FLUTE PLUG

Abstract

A pre-formed flute plug including compressed fire-resistant material (e.g., mineral wool) for fireblocking a head-of-wall assembly. The plugs can be pre-formed to shape and include an outer coating that contains the compressed fire-resistant material inside. Once installed within a flute void, the outer coating can be ruptured to allow expansion of the fire-resistant material to fill the flute void.

Description

CROSS REFERENCE

This application claims the benefit of U.S. Patent Application No. 63/076,801, filed Sep. 10, 2020, the entirety of which is hereby incorporated by reference.

BACKGROUND

Field

This disclosure generally relates to devices, systems, and methods for proofing a building joint against the passage of smoke, fire and/or noise.

Related Art

Building joints, such as head-of-wall joints can be labor intensive and/or time-consuming to fireproof using conventional methods. For example, firestopping joints located at the top or head of a wall are typically surrounded by electrical conduits, mechanical ducts, data lines, and plumbing (MEPs) leaving very little working room. This makes both installation of any firestopping materials and inspection of the firestopping materials a challenge. When fluted pan decking is used, open voids are located at the head-of-wall joint. A common technique for fire-stopping the open voids is to fill the voids with mineral wool and then spray an elastomeric fire spray over the surface of the mineral wool that laps onto the surface of the finish drywall and pan decking. This application is messy and can coat or spray the MEPs located at the head of wall.

SUMMARY

According to a first aspect, a head-of-wall assembly for providing fire, smoke and/or sound protection across a building joint includes a fluted pan deck with at least one flute void extending in a first direction. A header track attaches with a lower surface of the fluted pan deck and extends in a second direction across the flute void. The second direction is transverse to the first direction. The flute void defines a width in the second direction and a height perpendicular to the first direction and the second direction. At least one stud attached with the header track. A wallboard attaches with the stud and including an upper end that overlaps the header track. A pre-formed plug is disposed within the flute void and supported by the header track. The pre-formed plug has a fire-resistant material and an outer coating encasing the fire-resistant material. In a first configuration, the outer coating compresses the fire-resistant material along a first dimension. In a second configuration, the outer coating is released to allow expansion of the fire-resistant material along the first dimension.

According to another aspect, in the first configuration, the outer coating compresses the fire-resistant material along a second direction and the outer coating is released to allow expansion of the fire-resistant material along the second dimension in the second configuration. According to another aspect, the first dimension is parallel with the width of the flute void. According to another aspect, the second dimension is parallel with the height of the flute void. According to another aspect, in the first configuration, the first dimension is less than the width of the flute void and the second dimension is less than the height of the flute void. In the second configuration, the first dimension is expanded to the width of the flute void and the second dimension is expanded to the height of the flute void, and the fire-resistant material remains compressed within the flute void. According to another aspect, the first dimension is within 95-105% of the width of the flute void and the second dimension is within 95-105% of the height of the flute void. According to another aspect, the outer coating is shrink-wrapped about the fire-resistant material in the first configuration. According to another aspect, the outer coating is vacuum-sealed about the fire-resistant material in the first configuration. According to another aspect, the outer coating comprises a latex material about the fire-resistant material in the first configuration. According to another aspect, releasing the outer coating to allow expansion of the fire-resistant material includes rupturing the outer coating. According to another aspect, a release mechanism attaches with the outer coating and is configured to rupture the outer coating. According to another aspect, the pre-formed plug includes an indicator that shows whether the outer coating has been released.

According to a second aspect, a method of installing a head-of-wall fire blocking component, includes placing a pre-formed flute plug on an upper surface of a header track and within a flute void. The pre-formed flute plug has a compressed fire-resistant material within an outer coating. The outer coating is manipulated to allow expansion of the flute plug within the flute void.

According to another aspect, manipulating the outer coating includes perforating the outer coating. According to another aspect, manipulating the outer coating includes operating a release mechanism attached with the outer coating.

According to a third aspect, a pre-formed flute plug for installing within a flute void includes an outer coating encasing a compressed fire-resistant material. A length extends from a first end to a second end. A height extends from an upper surface to a lower surface. A width extending from a left surface to a right surface. In a first configuration, the outer coating compresses the fire-resistant material along a first dimension. In a second configuration, the outer coating is released to allow expansion of the fire-resistant material along the first dimension.

