FIRE-RATED COMPONENT AND WALL ASSEMBLY WITH FIRE-RATED COMPONENT

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Nos. 63/722,476, entitled “FIRE-RATED COMPONENT AND WALL ASSEMBLY WITH FIRE-RATED COMPONENT,” filed Nov. 19, 2024, pending, 63/742,182, entitled “FIRE-RATED COMPONENT AND WALL ASSEMBLY WITH FIRE-RATED COMPONENT,” filed Jan. 6, 2025, pending, and 63/742,193, entitled “FIRE-RATED COMPONENT AND WALL ASSEMBLY WITH FIRE-RATED COMPONENT,” filed Jan. 6, 2025, pending.

This application hereby incorporates by reference each of the above-identified provisional applications in its entirety. Any and all applications for which a foreign or domestic priority claim is identified in connection with the present application are hereby incorporated by reference herein and made a part of the present disclosure.

BACKGROUND

Field

The present disclosure generally relates to fire-rated building structures, which can include fire gaskets. In particular, the present disclosure relates to fire-rated joint systems, wall assemblies, and other building structures that incorporate fire-rated gaskets. In some configurations, the fire-rated gaskets may be configured to allow for relatively large deflection gaps.

Description of Related Art

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. A 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 wallboard 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 relative to the header track and upper horizontal support structure. 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 to reduce or prevent damage to the wall assembly. Non-slotted header tracks can also be used in a dynamic head-of-wall joint.

Recently, improvements to fire-rated head-of-wall assemblies have been developed. However, existing fire-rated head-of-wall components are not well-suited for large construction gaps, such as dynamic head-of-wall joints requiring about 1.5-2 inches or more of dynamic movement.

SUMMARY

Although existing fire-rated head-of-wall assemblies represent 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 relatively large 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.

An aspect of the present disclosure involves a fire-rated component for sealing an elongate building joint. The component includes a metal strip having a first side and a second side; a non-metal profile secured directly or indirectly to the first side of the metal strip; a fire-resistant material strip secured directly or indirectly to a portion of the second side of the metal strip; and a foam tape configured to secure the fire-rated component to a header track or other wall framing component.

In some configurations, the non-metal profile is a vinyl profile and the metal strip is a steel strip.

In some configurations, the fire-resistant material strip includes intumescent material.

In some configurations, the non-metal profile includes a C-shaped portion and a lower planar portion extending from a lower end of the C-shaped portion.

In some configurations, the foam tape is located on the lower planar portion, which is configured to be secured to a flange of a header track by the foam tape.

In some configurations, the metal strip and the fire-resistant material strip are located within an interior space of the C-shaped portion.

In some configurations, the fire-resistant material strip has a width that is less than a width of the metal strip.

In some configurations, the fire-resistant material strip is located towards an upper edge of the metal strip.

In some configurations, the metal strip is secured to the non-metal profile and the fire-resistant material strip is secured to the metal strip.

In some configurations, the metal strip is secured to the non-metal profile by a double-sided film tape and the fire-resistant material strip is secured to the metal strip by an adhesive tape or glue.

In some configurations, the fire-resistant material strip is positioned above the foam tape on the second side of the metal strip.

In some configurations, the non-metal profile includes an upper portion that extends over one or both of the metal strip and the fire-resistant material strip.

In some configurations, the fire-resistant material strip has a width that is equal to or greater than a width of the foam tape.

In some configurations, the width of the fire-resistant material strip is at least twice the width of the foam tape.

In some configurations, a thickness of the fire-resistant material strip is equal to or less than the thickness of the foam tape.

In some configurations, the non-metal profile includes an extension portion that extends above the metal strip.

In some configurations, the extension portion is linear.

In some configurations, the extension portion is co-planar with a main body portion of the non-metal profile.

In some configurations, the extension portion is pliable or flexible.

In some configurations, the extension portion is angled relative to a main body portion of the non-metal profile.

An aspect of the present disclosure involves a wall assembly. The wall assembly includes a header track configured to be coupled to a surface of an overhead structure. The header track has a web, first flange, and a second flange. The first flange and the second flange extend from the web in a same direction. A plurality of studs are coupled to the header track. An upper end of each of the plurality of studs is located between the first and second flanges. At least one wallboard is coupled to the plurality of studs. 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. The deflection gap is variable between a closed position and an open position. The fire-rated component of the second paragraph above in the Summary is positioned within the deflection gap between the at least one wallboard and the first flange of the header track.

