Fire-Rated Joint Component and Wall Assembly

Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference in their entirety.

The disclosure generally relates to fire-rated building structures. In particular, the disclosure relates to fire-rated joint systems, wall assemblies, and other building structures that incorporate the fire-rated joint systems.

Fire-rated construction components and assemblies are commonly used in the construction industry. These components and assemblies are aimed at inhibiting or preventing fire, heat, or smoke from leaving one room or other portion of a building and entering another room or portion of a building. The fire, heat or smoke usually moves between rooms through vents, joints in walls, or other openings. The fire-rated components often incorporate fire-retardant materials which substantially block the path of the fire, heat or smoke for at least some period of time. Intumescent materials work well for this purpose, because they swell and char when exposed to flames helping to create a barrier to the fire, heat, and/or smoke.

One particular wall joint with a high potential for allowing fire, heat or smoke to pass from one room to another is the joint between the top of a wall and the ceiling, which can be referred to as a head-of-wall joint. In modern multi-story or multi-level buildings, the head-of-wall joint is often a dynamic joint in which relative movement between the ceiling and the wall is permitted. This relative movement is configured to accommodate deflection in the building due to loading of the ceiling or seismic forces. The conventional method for creating a fire-rated head-of-wall joint is to stuff a fire-resistant mineral wool material into the head-of-wall joint and then spray an elastomeric material over the joint to retain the mineral wool in place. This conventional construction of a fire-rated head-of-wall joint is time-consuming, expensive and has other disadvantages.

A wall assembly commonly used in the construction industry includes a header track, bottom track, a plurality of wall studs and a plurality of wall board members, possibly among other components. A typical header track resembles a generally U-shaped (or some other similarly shaped) elongated channel capable of receiving or covering the ends of wall studs and holding the wall studs in place. The header track also permits the wall assembly to be coupled to an upper horizontal support structure, such as a ceiling or floor of a higher level floor of a multi-level building.

Header tracks generally have a web and a pair of flanges, which extend in the same direction from opposing edges of the web. The header track can be a slotted header track, which includes a plurality of slots spaced along the length of the track and extending in a vertical direction. When the wall studs are placed into the slotted track, each of the plurality of slots aligned with a wall stud accommodates a fastener used to connect the wall stud to the slotted track. The slots allow the wall studs to move generally orthogonally relative to the track, creating a variable deflection gap between the wallboard and the upper horizontal support structure. In those areas of the world where earthquakes are common, movement of the wall studs is important. If the wall studs are rigidly attached to the slotted track and not allowed to move freely in at least one direction, the stability of the wall and the building might be compromised. With the plurality of slots, the wall studs are free to move. Even in locations in which earthquakes are not common, movement between the studs and the header track can be desirable to accommodate movement of the building structure due to other loads, such as stationary or moving overhead loads.

Recently, improvements to fire-rated head-of-wall joints have been developed. One example is the use a metal profile having a layer of intumescent material in a head-of-wall joint, such as the fire-rated angle manufactured and sold by the Applicant under the trade name Deflection Drift Angle (DDA™). The DDA™ angle is further described in U.S. Pat. No. 8,595,999, the entirety of which is hereby incorporated by reference. The DDA™ angle can be installed along with the installation of the header track or can be installed after the installation of the header track. Such an arrangement avoids the need to have the framers return after the installation of the wall board to install fire sealant in the deflection gap between the edge of the wall board and the overhead structure. When temperatures rise (e.g., due to a fire), the intumescent material on the DDA™ fire block product expands. This expansion creates a barrier which fills the deflection gap and inhibits or at least substantially prevents fire, heat and smoke from moving through the head-of-wall joint and entering an adjacent room for at least some period of time.

Although the DDA™ fire block represents an improvement over the conventional method of stuffing mineral wool material into the head-of-wall joint and applying the elastomeric spray material over the mineral wool, there still exists room for improved or alternative products, materials and methods for efficiently and cost-effectively creating fire-rated wall joints. The systems, methods and devices described herein have innovative aspects, no single one of which is indispensable or solely responsible for their desirable attributes. Without limiting the scope of the claims, some of the advantageous features will now be summarized.

One aspect of the present disclosure is a head-of-wall assembly that allows dynamic movement. The assembly includes a header track configured to be coupled to an upper surface. The header track has a web and first and second flanges extending from the web in the same direction. Each of the first and second flanges is substantially planar such that the track defines a substantially U-shaped cross section. At least one stud is coupled to the header track. An upper end of the stud is located between the first and second flanges. A wallboard is coupled to the stud. An upper end of the wallboard overlaps the first flange of the header track. A deflection gap is formed between the upper end of the wallboard and the upper surface. The deflection gap being variable between a closed position and an open position. A gasket profile has a vinyl profile, the vinyl profile has an upper flange, a body flange defining an air gap, a bubble gasket, and a leg portion. The leg portion is substantially vertical. A foam tape is configured to couple the vinyl profile to the first flange of the header track.

In another aspect of the assembly, the foam tape is positioned between the leg flange and the wallboard and the leg portion and the foam tape space the wallboard out from the first flange of the header track to create a spacing.

In another aspect of the assembly, a head of a fastener attaching the at least one stud with the first flange of the header track fits within the spacing.

In another aspect of the assembly, the foam tape attaches the leg flange with the header track along a length of the vinyl profile.

In another aspect of the assembly, a foil lining is attached to the vinyl profile in the air gap, and an intumescent material is attached to the foil lining within the air gap.

In another aspect of the assembly, the foam tape creates a seal along an entire length of the leg portion.

One aspect of head-of-wall assemblies including a fire-blocking gasket according to the present disclosure is sealing of the head-of-wall joint against noise, heat and/or smoke. Noise, smoke, heat, etc. can pass between adjacent room across a head-of-wall assembly. In some head-of-wall assemblies, the noise, smoke or heat can pass through the deflection gap. The more open the deflection gap, the more noise, smoke or heat that can pass and the more closed the joint, the less noise, smoke or heat that can pass. Sealing against noise, smoke or heat passing across a head-of-wall joint can advantageously provide the benefits of sound, smoke or heat isolation and containment. Thus, various embodiments of this disclosure relate to improved sealing across a head-of-wall assembly using an improved fire-blocking gasket.

Another aspect of some header block assemblies having a fire-blocking gasket in the present disclosure is the use of a vinyl material (or other polymer or plastic material) for a profile of the fire-blocking gasket. Vinyl material offers several advantages over known materials in fire-blocking gaskets and similar assemblies. For example, vinyl material can be incredibly flexible and can function to aid in the sealing across head-of-wall assembly. The vinyl material can also allow for compressible track profiles that can collapse and expand within a head-of-wall assembly corresponding to the closed and open positions of the deflection gap. Vinyl material can be easily extruded and co-extruded with other materials. The vinyl material can also be produced cheaply and in large quantities and it also ships lighter than other materials (e.g. metals) having similar volumes and dimensions.

Another aspect of some head-of-wall assemblies including a fire-blocking gasket according to the present disclosure is the use of an air gap within the track profile. The air gap can be located within the fire-blocking gasket profile and can reduce the transfer of heat to a thermocouple for use in UL testing. This can allow the fire-blocking gasket profile to pass the test by reducing the transfer of heat via the air gap. The air gap can reduce heat transferred to an intumescent material assembled within the air gap. The intumescent material can be positioned within the air gap.

Another aspect of some head-of-wall assemblies having a fire-blocking gasket profile according to the present disclosure is the use of a foil tape or other foil layer lining the vinyl profile. For example, the foil tape can fully or partially line the air gap within the vinyl profile. The intumescent material can be attached to the foil tape and the foil tape can be attached to the vinyl material. The foil tape can provide additional protection for the vinyl material and the intumescent material and/or containment of the intumescent material during expansion of the intumescent material.

Another aspect of some head-of-wall assemblies having a fire-blocking gasket profile according to the present disclosure is a vinyl profile that has an outward facing contoured and/or round profile that can compress flatly against the leg of a header track of the head-of-wall assembly. The vinyl profile can compress flat against the leg of the header track when the deflection gap is in the fully closed position and it can spring back out when the deflection gap is in the open position.

In one embodiment a fire-blocking gasket profile is an elongate, multi-layer fire-rated joint component (e.g., head-of-wall component) comprising three layers. A first layer is a vinyl profile. A second layer is a foil liner. A third layer is a strip of intumescent material. The second layer (foil liner) can be located between the intumescent material and the vinyl profile. The third layer (intumescent strip) can be attached to the second layer or to the first layer on an inner surface of the leg of the vinyl profile.

Another aspect of the fire-blocking gasket profile is the vinyl profile has an outward facing round contoured profile that will compress generally flat against the leg of the track when a deflection gap of the head-of-wall assembly is in a closed position and spring back out when the deflection gap is in an open position. The round contoured profile can aid in sealing across the head-of-wall assembly by engaging with a ceiling structure thereof.

Another aspect of the fire-blocking gasket profile is that the foil liner provides further heat protection to the vinyl and/or intumescent material. This extra heat protection allows the intumescent material to expand and fully seal off the deflection gap even after the vinyl material begins to burn away and before the foil liner burns away. In some configurations, vinyl burns away at approximately 500° F. and foil tape burns away at approximately 1200° F.

Another aspect of the fire-blocking gasket profile is an air gap within the vinyl profile. The air gap can contain or partially contain the intumescent material. The foil liner can at least partially line the air gap. The air gap can slow the transfer of heat across the fire-blocking gasket profile to allow passage of UL testing and/or to delay or slow the expansion of the intumescent material.

