Two-piece track system

A fire-rated receiver channel includes at least one intumescent or other fire-resistant material strip. The receiver channel can nest with a framing member, such as metal tracks, headers, header tracks, sill plates, bottom tracks, metal studs, wood studs or wall partitions, and placed at a perimeter of a wall assembly to create a fire block arrangement. In other arrangements, a track assembly includes two nested tracks, an inner track and outer track. The assembly is designed so that the outside width of the outer track is equal to or less than the outside width of the inner track to present a substantially flush external surface for attachment of exterior sheathing elements when the assembly is used in an external wall.

RELATED APPLICATIONS

Related applications are listed in an Application Data Sheet (ADS) filed with the present application. The entirety of each application listed in the ADS is hereby incorporated by reference herein. Also incorporated by reference herein in their entireties are U.S. Pat. No. 7,617,643 entitled Fire-Rated Wall Construction Product, U.S. Publication No. 2009/0178369 entitled Exterior Wall Construction Product, U.S. Publication No. 2011/0113709 entitled Wall Gap Fire Block Device, System and Method, and U.S. patent application Ser. No. 13/083,328, filed Apr. 8, 2011, entitled Fire-Rated Wall Construction Product.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This application is directed toward a two-piece track system for use in building construction, particularly for use in the interior and/or exterior wall of a building.

2. Description of the Related Art

Two-piece track systems for use in building construction are generally well known, as are two-piece track systems for use in the exterior and/or interior wall of a building that can allow for independent environmental movement of the tracks relative to one another. Two-piece track systems generally resemble both an outer U-shaped (or some other similar shaped) elongated tube, or track, and an inner U-shaped (or some other similar shaped) elongated tube, or track. Typically, the inner track is designed to receive or cover the ends of wall studs, and the outer track is designed to receive the inner track.

In two-piece track systems, independent movement of the tracks is sometimes desirable. The inner track is generally not confined in all directions, and thus is able to move independently from the outer track. Often times in use, the inner track is able to generally slide alongside the outer track in a horizontal or longitudinal direction relative to the outer track. In those areas of the world where earthquakes are common, this longitudinal or horizontal movement is important. If the inner track were not allowed to move freely in a generally longitudinal or horizontal direction, the stability of the wall and the building might be compromised.

In building construction it is not uncommon to have pieces of sheathing, or facade, attached to the outside of the building. These pieces of sheathing generally extend vertically alongside and down the exterior portion of the tracks and wall studs. The pieces of sheathing are attached to the tracks and/or wall studs by some connection means such as a screw or screws. In current two-piece track systems, the outer track's greatest width is larger than the inner track's greatest width. This creates an uneven outer surface for attachment of the sheathing. As a result, often sheathing elements flare out at their ends to accommodate for the uneven surface created by the different track widths.

Also, it is often difficult to keep the inner track from pulling or slipping away relative to the outer track during the installation procedure. In current two-piece track systems, screws are used to temporarily hold the outer and inner tracks in place during construction. If these screws are not removed after the wall is framed, the inner track will not be able to move as is desired.

It is also desirable or even mandatory to provide fire block arrangements at one or more linear wall gaps, which may be present between the top, bottom or sides of a wall and the adjacent structure. The fire block arrangements often involve the time-consuming process of inserting by hand a fire resistant material into the wall gap and then applying a flexible sealing layer to hold the fire resistant material in place. More recently, heat-expandable intumescent fire block materials have been integrated into the top or bottom track of the stud wall assembly.

SUMMARY OF THE INVENTION

Still, a need exists for additional fire block arrangements for wall gaps that provide advantages over the prior art arrangements. For example, it can be desirable for the intumescent material to be secured to a track member that is separate from the top or bottom track that directly receives or supports the studs, or separate from the stud in the case of a side wall gap. Such an arrangement enhances or maximizes the deflection length available for a slotted track (or other dynamic header) for a given flange length by separating the intumescent-carrying flanges from the slotted flanges. The arrangement also provides flexibility in that it allows different header tracks, footer tracks or studs to be used in combination with a single track incorporating the intumescent material. In addition, a two-piece track or track/stud arrangement can facilitate the creation of a seal between the components of the wall assembly and the adjacent structure. The intumescent material can be placed at a suitable location on the track member, such as along a side flange and/or a side edge portion of the web. Preferably, the header track, bottom track or stud is snugly received in the track member incorporating the intumescent, such that little or no gap is present between them.