In some configurations, an upper end of the fire-rated component contacts the overhead structure.

In some configurations, the non-metal profile faces the at least one wallboard.

In some configurations, the at least one wallboard overlaps the metal strip.

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1 is a sectional view of an elongate fire blocking component, including a profile, a metal strip, and a fire-resistant material strip.

FIG. 2 illustrates the fire blocking component of FIG. 1 within a wall assembly to create a fire-rated joint between the wall assembly and a ceiling.

FIG. 3 illustrates the wall assembly of FIG. 2 with the fire blocking component exposed to a fire.

FIG. 4 is a sectional view of another version of a fire blocking component in the form of a fire gasket.

FIG. 5 is a sectional view of yet another version of a fire blocking component in the form of a fire gasket.

DETAILED DESCRIPTION

The various features and advantages of the systems, devices, and methods of the technology described herein will become more fully apparent from the following description of the embodiments illustrated in the figures. These embodiments are intended to illustrate the principles of this disclosure, and this disclosure should not be limited to merely the illustrated examples. The features of the illustrated embodiments can be modified, combined, removed, and/or substituted as will be apparent to those of ordinary skill in the art upon consideration of the principles disclosed herein.

The following disclosure provides an elongate, fire-rated gasket component, which can be configured to provide fire protection to a building structure, such as a building joint, and pass the relevant UL fire rating tests, or other relevant fire rating tests or standards. The fire-rated gasket component may be installed in a deflection gap of a wall assembly that allows dynamic movement according to the requirements of UL-2079. In some configurations, the fire-rated gasket component can be suitable to provide a fire-rating to a joint of 1.5-2 inches or greater. In some configurations, the fire-rated gasket component can provide a fire-rating to a joint of up to 4-5 inches, or greater. In some configurations, the fire-rated gasket component can provide a fire-rating that meets the requirements of UL-2079. The fire-rated gasket component can be used in other building joints, such as joints at the bottom of a wall, joints at the sides of a wall, or joints within a wall (e.g., where two wall portions meet or within a gap between two wallboard portions. In the context of the wall assembly, the fire-rated gasket component is one component amongst the other components of the overall wall assembly. However, the fire-rated gasket component can be an assembly of two or more pieces. Accordingly, the fire-rated gasket component can also be referred to as a fire-rated gasket assembly.

In some embodiments, the fire-rated gasket component can include at least one piece made of metal (e.g., steel) and at least one piece made of a non-metal material (e.g., plastic, such as PVC or vinyl). In some embodiments, the non-metal material, or at least one non-metal material, is a non-foamed material. References to any particular metal material(s) or any particular non-metal material(s) herein can be replaced with a reference to the appropriate one of a generic metal or non-metal material. One reason for including a steel material is that steel, generally, will not melt in a fire and will provide a continuous level of fire protection to the deflection joint. However, the steel piece by itself may not provide enough fire protection to pass a UL-2079 5th edition fire test and/or it may not provide adequate sound protection to the deflection gap. The second piece can be made of or include a vinyl material, such as a non-foamed or solid vinyl material, which may be formed by an extrusion process among other possibilities. The vinyl profile can be assembled to the steel piece and installed into the wall assembly as one integrated piece or as a single component. In some configurations, the fire-rated gasket component can also include a fire-resistant material, such as an intumescent material. In some configurations, the vinyl profile can provide a sealing function to improve sound protection or smoke protection, or both. Unlike steel, the vinyl profile is very flexible and when the vinyl profile meets the overhead structure it can compress and seal off against uneven overhead structures to improve sound and/or smoke protection.

FIGS. 1, 4, and 5 illustrate cross sectional views of embodiments of the fire-rated joint component 100. The fire-rated joint component 100 can be an elongate strip or gasket that can extend along the upper edge of a wall in a head-of-wall assembly as shown in cross-section in FIGS. 2 and 3. FIGS. 2 and 3 illustrate the fire-rated joint component 100 of FIG. 1 but could also incorporate the configurations of FIG. 4 or FIG. 5. The fire-rated joint component 100 can be installed across a head-of-wall assembly to inhibit or prevent the passage of smoke, heat, noise and/or other gases from passing through the head-of-wall assembly from one side of the wall to the other side. As described above, the fire-rated joint component 100 could also be used in wall gaps or joints other than a head-of-wall gap. The fire-rated joint component 100 can be formed in various lengths (e.g., 5 foot, 10 foot, 12 foot, or other lengths), preferably having the same cross-sectional shape throughout the length.

