INTUMESCENT COLLARED SCAB FRAMING ELEMENT

Description

TECHNICAL FIELD

The present invention relates generally to building construction systems and, more particularly, to building construction framing elements and related methods that facilitate the construction of fire-rated wall assemblies within a building.

BACKGROUND OF THE INVENTION

In the building construction industry, the construction of fire-rated wall assemblies within a building is an important construction detail that, if properly and compliantly done, promotes life safety (namely, by preventing and/or by reducing the spread of fire and smoke in the event of a building fire).

Nowadays, there are two primary methods used for sealing linear junctions (e.g., head-of-wall joints and expansion joints) against the spread of fire and smoke; namely, by (1) applying a firestop intumescent sealant (in the form of either a caulk, tape, or spray) along and into the linear joint, or (2) installing a specialty track (and/or other suitable specialty framing member) that has had a pre-applied intumescent tape appropriately placed on the track/framing member (such that the intumescent tape seals the linear construction joint). These two methods are widely used and both have been tested and certified by Underwriter Laboratories, Inc. (“UL” is an independent worldwide testing and regulatory compliance certification organization) as being compliant with certain specified fire and hose stream UL test standards.

For example, UL has tested and certified various building construction “joint systems” in accordance with their testing standards set forth in “UL 2079 Tests for Fire Resistance of Building Joint Systems, fifth edition (Aug. 26, 2015).” These enhanced UL fire test standards apply to a large number of building construction joint systems (and related wall assemblies) of various materials and construction. UL's joint system fire tests evaluate the length of time that a specified joint system will contain a fire during a predetermined/controlled exposure to fire. Consequently, UL's joint system fire tests evaluate the joint system's resistance to heat and, in some instances, to a hose stream, while carrying an applied load (if the assembly is load bearing). UL's joint system fire tests may, in some instances, include an air leakage test to determine the rate of air leakage through joint systems resulting from a specified air pressure difference applied across the surface of the joint system.

In the building construction industry, metal framing assemblies are commonly used to construct commercial and residential buildings. Metal framing assemblies are generally constructed from a plurality of metal framing elements including studs, joists, trusses, and other metal posts and beams (e.g., I-beams) formed from sheet metal (and frequently fabricated to have the same general cross-sectional dimensions as standard wooden members used for similar purposes). Metal framing elements are typically constructed by either brake-pressing or roll-forming (with both methods being referred to as “cold-formed” processing) 12-to-24-gauge galvanized sheet steel. Although many cross-sectional shapes are available, the primary shapes used in building construction are C-shaped studs and U-shaped tracks. For example, most wall assemblies are constructed from U-shaped tracks fastened to the floor (footer) and ceiling (header) with a plurality of C-shaped studs laterally spaced apart, and vertically positioned between, the opposing header and footer tracks.

The sealing of perimeter and head-of-wall linear joints (especially dynamic head-of-wall joints) is an important aspect of building construction because a robust and effective seal can impede and/or prevent the spread of fire, smoke and sound. In particular, it is especially important to adequately seal head-of wall joints around areas having cut-away through-hole penetrations (vertical and horizontal) that result from various piping (e.g., CPVC and PVC) and conduit installations.

Although some progress has been made over the years, there is still a need in the art for new and improved building construction products that better promote life safety-including innovative building construction products that facilitate the sealing of head-of-wall penetrations, which, in turn, better seal linear construction joints (for purposes of impeding the transmission of fire and smoke in the event of a building fire, and/or impending the transmission of sound from one room to another). In particular, there is a need in the art for new and improved devices that facilitate the sealing of areas around vertical and horizontal pipes/conduits that pierce through head-of-wall assemblies. The present invention fulfills these needs and provides for further related advantages.

SUMMARY OF THE INVENTION

In brief, the present invention in an embodiment is directed to an intumescent collared scab framing element for use in building construction. The inventive intumescent collared scab element is particularly useful for blocking (i.e., providing a backing substrate) and sealing a cut-away opening of a head-of-wall track installed on a ceiling within a building under construction, wherein the opening has a horizontal pipe (e.g., CPVC or PVC) or metal conduit penetration, and wherein the pipe or conduit is positioned along the ceiling perpendicular to the track. The intumescent collared scab framing element comprises (i) a flat sheet larger than the opening and having an upper flange, wherein the upper flange is configured to friction fit between the head-of-wall track and the ceiling, and wherein the flat sheet and upper flange include a downwardly extending notch sized and configured to receive the pipe or conduit when the flange is friction fitted between the head-of-wall track and the ceiling; (ii) a collar extending inwardly or outwardly away from the flat sheet, wherein the collar is attached to the flat sheet about the notch and is sized and configured to fit about the pipe or conduit; (iii) a solid strip of intumescent material positioned within the collar and adjacent to the pipe or conduit; and (iv) an intumescent caulk material positioned between the strip of intumescent material and the pipe or conduit, wherein the intumescent caulk material contacts both the strip of intumescent material and the pipe or conduit. The flat sheet and the collar are both preferably made of sheet metal and are generally U-shaped.

In another embodiment, the present invention is directed to a head-of-wall assembly comprising, in combination, an intumescent collared scab framing element as described above, wherein the intumescent collared scab framing element has been friction fitted to the head-of-wall track and the ceiling.

These and other aspects of the present invention will become more evident upon reference to the following detailed description and accompanying drawings. It is to be understood, however, that various changes, alterations, and substitutions may be made to the specific embodiments disclosed herein without departing from their essential spirit or scope.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings are intended to be illustrative and symbolic representations of certain exemplary embodiments of the present invention, and as such they are not necessarily drawn to scale. In addition, it is to be expressly understood that the relative dimensions and distances depicted in the drawings are exemplary and may be varied in numerous ways. Finally, like reference numerals have been used to designate like features throughout the different views of the drawings.

FIG. 1 is a perspective view of an intumescent collared scab framing element in accordance with an embodiment of the present invention.

FIG. 2 is a perspective view of the intumescent collared scab framing element shown in FIG. 1, but wherein the collar section is removed and spaced apart above the notched scab section

FIG. 3 is a perspective view of the intumescent collared scab framing element shown in FIGS. 1 and 2, wherein the element is shown friction fitted to a header track of a stud wall assembly, and having a conduit received within the notched scab section.

FIG. 4 is a perspective view of an intumescent collared scab framing element in accordance with another embodiment of the present invention.

FIG. 5 is a perspective view of the intumescent collared scab framing element shown in FIG. 3, but wherein but wherein the collar section is removed and spaced apart and away from the wall side of notched scab section.

FIG. 6 is a perspective view of the intumescent collared scab framing element shown in FIGS. 4 and 5, wherein the element is shown friction fitted to a header track of a stud wall assembly, and having a conduit received within the notched scab section.

DETAILED DESCRIPTION OF INVENTION

In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols or markings have been used to identify like or corresponding elements, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the invention disclosed herein. In addition, the terms “attached” and “connected” are to be construed broadly so as to cover various means of coupling or joining together of different components and/or elements. Similarly, the term “on” is likewise to be construed broadly so as to cover both direct and indirect attachments and/or connections.

Accordingly, and as best shown in FIG. 1-3 (showing preferred embodiments) and in FIGS. 4-6 (showing alternative embodiments), the present invention in an embodiment is directed to an intumescent collared scab framing element 10 that is specifically configured to block and seal a cut-out opening (i.e., a ceiling pipe or conduit cutout—the view of which is mostly obstructed by the intumescent collared scab framing element 10) positioned along a head-of-wall track 12 (that has been installed onto a ceiling as part of a stud wall assembly as best shown in FIGS. 3 and 6). The inventive intumescent collared scab framing element 10 comprises four main components; namely, (1) a flat sheet section 14, (2) a collar 16, (3) an intumescent strip 18, and (4) and an intumescent caulk 20. In combination, these elements synergistically work together to create a robust and fire-rated head-of-wall seal that is cheaper and easier to install than any of the devices or methods known in the art.

As best shown in FIG. 3, the intumescent collared scab framing element 10 is designed and configured to fit over and cover the head-of-wall track 12 cut-away opening, which opening, in turn, has a horizontal pipe or conduit 22 penetrating therethrough (with the pipe or conduit 22 being positioned along the ceiling perpendicular to the track 12). As shown, the intumescent collared scab framing element 10 comprises a flat sheet section 14 that is larger than the opening, wherein the flat sheet 14 includes an upper flange 24 (shown in FIGS. 1-2 and 5-6 in a bifurcated form)) that is configured to be friction fitted between the head-of-wall track 12 and the ceiling (not shown). The flat sheet section 14 and upper flange 24 include a downwardly extending notch 26 that is sized and configured to receive the pipe or conduit 22 (when the flange 24 is friction fitted between the head-of-wall track 12 and the ceiling).

As further shown in FIGS. 1-3, the collar 16 extends inwardly (by may extend outwardly as shown in FIGS. 4 and 5) away from the flat sheet section 14 and is attached to the flat sheet section 14 about the notch 26 (which notch 26 is sized and configured to fit about the pipe or conduit 22). In certain preferred embodiments, the flat sheet section 14 and the collar 16 are both made of sheet metal, while the cut-away opening and the notch 16 are both generally U-shaped and about the same in size and shape. As best shown in FIG. 2, the collar may further comprise a segmented perimeter flange 28 that abuts and connects to the flat sheet section 14. As best shown in FIGS. 4 and 5, one or more additional strips of intumescent material 18′ may be positioned on the exterior face of the flat sheet section 14.

In another embodiment, and as best shown in FIGS. 3 and 6, the present invention is directed to a dynamic head-of-wall framing assembly in combination with an intumescent collared scab framing element 10 as herein described.

While the present invention has been described in the context of the embodiments described herein, the invention may be embodied in other specific ways or in other specific forms without departing from its spirit or essential characteristics. Therefore, the described embodiments are to be considered in all respects as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.