In another aspect of this disclosure, the vinyl profile can be attached within the head of wall assembly by a foam tape. The foam tape can be attached along a leg flange of the vinyl profile. The foam tape can have adhesive on either side thereof; one side can attach with the leg of the vinyl profile and the other side can attach with a leg of the header track within the head of wall assembly.

In another aspect, the foam tape can improve the seal of the bubble gasket with the ceiling and/or the seal between the leg flange and the header track of the head of wall assembly. Mechanical fasteners attaching the vinyl profile with the header track can allow sagging. The sagging can inhibit the seal of the vinyl profile with the header track and/or the seal of the bubble gasket with the ceiling (e.g., at spans between mechanical fasteners). Accordingly, the foam tape can improve the seal by providing a continuous (or nearly continuous) support to the vinyl profile.

In another aspect, the foam tape can create a spacing between the header track and the wallboard. The spacing can fit a head of a fastener attaching the studs to the header track. The spacing can allows for movement of the fastener head within the head of wall assembly due to cycling movement between the ceiling and the studs.

In another aspect, the vinyl profile can include a foil and/or intumescent layer and be used for fire, smoke, and sound sealing. In another aspect, the vinyl profile can be without the foil and/or intumescent layer and be used for sound sealing.

An aspect of the present disclosure involves a fire-rated component for sealing a head of wall gap. The component includes an elongate body comprising at least a first layer of a first material. The first layer includes a planar lower portion configured to allow the component to be secured to a flange of a header track of a wall assembly and a non-planar upper portion configured to seal against an overhead structure above the wall assembly. The non-planar upper portion is further configured to define an air gap between an interior surface of the component and the flange of the header track.

In some configurations, the non-planar upper portion comprises a first portion and a second portion, the first portion being relatively closer to the planar lower portion and extending therefrom in a first direction, the second portion extending from the first portion in a second direction opposite the first direction such that, in an in-use orientation, the first portion extends away from the flange of the header track and the second portion extends toward to the flange.

In some configurations, the first portion comprises a planar section.

In some configurations, the second portion comprises a curved section.

In some configurations, the second portion comprises at least one planar section.

In some configurations, the second portion comprises a first planar section and a second planar section, wherein the second planar section is parallel to the planar lower portion.

In some configurations, the first layer further comprises a hollow gasket portion positioned on an upper end of the non-planar upper portion and configured to contact the overhead structure.

In some configurations, the hollow gasket portion has a circular cross-sectional shape.

In some configurations, the first material is a polymer.

In some configurations, the polymer is a vinyl.

In some configurations, the fire-rated component further includes a second layer of a foil material.

In some configurations, the second layer covers at least a portion of the interior surface of the first layer.

In some configurations, the second layer covers at least a portion of the interior surface of the non-planar upper portion.

In some configurations, the fire-rated component further includes a third layer, which comprises an intumescent material.

In some configurations, the third layer is located only on the interior surface side of the non-planar upper portion.

In some configurations, the second layer is located between the first layer and the third layer.

In some configurations, a melting temperature of the foil material is greater than an expansion temperature of the intumescent material.

In some configurations, the melting temperature of the foil material is greater than a melting temperature of the first material.

In some configurations, an adhesive tape is positioned on the interior surface side of the planar lower portion and configured to secure the component to the flange of the header track.

In some configurations, the adhesive tape is a foam tape.

An aspect of the present disclosure includes a wall assembly having a header track configured to be coupled to a surface of an overhead structure. The header track has a web and first and second flanges extending from the web in the same direction, wherein each of the first and second flanges is substantially planar such that the track defines a substantially U-shaped cross section. At least one stud is coupled to the header track, and an upper end of the stud is located between the first and second flanges. At least one wallboard is coupled to the stud, and an upper end of the wallboard overlaps the first flange of the header track. A deflection gap is formed between the upper end of the wallboard and the surface of the overhead structure, with the deflection gap being variable between a closed position and an open position. The wall assembly includes a fire-rated component as described herein, wherein the planar lower portion is coupled to the first flange of the header track and positioned between the first flange and the wallboard, and the non-planar upper portion is positioned at least partially within the deflection gap in the open position and contacts the surface of the overhead structure.

In some configurations, the non-planar upper portion is configured to collapse to reduce the air gap in response to upward movement of the at least one wallboard over the non-planar upper portion.

An aspect of the present disclosure involves a method of creating a fire-rated head-of-wall gap, the method including securing a header track to an overhead structure, positioning an upper end of a stud into the header track, and coupling a planar lower portion of a fire-rated component to the header track such that a non-planar upper portion of the fire-rated component cooperates with a flange of the header track to define an air gap between the fire-rated component and the header track.