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.

Description

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

The present invention deals generally with the field of firestopping and acoustical insulation, in particular firestopping for head-of-wall joints, including, intumescent components.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

It is an object of the sealing element for insulating head-of-wall joints of the present invention to minimize costs and maintenance requirements.

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.

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”.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

The support layer may be formed of a fabric (woven or non-woven) of fibers, like glass fibers or any other suitable material.

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.

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.

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.

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.

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.

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.

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.

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.

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

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;

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;

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;

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;

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

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

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.

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.

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.

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.

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.

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.

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.

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.

The sealing element 22 is designed as a single layer 22 extending over the intumescent material strip 21, to cover it completely.

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.

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.

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.

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.

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.