Fire or Sound Blocking Components and Wall Assemblies with Fire or Sound Blocking Components

This application is related to and claims the benefit of U.S. Provisional Application No. 63/651,658, filed May 24, 2024, titled FIRE OR SOUND BLOCKING COMPONENTS AND WALL ASSEMBLIES WITH FIRE OR SOUND BLOCKING COMPONENTS, the entirety of which is incorporated by reference herein and made a part of the present disclosure.

The present disclosure relates to fire-resistant or sound-resistant building structures. In particular, the present disclosure relates to a fire or sound blocking wall assemblies and related components.

Fire-rated or sound-rated construction components and assemblies are commonly used in the construction industry. These components and assemblies are aimed at inhibiting or preventing fire, heat, smoke or sound from leaving one room or other portion of a building and entering another room or portion of a building. The fire, heat, smoke or sound usually moves between rooms through vents, joints in walls, or other openings. The fire-rated components often incorporate fire-retardant materials that 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. Similarly, sound-rated components block sound from moving between rooms.

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.

One particular wall joint with a high potential for allowing fire, heat, smoke or sound 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. One 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.

Another feature that requires fire protection is an aesthetic reveal feature within or along an edge of a wall. A reveal is a gap within or along a top, bottom or side edge of the wall. Conventionally, the reveal is created by using an additional cosmetic layer of wall board over top of one or more underlying layers of wall board. The underlying layer(s) provide the desired fire rating to the wall-including to the reveal gap. However, this method of creating a cosmetic reveal requires nearly an entire extra layer of wall board material.

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.

An aspect of the present disclosure involves a fire-blocking bead element to provide a fire-rated seal to a gap of a wall assembly, the fire-blocking bead element including: A profile structure, including: a first leg, the first leg including a free edge portion and an attachment portion, the first leg configured to extend along an outward-facing surface of a wall board of the wall assembly in use; and a second leg, the second leg including a first surface and a second surface opposite the first surface, wherein the second leg is coupled to the first leg at the attachment portion of the first leg to form a corner of the profile structure, wherein the second leg is configured to be located between an edge of the wall board and an adjacent structure in use; a gasket element positioned on the first surface of the second leg, wherein the gasket element is compressible to conform to an irregular surface of the adjacent structure; and a flexible sealing leg located on the second leg between the compressible gasket element and a free end of the second leg such that the flexible sealing leg is located between the compressible gasket element and a header track of a wall assembly in use, wherein the flexible sealing leg is configured to contact the overhead structure; and a fire blocking material strip located on the second surface of the second leg and configured to expand in response to heat, wherein the fire blocking material strip includes a first side and a second side opposite the first side, wherein the first side is coupled to the second leg and the second side is configured to contact the edge of the wall board in use.

In some configurations, the profile structure includes an L-shape.

In some configurations, the gasket element is spaced away from the corner of the profile structure.

In some configurations, the first leg, the second leg, the gasket element, and

the flexible sealing leg form a unitary structure.

In some configurations, the unitary structure includes vinyl.

In some configurations, the fire blocking material strip includes intumescent material.

In some configurations, the first leg has a width of about 1⅛″.

In some configurations, the profile structure further includes a tear off strip coupled to the first leg.

In some configurations, the gasket element is a bubble gasket.

In some configurations, the bubble gasket is hollow.

In some configurations, the edge of the wall board is an upper edge of the wall board, a lower edge of the wall board, or a side edge of the wall board.

In some configurations, the first leg includes a plurality of perforations.

In some configurations, the attachment portion includes an L-shaped offset.

In some configurations, the gap is oriented vertically, horizontally, or at an angle across the wall assembly.

In some configurations, a height of the flexible sealing leg is larger than a height of the gasket element.

In some configurations, a height of the flexible sealing leg is between 120% and 180% of a height of the gasket element.

In some configurations, the first leg further includes a first surface and a second surface, wherein the first surface is configured to face the outward-facing surface of the wall board and the second surface is configured to face away from the outward-facing surface of the wall board, and wherein the flexible sealing leg does not extend past the second surface when in contact with the overhead structure.

