U.S. patent application number 14/803580 was filed with the patent office on 2016-01-21 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 | 20160017599 14/803580 |
Document ID | / |
Family ID | 55074123 |
Filed Date | 2016-01-21 |
United States Patent
Application |
20160017599 |
Kind Code |
A1 |
KLEIN; Manfred ; et
al. |
January 21, 2016 |
Insulating Sealing Element for Head-of-Wall Joints
Abstract
A sealing element for sealing a gap or joint between a support
structure and a track is disclosed. The track includes a web and
legs that extend vertically from the web. The sealing element
includes a cover layer where the cover layer has a first portion
that is adhesively attached to the support structure and a second
portion that is adhesively attached to a leg of the track. The
cover layer has a flexing point where the flexing point is disposed
near a gap or joint between the support structure and the leg of
the track.
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: |
55074123 |
Appl. No.: |
14/803580 |
Filed: |
July 20, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62026993 |
Jul 21, 2014 |
|
|
|
Current U.S.
Class: |
52/232 ;
52/717.03 |
Current CPC
Class: |
E04B 2/7457 20130101;
E04B 1/948 20130101; E04B 2/7411 20130101 |
International
Class: |
E04B 1/94 20060101
E04B001/94 |
Claims
1. A sealing element for sealing a gap or joint between a support
structure and a track, wherein the track includes a web and legs
that extend vertically from the web, comprising: a cover layer;
wherein the cover layer has a first portion that is adhesively
attached to the support structure; wherein the cover layer has a
second portion that is adhesively attached to a leg of the track;
wherein the cover layer has a flexing point; and wherein the
flexing point is disposed near a gap or joint between the support
structure and the leg of the track.
2. The sealing element according to claim 1, wherein the flexing
point is formed by a first folded side edge and a second folded
side edge of the cover layer.
3. The sealing element according to claim 2, wherein the first
folded side edge and the second folded side edge are
symmetrical.
4. The sealing element according to claim 2, wherein the first
folded side edge and the second folded side edge are
asymmetrical.
5. The sealing element according to claim 4, wherein the first
folded side edge is smaller than the second folded side edge and
wherein the first folded side edge is attached to the support
structure and the second folded side edge is attached to the leg of
the track.
6. The sealing element according to claim 1, wherein the flexing
point is formed by a single folded side edge of the cover
layer.
7. The sealing element according to claim 1, wherein the leg of the
track has a slot, wherein the second portion of the cover layer
extends along an entire length of the leg of the track, and wherein
the second portion of the cover layer includes an insulating
element.
8. The sealing element according to claim 7, wherein the second
portion of the cover layer envelops the insulating element.
9. The sealing element according to claim 7, wherein the insulating
element is an intumescent material.
10. The sealing element according to claim 7, wherein the
insulating element is an acoustical insulating material.
11. The sealing element according to claim 7, wherein the
insulating element is a pressure-resistant material.
12. The sealing element according to claim 7, wherein the
insulating element is disposed only on an end of the leg of the
track, wherein the end of the leg of the track is opposite from an
end of the leg of the track that is disposed adjacent to the
support structure.
13. The sealing element according to claim 1, wherein the cover
layer includes a first insulating element and a second insulating
element, wherein the first insulating element is disposed on the
leg of the track, and wherein the second insulating element is
disposed on a second leg of the track.
14. The sealing element according to claim 13, wherein the leg of
the track has a first slot, wherein the second leg of the track has
a second slot, and wherein the cover layer extends along an entire
length of the track.
15. The sealing element according to claim 14, further comprising
an insulating layer attached to the cover layer.
16. The sealing element according to claim 14, further comprising
an intumescent layer attached to the cover layer.
17. The sealing element according to claim 13, wherein the first
insulating element is disposed only on an end of the leg of the
track, wherein the second insulating element is disposed only on an
end of the second leg of the track, wherein the ends of the leg and
second leg of the track are opposite from respective ends of the
leg and second leg of the track that are disposed adjacent to the
support structure.
