U.S. patent application number 14/675743 was filed with the patent office on 2017-01-19 for header track wall assembly having caulk smear.
The applicant listed for this patent is James Alan Klein. Invention is credited to James Alan Klein.
Application Number | 20170016227 14/675743 |
Document ID | / |
Family ID | 57775119 |
Filed Date | 2017-01-19 |
United States Patent
Application |
20170016227 |
Kind Code |
A1 |
Klein; James Alan |
January 19, 2017 |
HEADER TRACK WALL ASSEMBLY HAVING CAULK SMEAR
Abstract
The present invention is directed to fire retardant head-of-wall
assembly as disclosed herein.
Inventors: |
Klein; James Alan;
(Bellevue, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Klein; James Alan |
Bellevue |
WA |
US |
|
|
Family ID: |
57775119 |
Appl. No.: |
14/675743 |
Filed: |
April 1, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61972995 |
Mar 31, 2014 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 2/7457 20130101;
E04B 1/948 20130101 |
International
Class: |
E04B 1/94 20060101
E04B001/94; E04B 2/58 20060101 E04B002/58; E04B 1/38 20060101
E04B001/38 |
Claims
1. A fire retardant head-of-wall assembly, comprising: first and
second linearly aligned and abutting head-of-wall track members
attached to an overhead ceiling structure, the first and second
head-of-wall track members each having substantially the same
cross-sectional profile, with each of the first and second
head-of-wall track members including at least one downwardly
extending flange member, and with each flange member including a
lengthwise outwardly protruding rib, hem, or combination thereof,
and with the outwardly protruding rib, hem, or combination thereof
being of the same shape and linearly aligned with each other; a
plurality of studs engaged with the first and second linearly
aligned and abutting head-of-wall track members; wallboard attached
to the plurality of studs, the wallboard being in contact with the
outwardly protruding rib, hem, or combination thereof, the
wallboard defining an upper linear wallboard edge, the upper linear
wallboard edge being positioned apart from the ceiling structure so
as to define a head-of-wall gap; a linear head-of-wall joint
located between the first and second linearly aligned and abutting
head-of-wall track members and the overhead ceiling structure; a
flange joint located between the first and second linearly aligned
and abutting head-of-wall track members; a contiguous bead of caulk
positioned along the linear head-of-wall joint and the flange
joint, but not on the upper linear wallboard edge.
2. The fire retardant head-of-wall assembly of claim 1, further
comprising a plurality of fasteners having fastener heads of a
selected height, wherein the height of the fastener heads is about
the same or less than the height of the outwardly extending
elongated rib or hem, and wherein the plurality of fasteners fasten
the plurality of studs to the first and second head-of-wall track
members.
3. The fire retardant head-of-wall assembly of claim 3, further
comprising a plurality of vertically oriented slots positioned
along each of the flanges, with the plurality of fasteners
extending through the plurality of slots.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S.
Provisional Application No. 61/972,995 filed on Mar. 31, 2014, all
of which application is incorporated herein by reference in its
entirety for all purposes.
TECHNICAL FIELD
[0002] The present invention relates generally head-of-wall tracks
(e.g., header tracks) used in the construction industry as part of
a fire retardant wall assembly and, more specifically, to a
head-of-wall assembly. A typical track resembles a generally
U-shaped (or some other similarly shaped) elongated channel capable
of receiving the ends of wall studs and holding the wall studs in
place. The track allows the wall assembly to be coupled to a
building support structure substrate, such as a ceiling, wall,
floor, floor of a higher level floor of a multi-level building, or
a support beam.
BACKGROUND OF THE INVENTION
[0003] Metal framing assemblies used to construct commercial and
residential buildings are common in the building construction arts.
These metal framing assemblies are generally constructed from a
plurality of metal framing members including studs, joist, trusses,
and other metal posts and beams made from sheet metal and
frequently fabricated to have the same general cross-sectional
dimensions as standard wood members used for similar purposes.
Metal framing members are typically constructed by roll-forming 12
to 24 gauge galvanized sheet steel. Although many cross-sectional
shapes are available, the primary shapes used in building
construction are generally C-shaped studs and generally U-shaped
tracks (i.e., header and footer tracks).