An embodiment involves a two-piece fire-rated track assembly for a linear wall gap. The assembly includes a first track that has a web, a first flange and a second flange. The web is substantially planar and has a first side edge and a second side edge. The first flange and the second flange extend in the same direction from the first and second side edges, respectively. Each of the first and second flanges is substantially planar such that the first track defines a substantially U-shaped cross section. A second track has a web, a first flange and a second flange. The web is substantially planar and has a first side edge and a second side edge. The first flange and the second flange extend in the same direction from the first and second side edges, respectively. Each of the first and second flanges is substantially planar such that the second track defines a substantially U-shaped cross section. Each of the first and second flanges has a free end opposite a respective one of the first side edge and second side edge. Each of the free ends defines a kick-out portion that extends in a direction opposite the web and away from the other kick-out portion. At least one heat-expandable intumescent strip is attached to the second track and extends lengthwise along an outer surface of one of the first and second flanges. The intumescent strip includes a portion that extends past an outer surface of the web of the second track. The first track is snugly nested within the second track such that there is little or no gap therebetween.

In some arrangements, the at least one intumescent strip extends along and is attached to a portion of the web of the second track. The at least one intumescent strip can define a total length in a cross-sectional direction, wherein a portion of the total length located on the flange is at least five times greater than a portion of the total length on the web. The at least one intumescent strip can cover a substantial entirety of the outer surface of the flange. The at least one intumescent strip can be a first intumescent strip and a second intumescent strip on the first and second flanges, respectively.

In some arrangements, the first and second flanges of the first track are longer than the first and second flanges of the second track. The first and second flanges of the first track can be at least about twice as long as the first and second flanges of the second track. The assembly can include a plurality of slots on the first and second flanges of the first track, wherein the slots extend in a direction perpendicular to a length of the first track. The first track can be a footer or header track, or a stud.

An embodiment involves a fire-rated wall assembly including a header track having a web, a first flange and a second flange. The first and second flanges extend downwardly from the web and include a plurality of slots that extend in a vertical direction and are spaced along a length of the header track. A bottom track has a web, a first flange and a second flange. The first and second flanges extend upwardly from the web. A plurality of studs each has an upper end and a lower end. The lower end of each stud is received within and secured to the bottom track and the upper end of each stud is received within the header track. For each of the plurality of studs, one of a plurality of fasteners is passed through one of the plurality of slots of the first flange and into the upper end of the stud and another of the plurality of fasteners is passed through one of the plurality of the slots of the second flange and into the upper end of the stud. A receiver channel has a web, a first flange and a second flange. The first and second flanges extend downwardly from the web. The header track is snugly nested within the receiver channel and the first and second flanges of the receiver channel are shorter than the first and second flanges of the header track such that lower portions of the first and second flanges of the header track, including at least lower portions of each of the plurality of slots, are exposed from the receiver channel. At least one heat-expandable intumescent strip is attached to the receiver channel and extends lengthwise along an outer surface of one of the first and second flanges. The intumescent strip includes a portion that extends past an outer surface of the web of the receiver channel.

In some arrangements, at least one wallboard is coupled to the plurality of studs. The wallboard overlaps the one of the first flange and the second flange of the header track to which the at least one intumescent strip is attached and the one of the first flange and the second flange of the receiver channel to which the at least one intumescent strip is attached. The wallboard can overlap the at least one intumescent strip.

In some arrangements, each of the first and second flanges of the receiver channel has a free end opposite the web, and each of the free ends defines a kick-out portion that extends in a direction opposite the web and away from the other kick-out portion. The at least one intumescent strip can extend along and can be attached to a portion of the web of the receiver channel. The at least one intumescent strip can define a total length in a cross-sectional direction, wherein a portion of the total length located on the flange is at least five times greater than a portion of the total length on the web. The at least one intumescent strip can cover a substantial entirety of the outer surface of the flange. The at least one intumescent strip can be a first intumescent strip and a second intumescent strip on the first and second flanges, respectively. The first and second flanges of the header track can be at least about twice as long as the first and second flanges of the receiver channel.