According to another aspect, in the first configuration, the outer coating compresses the fire-resistant material along a second direction and the outer coating is released to allow expansion of the fire-resistant material along the second dimension in the second configuration. According to another aspect, the first dimension is the width and the second dimension is the height. According to another aspect, the outer coating is shrink-wrapped about the fire-resistant material in the first configuration. According to another aspect, the outer coating is vacuum-sealed about the fire-resistant material in the first configuration. According to another aspect, the outer coating comprises a latex material about the fire-resistant material in the first configuration. According to another aspect, an outer perimeter extends about a transverse section of the of the flute plug. In a first configuration, the outer perimeter has a first length. In a second configuration, the outer perimeter has a second length, greater than the first length. According to another aspect, a release mechanism attaches with the outer coating and is configured to rupture the outer coating. According to another aspect, the release mechanism includes a material strip and a pull tab.

According to a fourth aspect, a method of manufacturing a flute plug includes compressing a flute plug comprising a mineral wool or other fire-resistant material utilizing an outer coating.

The foregoing summary is illustrative only and is not intended to be limiting. Other aspects, features, and advantages of the systems, devices, and methods and/or other subject matter described in this application will become apparent in the teachings set forth below. The summary is provided to introduce a selection of some of the concepts of this disclosure. The summary is not intended to identify key or essential features of any subject matter described herein

BRIEF DESCRIPTION OF THE DRAWINGS

Various examples are depicted in the accompanying drawings for illustrative purposes, and should in no way be interpreted as limiting the scope of the examples. Various features of different disclosed examples can be combined to form additional examples, which are part of this disclosure.

FIG. 1 shows a front view of a pre-formed flute plug in a non-expanded state within a flute void;

FIG. 2 shows a perspective view of a pre-formed flute plug in the non-expanded state;

FIG. 3 is a cross section of a head-of-wall assembly at the header track including a first pre-formed flute plug positioned within a first flute void in the non-expanded state and a second pre-formed flute plug in a second flute plug in an expanded state.

DETAILED DESCRIPTION

Head-of-wall joints that protect against fire, smoke, and/or noise (generically “firestopping joints”) can be difficult (e.g., labor intensive and/or time-consuming) to install. For example, firestopping joints can be located at the top or head of wall and are typically surrounded by electrical conduits, mechanical ducts, data lines, and plumbing (MEPs) leaving very little working room. This makes both installation of the firestopping materials and inspection of the firestopping materials a challenge. For this reason, the building industry is turning to “device” firestopping. Firestop devices are products that are fully cured and/or ready to use. The firestopping material is contained within the device and the devices can be mechanically attached with or friction fit into the joint at a void or opening. An example of a head-of-wall assembly is discussed in U.S. Pat. No. 8,087,205, the entirety of which is hereby incorporated by reference.

When walls run perpendicular or at an angle relative to the flutes of a fluted pan deck, open voids are located over the top track. A common technique for fire-stopping this type of head-of-wall joint is to fill the void with mineral wool (or other fire-retardant material) and then spray an elastomeric fire spray over the surface of the mineral wool that laps onto the surface of the finish drywall and pan decking. This application is messy and can coat or spray the MEPs located at the head of wall. While it can be desirable to fill the voids in the pan decking above the top track before the drywall and the MEPs are installed, the elastomeric fire spray needs to lap onto the surface of the drywall. Accordingly, the fire-stopping material in a conventional installation cannot be installed until after the drywall is installed.

One aspect of the present disclosure is way to install one or more fire-resistant material (e.g., mineral wool) plugs into a flute void or other joint space, gap or opening. The plugs can be pre-formed to shape and/or include an outer coating that contains the mineral wool inside. The fire-resistant material can be allowed to expand after positioning within the flute void or other space. In some configurations, the fire-resistant material can be allowed to expand prior to a fire, such as part of the installation process. For example, the fire-resistant material can expand or initiate expansion in response piercing or other penetration of the outer coating, or as a result of some other (pre-insertion, upon-insertion or post-insertion) manipulation of the plug.

In another aspect of the present disclosure, a pre-formed plug including mineral wool and a coating or other outer layer can be formed generally in the shape of the flute void. The coating can be factory-applied to the mineral wool so that the pre-formed plug can be ready to use when it arrives at the job site. There are several ways to apply the coating to the mineral wool. In one example, the mineral wool material can be compressed and then inserted into an outer layer or have an outer layer applied, which can constrain the mineral wool material in the compressed state or a compressed state that is compressed relative to the original state of the mineral wool material. Such an outer layer can be a sealable plastic bag or a plastic wrap (e.g., a material that is or comprises polymer plastic film).