An aspect of the present disclosure involves a fire-rated wall assembly including: a wall board; an adjacent structure, the adjacent structure spaced from the wall board to form a gap; a fire-blocking bead element, the fire-blocking bead element including: a profile structure, including: a first leg, the first leg including a first end and a second end opposite the first end, the second end including a terminal free edge, wherein the first leg is located along an outward-facing surface of the wall board of a wall; and a second leg, the second leg including a first surface and a second surface opposite the first surface, wherein the second leg is coupled to the first leg to form a generally L-shaped structure in cross-section having a corner, wherein the second leg is located between an edge of the wall board and the adjacent structure; a gasket element positioned on the first surface of the second leg and disposed within the gap, wherein the gasket element is compressible to engage with the adjacent structure to seal across the gap; and a flexible sealing leg located on the second leg between the compressible gasket element and a free end of the second leg such that the flexible sealing leg is located between the compressible gasket element and a header track of a wall assembly in use, wherein the flexible sealing leg is configured to contact the overhead structure. a fire blocking material strip located on the second surface of the second leg and configured to expand in response to heat, wherein the fire blocking material strip includes a first side and a second side opposite the first side, wherein the first side of the fire blocking material strip is connected to the second leg and the second side of the fire blocking material strip contacts the edge of the wall board.

In some configurations, the adjacent structure is an overhead structure, a lower structure, or a side structure.

In some configurations, the first surface of the second leg is an upper surface, a lower surface, or an outer side surface.

In some configurations, the first end of the first leg includes an offset from the second leg, the offset configured to receive a joint compound.

In some configurations, the gasket element is spaced away from the corner.

In some configurations, the gap is oriented vertically, horizontally, or at an angle across the wall assembly.

Embodiments of systems, components and methods of assembly and manufacture will now be described with reference to the accompanying figures, wherein like numerals refer to like or similar elements throughout. Although several embodiments, examples and illustrations are disclosed below, it will be understood by those of ordinary skill in the art that the inventions described herein extends beyond the specifically disclosed embodiments, examples and illustrations, and can include other uses of the inventions and obvious modifications and equivalents thereof. The terminology used in the description presented herein is not intended to be interpreted in any limited or restrictive manner simply because it is being used in conjunction with a detailed description of certain specific embodiments of the inventions. In addition, embodiments of the inventions can comprise several novel features and no single feature is solely responsible for its desirable attributes or is essential to practicing the inventions herein described.

Certain terminology may be used in the following description for the purpose of reference only, and thus are not intended to be limiting. For example, terms such as “above” and “below” refer to directions in the drawings to which reference is made. Terms such as “front,” “back,” “left,” “right,” “rear,” and “side” describe the orientation and/or location of portions of the components or elements within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the components or elements under discussion. Moreover, terms such as “first,” “second,” “third,” and so on may be used to describe separate components. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import.

An aspect of the present disclosure relates to a component, which can be referred to as a fire-blocking bead. In some configurations, the component can have at least a first leg and a second leg arranged to form a generally L-shaped structure when viewed from the end or in cross-section. The first leg is configured to extend along an upper edge of an outward-facing or exposed surface of wall board of a wall in use. The second leg is configured to extend along an upper end surface of the wall board in use. In a finished wall assembly, the first leg can be covered by joint compound and may include features (e.g., an array of openings) that facilitate attachment to the wall board and/or the use of joint compound. The component may also include a gasket element configured to contact and/or create a seal with a ceiling or other overhead structure associated with the wall. In some configurations, the gasket element is a bubble gasket having a wall that defines an interior air space. The wall of the bubble gasket can be compressible so that the bubble gasket can conform to the ceiling or other overhead structure. The bubble gasket can be hollow (e.g., filled with atmospheric air or another gas, which can be pressurized or not). The bubble gasket can be located on the second leg. The bubble gasket can be located at or near a corner or transition between the first leg and the second leg. The bead element can also include a fire-blocking material. In some configurations, the fire-blocking material is located on the second leg. The bubble gasket can be located between the fire-blocking material and the corner or the first leg. In some configurations, the fire-blocking material is located at or near a free end portion of the second leg. The bubble gasket can be set back from the corner to create a recessed reveal along the second leg. One or both of the fire-blocking material and the bubble gasket can be located on an upward-facing or outward-facing surface of the bead element. The fire-blocking material can be an intumescent material, such as an intumescent material strip or intumescent foam. Intumescent materials expand under exposure to elevated temperatures, but expansion alone may not provide a proper seal against fire, and smoke. It can be important to effectively contain the expanded intumescent material within the head of wall joint so that it does not expand in a manner that will allow it to fall out of the joint. Another aspect of the present disclosure is a wall assembly incorporating one or more of the above-described fire-blocking bead elements.

illustrates a fire-blocking bead element or component. The bead elementcan be constructed in whole or in part from a suitable polymer material, such as a vinyl. The illustrated bead elementincludes a first legand a second legarranged to form a generally L-shaped profile structurewhen viewed from the end or in cross-section. In the illustrated arrangement the first legis slightly set back from an attached edge of the second legto create a space to receive joint compound such that an outer surface of the joint compound ends up flush with the outer or attached edge of the second leg. In other arrangements, the profilecan include additional legs or portions.