18. The sealing element according to claim 13, wherein the cover
layer envelops the first insulating element and the second
insulating element.
Description
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/026,993, filed Jul. 21, 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 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-tensioned 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 through 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 studs 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 with 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. The
materials have the drawback that they are expensive.
[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 strip 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 strip for sealing
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 strip for sealing
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 strip for sealing
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 strip for sealing
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 strip for sealing
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 strip for sealing
head-of-wall joints of the present invention to minimize costs and
maintenance requirements.
[0019] It is an object of the sealing strip for sealing
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
"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 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] Preferred embodiments of the present invention provide an
adhesive sealing strip (herein also referred to as sealing 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 sealing 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
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 (firestopping) sealing means for use with dry wallboard, i.e.,
gypsum wallboard, in a head-of-wall or similar construction
comprising a cover material strip (herein also referred to as cover
layer), in particular an elongated cover material strip, an
adhesive layer, and optionally an insulating material layer (herein
also referred to as insulating layer) or spacer. The sealing strip
being positioned on at least one portion of the leg of the track,
the upper portion of the track, which is in abutment with the
construction element to which the track is fixed, and on the
construction element to cover the gap or joint between the track
and the construction element, whereas the insulating material strip
only in some embodiments will be affixed on the construction
element.
[0024] The sealing strip of the present invention can be applied to
any joint or gap between construction elements of any kind, e.g.,
wall to wall joints, wall to floor joints, wall to ceiling joints,
joints between construction elements such as floor, wall, or
ceiling, which are also referred to as support structure, and
construction elements other than the support structures such as dry
wall assemblies, in particular to the tracks, i.e., bottom and
header track. For a better understanding, the invention will be
described in view of the joint between an element of a dry wall
assembly, e.g., the track, in particular header track, and a
support structure, e.g., the ceiling, to which the track is fixed.
This however shall not be understood to limit the scope of the
invention.
[0025] After the sealing strip is being brought into its desired
positioned near the track, i.e., the sealing strip is fixed to the
construction element, e.g., the wall or ceiling, and the dry wall
assembly, e.g., the header or floor track by the adhesion layer,
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.
[0026] The sealing strip comprises a cover material strip and an
adhesive layer that covers the cover material strip at least
partially to secure the sealing strip to the ceiling (overhead
structure) and the header track. The sealing strip is installed
lengthwise along the joint and will preferably be fixed on the
ceiling and on the track between which the joint forms. In some
cases it is also possible to fix the sealing strip on only one of
the construction elements.
[0027] In a preferred embodiment the sealing strip is an elongated
strip to be positioned lengthwise at the leg of the header track.
The width of the elongated strip depends on the height of the legs
and is selected such that the sealing strip covers the area of the
ceiling next to the track and only part of the leg, in particular
the upper part of the leg. Preferably, the sealing strip is
designed as an endless strip having two opposing lateral edges
(side edges) and two opposing end edges, i.e., the back edge and
the front edge, whereas the side edges are arranged parallel with
the gap or joint to which the sealing strip will be applied.
[0028] The cover material layer provides a firestop means to
sufficiently seal the joint between the header track and the
ceiling, against fire to prevent the penetration of fire and in
some embodiments also of smoke for a given period of time.
[0029] Therefore, the cover layer is made of non-combustible, i.e.,
fire resistant, material. The cover layer can be made of a fabric,
which fabric comprises inorganic fibers such as fibers made of
glass, stone, ceramic and/or metal or any other suitable material,
in particular glass fibers. Alternatively, the cover layer can be
an inorganic film material, like metal films or any other suitable
film material, in particular metal films, e.g., aluminum foil
having a thickness of about 20 to 50 microns (20-50 .mu.m). It is
also possible that the cover layer comprises a combination of
inorganic fibers and an inorganic film material, e.g., a layer made
of inorganic fibers such as glass fibers, and a further layer (coat
layer) made of an inorganic film material such as an aluminum
foil.