In another example, the mineral wool can be compressed by the outer layer. For example, the mineral wool can be wrapped in a shrink wrap layer or material. When heat is applied to the shrink wrap, the shrink wrap shrinks tightly over the mineral wool. Since mineral wool is compressible, the shrink wrap process can compress the mineral wool as heat is applied to the shrink wrap. Compressing the mineral wool through a shrink wrap process will also allow the mineral wool to be compressed to a desired pre-formed shape that easily installs into the flute void.

In another aspect, the pre-formed plug can be formed in the shape of the flute void with a vacuum pack method. In this method of packaging, the coating can encompass the mineral wool and air can be removed from the package prior to sealing the coating. Removal of the air can compress the mineral wool into a smaller volume and/or the desired pre-formed shape. In another example, a separate vacuum bag material can be used in conjunction with the coating. Air can be removed from within the vacuum bag material. This vacuum packing method can reduce the size of the mineral wool, making the mineral easier to install into the flute void.

In another aspect, the surface of the mineral wool can be coated in a latex liquid coating to form the pre-formed plug. Latex coatings are very flexible and will allow the mineral wool to compress without damaging the coating. In one example, the coating can be applied in a wet state and allowed to fully cure. The curing can be completed before packaging and shipping. The curing can compress the mineral wool and/or shape the mineral wool into a desired pre-formed shape. The latex coating can also have an intumescent additive that will allow the coating to expand when introduced to elevated heat from a fire.

FIG. 1 shows a pre-formed plug 120 in a non-expanded state. The plug 120 can include a top side 121, a left side 122, a right side 123, a bottom side 124, a front side 125, and a rear side 126 (e.g., in FIG. 2). Any one or more of the sides can be generally planar faces and/or separated by distinct corners. Alternatively, the sides can be generally curves (e.g., due to compressed fire-resistant material within the outer covering) and/or include curves between the sides. As shown in FIG. 2, the pre-formed plug 120 can have a trapezoidal-prism shape with a trapezoid-shaped transverse cross section. Alternatively, the plug 120 can be rectangular, arched, or otherwise non-polygonal in cross sectional shape. The plug 120 can include lower or greatest width w1 and/or an upper or lesser width w2. The width can extend from the left side 122 to the right side 123 (e.g., corner to corner). The plug 120 can include a height h. The height h can extend from the bottom side 124 to the top side 121. The plug 120 can extend a length L. The length L can extend from the front side 125 to the rear side 126. A plug perimeter can be formed around the transverse cross section. The perimeter can be defined by the lengths of the top side 121, left side 122, right side 123, and the bottom side 124.

The pre-formed plug 120 can be slightly to moderately undersized relative to a desired location, such as a flute void 110, in the non-expanded state. In some configurations, the pre-formed plug 120 can be the same size or slightly oversized relative to the desired location so long as the plug 120 can be inserted into the location without substantial difficulty. The flute void 110 can be formed by a portion of a fluted pan deck (e.g., steel) including a plurality of concave flutes when viewed from below and considering the bottom surface of the fluted pan deck as the ceiling of the floor below the pan deck. The flutes can extend parallel to each other along a first direction. The flute void 110 can include a generally concave space including an upper wall 111, a left wall 112, and a right wall 113. A bottom side can be open. A header track 130 can extend partially or completely across the open side of the flute void 110. The header track 130 can be oriented to extend along a transverse direction (e.g., perpendicular) relative to the first direction or at an angle relative to the first direction that is not parallel to the first direction. The header track 130 can be a U-shaped track that attaches with the fluted pan deck (e.g., between the flute voids). The flute void 110 can have a generally trapezoidal-shaped cross-section. The flute void can include a height H and a lower width W1 and/or an upper width W2. A void perimeter can be formed around the transverse cross section of the flute void 110. The perimeter can be defined by the lengths of the top side 111, left side 112, right side 113, and the distance between the left and right sides 112, 113 across the open side of the flute void 110 along the track 130.

The pre-formed plug 120 can be installed within the flute void 110, as further shown in FIG. 3. The pre-formed plug 120 can be installed after installation of the top track 130 with the fluted pan decking. This installation of the plug 120 can be performed before or after attachment of the one or more studs and wallboards 104 with the track 130. The top side 121 can be aligned along the upper wall 111. The left side 122 can be aligned along the left wall 112. The right side 123 can be aligned along the right wall 113. The bottom side 124 can be supported on a web of the header track 130. The pre-formed plug 120 can be installed within the flute void 110 in the non-expanded state. In the non-expanded state, the plug 120 can be undersized such that a gap 115 can be located between an outer periphery of the plug 120 and an inner periphery of the flute void 110. This facilitates easy installation of the flute plug within the void 110. The width w1 of the plug 120 can be approximately 4 inches, or between about 3.5 and 6 inches. The width w1 can be approximately 10-30% smaller than the width W1 of the void 110. The height h of the plug 120 can be approximately 2.5 inches, or between about 1.5 and 4 inches. The height h can be approximately 10-30% smaller than the height H of the void 110. The length L can be sufficient such that the flute plug 120 can at least extend from a first side to a second side of a web of the track 130 and, preferably, can extend beyond the track 130 on one or both sides (e.g., about 4 inches). In some configurations, the length L can be approximately the same as or greater than a total width of the wall (e.g., track 130 and wallboard 104 and/or a second wallboard on a back side of the wall).

Alternatively, the plug 120 can be slightly compressible and slightly oversized to enable insertion and retention within the void 110. One or all of the sides (e.g., top side 121, left side 122, and right side 123) of the plug 120 can contact the respective sides of the fluid void 110 in the non-expanded state. The width w1 can be approximately 1-10% larger than the width W1 of the void 110, and/or the height h can be approximately 1-10% larger than the height H of the void 110. In another alternative, the width of the plug 120 can be within 95-105% of the width of the void 110. The height of the plug 120 can be within 95-105% of the height of the void 110.

The flute plug 120 can include an outer coating 127 that contains compressed mineral wool inside (or other fire-retardant material). The mineral wool can have a density of 2, 4, 6, or 8 lbs. per cubic foot. In the compressed state, the mineral wool can be approximately ⅔ of its original size and recover sufficiently when expanded to maintain a seal within the void. In one embodiment, a 5 inch tall mineral wool can be compressed to approximately a 2⅞ inch height.

The coating 127 can be formed generally in the shape of the flute void 110. The coating 127 can be factory-applied to the mineral wool so that the pre-formed plug can be ready to use when it arrives at the job site. As discussed above, the coating 127 can be a shrink wrap (e.g., a material that is or comprises polymer plastic film). The mineral wool material can be compressed and restrained by the coating 127 or other cover layer. In some configurations, the mineral wool material is first compressed and then the cover layer 127 is applied to restrain the mineral wool material. In other configurations, when heat is applied to the shrink wrap, the shrink wrap shrinks tightly to compress the mineral wool. In another configuration, the coating 127 can be vacuum sealed. Removal of the air can compress the mineral wool into a smaller volume and/or the desired pre-formed shape. Alternatively, the coating 127 (e.g., liquid latex) can be applied to the uncompressed mineral wool and compressed with the mineral wool to the non-expanded state. Overall, the height and/or width of the plug 120 can be reduced by approximately 30%.

In the installed configuration, the coating 127 can be fully or partially released and the mineral wool can be allowed to expand in place to an expanded state of the plug 120. Once the coating 127 is released, the compressed mineral wool will expand back toward or to its original size or close to its original size prior to application of the coating and any shrinking related thereto. The expanded mineral wool can contact the sides of the flute void 110 and/or the top track 130. Once the mineral wool is uncompressed within the flute void, the plug 120 will substantially or fully seal off any fire, smoke or sound from passing through the flute void.

To release the coating 127, the coating may be cut, perforated or otherwise structurally compromised (e.g., with a knife or other sharp instrument). Preferably, the pre-formed plug can be cut, perforated or compromised across the top and/or bottom sides 121, 124, on the front or back sides, 125, 126 or on the left or right sides 122, 123. This can direct the compressed mineral foam outwardly against the sides of the flute void 110 and/or top track 130. In some such embodiments, the pre-formed plug 120 can include a longitudinal restraint that limits or prevents expansion in a longitudinal direction of the plug or flute (e.g., along the length L). In the case of the heat-shrunk plug, the heat-shrink material can be cut along one or more lines to allow expansion of the mineral wool. In the case of the vacuum-sealed coating, breaking of the seal (e.g., by puncturing the coating) to allow air to reenter the pre-formed plug may be sufficient to expand the pre-formed plug. In the case of the coated and compress plug, a strap or wrap can be cut to allow expansion. In certain implementations, the coating 127 can be ruptured but remain partially or fully in-place over the compressed mineral wool. Advantageously, the coating 127 can inhibit or prevent foreign matter (possibly including but not limited to organisms that may cause infectious disease) from becoming embedded in the open fibers of exposed mineral wool even when perforated or punctured.