Similarly, a need exists for improved two-piece track arrangements that may or may not include fire-resistant materials and that can be constructed for interior or exterior applications. A preferred system comprises an inner track configured to receive a plurality of wall studs therewithin, and an outer track configured to receive the inner track within the outer track. The outer track is configured so that its greatest width is equal to or less than the greatest width of the inner track, thus presenting a general flush surface for attachment of sheathing to the track when the system is used in an exterior wall. In some embodiments, the track flanges may comprises a plurality of angled surfaces to permit a mating nesting arrangement that has an added benefit of preventing separation of the two tracks once nested. The system may further comprise a strap or series of engaging surfaces on the inner and outer tracks that generally restrain the inner track relative to the outer track in addition and/or in lieu of angled flange surfaces.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring toFIG. 1, a first embodiment of the inventive track assembly10comprises a first outer track12and a second nested track14therewithin. The track assembly is configured to be attached via one of various known fastening means to a ceiling surface16of a building and to engage a plurality of vertical stud members18. The outer track12comprises a web22and two side flanges24aand24b. Similarly, the inner track14comprises a web26and two side flanges28aand28b. The outer and inner tracks12,14are matingly configured so that the inner track14can nest within the outer track12when assembled to prevent generally side-to-side movement but permit relative longitudinal movement along the length of the tracks.

It is desirable that the greatest width of the outer track12be no greater than the greatest width of the inner track14; i.e., equal to or less than the greatest width of the inner track14. In the embodiments shown by example inFIGS. 1 and 2, the widths of the two tracks are substantially equivalent. In these embodiments, the essentially flush configuration is accomplished by flaring the side flanges28aand28bof inner track14at their ends to a width equal to that of the outer track.

Although the present invention is applicable to both interior and exterior walls, in the context of an exterior wall specifically, it is contemplated that outer sheathing would be attached to the track assembly10, with an upper sheathing board30and a lower sheathing board32positioned below it. By configuring the outer and inner tracks12,14as described herein, the two-piece track system10may present a substantially flush surface profile alongside sheathing board30and32, which minimizes flaring of the sheathing boards and creates a desirable building surface. Where the width of the outer track is meaningfully less than the width of the inner track, it is still possible to utilize and attach flat sheathing elements to maintain a flush building profile, although a small gap may exist (not shown) between the flange24band upper sheathing board30undetectable from outside the building.

When applied to a building, the track assembly10is secured to the ceiling surface16by securing the web22of outer track12to the ceiling surface by way of conventional fastening means (not shown). The inner track14may be slipped into the outer track either by way of a snap fit or other application. When shipped as a combined assembly, each track web22,26comprises aligned holes and/or slots for permitting a fastener to be directed through the inner track web26and to engage the web22of the outer track12to the ceiling surface.

In current two-piece track systems, it is often necessary to use screws or similar devices to hold the two tracks together during installation or building construction. If the screws are not eventually pulled out after the wall is framed, the screws that were installed will prevent the inner track from being able to move independently from the outer track. One embodiment of the present invention overcomes this deficiency. Referring toFIG. 2, another embodiment of the invention comprises the two-piece track system10ofFIG. 1further comprising a plurality of slots38along side flange28bto permit vertical movement of the stud members18relative to the track assembly10. The embodiment further comprises a setting strap40for securing tracks12and14together during transport and installation. In one application, the strap40may be placed over the outer track12and extend down along side flanges24and28of the outer and inner tracks, respectively. Once the inner track14is installed within, or relative to, the outer track12, the setting strap40is desirably flared inwardly at its end. This is done to generally restrain the inner track from being pulled away from the outer track, while still allowing for at least some movement of the tracks relative to one another. For each length of track assembly10, one or more setting straps40may be used. Other mechanisms are contemplated for securing the inner and outer tracks together for shipment and/or installation purposes but removed after installation to permit relative longitudinal movement. Such mechanisms include toggle bolts and other known devices.