[0004] In the building construction trade, a head-of-wall joint
refers to the linear junction existing between a top section of a
framing/wallboard wall assembly and the ceiling. Head-of-wall
joints often present a serious challenge in terms of reducing or
prevention the spread of smoke and fire during a building fire, as
well as reducing the transmission of sound. In this regard, a wall
to ceiling connection of many newly constructed building consists
essentially of an inverted generally U-shaped elongated steel
channel or track 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.
[0005] Thus, and although construction joints and gaps are
generally sealed in some manner (e.g., mineral wool and/or
elastomeric coatings), there are relatively few products and
methods available that effectively/efficiently seal head-of-wall
construction joints and gaps (to thereby enhance the ability of
such joints and gaps to withstand smoke and fire penetration, as
well as to reduce the transmission of sound). In particular, there
are very few products available that address the needs for adequate
fire protection and sealing of dynamic head-of-wall systems
associated with steel stud wall constructions. Thus, there is still
a need in the art for new and improved fireblock systems and fire
retarding devices, including related wall assemblies and methods.
The present invention fulfills these needs and provides for further
related advantages.
SUMMARY OF THE INVENTION
[0006] The present invention relates to a fire retardant
sheet-metal wall assembly and includes first and second linearly
aligned and abutting track members attached to a substrate and a
plurality of studs received within the first and second track
members. The first and second track members each have substantially
the same cross-sectional profile and include a planar web having at
least one outwardly and/or downwardly extending flange
substantially perpendicular to the web. Each flange includes at
least one outwardly extending elongated rib and/or hem of a
selected height that runs parallel to each flange. The first and
second track members are attached to the substrate at a
horizontally oriented track/substrate intersection, wherein the
first and second track members abut (have a common boundary
together) each other at a vertically oriented track/track
intersection. To accomplish a fire-rated wall assembly a continuous
fire retardant caulk bead is applied, creating a fire/heat and
smoke/air seal, and positioned along the horizontally oriented
track/substrate intersection and along the vertically oriented
track/track intersection.
[0007] The present invention in one embodiment is directed to the
track that includes a plurality of fasteners having fastener heads
of a selected height, wherein the height of the fastener heads is
about the same or less than the height of the outwardly extending
elongated rib or hem. The plurality of fasteners fastens the
plurality of studs to the first and second track members. In this
embodiment, the wallboard is attached to the plurality of studs and
is in continuous contact with the rib or hem along the track.
[0008] In another embodiment of the present invention, the track
also includes a plurality of vertically oriented slots positioned
along the flange, wherein the plurality of fasteners are positioned
at and penetrate through the plurality of slots.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In the drawings like reference numerals are used to
designate like features throughout the several views of the
drawings.
[0010] FIG. 1a illustrates a side cross-sectional view of an upper
section of a dynamic head-of-wall assembly in accordance with the
prior art.
[0011] FIG. 1b illustrates a side cross-sectional view of an upper
section of a fire retardant dynamic head-of-wall assembly shown in
FIG. 1a, but wherein the intumescent and/or sound caulk has been
applied to seal a linear head-of-wall construction joint or gap in
accordance with the prior art.
[0012] FIG. 2 illustrates a side view perpendicular of the upper
section of the dynamic head-of-wall assembly shown in FIG. 1a.
[0013] FIG. 3a illustrates a side cross-sectional view of a header
track wherein each flange includes an elongated rib (protrusion)
running parallel to each flange.
[0014] FIG. 3b illustrates a side cross-sectional view of a header
track wherein each flange includes an elongated hem running
parallel to each flange.
[0015] FIG. 4 illustrates a side cross-sectional view of a portion
of a head-of-wall assembly where the header track is affixed to the
ceiling with an intumescent caulk applied along the interface or
joint existing between the track and the ceiling.
[0016] FIG. 5 illustrates an elevated perspective view of abutting
header tracks wherein an intumescent caulk has applied on a flange
joint located between adjacent tracks and along the upper edge of
each track (where the web and flange are connected).