[0030] To enhance the inherent (dimensional) stability and to
increase the mechanical strength of the cover layer, in particular
when the fabric consists essentially of glass, stone or ceramic
fibers, the fabric may contain weft thin metal wires. Preferably,
the metal wires are woven into the fabric in a direction
perpendicular to the length of the strip to provide superior
dimensional stability.
[0031] The cover layer preferably is abrasive-resistant to resist
abrasion caused by the gypsum wall member of the dry wall assembly
rubbing against the sealing strip when moving up and down due to
movement of the building. The optional weft metal wires enhance the
abrasive-resistant properties.
[0032] To fix the sealing strip either on the ceiling or on the leg
of the track or on both, the sealing strip also comprises at least
one adhesive layer. In the simplest embodiment the sealing strip
consists of the cover layer which is provided on one side with an
adhesion layer that completely covers one surface of the cover
layer.
[0033] The adhesive layer is not restricted to any particular
material provided that it provides sufficient adhesion to
constructional elements made of various materials, like concrete,
brick, wood, metal and the like. The adhesive layer can consists of
material that does not lose its adhesive power at elevated
temperatures. Alternatively, the adhesive layer can be any
conventional adhesive for applications on constructional materials,
such as concrete and steel, e.g., acrylic adhesives, or a
self-adhesive putty material, such as rubber, e.g., polyisobutylene
based rubber, bitumen or the like. These adhesives are all
commercially available. It is also possible to apply different
adhesives to the cover layer, e.g., a high temperature resistant
adhesive applied on that portion of the cover layer which will be
fixed on the ceiling and another adhesive not being high
temperature resistant applied on the portion of the cover layer
which will fixed on the leg of the track. The adhesive layer can be
applied as a layer or as strips separated from each other.
[0034] Preferably a removable protective layer covers the adhesive
layer until the insulating strip is ready to be applied.
[0035] In one embodiment, in particular where the cover layer
comprises a fabric made of non-combustible (fire resistant) fibers
made of glass, stone, ceramic or the like, and therefore only
partly stays in form when bent in the longitudinal direction to
better fit the joint between the track and the ceiling, the sealing
strip contains a predefined flexing or bending point, such as a
movement pleat or kink (herein referred to as flexing point). The
flexing point can, for example, be provided by a material weakness.
The material weakness can be achieved, for example, by folding the
cover layer to result in the flexing or bending point. For this,
one side edge or both side edges of the cover layer is/are folded
up to result in a portion/portions of the cover layer that has/have
a cover double layer. When both side edges of the cover layer are
folded up, the folded parts may be symmetrical if both resulting
cover double layers are of the same size (symmetrical folding). The
joint edges of the folded cover layer will then form the flexing
point. Alternatively, the folded parts may be asymmetrical if the
resulting cover double layers have a different size (asymmetrical
folding). Again, the joint edges of the cover layer will then form
the flexing point. The symmetrical folded cover layer enables the
user to install the sealing strip from any side but the portion of
the sealing strip which will be fixed to the ceiling might extend
beyond the wallboard. If the sealing strip shall not be visible
after the wallboard is installed, the asymmetrical folded cover
layer is preferred, whereas the smaller part will be positioned on
the ceiling and the larger part will be positioned on the leg. When
only one side edge of the cover layer is folded up, the cover is
folded asymmetrical. The side edge which is folded up then forms
the flexing point.
[0036] To adapt the sealing strip to better fit in the corner
between the track and the ceiling, the sealing strip can either
show one portion of a folded cover layer, i.e., that portion which
will be fixed at the construction element, or that portion which
will be fixed on the track, or two portions, i.e., both the portion
which will be fixed at the construction element and the portion
which will be fixed on the track, so that the flexing or bending
point matches the corner, i.e., gap between the construction
element and the track. This will assure a precise installation of
the sealing strip and enables a perfect fitting installation at the
gap or joint.
[0037] Folding the cover layer additionally provides an edge
protection to prevent frayed edges and sharp edges resulting from
the weft metal wires. This contributes to the safety and the
quality of the sealing strip.