It is contemplated that the inner and outer tracks may be configured in one of a large number of mating configurations that permit relative longitudinal movement of the inner track within the outer track and yet preserve the assembly in tact. Examples of other configurations are shown inFIGS. 3-5. In each of these examples, the side flanges comprises multiple angled surfaces that permit mating of the inner and outer tracks in such a way as to restrain the two tracks from being easily pulled apart once nested. By way of example, referring toFIG. 3, an alternative embodiment of a two-piece nested track assembly110comprises an outer track112and inner track114. The outer track112comprises a web116and side flanges118aand118b; the inner track114comprises a web122and side flanges124aand124b. Side flange118comprises a first surface126and a second surface128angled with respect to first surface128. Correspondingly, side flange124comprises a first surface130, a second surface132, and a third surface134. With such an arrangement, the inner track114may be nested within outer track112so as to restrain the tracks from being easily pulled apart. They may be shipped as discrete track pieces and snapped in place as a nested assembly. Similarly,FIG. 4also reflects a plurality of surfaces in the corresponding flanges of outer and inner tracks212and214so that a mating nested arrangement can be made to make it more difficult to pull the tracks apart.

Referring toFIG. 5, another embodiment of a nested track assembly310can include an outer track312and inner track314. The outer track312can include a strip or strips of intumescent material338attached along portions of the web320of outer track312. In use, the intumescent material338can act in helping to prevent fire, smoke, or other debris from moving past the track assembly310. Additionally, the inner track314can include an opening or openings340along the web322of inner track314. By incorporating openings340in the inner track314, the weight of inner track314can be reduced while still maintaining the structural stability of the track assembly310.

FIGS. 6 and 7illustrate another two-piece track assembly400.FIGS. 8 and 9illustrate the two-piece track assembly400incorporated into a head-of-wall assembly. The two-piece track assembly400can be used in a variety of perimeter wall gap applications, including gaps at the top of a wall (“head-of-wall” gap), gaps at the bottom of a wall, and gaps at the side of a wall. The two-piece track assembly400can be used in interior or exterior wall applications. However, the illustrated two-piece track assembly400is well-suited for interior wall applications and is shown in an interior wall environment. The two-piece track assembly400is shown in the context of a dynamic head-of-wall assembly, but can also be employed in a static head-of-wall assembly, as discussed below.

With reference toFIGS. 6 and 7, the two-piece track assembly400includes a first track member, or first track402. The illustrated first track402is a header track intended to be coupled to an overhead structure and receive upper ends of a plurality of wall studs. However, the first track402could also be a bottom track or a wall stud. The illustrated header track402includes a web404, a first flange406and a second flange408. The first flange406and second flange408extend downwardly from opposing first and second side edges of the web404. Preferably, a substantial portion or the entirety of each of the first flange406and second flange408is planar. Accordingly, the header track402is substantially U-shaped in cross-section. In some arrangements, the first flange406and the second flange408can include non-planar portions, such as the upper portions of the second tracks14illustrated inFIGS. 1-5or lengthwise-extending elongated protrusion(s) for the wallboard to rest against.

Preferably, each of the first flange406and the second flange408include a plurality of elongated slots410that extend in a vertical direction, or in a direction from a free end of the flange406,408toward the web404and perpendicular to a length direction of the track400. The centerlines of adjacent slots410are spaced from one another along a length of the track400by a distance, such as one inch, in one embodiment. However, other offset distances could be provided, depending on the desired application. Preferably, the slots410are linear in shape and sized to receive and guide a fastener that couples a stud to the header track400, as described below. The slots410allow relative movement between the header track400and the studs. The linear shape of the slots410constrains the fasteners to substantially vertical movement.

The two-piece track assembly400also includes a second track412, which is also referred to as a receiver channel. The receiver channel412includes a web414, a first flange416and a second flange418. The first flange416and the second flange418each extend downwardly from opposing first and second side edges of the web414. Preferably, a substantial portion or the entirety of each of the first flange416and second flange418is planar. Accordingly, the receiver channel412is substantially U-shaped in cross-section. However, in another arrangement, the receiver channel412could be provided in two pieces with the first flange416and a portion of the web414as one piece and the second flange418and portion of the web414as a second piece. Each piece of the receiver channel412could be separately attached to the first track402and/or the adjacent support structure.