illustrates the bead elementincorporated into a wall assemblyhaving a head-of-wall arrangement. The illustrated wall assemblyis an interior wall of a well-known stud wall arrangement having a dynamic head-of-wall. The wall assemblyincludes a bottom track (not shown), a header track, and a plurality of studsthat extend between and have ends attached to the bottom track and the header track. One or more pieces of wall board(e.g., gypsum board or drywall) is attached to the studsand bottom track so that the wall board, studsand bottom track are free to move relative to the header trackand an overhead structureto which the header trackis attached. The overhead structurecan be a ceiling or a floor of a higher-level floor of a multi-story building.

The first legof the componentis configured to extend along an upper edge of an outward-facing or exposed surface of the wall boardin use, as shown in. The second legis configured to extend along an upper end surface of the wall boardin use, as shown in. In a finished wall assembly, the first legcan be covered by joint compoundand may include features (e.g., an array of openings) that facilitate attachment of the componentto the wall boardand/or the use of the joint compound.

In some configurations, the bead elementcan also include a gasket portion or gasket elementconfigured to contact and/or create a seal with the ceilingor other overhead structure associated with the wall, as shown in. In some configurations, the gasket element is in the form of a bubble gasket, which has a wall that defines an interior space. The wall of the bubble gasketcan be compressible so that the bubble gasketcan conform to the ceilingor other overhead structure. That is, the bubble gasketpreferably conforms to irregularities in the ceilingor other overhead structure to maintain a seal with the ceiling. In addition, the bubble gasketis configured to accommodate relative movement between the walland the ceilingthat causes variations in the size of the deflection gap. Preferably, the bubble gasketis configured to maintain a seal or at least a substantial seal with the ceilingdespite relative movement between the walland the ceiling.

The bubble gasketcan be hollow (e.g., filled with atmospheric air or another gas, which can be pressurized or not) or filled with a non-gas substance (e.g., compressible foam). In the illustrated arrangement, the bubble gasketis unitarily-formed with the first legand/or the second leg. In other arrangements, the bubble gasketcan be formed separately from the first legand/or the second legand affixed thereto. In some configurations, the bubble gasketis co-extruded with the first legand the second leg. The bubble gasketcan be the same or a different material from the first legand/or the second leg. In some configurations, the first legand the second legare constructed from a vinyl material, or a similar material. The bubble gasketcan be constructed of a vinyl material or can be another suitable material, such as an elastomeric or rubber-like material. The bubble gasketcan have a different wall thickness (e.g., smaller or larger wall thickness) than one or both of the first legand/or the second leg. Any one or combination of the first leg, the second leg, and the bubble gasketcould also have multiple layers, which can include a vinyl (or similar) layer and a foil (or similar, preferably metal or metalized) layer (e.g., foil tape).

The bubble gasketcan be located only on the second leg. The bubble gasketcan be located at or near a corner or transition between the first legand the second leg. In such configurations, a portion of the bubble gasketcan be aligned with or substantially aligned with the first leg. As used herein, the bubble gasketbeing substantially aligned with the first legmeans that the relevant portion of the bubble gasketis configured to be aligned with a surface of the joint compoundin an installed configuration. In some arrangements, the bubble gasketincludes a planar or substantially planar wall that faces outwardly as installed. However, other cross-sectional shapes of the bubble gasketare also possible. Furthermore, in other arrangements, the bubble gasketcan be set back along the second legsuch that it is spaced rearwardly or inwardly from an exposed surface of the wall boardand/or joint compound.

The bead elementcan also include a fire-blocking material. In some configurations, the fire-blocking materialis located on the second leg. The second legcan have a portion located inward (relative to an exposed surface of the wall) of the bubble gasketon which the fire-blocking materialis located. In other words, the bubble gasketcan be located between the fire-blocking materialand the corner or the first leg. In some configurations, the fire-blocking materialis located at or near a free end portion of the second leg. One or both of the fire-blocking materialand the bubble gasketcan be located on an upward-facing or outward-facing surface of the bead element. The fire-blocking materialcan be an intumescent material, such as an intumescent material adhesive strip, an intumescent paint or an intumescent foam. As is known, an intumescent material expands in response to elevated temperature to create a fire-blocking char.

As used herein, a fire-blocking material, component or arrangement provides greater fire-blocking properties than some or all of the surrounding building materials, such as the wall board, for example. A fire-blocking material, component or arrangement preferably permits the associated structure to achieve a fire rating by passing relevant fire tests, such as but not limited to relevant UL fire tests or other relevant fire rating tests or standards (e.g., UL-2079). Similarly, a sound blocking material, component or arrangement provides greater sounding blocking properties than the surrounding building materials or than conventional arrangements. A sound blocking material preferably permits the associated structure to achieve a sound rating (e.g., Sound Transmission Class (STC) ratings) that is higher than a standard metal stud wall assembly. Fire-blocking or sound blocking is not intended to require the prevention of heat, smoke, fire or sound passage across the wall.

The illustrated bead elementis well-suited for use in a wall assembly having a single layer of wall board. The bead elementcan be elongate and have a consistent cross-sectional shape throughout its length. The length can be selected to provide a compromise between case of manufacture/storage/shipping and wall length coverage in use. Suitable lengths can be between about 8 feet and about 16 feet, for example and without limitation. In some configurations, a width of the bubble gasketand a width of the intumescent material(or a portion of the second leglocated inward of the bubble gasket) can be equal or substantially equal (e.g., about one-quarter or five-sixteenths inch). In wall assemblies having additional layers of wall board, a width (or cross-sectional length) of the second legmay be increased. In some configurations, the width (or cross-sectional length) of the second legcan be approximately equal to the total thickness of the wall board. In such arrangements, the width of the bubble gasketand the width of the intumescent materialcan be the same as one another and/or the same as in the bead elementconfigured for a single layer of wall board. Alternatively, a width of one or both of the bubble gasketand the intumescent materialcan be increased. A height of the bubble gasketcan be equal to or slightly greater than a desired maximum deflection gap of the associated wall assembly. In some cases, the height of the bubble gasketcan be between about one-half inch to about one inch.

illustrates the bead elementin the wall assemblyat an elevated temperature. The profileportion and/or bubble gasketof the bead elementare illustrated in dashed line indicating that they are starting to melt away. The intumescent stripis illustrated as expanding. Preferably, expansion of the intumescent stripbegins before one or both of the profileportion and the bubble gasketfully melt or dissipate.

illustrates additional embodiments of the bead element. These bead elementsmay be similar in many respects to the bead elements described above and are described below with an emphasis on the differences relative to the previously-described bead elements. Therefore, features that are not described below can be the same as or similar to the corresponding features of the other embodiments described herein, or can be of another suitable arrangement.

With respect to, an outermost portion of the gasket elementis set back from the corner or the outer edge of the second leg. Such an arrangement provides a space or reveal above the upper end of the wall board(). In the illustrated arrangement, the gasket elementis a single wall construction having an edge (or end in cross-section) connected to the second legand a free edge (or end). The gasket elementis planar or substantially planar and is oriented perpendicular or substantially perpendicular to the second leg. However, in other arrangements, the gasket elementcould have multiple walls or wall portions that connect to the profileat two or more locations to define an enclosed interior space.

illustrated a bead elementhaving a slightly curved single wall gasket element. In the illustrated arrangement, the gasket elementis located at or near the corner between the first legand the second legor at the outer edge of the second leg. Accordingly, the gasket elementcan be align with or substantially aligned with the first leg. The gasket elementis oriented perpendicular or substantially perpendicular to the second leg. In other arrangements, the gasket elementcould be set back along the second legand/or could have multiple walls or wall portions that connect to the profileat two or more locations to define an enclosed interior space.

illustrate another fire-blocking bead elementand a wall assemblyincorporating the bead element. The bead elementis similar in many respects to the bead elements described above and is described below with an emphasis on the differences relative to the previously-described bead elements. Therefore, features that are not described below can be the same as or similar to the corresponding features of the other embodiments described herein, or can be of another suitable arrangement.

The bead elementofincludes a first legand a second legthat cooperate to form a profile. In the illustrated arrangement, the profileis in the form of an angleand is made up in whole or a substantial entirety by the first legand the second leg. However, in other arrangements, the profilecan include additional legs or portions. In the illustrated arrangement, the first legand the second legare oriented perpendicular or substantially perpendicular to one another.

The bead elementincludes a gasket element, which can be in the form of a bubble gasketsuch as those described herein. The bubble gasketextends upwardly from an upper surface of the second legwith the bead elementoriented as employed in a head-of-wall gap. In the illustrated arrangement, the bubble gasketis located at or adjacent a corner defined between the first legand the second leg. The illustrated bubble gaskethas one end connected to the first legand one end connected to the second leg. However, in some arrangements, both ends can be connected to a single one of the first legand the second leg.