[0038] In a preferred embodiment, the folded portions of the cover
layer are secured by an additional adhesive between the folded
portions which are in contact with each other. This prevents
unwanted and unintentional unfolding of the folded (superimposed)
layers. The additional adhesive further enhances the mechanical
strength of the sealing strip, in particular in case the cover
layer is made of a material other than a metal foil, metal fabric
or metal reinforced fabric. However, this also simplifies the
handling and installation of the sealing strip.
[0039] In case the sealing strip comprises only one portion where
the side edges of the cover layer is folded inwardly to provide one
portion with a single cover layer and one portion with a double
cover layer, the adhesive to secure the double cover layer may also
form part of the adhesive layer with which the single cover layer
is fixed to the construction element, e.g., the ceiling. For this,
the adhesive will be applied to one entire surface of the cover
layer and then one side edge of the cover layer will partly be
folded inwardly.
[0040] In one aspect of the invention the sealing strip comprises a
cover layer and an adhesive layer. The dimension of the sealing
strip shall be selected such that sufficient adhesion to the
ceiling and the track will be assured. But, for improved appearance
the sealing strip 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. For easier
inspection it, however, could be necessary that the sealing strip
extends beyond the joint to be visible after installing the dry
wall.
[0041] With a first portion of the cover layer the sealing strip of
the first aspect of the invention will be fixed to the ceiling.
With a second portion of the cover layer the sealing strip of the
first aspect of the invention will also be fixed to the leg of the
track, in particular the upper part of the leg. For this an
adhesive layer is used with which both portions of the cover layer
are fixed to the construction elements.
[0042] The first portion or the second portion of the cover layer
or both portions of the cover layer may show two layers, wherein
each loose side edge of the cover layer is folded inward. This
results in a flexing point or bending point, which more or less is
a flexing line or bending line extending in the longitudinal
direction. The flexing line or bending line will then cover the gap
or joint between the track and the respective construction
element.
[0043] The sealing strip can be applied to solid and slotted tracks
of a dry wall assembly, preferably to solid tracks. When used with
slotted tracks, the sealing strip is preferably adapted to the
structure of the slotted track.
[0044] Therefore, in another embodiment the sealing element to be
particularly used with slotted tracks additionally comprises a
spacer or additional insulating element. In this embodiment, the
sealing strip preferably covers the entire leg of the track. The
sealing strip is preferably designed such that the additional
insulating element or the additional spacer is positioned on the
bottom part of the leg to align with that portion of the leg
beneath the slots so that the slots are entirely covered by the
sealing strip. In this embodiment, that portion of the sealing
element covering the leg of the track will be fixed on the track
below the slots. The thickness of the additional insulating element
or spacer corresponds to the size, in particular height, of the
screw heads used for securing the studs to the track. The screws
can freely move between the track and the cover layer. It is also
possible that the additional insulating element or spacer extends
over the width of the leg.
[0045] In a preferred embodiment of the sealing strip, the
additional sealing element or spacer is enveloped by the cover
layer, i.e., is positioned between a double cover layer. This is
particularly important in case the additional sealing element or
spacer extends over the entire leg of the track to protect the
additional insulating element or spacer against damage caused by
the screw and to resist abrasion caused by the wall member rubbing
against the insulating material when moving up and down to due
movement of the building.
[0046] The material of the additional insulating element or spacer
is not limited. It may provide additional fire protection or sound
insulation. The additional insulating element may comprise
non-intumescent and/or intumescent materials. An intumescent
material will be used if enhanced sealing in the event of fire is
intended. The intumescent material 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. When
the temperature rises the intumescent material will expand quickly
and block air pathways.
[0047] An acoustical insulating material is intended for
applications where sealing against sound transmissions is found to
be desirable. 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.
[0048] In one embodiment the additional insulating element or the
spacer 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.
[0049] In another, preferred embodiment, the additional insulating
element or the spacer 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 comprise 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.
[0050] In all embodiments described above two sealing strips are
necessary to seal the joint on both sides of the track.