[0017] FIG. 6 illustrates a side cross-sectional view of an upper
section of a fire retardant dynamic head-of-wall assembly, but
wherein an intumescent (or sound) caulk has been applied to seal a
linear head-of-wall construction gap and the header track includes
an elongated rib running parallel to each flange.
[0018] FIG. 7 illustrates a side cross-sectional view of an upper
section of a fire retardant dynamic head-of-wall assembly, but
wherein the intumescent caulk applied to seal a linear head-of-wall
construction joint on the left and between the ceiling and the rib
running parallel to each flange on the right.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring to the drawings wherein like reference numerals
are used to identify corresponding elements throughout the
drawings, the present invention is directed in one embodiment to a
fire retardant head-of-wall assembly 10. As shown, the fire
retardant head-of-wall assembly 10 comprises first and second
linearly aligned and abutting head-of-wall track members 12, 14
attached to an overhead ceiling structure 15 (and wherein each
track members having substantially the same cross-sectional
profile). Each of the first and second head-of-wall track members
12, 14 include at least one downwardly extending flange member 16,
and with each flange member 16 including a lengthwise outwardly
protruding rib 18, hem 20, or combination thereof. The outwardly
protruding ribs 18, hem 20, or combination thereof have the same
basic shape and linearly aligned with each other.
[0020] As shown, plurality of studs 22 are engaged with (received
into) the first and second linearly aligned and abutting
head-of-wall track members 12, 14. In addition, wallboard 24 is
attached to the plurality of studs 22. As shown, the wallboard 24
is in intimate contact with the outwardly protruding rib 18, hem
20, or combination thereof. The wallboard 24 defines an upper
linear wallboard edge 26. The upper linear wallboard edge 26 is
positioned apart from the ceiling structure so as to define a
head-of-wall gap 28.
[0021] As shown, a linear head-of-wall joint 30 is located between
the first and second linearly aligned and abutting head-of-wall
track members 12, 14 and the overhead ceiling structure 15.
Similarly, a flange joint 32 is located between the first and
second linearly aligned and abutting head-of-wall track members 12,
14. Finally, a contiguous bead of caulk 34 positioned along the
linear head-of-wall joint 30 and the flange joint 32, but not on
the upper linear wallboard edge 26.
[0022] The fire retardant head-of-wall assembly 10 further
comprises a plurality of fasteners 36 having fastener heads 37 of a
selected height, wherein the height of the fastener heads 37 is
about the same or less than the height of the outwardly extending
elongated rib 18 or hem 20. Finally, a plurality of vertically
oriented slots 38 positioned along each of the flanges 16, with the
plurality of fasteners 36 extending through the plurality of slots
38.
[0023] Stated somewhat differently, the present invention is
directed to a wall assembly that comprises: a plurality of studs
having upper and lower ends, the studs being vertically positioned
relative to the ceiling and floor such that the uppers ends are
engaged within a header track and the lower ends are engaged within
a footer track; first and second pieces of wallboard attached to
the plurality of studs, the first and second pieces of wallboard
being adjacent to each other and separated apart from each other so
as to define a control gap between them; a first strip of a
sheet-metal material positioned within the wall and connecting the
first and second pieces of wallboard together along the length of
the control gap, the first material strip having a flexible first
central portion that runs the length of the control gap and allows
for expansion and contraction of the first and second pieces of
wallboard without cracking; and a second strip of a sheet-metal
material positioned on the wall and connecting the first and second
pieces of wallboard together along the control gap, the first
material strip having a flexible second central portion that runs
the length of the control gap and allows for expansion and
contraction of the first and second pieces of wallboard without
cracking, and wherein the first and second strips seal the control
gap from the interior and exterior wall spaces. As shown, an
intumescent material strip positioned along the first central
portion of the first material strip, the second central portion of
the second material strip, or both.
[0024] While the present invention has been described in the
context of the embodiments illustrated and described herein, the
invention may be embodied in other specific ways or in other
specific forms without departing from its spirit or essential
characteristics. Therefore, the described embodiments are to be
considered in all respects as illustrative and not restrictive. The
scope of the invention is, therefore, indicated by the appended
claims rather than by the foregoing description, and all changes
that come within the meaning and range of equivalency of the claims
are to be embraced within their scope.
* * * * *