The illustrated fire-rated joint component 100 of FIG. 1 includes non-metal layer 105 which can be or formed into a profile 110. The profile 110 can be a base layer or a primary layer to which other components (further described below) are attached. The profile 110 can also be primarily influential to the overall geometry of the fire-rated joint component 100. The non-metal layer 105 can be constructed from or include a non-metal material, such as a plastic material. In some configurations, the non-metal layer 105 is constructed from or includes a vinyl material. The illustrated fire-rated joint component 100 can include a metal strip 112. The metal strip 112 can be constructed from or include a steel material. In some configurations, the metal strip 112 can have a thickness of between about 10 Mils and about 40 Mils, such as 18 Mils. However, other suitable thicknesses can also be used. The metal strip 112 can be generally resistant to deformation when exposed to heat or fire for at least a limited amount of time. The metal strip 112 can facilitate the fire-rated joint component 100 retaining its shape at least partially or temporarily when exposed to heat or fire.

The illustrated fire-rated joint component 100 can include a fire-resistant material strip 114. In some configurations, the fire-resistant material strip 114 can be or include an intumescent material. The fire-resistant material strip 114 can have a thickness between about 1 mm to about 5 mm, such as about 3 mm. However, other suitable thicknesses can also be used. Assembled together, the non-metal layer 105, the metal strip 112, and the fire-resistant material strip 114 can form the fire-rated joint component 100.

In some configurations, the fire-resistant material strip 114 of FIGS. 1, 4, and 5 can be of a multi layer construction. For example, a 3 mm fire-resistant material strip 114 can be made of 2×1.5 mm or 3×1 mm fire-resistant material strips, when combined total 3 mm. In other configurations, other combinations of multiple fire-resistance material layers can be used to achieve a desired final thickness.

The metal strip 112 can be adhered to the non-metal layer 105, such as with a double-sided film tape 120. However, other suitable adhesives could be used. The fire-resistant material strip 114 can be adhered to the metal strip 112, such as with an adhesive tape or glue 122. However, other suitable adhesives could be used. In other configurations, the arrangement of the non-metal layer 105, the metal strip 112, and the fire-resistant material strip 114 can be altered relative to that illustrated in FIG. 1.

In some configurations the fire-resistant material strip 114 and the adhesive tape or glue 122 can be an integrated component and ready to install on to the fire-rated joint component 100. Also, in some configurations, an integrated fire-resistant material strip 114 and adhesive tape or glue 122 can be assembled such that there is a thin plastic film or layer covering the surface of the foamed intumescent material of the fire-resistant material strip 114 that is opposite the adhesive tape or glue 122. Such an arrangement is commonly found for manufacturing ease of the fire-resistant material strip 114.

In the illustrated configuration, the non-metal layer 105 includes a generally C-shaped portion 130 with a lower planar portion 132 that extends downwardly from the C-shaped portion 130. The C-shaped portion 130 defines a recess or interior space 134. The metal strip 112 and/or the fire-resistant material strip 114 can be positioned within the interior space 134. The upper end of the C-shaped portion 130 can have a rounded, flexible edge 136, which can contact the ceiling 140 (FIGS. 2 and 3). The flexible edge 136 can seal against the ceiling 140 to reduce or eliminate the passage of smoke or sound between the ceiling 140 and the fire-rated joint component 100. The planar portion 132 can permit the fire-rated joint component 100 to be secured to a wall component, such as a header track 150 (FIGS. 2 and 3). A tape, such as a double-sided foam tape 160, can be positioned on the planar portion 132 and can be used to secure the fire-rated joint component 100 to the wall component, such as the header track 150. The fire-rated joint component 100 can include a release layer (not shown in FIG. 1—s ee release layer 124 in FIGS. 4 and 5).