[0051] In another alternative embodiment the sealing strip may by
designed such that the joint on both sides of the track will be
sealed with a single sealing strip.
[0052] In this embodiment 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 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 the 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. To
provide double layered cover layers on each leg, the width of the
side sections of the cover layer correspond to at least twice the
width of leg. To provide flexing points, the side edges are folded
inwardly to obtain double layered side sections that cover the leg.
If an additional insulating element or a spacer is positioned
between the double layers the width of the side sections is adapted
correspondingly.
[0053] The sealing strip will be mounted on the track such that the
additional insulating elements or spacer on the first and second
side section 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
additional elements or spacers are located near the lower edges of
the leg distal from the web to have a maximum distance between each
other.
[0054] For enhanced acoustic or smoke sealing a further additional
insulating element can be positioned on the portion of the cover
layer that covers the web of the track. Preferably, the further
additional insulating element will face towards the ceiling.
[0055] 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
[0056] FIG. 1 is a cross-sectional view of a portion of a stud wall
assembly with a sealing strip installed at the head-of-wall
according to one embodiment of the invention;
[0057] FIG. 2 shows a schematic sectional view of a sealing strip
according to the exemplary embodiment of FIG. 1;
[0058] FIG. 3 is a cross-sectional view of a portion of a stud wall
assembly with a sealing strip installed at the head-of-wall
according to another embodiment of the invention;
[0059] FIG. 4 shows a schematic sectional view of a sealing strip
according to the exemplary embodiment of FIG. 3;
[0060] FIG. 5 is a cross-sectional view of a portion of a stud wall
assembly with slotted tracks and with a sealing strip installed at
the head-of-wall according to another embodiment of the
invention;
[0061] FIG. 6 is a cross-sectional view of a portion of a stud wall
assembly with slotted tracks and with a sealing strip installed at
the head-of-wall according to another embodiment of the invention;
and
[0062] FIG. 7 is a cross-sectional view of a portion of a stud wall
assembly with slotted tracks and with a sealing strip installed at
the head-of-wall according to another embodiment of the
invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0063] FIGS. 1, 3, 5 and 6 illustrate various embodiments of the
sealing strip 1 of the invention to the dry wall assembly. The dry
wall assembly comprises a header track 20 with a web 21, legs 22,
wallboards 23 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 20 and may be configured
for vertical movement relative to the header track 20. A wallboard
23 is attached to the studs such as by a plurality of suitable
fasteners.
[0064] As shown in more detail in FIG. 2, the sealing strip 1, in
particular an elongated strip, according to the first embodiment of
the invention comprises a cover layer 2, an adhesive layer 3 shown
by the dashed line, an additional adhesive layer 5 and a flexing
point indicated by the line 4. The flexing point 4 is achieved by
asymmetrically folding the cover layer 2. This results in two
asymmetric portions with double layered portions of the cover
layer, one smaller portion shown on the left hand side of the
flexing point 4 and the other shown on the right hand side of the
flexing point 4. The folded areas of the cover layer 2 are fixed by
the additional adhesive layer 5 to prevent unintended unfolding of
the double layers.
[0065] As shown in FIG. 1 the sealing strip 1 is affixed on the
ceiling with the smaller portion of the folded cover layer 2 (see
FIG. 2) by the adhesive layer 3 (not shown in FIG. 1) and on the
upper part of the solid leg 22 with the larger portion of the
folded cover layer 2 (see FIG. 2) by the adhesive layer 3 (not
shown in FIG. 1). The sealing strip is installed so that the
flexing point 4 (see FIG. 2) is located near the joint between the
track 20 and the ceiling 10.
[0066] The cover layer 2 supports movement of the wallboard 23.
Since the larger portion of the cover layer 2 (see FIG. 2) is fixed
on the solid leg 22 by the adhesive layer 3, the sealing strip will
stay in place and will not follow the movement of the wallboard
23.