Preferably, the free ends of each of the first flange416and the second flange418form a kick-out420. The kick-out420extends outwardly from the remainder of the flange416,418in a direction away from the web414(and away from the header track402when the two-piece track assembly400is assembled). The illustrated kick-out420is an outwardly-bent end portion of the flange416,418, which is oriented at an oblique angle relative to the remaining, preferably planar, portion of the flange416,418. As described further below, the kick-out420functions as a lead-in surface for the fasteners that pass through the slots410of the header track402when the heads of the fasteners move toward the top of the slots410and in between the flanges416,418of the receiver channel412and the flanges406,408of the header track402. However, the kick-out420can be otherwise shaped if desired, depending on the intended application and/or desired functionality. For example, the kick-out420can be configured to contact the wallboard of an associated wall assembly to assist in creating a seal between the receiver channel412and the wallboard or to inhibit damage to the fire-resistant material on the receiver channel412, as described below. In one arrangement, the kick-out420extends outwardly less than about ¼ inch, less than about ⅛ inch or less than about 1/16 inch.

The illustrated receiver channel412is a fire-rated channel and includes a fire-resistant material arranged to seal the head-of-wall gap at which the two-piece track assembly400is installed. Preferably, the fire-resistant material is an intumescent material strip422, such as an adhesive intumescent tape. The intumescent strip422is made with a material that expands in response to elevated heat or fire to create a fire-blocking char. On suitable material is marketed as BlazeSeal™ from Rectorseal of Houston, Tex. Other suitable intumescent materials are available from Hilti Corporation, Specified Technologies, Inc., or Grace Construction Products. The intumescent material expands to many times (e.g., up to 35 times or more) its original size when exposed to sufficient heat (e.g., 350 degrees Fahrenheit. Thus, intumescent materials are used as a fire block because the expanding material tends to fill gaps. Once expanded, the intumescent material is resistant to smoke, heat and fire and inhibits fire from passing through the head-of-wall. It is understood that the term intumescent strip422is used for convenience and that the term is to be interpreted to cover other expandable fire-resistant materials as well, such as intumescent paints (e.g., spray-on) or fire-rated dry mix products, unless otherwise indicated. The intumescent strip422can have any suitable thickness that provides a sufficient volume of intumescent material to create an effective fire block, while having small enough dimensions to be accommodated in a wall assembly. That is, preferably, the intumescent material strips422do not cause unsightly protrusions or humps in the wall from excessive build-up of material. In one arrangement, the thickness of the intumescent strip422is between about 1/16 (0.0625) inches and ⅛ (0.125) inches, or between about 0.065 inches and 0.090 inches. One preferred thickness is about 0.075 inches. The kick-out420can extend outwardly a distance greater than the thickness of the intumescent strip422, a distance approximately equal to the thickness of the intumescent strip422or a distance less than the thickness of the intumescent strip422. The size of the kick-out420can be selected based on whether it is desirable for the wall board material to contact the kick-out420(e.g., to create a seal or protect the intumescent strip422), the intumescent strip422, or both the kick-out420and the intumescent strip422.

An intumescent strip422is positioned on at least one side of the receiver channel412and, preferably, on each side of the receiver channel412. The intumescent strip422preferably is positioned on one or both of the flange416,418and the web414. In the illustrated arrangement, the intumescent strip422is attached on both the flange416and the web414on one side of the receiver channel412and on both the flange418and the web414on the other side of the receiver channel412. Preferably, the intumescent strip422covers a substantial entirety of the flange416,418and also extends beyond the web414. That is, each intumescent strip422preferably extends from the kick-out420of the respective flange416,418to the web414and beyond the web414. Such an arrangement permits the intumescent strip422to contact the ceiling or other overhead support structure to create an air seal at the head-of-wall. Preferably, the upper edge of the intumescent strip422wraps around the corner of the receiver channel412and is attached to the web414. Such an arrangement causes the intumescent strip422to be pinched between the receiver channel412and the ceiling or other overhead support structure to assist in keeping the intumescent strip422in place when exposed to elevated heat, which may cause failure of an adhesive that secures the intumescent strip422to the receiver channel412. However, although less preferred, the upper edge of the intumescent strip422could simply extend beyond (above, in the illustrated arrangement) the web414without being attached to the web414.