In the illustrated arrangement, the metal strip 112 can have a greater width (when considering the strip 112 itself, or height when considering the overall fire-rated joint component 100 in the orientation of FIG. 1) than a width (or height) of the fire-resistant material strip 114. In some configurations, the fire-resistant material strip 114 can have a width (or height) that is between about one-quarter and about three-quarters, or is about two-thirds, of a width (or height) of the metal strip 112. In some configurations, an upper edge of the fire-resistant material strip 114 is located closer to the upper end of the metal strip 112 than the lower edge of the fire-resistant material strip 114 is located relative to the lower end of the metal strip 112. In some configurations, an upper edge of the fire-resistant material strip 114 can be aligned with an upper edge of the metal strip 112. In some configurations, the fire-resistant material strip 114 can have a width of about ¼ of an inch to about ¾ of an inch. In other configurations the fire-resistant material strip 114 can have a width of about ¾ of an inch to about 1.5 inches, about 1.5 inches to about 3 inches. In other configuration the fire-resistant material strip 114 can have larger or smaller widths as desired for an application. In some cases, it can be desirable to keep the fire-resistant material strip 114 of a narrow width to reduce material costs.

The width (or height) of the metal strip 112 can be configured to be approximately the same as or greater than the maximum height of the deflection gap. A thickness of the metal strip 112 can be sufficient to inhibit the passage of heat through the metal strip 112, in combination with the non-metal layer 105 and fire-resistant material strip 114, to allow the fire-rated joint component 100 to provide sufficient protection to the construction joint to pass the UL-2079 5th edition fire test or a similar or other applicable standard. The width (or height) and a thickness of the fire-resistant material strip 114 can be sufficient to provide a seal to the construction joint in the event of a fire such that the construction joint can pass the UL-2079 5th edition fire test or a similar or other applicable standard.

FIG. 2 shows the fire-rated joint component 100 installed within a head-of-wall assembly 200. The head-of-wall assembly can include a ceiling or overhead structure 140. The header track 150 can be attached to the overhead structure 140. The header track 150 can include a web 152, a first flange 154 extending from the web 152 and a second flange (not shown) extending from the web 152. The first flange 154 and the second flange can extend generally perpendicular to and on opposite sides of the web 152. A plurality of studs 156 (one shown) can be received between the first flange 154 and the second flange. A wallboard 210 can be attached to the plurality of studs 156. The upper end of the wallboard 210 can form a deflection gap 220 between the overhead structure 140 and the wallboard 210. The deflection gap 220 can be variable as the plurality of studs 156 and the wallboard 210 move relative to the overhead structure 140.

In some configurations, the deflection gap 220 can be of a relatively large size. Such a large deflection gap 220 can be commonly seen in multi story buildings with large floor and ceiling deflections due to various loads. Large deflection gaps can also been seen in other building construction gaps. In some configurations the deflection gap 220 can be approximately 0 to 1 inch. In other configurations the deflection gap 220 can approximately 0 to 2 inches, 0 to 3 inches, 0 to 4 inches, or other larger or smaller deflection gaps.

The fire-rated joint component 100 can be assembled within the deflection gap 220 between the wallboard 210 and the header track 150. The flexible edge 136 can be positioned to contact the overhead structure 140. The fire-rated joint component 100 can be secured to the header track 150 with the double-sided foam tape 160 prior to the wallboard 210 being secured to the plurality of studs 156. The fire-rated joint component 100 could additionally or alternatively be secured to the header track 150 by a fastener, such as a metal screw. The wallboard 210 can overlap at least the planar portion 132 of the fire-rated joint component 100 when the deflection gap 220 is at a maximum. Preferably, the wallboard 210 overlaps at least a portion of the metal strip 112 when the deflection gap 220 is at a maximum.

FIG. 3 illustrates the head-of-wall assembly 200 of FIG. 2 in the event of a fire. The fire-resistant material strip 114 can expand in response to the elevated temperature resulting from the fire. The overlap between the wallboard 210 and the metal strip 112 can assist in holding the metal strip 112 in place. In turn, the metal strip 112 can facilitate the retention of the expanding intumescent material of the fire-resistant material strip 114 within the deflection gap 220. Because the fire-resistant material strip 114 is held in place and prevented from falling completely out of the deflection gap 220, the intumescent material can effectively seal the deflection gap 220.