[0067] Another embodiment of the sealing strip 1 of the present
invention is shown in FIG. 4. This embodiment is very similar to
the one shown in FIG. 2 with the difference that only one side of
the cover layer 2 is asymmetrically folded inwardly. The sealing
strip 1 according to the embodiment shown in FIG. 4 comprises a
cover layer 2, an adhesive layer 3 shown by the dashed line, an
additional adhesive layer 5 and a flexing point indicated by the
line 4. The flexing point 4 is achieved by asymmetrically folding
only one edge of the cover layer 2. This results in two asymmetric
portions, one smaller portion shown on the left hand side of the
flexing point 4 with a single layered portion of the cover layer 2
and the other shown on the right hand side of the flexing point 4
with a double layered portion of the cover layer 2. The folded area
of the cover layer 2 is fixed by the additional adhesive layer 5 to
prevent unintended unfolding of the double layers. The additional
adhesive layer 5 on the left hand side of the flexing point 4
functions as adhesive to fix the sealing strip on the ceiling as
shown in FIG. 3.
[0068] As shown in FIG. 3 the sealing strip 1 is affixed on the
ceiling with the smaller portion of the single layered portion of
the cover layer 2 (see FIG. 4) by the adhesive layer 5 (not shown
in FIG. 3) and on the upper part of the leg 22 with the larger
double layered portion of the cover layer 2 (see FIG. 4) by the
adhesive layer 3 (not shown in FIG. 3). The sealing strip 1 is
installed so that the flexing point 4 (see FIG. 4) is located near
the joint between the track 20 and the ceiling 10.
[0069] The sealing strip 1 shown in FIGS. 3 and 4 will be installed
the same way as described for the sealing strip 1 shown in FIGS. 1
and 2.
[0070] FIG. 5 shows the sealing strip 1 designed to be used with
slotted tracks. The slots 24 are shown as brighter areas in the
legs 22. The sealing strip 1 of this embodiment is very similar to
the one shown in FIGS. 1 and 2 with the difference that in the
larger portion of the folded cover layer 2 to be fixed to the leg
22 an additional insulating element 6 is positioned between the two
layers. In this area the cover layer 2 almost completely wraps the
additional insulating element 6.
[0071] FIG. 6 shows an alternative embodiment of the sealing strip
1 designed to be used with slotted tracks. The sealing strip 1
shown is very similar to the one shown in FIG. 5 with the
difference that the additional sealing element 6 has a smaller
size. With this, the additional sealing element 6 is completely
wrapped by the double layer portion of the cover layer 2 which is
fixed to the leg 22. The additional sealing element 6 is positioned
on the lower portion of the leg 22 and is fixed below the slots 24.
As a result, the slots 24 are completely covered by the insulating
strip 1.
[0072] In both the embodiments shown in FIGS. 5 and 6 the width of
the additional sealing element 6 is adapted to the size in
particular the height of the heads of the screws (not shown) so
that the screws can move without damaging the sealing strip 1.
[0073] FIG. 7 illustrates the sealing strip 1 according to another
embodiment of the invention applied to a head-of-wall structure, in
particular to a slotted header track 20. The sealing strip 1
comprises two additional insulating elements 6. The insulating
strip 1 is attached to the header track 20 so that a portion, i.e.,
the middle section, is positioned between the header track 20 and
the ceiling 10 and another portion, i.e., the side sections
containing the additional insulating elements 6, is positioned
between the legs 22 and the wallboard 23. The additional sealing
elements 6 are completely wrapped by the double layered side
portions of the cover layer 2 which are fixed to the leg 22. The
additional sealing elements 6 are positioned on the lower portions
of the legs 22 and are fixed below the slots 24. As a result, the
slots 24 are completely covered by the insulating strip 1.
[0074] To enhance acoustic insulation and/or fire protection, the
embodiment shown in FIG. 7 additionally comprises an insulating
layer 7 which is fixed to the cover layer of the sealing element by
an intumescent layer 9. The insulating layer 7 faces the ceiling 10
structure to better adapt to an uneven contour of the ceiling
10.
[0075] 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.
[0076] 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.
* * * * *