Preferably, a relatively small amount of the intumescent strip422is positioned on the web414relative to the amount positioned on the flange416,418. For example, the intumescent strip422has a width, which in cross-section can be viewed as a length. Preferably, a length LFof the intumescent strip422on the flange416,418is at least about 3 times the length LWof the intumescent strip422on the web414. In one arrangement, the length LFof the intumescent strip422on the flange416,418is at least about 5 times the length LWof the intumescent strip422on the web414. In another arrangement, the length LFof the intumescent strip422on the flange416,418is at least about 10 times the length LWof the intumescent strip422on the web414. Preferably, the length LFof the intumescent strip422on the flange416,418is between about ½ inches and 1½ inches and the length LWof the intumescent strip422on the web414is between about ⅛ inches and ½ inches. In one preferred arrangement, the length LFof the intumescent strip422on the flange416,418is about ¾ inches and the length LWof the intumescent strip422on the web414is about ¼ inches.

In the illustrated arrangement, the flanges416,418of the receiver channel412are shorter than the flanges406,408of the header track402. The flanges416,418of the receiver track412can cover an upper portion of the slots410of the header track402. Preferably, at least a lower portion of the slots410are exposed or left uncovered by the flanges416,418of the receiver track412. In one arrangement, the length of the flanges416,418are about one-half of the length of the flanges406,408. The flanges416,418can have a length of between about ¾ inches and 3 inches, or between about 1 and 2 inches. In one arrangement, the flanges416,418have a length of about 1½ inches or 1¼ inches. The flanges406,408of the header track402can be any suitable length. For example, the flanges406,408can be between about 2 and 4 inches in length, with specific lengths of about 2½ inches, 3 inches, 3¼ inches and 3½ inches, among others.

The web404of the header track402can be any suitable width. For example, the web404can have a width between about 2½ and 10 inches, with specific lengths of about 3.5 inches, 4 inches, 5.5 inches, 6 inches and 7.5 inches, among others. Preferably, the width of the web414of the receiver channel412corresponds to the width of the web404of the header track402. Although, preferably, the web414of the receiver channel412will be slightly wider than the web404of the header track402so that the header track402can be received within, or nest within, the receiver channel412. The web414preferably is wider than the web404at least by an amount equal to twice the wall thickness of the header track402to accommodate the combined thickness of the flanges406and408. However, preferably, the web414is not significantly wider than the web404such that there is no significant gap between the flanges406,408of the header track402and the flanges416,418of the receiver channel412. Preferably, the gap, if any, between the flanges406and416or408and418is less than about the size of a head of the fastener used to attach the wall studs to the header track402. In one arrangement, the gap on either side is less than about ⅛ inches or less than about ¼ inches. However, in other arrangements, it may be desirable to provide a significant gap. For example, it may be desirable to provide an air gap between the flanges406and416and/or408and418, such as to inhibit direct contact and, thus, direct transfer of heat between the flanges406and416and/or408and418. Such a gap may be less than or equal to about 2 inches, less than or equal to about 1 inch or less than or equal to about ½ inch. If desired, a thermal break material can be positioned between any or all corresponding surfaces of the tracks402,412. The thermal break material can be applied to the inner surfaces of the receiver channel412. The thermal break material can be a liquid applied material, or an adhesively applied sheet membrane material to provide thermal break insulation to slow down heat passage during a fire. Any suitable insulating materials can be used.

The header track402and the receiver channel412can be constructed of any suitable material by any suitable manufacturing process. For example, the header track402and receiver channel412can be constructed from a rigid, deformable sheet of material, such as a galvanized light-gauge steel. However, other suitable materials can also be used. The header track402and receiver channel412can be formed by a roll-forming process. However, other suitable processes, such as bending (e.g., with a press brake machine), can also be used. Preferably, the intumescent strip(s)422are applied during the manufacturing process. However, in some applications, the intumescent strip(s)422could be applied after manufacturing (e.g., at the worksite).