FIG. 4 illustrates an alternative fire-rated joint component 100. The fire-rated joint component 100 of FIG. 4 is similar in many respects to the fire-rated joint component 100 described above with respect to FIG. 103 and is described below with an emphasis on the differences relative to the previously-described fire-rated joint component 100. Therefore, features of the fire-rated joint component 100 not described in detail 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 illustrated fire-rated gasket component 100 of FIG. 4 can include a metal strap or a metal strip 112. The metal strip 112 can be constructed from or include a steel material. In some configurations, the metal strip 112 can have a thickness of between about 10 Mils and about 40 Mils, between about 10 Mils and about 30 Mils, or between about 15 Mils and about 20 Mils, such as 18 Mils. However, other suitable thicknesses can also be used. The metal strip 112 can be generally resistant to deformation when exposed to heat or fire for at least a limited amount of time. The metal strip 112 can facilitate the fire-rated gasket component 100 retaining its shape at least partially or temporarily when exposed to heat or fire. In some configurations, the metal strip 112 may be considered as creating the base structure to which one or more of the other constituent parts of the fire-rated gasket component 100 are attached.

The illustrated fire-rated gasket component 100 can include a fire-resistant material strip 114. In some configurations, the fire-resistant material strip 114 can be or include an intumescent material. The fire-resistant material strip 114 can have a thickness between about 1 mm to about 5 mm or between about 2 mm to about 4 mm, such as about 3 mm. However, other suitable thicknesses can also be used. As described above, the fire-resistant material strip 114 can be a multi-layer component including multiple layers of an intumescent or other suitable fire-resistant material. In some configurations, the one or more layers of material can have a total thickness sufficient to achieve a desired level of fire rating together with the other portions of the component 100. The fire-resistant material strip 114 may be adhered to the metal strip 112. To achieve this, many different adhesives may be used, such as any suitable glue or other adhesive, such as a double-sided film tape. In some cases, a heat-resistant adhesive can be used.

The illustrated fire-rated gasket component 100 can include a foam layer, which can be a double-sided foam tape 160. However, other suitable adhesives or attachment mechanisms could be used. The double-sided foam tape 160 can be adhered to the metal strip 112 with the adhesive present in the foam tape 160. Alternatively, the foam layer may be constructed with adhesive on only one side, or on neither side, and an additional adhesive could be added to one or both sides of the foam layer during the manufacturing process, such as a glue or other suitable adhesive. The double-sided foam tape 160 can have a thickness between about 1 mm to about 5 mm, or between about 2 mm to about 4 mm, such as about 3 mm. In some configurations, the double-sided foam tape 160 can have the same thickness or a similar thickness as the fire-resistant material strip 114. In some configurations, the double-sided foam tape 160 can have a thickness that is equal to or slightly greater than a thickness of the fire-resistant material strip 114. A release paper 124 may be adhered to the side of the double-sided foam tape 160 opposite the metal strip 112. The release paper 124 may be removed for use when using the double-sided foam tape 160 to attach the fire-rated gasket component 100 to an object, such as a header track or other wall structure.

The illustrated fire-rated gasket component 100 can include a non-metal layer 105, which may be adhered to the side of the metal strip 112 opposite the fire-resistant material strip 114 and/or the double-sided foam tape 160. In some configurations, the non-metal layer 105 is or includes a plastic material, such as vinyl or polyvinylchloride. The plastic material can be a thin solid plastic material, which can be formed into a plastic profile 111, such as by an extrusion process. Any suitable plastic material or combination of plastic materials can be used. In some configurations that utilize a solid plastic profile 111, there is no foam layer between the solid plastic profile 111 and the metal strip 112. Preferably, the solid plastic profile 111 is adhered directly to the metal strip 112 by a suitable thin adhesive layer, which could be a double sided film tape. The non-metal layer 105 could be formed, in whole or in part, by other materials. For example, the non-metal layer may be or include an ASJ (all service jacketing) tape 106, such as that sold by 3M, for example under the Venture™ brand. The non-metal layer 105 may be or include another type of tape, such as a single-sided foam tape 108. In some configurations, the non-metal layer 105 can be a combination of materials, such as any one or more of the ASJ tape 106, the plastic profile 111, and the single-sided foam tape 108.

The material(s) that make up the non-metal layer 105 can span either part of or the entire width (when considering the component 100 on its own, or the height or the vertical dimension in the orientation of FIG. 1) of the fire-rated gasket component 100. In some cases, the non-metal layer 105 can extend past one or both of the upper edge or the lower edge of the other constituent parts of the fire-rated gasket component 100. For example, the non-metal layer 105 may extend past the edge of the metal strip 112 and the fire-resistant material strip 114. In some configurations, the non-metal layer 105 can bend or fold to extend over the upper edge of one or both of the metal strip 112 and the fire-resistant material strip 114. In such configurations, the non-metal layer 105 can form the uppermost surface of the fire-rated gasket component 100, which can be the surface that contacts the upper horizontal support structure when used in a head-of-wall joint. In the case of the ASJ tape 106, the single-sided foam tape 108, or another similar material layer, the non-metal layer 105 can be flexible enough to fold over the metal strip 112 and/or the fire-resistant material strip 114. In the case of the plastic profile 111, the plastic profile 111 can be formed with an extension in the form of an upper return or a curved upper edge 137 that can extend over the upper edge of one or both of the metal strip 112 and the fire-resistant material strip 114. In the illustrated arrangement, the curved upper edge 137 extends past the fire-resistant material strip 114 and curves downwardly to extend along the opposite side of the fire-resistant material strip 114 from the metal strip 112. However, the curved upper edge 137 could extend only partially across a thickness of the fire-rated gasket component 100. The extension of the plastic profile 111 can be on one edge or on both ends, if desired. In some configurations, the curved upper edge 137 is flexible to facilitate the creation of a seal with the upper horizontal support structure or other adjacent structure.

The fire-resistant material strip 114 and the double-sided foam tape 160 can cooperate to cover a portion or an entirety of the metal strip 112. In the illustrated arrangement, the fire-resistant material strip 114 and the double-sided foam tape 160 together cover the entirety of the metal strip 112. In some configurations, the fire-resistant material strip 114 has a greater width than the double-sided foam tape 160. For example, the width of the fire-resistant material strip 114 can be about twice the width, or about three times the width, of the double-sided foam tape 160. In other configurations, the widths of the fire-resistant material strip 114 and the double-sided foam tape 160 can be the same or substantially the same. The non-metal layer 105 can cover a portion or an entirety of the metal strip 112. In the illustrated arrangement, the non-metal layer 105 covers the entirety of the metal strip 112.

FIG. 5 illustrates additional fire-rated joint components 100. The fire-rated joint components 100 are similar in many respects to the fire-rated joint component described above and is described below with an emphasis on the differences relative to the previously-described fire-rated joint component. Therefore, features of the fire-rated joint component 100 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 illustrated fire-rated gasket component 100 of FIG. 5 can include a metal strap or a metal strip 112. The metal strip 112 can be constructed from or include a steel material. In some configurations, the metal strip 112 can have a thickness of between about 10 Mils and about 40 Mils, between about 10 Mils and about 30 Mils, or between about 15 Mils and about 20 Mils, such as 18 Mils. However, other suitable thicknesses can also be used. The metal strip 112 can be generally resistant to deformation when exposed to heat or fire for at least a limited amount of time. The metal strip 112 can facilitate the fire-rated gasket component 100 retaining its shape at least partially or temporarily when exposed to heat or fire. In some configurations, the metal strip 112 can be considered as creating the base structure to which one or more of the other constituent parts of the fire-rated gasket component 100 are attached.

The illustrated fire-rated gasket component 100 can include a fire-resistant material strip 114. In some configurations, the fire-resistant material strip 114 can be or include an intumescent material. The fire-resistant material strip 114 can have a thickness between about 1 mm to about 5 mm, or between about 2 mm to about 4 mm, such as about 3 mm. However, other suitable thicknesses can also be used. As described above, the fire-resistant material strip 114 can be a multi-layer component including multiple layers of an intumescent or other suitable fire-resistant material. In some configurations, the one or more layers of material can have a total thickness sufficient to achieve a desired level of fire rating together with the other portions of the component 100. The fire-resistant material strip 114 may be adhered to the metal strip 112. To achieve this, many different adhesives may be used, such as any suitable glue or other adhesive, such as a double-sided film tape. In some cases, a heat-resistant adhesive can be used.

