HEADER TRACK WALL ASSEMBLY HAVING CAULK SMEAR

Abstract

The present invention is directed to fire retardant head-of-wall assembly as disclosed herein.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

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

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

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).

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.

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

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.

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.

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

In the drawings like reference numerals are used to designate like features throughout the several views of the drawings.

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.

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.

FIG. 2 illustrates a side view perpendicular of the upper section of the dynamic head-of-wall assembly shown in FIG. 1a.

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.

FIG. 3b illustrates a side cross-sectional view of a header track wherein each flange includes an elongated hem running parallel to each flange.

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.

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).

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.

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

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.

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.

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.

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.

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.

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.

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.