In FIG. 2, the pre-formed plug 120 includes a release mechanism 140. The release mechanism 140 can be formed within or attached with the coating 127. The release mechanism 140 can be located on the front side 125 or along an edge surrounding the front side 125. Advantageously, the front side 125 is accessible when the plug 120 is installed within the flute void 110. Alternatively, the release mechanism 140 can be located along an alternate side, such as the left or right sides 122, 123 or along the top or bottom sides 121, 124. A release mechanism 140 in one these locations can be assessable to an installer by shifting and/or compressing the plug 120 within the fluid void (e.g., shifting to one side of the flute void 110) during installation.

The release mechanism 140 can include the coating 127 with one or more lines of perforations on one of the sides (e.g., front side 125). Breaking the perforations can cause a disruption of the integrity of the coating 127. The disruption of the integrity of the coating 127 can spread to disrupt the integrity of the coating 127 along one or more sides of the plug 120 (e.g., left/right sides 122, 123) and allow expansion of the compressed contents of the pre-formed plug 120. Advantageously, the strip 142 and/or the perforations can extend onto multiple sides of the plug 120. In one example, the strip 142 and/or the perforations can extend across the front side 125 and extend onto left and/or right sides 122, 123.

The release mechanism 140 can include one or more strips 142 on one or more of the sides of the pre-formed plug. The perforations can extend along or form the strip 142. The strip 142 can comprise the material of the coating 127 alone or an additional plastic material (or other material) attached with the outer coating 127. The strip 142 can be attached with a pull tab 141. By pulling on the pull tab 141 (or directly on the strip 142), the coating 127 can fully or partially separated along the lines of perforations (if present). The release mechanism 140 can include one or more strips 142 on one or more of the sides of the pre-formed plug.

In another example of the release mechanism 140, a rod or string can be attached with the coating 127, either within or without the coating 127. A first end of the rod or string can be accessible after installation (e.g., at the front side 125 of the pre-formed plug proximate the location of the pull tab above). A second end of the rod or string can include a blade, the strip, or be attached with the coating (e.g., on a left/right side 122/123 and/or at the rear side 126). Pulling the rod or string can tear the coating to fully or partially separate the coating into two or more pieces.

In another aspect, the pre-formed plug 120 can include an indicator or indicia. The indicator can facilitate visual inspection of each of the pre-formed plugs to direct the installer to release the coating and/or to provide a visual indication that the coating 127 has been released. Such an arrangement can facilitate proper installation and/or visual inspection. In one example, the pull tab 141 can serve as the indicator. If the pull tab 141 is visible, then the coating has not been released. In another example, the front or back face of the pre-formed plug can include a geometric pattern (e.g., symbols, numerals, other recognizable geometric patterns) that distorts when the coating is released. An undistorted geometric pattern indicates that the coating has not been released.

Although mineral wool is disclosed herein, other suitable materials can also be used. Accordingly, references to mineral wool equally refer to other suitable materials. Similarly, any suitable material(s) can be used for the coating and, thus, references to any coating herein can equally refer to other suitable materials. As described above, the coating can include an intumescent or other expandable, fire-blocking or charring materials. In addition, the mineral or other material of the plug can also or alternatively include an intumescent material.

In FIG. 3, a partial cross section of a head-of-wall assembly 100 includes the pre-formed plug 120. The assembly 100 can include a ceiling comprising a concrete-filled fluted pan deck 101 including first and second flute voids 110a, 110b. The header track 130, including a pair of vertical flanges 131 (only one shown) with slots 132, is attached with a lower surface of the deck 101 and extends across the voids 110a, 110b. One or more studs (not shown) are attached with the header track 130. One or more wallboards 104 are attached with the studs to form a wall. The installation of the plug 120 can be performed before or after attachment of the one or more studs and wallboards 104 with the track 130. The plug 120 is shown in the non-expanded state 120a positioned within a first flute void 110a resting on a support surface of the track 130. After insertion, the release mechanism 140 can be activated and the compressed mineral wool released and expanded to contact the sides of the void 110a, as shown by the plug 120b in the expanded state within void 110b.