The illustrated fire-rated gasket component 100 can include a foam layer, which can be a double-sided foam tape 160. However, other suitable adhesives or attachment mechanisms could be used. The double-sided foam tape 160 can be adhered to the metal strip 112 with the adhesive present on the foam tape 160. Alternatively, the foam layer may be constructed with adhesive on only one side, or on neither side, and an additional adhesive could be added to one or both sides of the foam layer during the manufacturing process, such as a glue or other suitable adhesive. The double-sided foam tape 160 can have a thickness between about 1 mm to about 5 mm, or between about 2 mm to about 4 mm, such as about 3 mm. In some configurations, the double-sided foam tape 160 can have the same thickness or a similar thickness as the fire-resistant material strip 114. In some configurations, the double-sided foam tape 160 can have a thickness that is equal to or slightly greater than a thickness of the fire-resistant material strip 114. A release paper 124 may be adhered to the side of the double-sided foam tape 160 opposite the metal strip 112. The release paper 124 may be removed for use when using the double-sided foam tape 160 to attach the fire-rated gasket component 100 to an object, such as a header track or other wall structure.

The illustrated fire-rated gasket component 100 can include a non-metal layer 105, which may be adhered to the side of the metal strip 112 opposite the fire-resistant material strip 114 and/or the double-sided foam tape 160. In some configurations, the non-metal layer 105 is or includes a plastic material, such as vinyl or polyvinylchloride. The plastic material can be a solid plastic material, which can be formed into a thin profile, such as by an extrusion process. Any suitable plastic material or combination of plastic materials can be used. In some configurations that utilize a solid plastic profile 111, there is no foam layer between the solid plastic profile 111 and the metal strip 112. Preferably, the solid plastic profile 111 is adhered directly to the metal strip 112 by a suitable thin adhesive layer, which could be a double sided film tape.

The material(s) that make up the non-metal layer 105 can span either part of or the entire width (when considering the component 100 on its own, or the height or the vertical dimension in the orientation of FIG. 1) of the fire-rated gasket component 100. In some cases, the non-metal layer 105 can extend past one or both of the upper edge or the lower edge of the other constituent parts of the fire-rated gasket component 100. For example, the non-metal layer 105 can extend past the edge of the metal strip 112 and the fire-resistant material strip 114. In some configurations, the non-metal layer 105 can form the uppermost surface of the fire-rated gasket component 100, which can be the surface that contacts the upper horizontal support structure when used in a head-of-wall joint. In some configurations, the non-metal layer 105 includes an extension portion 138, which may be flexible in order to compress against an adjacent structure, such as the upper horizontal support structure when used in a head-of-wall joint, in order to fill or bridge any gaps. The extended portion 138 can range in length from between about ⅛ of an inch to about 1 inch, between about ¼ of an inch to about ¾ of an inch, between about ⅜ of an inch to about ⅝ of an inch, or about 1/2 of an inch in order to cover a gap that may be present. The extension portion 138 can have one of a variety of shapes. In some configurations, the extension portion 138 is linear or substantially linear. The extension portion 138 can be co-planar with a main body portion or a remainder of the non-metal layer 105 or can extend at an angle relative to the main body portion or the remainder of the non-metal layer 105. In some configurations, the extension portion 138 can have a corrugated shape to facilitate compression. Other suitable shapes can also be used, such as the gently-curved shape of the horizontal seal portion of the Fire Bead® fire-rated seal component or the vertical seal portion of the HotRod® XL fire-rated seal component sold by the applicant of this application, Cemco, LLC.

The fire-resistant material strip 114 and the double-sided foam tape 160 can cooperate to cover a portion or an entirety of the metal strip 112. In the illustrated arrangement, the fire-resistant material strip 114 and the double-sided foam tape 160 together cover the entirety of the metal strip 112. In some configurations, the fire-resistant material strip 114 has a greater width than the double-sided foam tape 160. For example, the width of the fire-resistant material strip 114 can be about twice the width, or about three times the width, of the double-sided foam tape 160. In other configurations, the widths of the fire-resistant material strip 114 and the double-sided foam tape 160 can be the same or substantially the same. The non-metal layer 105 can cover a portion or an entirety of the metal strip 112. In the illustrated arrangement, the non-metal layer 105 covers the entirety of the metal strip 112.

Certain Terminology

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

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

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

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

Summary

Components, elements, features, acts, or steps can be arranged or performed differently than described and components, elements, features, acts, or steps can be combined, merged, added, or left out in various embodiments. All possible combinations and sub-combinations of elements and components described herein are intended to be included in this disclosure. No single feature or group of features is necessary or indispensable.

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

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

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

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