FIGS. 8 and 9illustrate an upper portion of a wall assembly, or a head-of-wall assembly430, incorporating the two-piece header track assembly400ofFIGS. 6 and 7. The illustrated head-of-wall assembly430is a dynamic head-of-wall assembly, meaning that relative movement between the header track assembly400and the remainder of the wall is permitted. Such arrangements are intended to accommodate deflections caused by seismic events or moving overhead loads.FIG. 8illustrates the head-of-wall assembly430in or near a position in which the deflection joint is closed, or the head-of-wall gap is reduced in size or minimized.FIG. 9illustrates the head-of-wall assembly430in a position in which the deflection joint is open, or a head-of-wall gap exists. The two-piece header track assembly400can also be employed in static head-of-wall assemblies.

The wall assembly ofFIGS. 8 and 9extends in a vertical direction between a floor, or other lower support structure (not shown), and a ceiling432, or other overhead support structure. The ceiling432can be of any suitable arrangement, including a fluted pan deck that supports a concrete layer. The wall assembly includes a bottom track (not shown) that is secured to the floor. A plurality of studs434have lower ends supported within and secured to the bottom track. The studs434are spaced from one another at a desired interval along a length of the bottom track. The studs434extend upward in a vertical direction from the bottom track to the two-piece header track assembly400. The upper ends of the studs434are received within the header track402and, preferably, spaced from the web404of the header track402(FIG. 9) in a neutral position or an unloaded condition of the ceiling432. For each stud434, a first fastener436(e.g., a threaded framing screw) is passed through a corresponding slot410of the flange406and into the stud434and a second fastener436is passed through a corresponding slot410of the flange408and into the stud434. Preferably, the fasteners436are positioned at or near the center of the slots410to permit deflection movement in either an up or down direction.

The two-piece header track assembly400is secured to the ceiling432in any suitable manner, such as by a plurality of suitable fasteners438. In some arrangements, it is preferred that the header track402and the receiver channel412are both secured to the ceiling432. For example, each of the plurality of fasteners436can pass through the webs404and414of the header track402and receiver channel412, respectively, to secure both tracks402and412to the ceiling432. The header track402and the receiver channel412can be secured to the ceiling432separately from one another (e.g., using separate fasteners) or simultaneously. In one arrangement, the receiver channel412is secured to the ceiling432first and then the header track402is nested within the receiver channel412and secured to the ceiling432, alone or as part of a wall assembly. In another arrangement, the receiver channel412and header track402are secured to the ceiling432at the same time utilizing the same fasteners438. Thus, in such an arrangement, relative longitudinal (or “drift”) movement of the tracks402and412is minimized or prevented. However, if drift movement is desired, the receiver channel412can be fixedly secured to the ceiling432and the header track402can be free floating within the receiver channel412or otherwise secured to allow some relative drift movement, such as in any manner described above with reference toFIGS. 1-5. As illustrated, preferably, a portion of the intumescent strip422is pinched between the ceiling432and the receiver channel412. As described above, such an arrangement assists in keeping the intumescent strip422in place over time and/or in the event of elevated heat or fire that causes failure of the adhesive that secures the intumescent strip422to the receiver channel412.

One or more pieces of wallboard440are attached to one or both sides of the studs434by a plurality of suitable fasteners, such as drywall screws442. Preferably, the uppermost drywall screws442are positioned close to the header track402but spaced sufficiently therefrom so as to not inhibit complete upward movement of the studs434relative to the header track402.

As illustrated, preferably, in a neutral or unloaded condition, the heads of the fasteners436securing the studs434to the header track402are positioned below the lowermost ends, or free ends, of the flanges416,418of the receiver channel412. Preferably, in such a position, an upper end of the wallboard440rests against the intumescent strip442and/or the kick-out420. When the wall is deflected such that the studs434move upwardly towards or to a closed position of the deflection gap (FIG. 8), the heads of the fasteners436may enter in between the flanges406,408of the header track402and the flanges416,418of the receiver channel412. If the gap between the flanges406and416and/or408and418is less than the width of the head of the fastener436, the flanges416and/or418of the receiver channel412may flex or deflect outwardly to accommodate the heads of the fasteners436. The shape and/or angle of the kick-out420can facilitate the entry of the heads of the fasteners436in between the flanges406and416and/or408and418without getting hung up on the flanges416and/or418.

FIGS. 10-12illustrate a wall assembly utilizing a first two-piece track assembly500at a gap at the bottom of the wall assembly and a second two-piece track assembly600at a gap at the side of the wall assembly. Preferably, each two-piece track assembly500,600is similar to the two-piece track assembly400described above. In particular, preferably, each two-piece track assembly500,600creates a fire-resistant structure at the respective wall gap.

The first two-piece track assembly500includes a sill plate, first track, or bottom track502, and a second track, or receiver channel512. The bottom track502preferably is substantially similar to the header track402described above. However, preferably, the bottom track502does not include slots on the side flanges (such as slots410of the header track402) because relative movement between the studs434and the bottom track502is typically not desired. The receiver channel512preferably is identical or substantially identical to the receiver channel412described above. The bottom track502is snugly nested within the receiver channel512. The combined bottom track502and receiver channel512(the two-piece track assembly500) is secured to a lower support structure, such as a floor532, which can also function as a ceiling of a lower level of the building. The two-piece track assembly500can be secured to the floor532with a plurality of suitable fasteners (not shown) similar to the fasteners438described above. The receiver channel512includes one or more intumescent strips522, which expand in response to elevated heat or fire to create a fire block at the gap at the bottom of the wall assembly. The particular structure and arrangement of the intumescent strips522can be identical to the arrangements discussed above with respect to the receiver channel412. With reference toFIG. 12, one or more pieces of wallboard440can be secured to one or both sides of the studs434

Similarly, the second two-piece track assembly600includes a first track, or stud602, and a second track, or receiver channel612. The stud602preferably is substantially similar to the studs434described above. Thus, with reference toFIG. 11, the stud602can be C-shaped in cross-section. The stud602includes a web and flanges that create a U-shaped portion. In addition, the free ends of the flanges can also include return leg portions that extend inwardly toward one another to create the C-shape. However, other suitable stud shapes and/or types, including wood studs, can also be used. Thus, the assemblies described herein are referred for convenience as “two-piece track” assemblies; however, it is not necessary that each assembly includes two “tracks.” Therefore, assemblies incorporating a wood stud (header or footer) can be included within the scope of a “two-piece track” assembly, unless specifically excluded. The receiver channel612preferably is identical or substantially identical to the receiver channels412,512described above. The stud602is snugly nested within the receiver channel612. The combined stud602and receiver channel612(the two-piece track assembly600) is secured to a side support structure, such as a wall632. The two-piece track assembly600can be secured to the side wall632with a plurality of suitable fasteners (not shown) similar to the fasteners438described above. The receiver channel612includes one or more intumescent strips622, which expand in response to elevated heat or fire to create a fire block at the gap at the side of the wall assembly.

The described two-piece track assemblies400,500and600provide convenient and adaptable fire block structures for a variety of linear wall gap applications, which in at least some embodiments permit the creation of a fire rated joint according to UL 2079. The separate receiver channels412,512,612include fire-retardant materials (e.g., intumescent material strips) secured (e.g., adhesively attached or bonded) to appropriate locations on the channels412,512,612and can be used with a variety of headers, footers (bottom tracks or sill plates) and studs to create a customizable assembly. Thus, one particular type of channel412,512,612can be combined with multiple sizes or types of base tracks, headers, sill plates or studs to result a large number of possible combinations. The receiver channels412,512,612can be configured for use with commonly-available tracks, headers, sill plates or studs, in addition to customized tracks, headers, sill plates or studs specifically designed for use with the receiver channels412,512,612. Thus, the advantages of the described systems can be applied to existing wall assemblies. Therefore, the channels412,512,612can be stocked in bulk and used as needed with an appropriate framing component.

Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In particular, while the present two-piece track assemblies have been described in the context of particularly preferred embodiments, the skilled artisan will appreciate, in view of the present disclosure, that certain advantages, features and aspects of the assemblies may be realized in a variety of other applications, many of which have been noted above. Additionally, it is contemplated that various aspects and features of the invention described can be practiced separately, combined together, or substituted for one another, and that a variety of combination and subcombinations of the features and aspects can be made and still fall within the scope of the invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims.