SEALING DEVICES FOR USE WITH WALL CONFIGURATIONS

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/700,081 filed on Sep. 17, 2024. The content of this U.S. Provisional patent application is incorporated herein by reference in its entirety.

BACKGROUND

Description of the Related Art

In a typical wall configuration, a ceiling runner is attached to the underside of the fluted metal deck and a floor runner is attached to the upper surface of a floor or roof. Gypsum boards are attached to the ceiling runner, wall studs and/or floor runner to provide the wall configuration. The fluted metal deck may move relative to the gypsum boards. Thus, a movement joint is provided between the fluted metal deck and the gypsum boards. The gypsum boards may be castle cut at a top end to have merlon portions sized and shaped to fit in wave portions of the fluted metal deck and crenel portions sized and shaped to receive trench portions of the fluted metal deck. In fire-rated applications, it is desirable and required by building codes to provide the wall configuration with fire-stopping, fire-resistance and smoke-resistance. This is achieved by sealing the movement joint. Caulk has conventionally been used to seal the movement joint provided between the castle cut end of the gypsum board and the fluted metal deck.

SUMMARY

The present document concerns implementing systems and methods for sealing a joint between drywall and a deck panel. The methods comprise: coupling a firestopping device to an end of the drywall (the firestopping device comprising a carrier structure having a channel into which at least a portion of the end of the drywall is received during the coupling); placing the drywall adjacent to the deck panel so as to cause a firestopping structure of the firestopping device to be compressed between the carrier structure and the deck panel for sealing the joint; and allowing, by the firestopping device, relative movement of the drywall and deck panel when the drywall is being used to provide a wall configuration.

The present document also concerns a firestopping device. The firestopping device comprises: a carrier structure comprising a channel into which at least a portion of an end of drywall can be received during a coupling of the firestopping device to drywall; and a firestopping structure coupled to the carrier structure and configured to be compressed between the carrier structure and a deck panel to seal a joint between the drywall and the deck panel. The firestopping device is configured to allow relative movement of the drywall and deck panel when the drywall is being used to provide a wall configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

This disclosure is facilitated by reference to the following drawing figures, in which like numerals represent like items throughout the figures.

FIGS. 1A-1B (collectively referred to as “FIG. 1”) provide illustrations of a wall configuration.

FIG. 2 provides an illustration of fluted metal deck.

FIG. 3 provides an illustration of firestopping devices disposed between castle cut drywall and a fluted metal deck.

FIG. 4 provides a side view of a firestopping device disposed between castle cut drywall and a fluted metal deck.

FIG. 5 provides a front perspective view of a firestopping device.

FIG. 6 provides a side view of the firestopping device shown in FIG. 5.

FIG. 7 provides a front perspective view of another firestopping device.

FIGS. 8A-8B provide front and back perspective views showing two modular firestopping devices arranged adjacent to each other. FIG. 8C provides a back view of the modular arrangement shown in FIGS. 8A-8B. FIGS. 8A-8C are collectively referred to as “FIG. 8”.

FIGS. 9A-9B (collectively referred to as “FIG. 9”) provide illustrations showing a plurality of firestopping devices coupled together to have a combined cross-sectional shape that follows a cross-sectional shape of at least a portion of the fluted metal deck.

FIGS. 10A-10B (collectively referred to as “FIG. 10) each provides a side view of a carrier of a firestopping device with internal members and/or adhesive to facilitate retention of the firestopping device on drywall.

FIG. 11 provides a front perspective view of another firestopping device.

FIG. 12 provides a flow diagram of an illustrative method for sealing a joint between drywall and deck panel(s).

FIGS. 13A-13B (collectively referred to as “FIG. 13”) provide illustrations of another wall configuration.

FIG. 14 provides a side view of a firestopping device disposed between drywall and a fluted metal deck.

FIG. 15 provides a front perspective view of the firestopping device shown in FIG. 14.

FIG. 16 provides an illustration showing a plurality of firestopping devices arranged in a modular construction.

FIG. 17 provides a flow diagram of an illustrative method for sealing a joint between drywall and a deck panel.

DETAILED DESCRIPTION

It will be readily understood that the solution described herein and illustrated in the appended figures could involve a wide variety of different configurations. Thus, the following more detailed description, as represented in the figures, is not intended to limit the scope of the present disclosure, but is merely representative of certain implementations in various different scenarios. While the various aspects are presented in the drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussions of the features and advantages, and similar language, throughout the specification may, but do not necessarily, refer to the same embodiment.

As noted above, wall configurations may be provided with fire-stopping, fire-resistance and smoke-resistance as required by building codes. Conventional solutions have many drawbacks such as being manually intensive, cumbersome to install, and provide inconsistent sealing quality. The present solution provides a novel solution that overcomes the drawbacks of conventional solutions.

The present solution concerns a novel device designed to provide a firestopping solution to a wall configuration. The novel firestopping device is configured to seal flutes of a fluted metal deck and joints between the fluted metal deck and adjacent drywall. The firestopping device comprises a plastic carrier overmolded with a compressible firestopping material. The compressible firestopping material can include, but is not limited to, an intumescent material that expands when exposed to heat. The purpose of the firestopping device is to seal openings and fill elements in the fluted metal deck, as well as the connections between adjacent fluted decks. The present solution provides a one-product firestopping solution, rather than a multi-product firestopping system.

The firestopping device is configured to sit on top of the adjacent drywall, with the compressible firestopping material allowing for movement between the fluted metal deck and the adjacent drywall. The firestopping device can feature overlapping seams to maximize firestopping coverage and provide two different shapes to fill the appropriate elements in the metal fluted deck. These shapes may be round, substantially round, trapezoidal, or substantially trapezoidal. The term “substantially” as used here means to a large degree or percentage. For example, a substantially round or trapezoidal shape occurs when the shape is more than 50%, 55% 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98% or 99% round or trapezoidal. The present solution is not limited to the listed percentages. The percentage may be selected in accordance with a given application.

FIG. 1 provides an illustration of a wall configuration 100. The wall configuration 100 comprises a fluted metal deck 102 with concrete 106 poured on top thereof. A top track or ceiling runner 120 is attached to the underside of the fluted metal deck 102. The top track or ceiling runner 120 provides structural support for drywall 104, 122 and allows for building movement. A bottom track or floor runner 124 is attached to the upper surface of floor 112. Wall studs 126 are attached and extend between the ceiling runner 120 and the bottom track or floor runner 124. The wall studs 126 provide structural integrity for the wall configuration and load distribution. One or more pieces of drywall 104, 122 are attached to the runner 120, wall studs 126 and/or runner 124 to provide the wall configuration 100.

The drywall 104, 122 can include, but is not limited to, gypsum board. The drywall has a top end 140 and a bottom end 142. The top end 140 is castle cut such that merlon portions 128 and crenel portions 130 are formed therein. The merlon portions 128 are sized and shaped to fit in wave portions (e.g., wave portions 208 of FIG. 2) of the fluted metal deck 102. The crenel portions 130 are sized and shaped to receive trench portions (e.g., trench portions 210 of FIG. 2) of the fluted metal deck 102. A gap 116 is provided between the top end 140 of the drywall and the fluted metal deck 102. As such, the drywall 104, 122 may move relative to the fluted metal deck 102. Thus, a movement joint 114 is provided between the fluted metal deck 102 and the drywall 104, 122.

In fire-rated applications, it is desirable and required by building codes to provide the wall configuration 100 with fire-stopping, fire-resistance and smoke-resistance. This is achieved by sealing the gap 116 and/or movement joint 114 using a novel firestopping device of the present solution. The novel firestopping device will be discussed below in detail. Still, it should be noted here that the novel firestopping device overcomes various drawbacks of conventional solutions, such as the caulking solution described above. For example, the present solution is less manually intensive to install, less time consuming to install, less cumbersome to install, and less costly to install.

Prior to discussing the novel firestopping device, the fluted metal deck 102 will be discussed briefly to facilitate understanding of the present solution. An illustrative architecture for a fluted metal deck is provided in FIG. 2. Other fluted metal deck architecture may be used with the present solution.

With reference to FIG. 2, the fluted metal deck 102 comprises a piece of metal that is shaped to have a plurality of wave portions 208 that alternate with a plurality of trench portions 210. Each wave portion 208 has a generally trapezoidal shape that protrudes upward from a bottom 220 of the fluted metal deck 102. A flute 108 is defined by each of the wave portions 208. Each trench portion 210 has a generally trapezoidal shape that protrudes downward from a top 222 of the fluted metal deck 102. A concave embossment 200 may be provided on a top wall 224 of each wave portion 208. Similarly, a convex embossment 206 may be provided on a bottom wall 226 of each trench portion 210.

Two opposing sides 230, 232 of the fluted metal deck 102 are provided with side lap members 202, 204. The side lap members 202, 204 are configured to lap, overlap or otherwise project over or under side lap members of adjacent fluted metal decks when in an installed state. The overlapping portions of adjacent fluted metal decks provide deck seams that should also be sealed by the firestopping device.

FIGS. 3-4 provide illustrations of firestopping devices 300₁, 300₂, . . . , 300_n disposed between castle cut drywall 104 and fluted metal deck 102. n is any integer equal to or greater than one. Each of the firestopping devices 300₁, 300₂, . . . , 300_n is configured to sit on top of, engage, and/or receive a portion 400 of the drywall 104. In this regard, each firestopping device 300₁, 300₂, . . . , 300_n has a carrier 304 having a u-shape to define a hollow channel 402 in which the portion 400 of the drywall 104 may be received and inserted. The firestopping devices 300₁, 300₂, . . . , 300_n are disposed on the drywall prior to the drywall being installed on-site to provide the wall configuration 100 (e.g., prior to being coupled to the top track or ceiling runner 120, wall studs 126, and/or bottom track or floor runner 124). In some scenarios, the firestopping devices may be coupled to the drywall off-site to provide a drywall/firestopping device assembly, which may be shipped or otherwise delivered to the building site. In other scenarios, the firestopping devices may be coupled to the drywall at the building site.

A compressible firestopping material 306 is coupled to the carrier 304. The firestopping material 306 is compressed between the drywall 104 and the fluted metal deck 102 when the drywall is installed to provide the wall configuration 100. The firestopping material 306 seals the mechanical joint 114 and gap 116 between the drywall 104 and the fluted metal deck 102. The firestopping material 306 can include, but is not limited to, an intumescent material, a mineral fiber material, silicone, rubber, and/or other firestopping material.

The firestopping devices 300₁, 300₂, . . . , 300_n are designed to be modular in that each provides a module for flexibility and variety in use. In the scenario of FIG. 3, each module may be the same or substantially similar to the other modules. The modular design of the present solution allows for any number n of firestopping devices to be used together to provide a larger firestopping assembly 302 in accordance with a given application. The modular design of the present solution allows for each of the firestopping devices to be interchanged or replaced with another one of the firestopping devices.

FIG. 5 provides a front perspective view of a firestopping device 500. FIG. 6 provides a front view of the firestopping device 500. Firestopping device 500 and firestopping devices 300₁, 300₂, . . . , 300, are similar except for the shape of protruding portions 522, 308 at corresponding ends thereof. Thus, the discussion of firestopping device 500 is sufficient for understanding firestopping devices 300₁, 300₂, . . . , 300_n.

Firestopping device 500 comprises a carrier 552 to which a compressible firestopping material 502 is coupled. This coupling may be achieved in a variety of ways. For example, the firestopping material 502 may be adhered to the carrier 552 using an adhesive (such as glue), 3D printed as a single piece with the carrier 552, injection molded onto the carrier 552, over molded on the carrier 552, and/or via a chemical reaction between the material of the carrier 552 and the firestopping material 502. The present solution is not limited to the particulars of this example. Other known or to be known coupling techniques can be used here.

The carrier 552 is a rigid or semi-rigid structure. In this regard, the carrier 552 can include, but is not limited to, plastic and/or rubber. The firestopping material 502 can include, but is not limited to, an intumescent material, a mineral fiber material, silicone, rubber, other firestopping material, and/or other material that is compressible.

The carrier 552 comprises a body 540 with a hollow channel 506 sized and shaped to receive a portion (e.g., portion 400 of FIG. 4) of drywall (e.g., drywall 104 of FIGS. 1 and 3-4). One or more coupling means (not visible in FIG. 5) may be provided on an inner surface of channel 506 to facilitate retention of the firestopping device 500 on the drywall. The coupling means can include, but is not limited to, an adhesive, gripping protrusion(s) or mechanisms (e.g., protrusions 1000, 1002 of FIG. 10A, protrusions 1010, 1012 of FIG. 10B), slits (e.g., slits 1100 of FIG. 11), mechanical fasteners (e.g., nails, screws, snaps, etc.), and/or a surface texturing or roughening to exhibit higher friction with the drywall. The slits (e.g., slits 1100 of FIG. 11) may be cut into the sidewall(s) of the carrier to allow the gripping protrusion(s) or mechanism(s) to act like spring(s) for applying a griping force and/or a compression force on the drywall. The slits may also facilitate the release of the carrier from an injection mold. It should be noted that carrier 552 abuts the legs of the top track runner 120. The carrier 552 is not directly coupled to the top track runner 120.

The carrier 552 comprises two opposing side portions 530, 532 and a middle portion 534. These portions 530, 532, 534 are designed to follow the cross-section shape of at least a portion of the fluted metal deck (for example, as shown in FIG. 9). Accordingly, each of the side portions 530, 532 is configured to partially receive a trench portion (e.g., trench portion 210 of FIG. 2) of a fluted metal deck (e.g., fluted metal deck 102 of FIGS. 1-2) or to receive side lap members (e.g., side lap members 202, 204 of FIG. 2) of two adjacent fluted metal decks.

The middle portion 534 comprises an insert space 508 sized and shaped to receive a merlon portion (e.g., merlon portion 128 of FIG. 1) of the castle cut drywall (e.g., drywall 104 of FIG. 1). The middle portion 534 is also sized and shaped to fit in a wave portion (e.g., wave portion 208 of FIG. 2) of the fluted metal deck. In this regard, the middle portion 534 has a trapezoidal or substantially trapezoidal shape that is smaller in one or more dimensions than that of the fluted metal deck's wave portion so that (i) the middle portion 534 fits in the fluted metal deck's wave portion, (ii) a gap (e.g., gap 116 of FIG. 1) is provided between the firestopping device 500 and the fluted metal deck, and/or (ii) a movement joint (e.g., movement joint 114 of FIG. 1) is provided between the firestopping device 500 and the fluted metal deck.

As noted above, the fluted metal deck may comprise embossments in the wave portions and/or trench portions. For example, as shown in FIG. 2, each wave portion may have a concave embossment 200. As such, the middle portion 534 is provided with an open area or cut-out member 518 to accommodate or allow for deck movement in a downward direction 550 relative to the firestopping device 500.

The firestopping material 502 is used to seal the space and joint between the drywall (e.g., drywall 104 of FIG. 1) and the fluted metal deck (e.g., fluted metal deck 102 of FIG. 1). The firestopping material 502 has pre-defined geometries designed to effectively fill the elements in the fluted metal deck, as well as the connections between adjacent fluted metal decks. In this regard, the firestopping material 502 has the same or similar cross-sectional shape as the carrier 552 and/or fluted metal deck. The thickness 606 of the firestopping material 502 is greater than the gap (e.g., gap 116 of FIG. 1) provided between the drywall and the fluted metal deck. This ensures that the firestopping material 502 is compressed between the drywall and the fluted metal deck. Since the size of the gap can vary along the drywall, the amount of compression of the firestopping material 502 may also vary along its length 602 and/or the length of the carrier 552. In some cases, it is possible that the amount of compression of the firestopping material 502 may not vary along the length 600, 602.

A protrusion 520, 522 is provided at a free end of each side portion 560, 562 of the firestopping material 502. Each protrusion 520, 522 is trapezoidal or substantially trapezoidal in shape. Each protrusion 520, 522 is sized and shaped to seal a deck scam or fit within a convex embossment (e.g., convex embossment 206 of FIG. 2) of the fluted metal deck.

The middle portion 564 of the firestopping material 502 has an open area or cut-out member 514 configured to receive an embossment (e.g., embossment 200 of FIG. 2) of a wave portion of the fluted metal deck. This member is sized and shaped to accommodate or allow for deck movement in a downward direction 550 relative to the firestopping device 500. It should be noted that the firestopping material 502 extends into open area or cut-out member 518 of the carrier 552 to facilitate provision of the seal between the drywall and the fluted metal deck.

The free ends 564, 566 of the firestopping material 502 extend beyond the end portions 530, 532 of carrier 552. As such, free ends 564, 566 allow overlapping and/or interference between firestopping materials of adjacent firestopping devices in a modular system to provide an airtight seal between adjacent modules.

FIG. 7 provides an illustration of another architecture for a firestopping device 700. Firestopping devices 300₁, 300₂, . . . , 300_n of FIG. 3 may be the same as or similar to firestopping device 700. Firestopping device 700 is similar to firestopping device 500. The above discussion is sufficient for understanding any common or similar elements, features, components and/or members of the two firestopping devices.

As seen in FIG. 7, there are three main differences between the firestopping device 700 and firestopping device 500. These main differences are provided at ends 730, 732 of carrier 752 and ends 760, 762 of the firestopping material 702. At end 730 of carrier 752, a sidewall 770 of the rigid structure extends further in horizontal direction 784 than the amount that the opposing sidewall 772 extends in the same direction. At end 732 of carrier 752, sidewall 772 of the rigid structure extends further in horizonal direction 782 than the opposing sidewall 770.

The width of the firestopping material 702 is varied at end 760 such that a smallest width thereof is provided in the area in which the sidewall 770 of the carrier's rigid structure extends further in the horizontal direction 784 than the opposing sidewall 772. In this way, end portion 780 of the firestopping device is able to horizontally overlap a corresponding end portion of an adjacent firestopping device in a manner that provides an airtight seal.

The width the firestopping material 702 is also varied at end 762 such that a smallest width thereof is provided in the area in which the sidewall 772 of the carrier's rigid structure extends further in the horizontal direction 782 than the opposing sidewall 770. In this way, end portion 782 of the firestopping device is able to horizontally overlap a corresponding end portion of an adjacent firestopping device in a manner that provides an airtight seal. This overlapping feature of the present solution maximizes firestopping coverage and optimizes firestopping sealing in the elements of the fluted metal deck.

Another main difference between the firestopping device 700 and firestopping device 500 is that the sealing protrusion 720 corresponding to protrusion 520 of FIG. 5 is rounded rather than trapezoidal. The rounded shape is provided to seal corresponding rounded elements of fluted metal decks.

The third main difference is that protrusion 522 is set-back from or otherwise offset from the end surface 718 to facilitate an alignment between the trapezoidal protrusion 522 and the rounded sealing protrusion of an adjacent firestopping device as shown in area 800 of FIG. 8. This protrusion alignment ensures that embossment(s) of the fluted metal deck or a scam between two adjacent metal decks is sealed. The rounded and trapezoidal shapes can fill the elements of the fluted metal deck more effectively than a single triangular shape or relying on interference with only the trapezoidal shaped protrusions as shown in FIGS. 5-6. The rounded shape may be used to fill the round fluted metal deck elements, while the trapezoidal shape may be used to fill the connections between adjacent fluted metal deck elements.

As seen in FIGS. 8-9A, any number n of the firestopping device 700 may be used to seal a gap and/or movement joint between drywall and a fluted metal deck. n is any integer equal to or greater than one. Each individual firestopping device is configured to have a cross-sectional shape that generally follows a cross-sectional shape of at least a portion of the fluted metal deck, as shown in FIG. 9A. The firestopping devices are also configured so that when coupled together their combined cross-sectionals shape generally follows the cross-sectional shape of at least a portion of the fluted metal deck, as also shown in FIG. 9A.

It should also be noted that the present solution was described above with each firestopping device configured to be used in relation to a single wave portion of a fluted metal deck. The present solution is not limited in this regard. One or more of the firestopping devices may be configured to be used in relation to two or more wave portions of the fluted metal deck. An illustrative firestopping device 900 is shown in FIG. 9B that is configured to be used in relation to three consecutive wave portions of a fluted metal deck. Firestopping device 900 is also configured to be used with other firestopping devices configured for use with any number of wave portions of the fluted metal deck, such as firestopping device 700 described above.

FIG. 12 provides a flow diagram of an illustrative method 1200 for using firestopping devices (e.g., firestopping device(s) 300₁, 300₂, . . . , 300_n of FIG. 3, 500 of FIGS. 5-6, 700 of FIGS. 7, and/or 700₁, 700₂ of FIG. 8) of the present solution. Method 1200 begins with 1202 and continues with 1204 where a firestopping device is aligned with a piece of pre-cut drywall (e.g., drywall 104 of FIG. 1). Next in block 1206, a merlon portion (e.g., merlon portion 128 of FIG. 1) of the drywall is received in an insert area (e.g., insert area 508 of FIG. 5) of the firestopping device. The firestopping device is then pushed toward the drywall, as shown by block 1208. This causes the drywall to enter into a hollow channel (e.g. hollow channel 506 of FIG. 5) of the firestopping device. The firestopping device is then optionally attached to the drywall, as shown by block 1210. This attachment may be achieved, for example, using screws and/or other mechanical fasteners. The operations of block 1204-1210 may optionally be repeated so that one or more other firestopping devices are coupled to the drywall. Adjacent firestopping devices may at least partially overlap each other in the manner(s) discussed above.

Next in 1214, the drywall is installed to build a wall structure. A check is performed to ensure that a gap (e.g., gap 116 of FIG. 1) exists between a top of the drywall and a fluted metal deck (e.g., fluted metal deck 102 of FIG. 1). The gap can include, but is not limited to, a 0.25-1.00 inch gap, and/or a 0.50 inch gap. In 1218, the installer verifies that there is a certain amount of compression in the firestopping material (e.g., firestopping material 502 of FIGS. 5-6, and/or 702 of FIG. 7). For example, a verification is made that there is about 50% compression in the firestopping material around the firestopping device. This verification may be made visually by the installer, and/or by comparing a measured height of the firestopping material in the compressed state with the measured or known height of the firestopping material in an uncompressed state. The position of the drywall may be adjusted in block 1220 relative to the fluted metal deck. This adjustment of the drywall's position may be made based on the size of the gap checked in block 1216 and/or the amount of compression of the firestopping material determined in block 1218. For example, an adjustment to the drywall's position may be made to provide or maintain a desired gap and/or amount of compression of the firestopping material.

The drywall is then secured to the wall studs (e.g., wall stud 126 of FIG. 1) in block 1022. Any known or to be known technique for securing drywall to wall studs can be used here. The installer should ensure that the drywall is level and that the firestopping device is properly seated and aligned with the fluted metal deck, prior to securing the drywall to the wall studs. This may be re-checked after the drywall is secured to the wall studs. Subsequently, method 1200 ends or other operations are performed (e.g., return to 1202).

FIGS. 13A-13B provide illustrations of a wall configuration 1300. The wall configuration 1300 comprises a fluted metal deck 1302 with concrete 1306 poured on top thereof. A top track or ceiling runner 1320 is attached to the underside of the fluted metal deck 1302. The top track or ceiling runner 1320 provides structural support for drywall 1304, 1322 and allows for building movement. A bottom track or floor runner 1324 is attached to the upper surface of floor 1312. Wall studs 1326 are attached and extend between the ceiling runner 1320 and the floor runner 1324. The wall studs 1326 provide structural integrity for the wall configuration and load distribution. One or more pieces of drywall 1304, 1322 are attached to the runner 1320, wall studs 1326 and/or runner 1324 to provide the wall configuration 1300.

The drywall 1304, 1322 can include, but is not limited to, gypsum board. The drywall has a top end 1340 and a bottom end 1342. Both ends 1340, 1342 are cut straight or substantially straight. A gap 1316 is provided between the top end 1340 of the drywall and the fluted metal deck 1302. As such, the drywall 1304, 1322 may move relative to the fluted metal deck 1302. Thus, a movement joint 1314 is provided between the fluted metal deck 1302 and the drywall 1304, 1322.

In fire-rated applications, it is desirable to provide the wall configuration 1300 with fire-stopping, fire-resistance and smoke-proof features. This is achieved by sealing the gap 1316 and/or movement joint 1314 using another novel firestopping device of the present solution. The novel firestopping device will be discussed below in detail. Still, it should be noted here that the novel firestopping device overcomes various drawbacks of conventional solutions, such as the caulking solution described above. For example, the present solution is less manually intensive to install, less time consuming to install, less cumbersome to install, and less costly to install.

FIG. 14 provides an illustration of firestopping devices 1450 disposed between straight cut drywall 1304 and fluted metal deck 1302. Each of the firestopping devices 1450 is configured to sit on top of, engage, and/or receive a portion 1400 of the drywall 1304. In this regard, each firestopping device 1450 has a carrier 1404 having a u-shape to define a hollow channel 1402 in which the portion 1400 of the drywall 1304 may be received and inserted. The firestopping devices 1450 may be disposed on the drywall prior to the drywall being installed on-site to provide the wall configuration 1300 (e.g., prior to being coupled to the top track or ceiling runner 1320, wall studs 1326, and/or bottom track or floor runner 1324). In some scenarios, the firestopping devices 1450 may be coupled to the drywall off-site to provide a drywall/firestopping device assembly, which may be shipped or otherwise delivered to the building site. In other scenarios, the firestopping devices may be coupled to the drywall at the building site.

A compressible firestopping material 1406 is coupled to the carrier 1404. The firestopping material 1406 is compressed between the drywall 1304 and the fluted metal deck 1302 when the drywall is installed to provide the wall configuration 1300. The firestopping material 1406 seals the mechanical joint 1314 and gap 1316 between the drywall 1304 and the fluted metal deck 1302. The firestopping material 1406 can include, but is not limited to, an intumescent material, a mineral fiber material, silicone, rubber, and/or other firestopping material.

The firestopping devices 1450 are designed to be modular in that each provides a module for flexibility and variety in use. In some scenarios, each module may be the same as or substantially similar to the other modules. The modular design of the present solution allows for any number n of firestopping devices to be used together to provide a larger firestopping assembly in accordance with a given application. This multi-firestopping device arrangement is shown in FIG. 15 where firestopping devices 14501, 14502, . . . , 1450n are arranged serially or end-to-end to provide a larger firestopping assembly 1600. The modular design of the present solution allows for each of the firestopping devices to be interchanged or replaced with another one of the firestopping devices.

FIG. 15 provides a front perspective view of a firestopping device 1450. The rear perspective view of fire stopping device 1450 would be the same or similar as that shown in FIG. 15. Firestopping device 500 comprises a carrier 1404 to which a compressible firestopping material 1406 is coupled. This coupling may be achieved in a variety of ways. For example, the firestopping material 1406 may be adhered to the carrier 1404 using an adhesive (such as gluc), 3D printed as a single piece with the carrier 1404, injection molded onto the carrier 1404, over molded on the carrier 1404, and/or via a chemical reaction between the material of the carrier 1404 and the firestopping material 1406. The present solution is not limited to the particulars of this example. Other known or to be known coupling techniques can be used here.

The carrier 1404 is a rigid or semi-rigid structure. In this regard, the carrier 1404 can include, but is not limited to, plastic and/or rubber. The firestopping material 1406 can include, but is not limited to, an intumescent material, a mineral fiber material, silicone, rubber, other firestopping material, and/or other material that is compressible.

The carrier 1404 comprises a body 1540 with a hollow channel 1506 sized and shaped to receive a portion (e.g., portion 1400 of FIG. 14) of drywall (e.g., drywall 1304 of FIGS. 13-14). The body 1540 has an elongate straight shape with a generally U-shaped cross-sectional view. One or more coupling means (not visible in FIG. 15) may be provided on an inner surface of channel 1506 to facilitate retention of the firestopping device 1450 on the drywall. The coupling means can include, but is not limited to, an adhesive, gripping protrusion(s) or mechanisms 1502, slit(s) 1500, mechanical fasteners (e.g., nails, screws, snaps, etc.), and/or a surface texturing or roughening to exhibit higher friction with the drywall. Slits 1500 may be cut into the sidewall(s) 1508, 1510 of the carrier 1404 to allow the gripping protrusion(s) or mechanism(s) 1502 to act like spring(s) for applying a griping force and/or a compression force on the drywall. The slit(s) 1500 may also facilitate the release of the carrier 1404 from an injection mold. It should be noted that carrier 1404 abuts the legs of the ceiling or top track runner 1320. The carrier 1404 is not directly coupled to the ceiling or top track runner 1320.

The firestopping material 1406 is used to seal the space and joint between the drywall (e.g., drywall 1304 of FIG. 13) and the fluted metal deck (e.g., fluted metal deck 1302 of FIG. 13). The firestopping material 1406 has pre-defined geometries designed to effectively fill the movement joint 1314 between the fluted metal deck 1302 and the drywall. In this regard, the width 1560 and/or height 1562 of the firestopping material 1406 is/are greater than the corresponding dimensions of the gap 1316 provided between the drywall and the fluted metal deck. This ensures that the firestopping material 1406 is compressed between the drywall and the fluted metal deck. Since the size of the gap can vary along the drywall, the amount of compression of the firestopping material 1406 may also vary along its length 1564 and/or the length of the carrier 1404. In some cases, it is possible that the amount of compression of the firestopping material 1406 may not vary along the length 1564 when installed between drywall and a fluted metal deck.

It should be noted that firestopping device 1450 was described in relation to fluted metal decks. However, the present solution is not limited in this regard. Firestopping device 1450 may be used with other types of deck panels (such as planar deck panels) and/or other ceiling structures.

FIG. 17 provides a flow diagram of an illustrative method 1700 for sealing a joint (e.g., joint 114 of FIG. 1 or 1314 of FIG. 13) between drywall (e.g., drywall 104, 122 of FIG. 1 or 1304, 1322 of FIG. 13) and a deck panel (e.g., deck panel 102 of FIG. 1 or 1302 of FIG. 13). The operations of method 1700 may be performed in the same or different order than that shown.

Method 1700 begins with block 1702 and continues to block 1704 where a firestopping device (e.g., firestopping device 300₁, 300₂, . . . , 300_n of FIG. 3, 500 of FIG. 5, 700 of FIG. 7, 700₁, 700₂, . . . , 700_n of FIG. 8-9, or 1450 of FIG. 14) is optionally 3D printed or injection molded so that a firestopping structure (e.g., firestopping material 306 of FIG. 3, 502 of FIG. 5, 702 of FIG. 7, or 1406 of FIG. 14) is integral with a carrier structure (e.g., carrier 304 of FIG. 3, 552 of FIG. 5, 752 of FIG. 7, or 1404 of FIG. 14) to form a single modular part.

In a next block 1706, the firestopping device is coupled to an end (e.g., end 140 of FIG. 1 or 1340 of FIG. 13) of the drywall. This coupling may be achieved manually or automatedly by robots. The robots may comprise articulating arms. The firestopping device comprises a carrier structure having a channel (e.g., channel 402 of FIG. 4, 506 of FIG. 5, or 1402 of FIG. 14) into which at least a portion of the end of the drywall is received during the coupling.

In some scenarios, the coupling of block 1706 may involve using the carrier structure to apply one or both of a compression force and a gripping force on the drywall. Additionally or alternatively, the coupling of block 1706 may involve: expanding a distance between two opposing sidewalls (e.g., sidewalls 770, 772 of FIG. 7) of the carrier structure as the end of the drywall is being inserted into the channel; and allowing the two opposing sidewalls of the carrier structure to automatically spring back to an unexpanded state when the end of the drywall is partially or fully inserted into to channel.

The end of the drywall may be castle cut, and the deck panel may comprise a fluted metal deck. In this case, the firestopping device is configured to have a cross-sectional shape similar to a cross-sectional shape of the fluted metal deck. The coupling of block 1706 may additionally or alternatively involve: inserting a middle portion (e.g., middle portion 534 of FIG. 5) of the firestopping device into a wave portion (e.g., wave portion 208 of FIG. 2) of the fluted metal deck (e.g., fluted metal deck 102 of FIGS. 1-2); and receiving (a) at least a part of a trench portion (e.g., trench portion 210 of FIG. 2) of the fluted metal deck or (b) a side lap member (e.g., side lap member 202 or 204 of FIG. 2) of the fluted metal deck in each one of two opposing side portions (e.g., side portions 530, 532 of FIG. 5) of the firestopping device between which the middle portion resides. The middle portion may have a substantially trapezoidal shape configured to allow the firestopping material to be compressed between the carrier structure and the deck panel when the drywall is being used to provide a wall configuration.

The coupling of block 1706 may additionally or alternatively involve: receiving an embossment (e.g., embossment 200 of FIG. 2) of the fluted metal deck in an open area or a cut-out (e.g., open area or cut-out 514 of FIG. 5) of the middle portion of the firestopping device; receiving a protruding portion (e.g., protrusion 520, 522 of FIG. 5, or 720 of FIG. 7) of the firestopping structure in an embossment (e.g., embossment 206 of FIG. 2) formed in the trench portion of the fluted metal deck; and/or receiving, in a middle portion of the firestopping device, a merlon portion of the castle cut end of the drywall. The open area or cut-out of the middle portion of the firestopping device is sized and shaped to allow for the relative movement of the drywall and deck panel while maintaining the sealing of the joint. The protruding portion of the firestopping structure may have a trapezoidal shape, or a curved shape. The middle portion may have a substantially trapezoidal shape configured to allow the merlon portion to snugly fit therein when the merlon portion is fully inserted into the channel.

Another firestopping device may also be coupled to the end of the drywall in block 1706. The another firestopping device may be coupled to the drywall such that it abuts the firestopping device. The firestopping device and the another firestopping device may at least partially overlap when coupled to the end of the drywall. The firestopping device and the another firestopping device may comprise modular parts that have a same overall structure or different overall structures. The different overall structures may comprise a first structure configured to be used with a first number of wave portions of the deck panel, and a second structure configured to be used with a different second number of wave portions of the deck panel.

The firestopping device(s) is (are) retained on the end of the drywall as shown by block 1708. This may be achieved, for example, using structural feature(s) of the carrier structure(s). The structural feature(s) can include, but is not limited to, an inward pointing protrusion (e.g., protrusion 1000, 1002, 1010, or 1012 of FIG. 10), a slit (e.g., slit 1100 of FIG. 11), a mechanical fastener (e.g., screw), and/or a surface texturing (e.g., surface texturing 1004 of FIG. 10).

Next in block 1710, the drywall is placed adjacent to the deck panel. The firestopping structure of each firestopping device is caused to be compressed between the carrier structure and the deck panel for sealing the joint, as shown by block 1712. In optional block 1714, the protruding portion(s) of the firestopping structure(s) may be used to seal seam(s) between the deck panel and other adjacent deck panel(s). The protruding portion(s) may be at least partially curved or rounded.

In 1716, the firestopping device(s) allow(s) relative movement of the drywall and deck panel when the drywall is being used to provide a wall configuration. Subsequently, method 1700 continues to block 1718 where it ends or other operations are performed (e.g., return to 1702).

In view of the forgoing discussion, the present solution concerns a firestopping device comprising: a carrier structure comprising a channel into which at least a portion of an end of drywall can be received during a coupling of the firestopping device to drywall; and a firestopping structure coupled to the carrier structure and configured to be compressed between the carrier structure and a deck panel to seal a joint between the drywall and the deck panel. The firestopping device is configured to allow relative movement of the drywall and deck panel when the drywall is being used to provide a wall configuration.

The carrier structure may comprise two opposing sidewalls configured to bend away from each other as the portion of the end of the drywall is being inserted into the channel, and automatically spring back to an unexpanded state when the portion of the end of the drywall is partially or fully inserted into the channel. The carrier structure may additionally or alternatively comprise a structural feature configured to facilitate retention of the firestopping device on the end of the drywall. The structural feature may include, but is not limited to, an inward pointing protrusion, a slit, a mechanical fastener, or a surface texturing. Additionally or alternatively, the carrier structure may be configured to apply one or both of a compression force and a gripping force on the drywall.

The end of the drywall may be cut straight or castle cut. In the castle cut scenarios, the deck panel may comprise a fluted metal deck. The firestopping device may be configured to have a cross-sectional shape similar to a cross-sectional shape of the fluted metal deck. In this regard, the firestopping device may also comprise: a middle portion configured to have a wave portion of the fluted metal deck inserted therein; and two opposing side portions, between which the middle portion resides, that are each configured to receive (a) at least a part of a trench portion of the fluted metal deck or (b) a side lap member of the fluted metal deck. The middle portion may have a substantially trapezoidal shape configured to allow the firestopping structure to be compressed between the carrier structure and the deck panel when the drywall is being used to provide a wall configuration.

The middle portion may comprise an open area or a cut-out size and shaped to receive an embossment of the fluted metal deck and allow for said relative movement of the drywall and deck panel while the sealing of the joint is maintained. One or both of the opposing side portions may comprise a protruding member configured to be received in an embossment formed in the trench portion of the fluted metal deck. The protruding member may have a trapezoidal shape, or a curved shape. One or both of the opposing side portions may comprise a protruding member configured to seal a seam between the deck panel and another adjacent deck panel. The protruding member may be at least partially curved or rounded.

Additionally or alternatively, the middle portion may be configured to receive a merlon portion of the castle cut end of the drywall. The middle portion can have a substantially trapezoidal shape configured to allow the merlon portion to snugly fit therein when the merlon portion is fully inserted into the channel.

The firestopping structure may be overmolded on the carrier structure. The firestopping structure may comprise an intumescent material. The firestopping device may be 3D printed or injection molded so that the firestopping structure is integral with the carrier structure to form a single modular part. The carrier structure may be rigid or semi-rigid, while the firestopping structure is compressible.

The firestopping device may be configured to abut another firestopping device when coupled to the end of the drywall. The firestopping device and the another firestopping device may be configured to at least partially overlap when coupled to the end of the drywall. The firestopping device and the another firestopping device may comprise modular parts that have a same overall structure or different overall structures. The different overall structures may comprise a first structure configured to be used with a first number of wave portions of the deck panel, and a second structure configured to be used with a different second number of wave portions of the deck panel.

The described features, advantages and characteristics disclosed herein may be combined in any suitable manner. One skilled in the relevant art will recognize, in light of the description herein, that the disclosed systems and/or methods can be practiced without one or more of the specific features. In other instances, additional features and advantages may be recognized in certain scenarios that may not be present in all instances.

As used in this document, the singular form “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used in this document, the term “comprising” means “including, but not limited to”.

Although the systems and methods have been illustrated and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In addition, while a particular feature may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Thus, the breadth and scope of the disclosure herein should not be limited by any of the above descriptions. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents.