the sealing layer 22 facing towards the
web 11 of the header track 10. The intumescent sealing element 20
can include an adhesive layer (not shown), with which the
intumescent sealing element 20 can be fixed either to the top
surface of the web 11 or the bottom surface of the overhead
structure 1. If there is an adhesive layer, the layer can on the
one hand be positioned underneath the sealing layer 22 to affix the
intumescent sealing element 20 on the header track 10. On the other
hand, the adhesive layer can be positioned on top of the
intumescent material strip 21 to affix the intumescent sealing
element 20 on the bottom of the overhead structure 1. It is
preferable to provide the header track 11 with the intumescent
sealing element 20 before the track 10 is mounted on the overhead
structure 1.
[0057] An alternative structure of the intumescent sealing element
20 shown in FIG. 3 is best shown in FIG. 4. In this structure the
intumescent material strip 21 faces the web 11 of the header track
10 and the sealing layer 22 faces the overhead structure 1. If the
intumescent material strip 21 includes a self-adhesive material
like putty, an adhesive layer (not shown) can be omitted. The
embodiment shown (FIG. 4) is preferred, in particular when the
intumescent material strip includes a more or less incompressible
material to better adapt to an uneven contour of the horizontal
support structure.
[0058] The intumescent sealing element 20 can include an adhesive
layer (not shown), with which the intumescent sealing element 20
can be fixed either to the top surface of the web 11 or the bottom
surface of the overhead structure 1. If there is an adhesive layer,
the layer can on the one hand be positioned underneath the
intumescent material strip 21 to affix the intumescent sealing
element 20 on the header track 10. On the other hand, the adhesive
layer can be positioned on top of the sealing layer 22 to affix the
intumescent sealing element 20 on the bottom of the overhead
structure 1. It is preferable to provide the header track 11 with
the intumescent sealing element 20 before the track 10 is mounted
on the overhead structure 1.
[0059] The intumescent sealing element 20 shown in FIG. 5 includes
the intumescent material strip 21, the support layer 23 facing the
web 11 of the header track 10, and a sealing layer 22 facing the
bottom of the overhead structure 1. As such, the intumescent
material strip 21 is positioned between the sealing layer 22 and
the support layer 23. Again, the intumescent sealing element 20 can
include an adhesive layer (not shown), with which the intumescent
sealing element 20 can be fixed either to the top surface of the
web 11 or the bottom surface of the overhead structure 1. If there
is an adhesive layer, the layer can on the one hand be positioned
underneath the support layer 23 to affix the intumescent sealing
element 20 on the header track 10. On the other hand, the adhesive
layer can be positioned on top of the sealing layer 22 to affix the
intumescent sealing element 20 on the bottom of the overhead
structure 1.
[0060] The sealing element 22 is designed as a single layer 22
extending over the intumescent material strip 21, to cover it
completely.
[0061] The structure of the intumescent sealing element 20 shown in
FIG. 6 is similar to the one shown in FIG. 5; it includes the
support layer 23, the intumescent material strip 21 and the sealing
element 22, whereas the intumescent material strip 21 is positioned
between the support layer 23 and the sealing element 22. The
intumescent sealing element 20, however, differs from the one shown
in FIG. 5 in that the sealing element 22 is configured as two small
strips which are positioned at both end sections of the intumescent
sealing element 20 (FIG. 6). The total width of the additional
sealing elements 22 is smaller than the width of the header track
10, i.e., the web 11. Although small sealing elements 22 will be
sufficient to seal the joint between the overhead structure 1 and
the header track 10 against sound, smoke and cold gas transfer, a
sealing element designed as a layer is preferable from the
viewpoint of production.
[0062] In most prior art constructions the header tracks 10 are
attached directly to the bottom of the overhead structure 1 by the
use of fasteners such as staples, nails, screws or other
penetrating fastening members usually made of steel. It is an
important consideration of the present invention to appreciate that
when an intumescent sealing element 20 is positioned in surrounding
relationship with respect to a header track 10 prior to affixing of
the track 10 to the bottom of the overhead structure 1, then
attachment to the overhead structure 1 thereof is performed by
placement of such penetrating fasteners in engagement with and
extending through the intumescent sealing element 20 simultaneously
with placing thereof through the web 11 which allows attachment to
be made without requiring any additional labor expense of time
and/or effort. That is, normally such fasteners penetrate through
the web 11 of a header 10 for securement of the header track 10 to
the bottom of the overhead structure 1. The conventional labor
process for making this attachment will, thusly, also attach the
intumescent sealing element 20 in proper position without requiring
any additional labor effort. This is a very important aspect of the
present invention because it minimizes costs by not increasing the
labor time for installation when installing the insulating gasket
of the present invention.
[0063] 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.
[0064] 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.
* * * * *