Certain Terminology

Terms of orientation used herein, such as “top,” “bottom,” “upper,” “lower,” “left,” “right,” “proximal,” “distal,” “longitudinal,” “front,” and “rear,” are used in the context of the illustrated example. However, the present disclosure should not be limited to the illustrated orientation. Indeed, other orientations are possible and are within the scope of this disclosure. Terms relating to circular shapes as used herein, such as diameter or radius, should be understood not to require perfect circular structures, but rather should be applied to any suitable structure with a cross-sectional region that can be measured from side-to-side. Terms relating to shapes generally, such as “circular,” “cylindrical,” “semi-circular,” or “semi-cylindrical” or any related or similar terms, are not required to conform strictly to the mathematical definitions of circles or cylinders or other structures, but can encompass structures that are reasonably close approximations.

Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain examples include or do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more examples.

Conjunctive language, such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain examples require the presence of at least one of X, at least one of Y, and at least one of Z.

The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, in some examples, as the context may dictate, the terms “approximately,” “about,” and “substantially,” may refer to an amount that is within less than or equal to 10% of the stated amount. The term “generally” as used herein represents a value, amount, or characteristic that predominantly includes or tends toward a particular value, amount, or characteristic. As an example, in certain examples, as the context may dictate, the term “generally parallel” can refer to something that departs from exactly parallel by less than or equal to 20 degrees. All ranges are inclusive of endpoints.

SUMMARY

Several illustrative examples of flute plugs have been disclosed. Although this disclosure has been described in terms of certain illustrative examples and uses, other examples and other uses, including examples and uses which do not provide all of the features and advantages set forth herein, are also within the scope of this disclosure. Components, elements, features, acts, or steps can be arranged or performed differently than described and components, elements, features, acts, or steps can be combined, merged, added, or left out in various examples. All possible combinations and subcombinations of elements and components described herein are intended to be included in this disclosure. No single feature or group of features is necessary or indispensable.

Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation also can be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can in some cases be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.

Any portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in one example in this disclosure can be combined or used with (or instead of) any other portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in a different example or flowchart. The examples described herein are not intended to be discrete and separate from each other. Combinations, variations, and some implementations of the disclosed features are within the scope of this disclosure.

While operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Additionally, the operations may be rearranged or reordered in some implementations. Also, the separation of various components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. Additionally, some implementations are within the scope of this disclosure.

Further, while illustrative examples have been described, any examples having equivalent elements, modifications, omissions, and/or combinations are also within the scope of this disclosure. Moreover, although certain aspects, advantages, and novel features are described herein, not necessarily all such advantages may be achieved in accordance with any particular example. For example, some examples within the scope of this disclosure achieve one advantage, or a group of advantages, as taught herein without necessarily achieving other advantages taught or suggested herein. Further, some examples may achieve different advantages than those taught or suggested herein.

Some examples have been described in connection with the accompanying drawings. The figures are drawn and/or shown to scale, but such scale should not be limiting, since dimensions and proportions other than what are shown are contemplated and are within the scope of the disclosed invention. Distances, angles, etc. are merely illustrative and do not necessarily bear an exact relationship to actual dimensions and layout of the devices illustrated. Components can be added, removed, and/or rearranged. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with various examples can be used in all other examples set forth herein. Additionally, any methods described herein may be practiced using any device suitable for performing the recited steps.

For purposes of summarizing the disclosure, certain aspects, advantages and features of the inventions have been described herein. Not all, or any such advantages are necessarily achieved in accordance with any particular example of the inventions disclosed herein. No aspects of this disclosure are essential or indispensable. In many examples, the devices, systems, and methods may be configured differently than illustrated in the figures or description herein. For example, various functionalities provided by the illustrated modules can be combined, rearranged, added, or deleted. In some implementations, additional or different processors or modules may perform some or all of the functionalities described with reference to the examples described and illustrated in the figures. Many implementation variations are possible. Any of the features, structures, steps, or processes disclosed in this specification can be included in any example.

In summary, various examples of flute plugs and related methods have been disclosed. This disclosure extends beyond the specifically disclosed examples to other alternative examples and/or other uses of the examples, as well as to certain modifications and equivalents thereof. Moreover, this disclosure expressly contemplates that various features and aspects of the disclosed examples can be combined with, or substituted for, one another. Accordingly, the scope of this disclosure should not be limited by the particular disclosed examples described above, but should be determined only by a fair reading of the claims.

Claims

1. A head-of-wall assembly for providing fire, smoke and/or sound protection across a building joint, comprising:

a fluted pan deck including at least one flute void extending in a first direction;

a header track attached with a lower surface of the fluted pan deck and extending in a second direction across the flute void, the second direction being transverse to the first direction;

wherein the flute void defines a width in the second direction and a height perpendicular to the first direction and the second direction;

at least one stud attached with the header track;

a wallboard attach with the stud and including an upper end that overlaps the header track;

a pre-formed plug disposed within the flute void and supported by the header track, the pre-formed plug comprising: a fire-resistant material; and an outer coating encasing the fire-resistant material;

wherein in a first configuration, the outer coating compresses the fire-resistant material along a first dimension;

wherein in a second configuration, the outer coating is released to allow expansion of the fire-resistant material along the first dimension.

2. The head-of-wall assembly of claim 1, wherein in the first configuration, the outer coating compresses the fire-resistant material along a second direction and the outer coating is released to allow expansion of the fire-resistant material along the second dimension in the second configuration.

3. The head-of-wall assembly of claim 2, wherein the first dimension is parallel with the width of the flute void.

4. The head-of-wall assembly of claim 3, wherein the second dimension is parallel with the height of the flute void.

5. The head-of-wall assembly of claim 4, wherein in the first configuration, the first dimension is less than the width of the flute void and the second dimension is less than the height of the flute void, and in the second configuration, the first dimension is expanded to the width of the flute void and the second dimension is expanded to the height of the flute void, and the fire-resistant material remains compressed within the flute void.

6. The head-of-wall assembly of claim 4, wherein the first dimension is within 95-105% of the width of the flute void and the second dimension is within 95-105% of the height of the flute void.

7. The head-of-wall assembly of claim 1, wherein the outer coating is shrink-wrapped about the fire-resistant material in the first configuration.

8. The head-of-wall assembly of claim 1, wherein the outer coating is vacuum-sealed about the fire-resistant material in the first configuration.

9. The head-of-wall assembly of claim 1, wherein the outer coating comprises a latex material about the fire-resistant material in the first configuration.

10. The head-of-wall assembly of claim 1, wherein releasing the outer coating to allow expansion of the fire-resistant material includes rupturing the outer coating.

11. The head-of-wall assembly of claim 1, further comprising a release mechanism attached with the outer coating and configured to rupture the outer coating.

12. The head-of-wall assembly of claim 1, wherein the pre-formed plug includes an indicator that shows whether the outer coating has been released.

13. (canceled)

14. (canceled)

15. (canceled)

16. A pre-formed flute plug configured to be installed within a flute void, comprising:

an outer coating encasing a compressed fire-resistant material.

17. The flute plug of claim 16, further comprising:

a length extending from a first end to a second end;

a height extending from an upper surface to a lower surface; and

a width extending from a left surface to a right surface;

wherein in a first configuration, the outer coating compresses the fire-resistant material along a first dimension;

wherein in a second configuration, the outer coating is released to allow expansion of the fire-resistant material along the first dimension.

18. The flute plug of claim 17, wherein in the first configuration, the outer coating compresses the fire-resistant material along a second direction and the outer coating is released to allow expansion of the fire-resistant material along the second dimension in the second configuration.

19. The flute plug of claim 18, wherein the first dimension is the width and the second dimension is the height.

20. The flute plug of claim 17, wherein the outer coating is shrink-wrapped about the fire-resistant material in the first configuration.

21. The flute plug of claim 17, wherein the outer coating is vacuum-sealed about the fire-resistant material in the first configuration.

22. The flute plug of claim 17, wherein the outer coating comprises a latex material about the fire-resistant material in the first configuration.

23. The flute plug of claim 16, further comprising:

an outer perimeter extending about a transverse section of the of the flute plug;

wherein in a first configuration, the outer perimeter has a first length;

wherein in a second configuration, the outer perimeter has a second length, greater than the first length.

24. The flute plug of claim 16, further comprising a release mechanism attached with the outer coating and configured to rupture the outer coating.

25. The flute plug of claim 23, wherein the release mechanism includes a material strip and a pull tab.

26. (canceled)