Patent Publication Number: US-2021164222-A1

Title: Fire-rated wall joint component and related assemblies

Description:
CROSS-REFERENCE 
     This application claims the benefit of U.S. Application No. 62/942,423 filed on Dec. 2, 2019, the entirety of which is hereby incorporated by reference. 
    
    
     BACKGROUND 
     Field 
     This application is directed to fire-rated wall construction components for use in building construction joints. 
     Related Art 
     Fire-rated wall construction components and assemblies are commonly used in the building construction industry. These components and assemblies are aimed at preventing fire, heat, and smoke from leaving one portion of a building or room and entering another, usually through vents, joints in walls, or other openings. The components can incorporate fire-retardant materials which substantially block the path of the fire, heat, and/or smoke for at least some period of time in accordance with certain standards, such as UL-2079 “Test For Fire-rated Building Joints”. 
     Conventional fire-rated wall construction components are typically labor intensive and expensive to install. One example of a conventional fire block arrangement includes using a fire-resistant material such as mineral wool stuffed in the gaps within a head-of-wall assembly including deflection gaps between the top of the wall boards and the ceiling. Once the gaps are filled with the fire block material, a flexible coating such as a spray-on elastomeric coating can cover the entire head-of-wall to secure the fire block material in place. Over time and cycles of movement the flexible coating may degrade and cause cracks or flaking. As a result, it is possible that the fire-resistant material may become dislodged and thereby reduce the effectiveness of the fire block. 
     SUMMARY 
     One aspect of the present disclosure is a fire-rated component for a linear gap between a wall assembly and an adjacent structure. The component includes an elongate metal profile and a fire-rated board member. The elongate metal profile includes a vertical leg, an upper leg and a lower leg. The upper leg extends in a first direction from an upper edge of the vertical leg. The lower leg extends in the first direction from a lower edge of the vertical leg. The fire-rated board member is positioned within a space defined by the vertical leg, the upper leg and the lower leg to form a composite component. 
     According to another aspect, the upper leg includes a downward facing v-groove. According to another aspect, the upper leg includes an extended free end attachment leg. According to another aspect, an outward facing protrusion on the vertical leg rests against the drywall board of the framed wall assembly with the outward facing protrusion extending in a second direction, opposite the first direction. According to another aspect, the gypsum board member is adhesively attached with the vertical leg. According to another aspect, the lower leg includes a kick-out configured to retain a gypsum board member within the space. According to another aspect, the upper leg, the lower leg, the v-groove, and the kick-out are configured to exert a force against the gypsum board member to retain the gypsum board in the space. According to another aspect, the lower leg determines the thickness of the layer or layers of the gypsum board member. According to another aspect, the metal profile is formed from a unitary piece of sheet steel and bent to form the vertical leg. According to another aspect, the board member comprises a gypsum material. 
     In another aspect of the present disclosure, a building construction joint includes a wall assembly and an adjacent structure formed along a linear gap. A fire-rated component including an elongate metal profile and a fire-rated board member is positioned at a joint between the wall assembly and the adjacent structure to provide fire-blocking across the linear gap. According to another aspect, the adjacent structure is a ceiling and the wall assembly is a vertical wall. 
     The foregoing summaries are illustrative only and are not intended to be limiting. Other aspects, features, and advantages of the systems&#39; devices and methods and/or other subject matter described in this application will become apparent in the teaching set forth below. The summaries provided introduce a selection of some of the concepts of this disclosure. The summary is not intended to identify key or essential features of any subject matter described herein. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various examples are depicted in the accompanying drawings for illustrative purposes and should in no way be interpreted as limiting the scope of the examples. Various features of different disclosed examples can be combined to form additional examples which are part of this disclosure. 
         FIG. 1  illustrates a cross section of a head-of-wall assembly including a composite fire-blocking component. 
         FIG. 2A  shows a cross-section of the head-of-wall assembly in a fully closed configuration. 
         FIG. 2B  shows a cross-section of the head-of-wall assembly in a fully opened configuration. 
         FIG. 3  shows a cross-section of the composite fire-blocking component including a metal profile and board member. 
         FIG. 4  shows a cross-section of an elongate metal profile. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1-2B  illustrate a building construction joint between a wall assembly and an adjacent structure having a linear gap in the form of a head-of-wall assembly  100 . The embodiments disclosed herein often are described in the context of an interior of a building and configured for preventing passage of smoke and/or fire between adjacent rooms in an elevated-temperature environment. However, the embodiments herein can be applied to wall systems configured for other types of environments as well, such as for exterior wall applications, and can include different and/or additional components and types of materials other than those described herein. 
     The head-of-wall assembly  100  can generally include an overhead structure or ceiling  105 . The ceiling  105  can be generally formed in a horizontal plane and/or include one or more flutes or grooves therein. The ceiling  105  can be a floor of a higher level of a building. The head-of-wall assembly  100  can include a header track or channel  107 . The channel  107  can include a web  107   a  to which are attached one or more flanges  107   b ,  107   c . The first and second flanges  107   b ,  107   c  can extend from opposite ends of the web  107   a  in the same direction to form a generally u-shaped cross section. Optionally, the channel  107  can be a deep leg header track. 
     One or more studs  109  forming the wall can be received within the channel  107  between the first and second flanges  107   b ,  107   c . The first and second flanges  107   b ,  107   c  can include slots to which fasteners can be received to attach the channel  107  with the studs  109 . The slots can be oriented generally orthogonal to a length of the channel  107 . The studs  109  can be attached with the channel  107  via fasteners through the slots of the flanges  107   b ,  107   c.    
     One or more wall board members (e.g., gypsum drywall)  111 ,  113  can be attached with the studs  109  to form the wall. Assembly of the wall boards  111 ,  113  with the studs  109  can define a deflection gap  101  between the ceiling  105  and upper ends of the wall boards  111 ,  113 . The deflection gap  101  can vary in width depending on the relative position of the wall (e.g., wall boards  111 ,  113  and the studs  109 ) and the ceiling  105 . The head-of-wall assembly  100  can cycle between a more closed position (such as the fully closed position in  FIG. 2A ) and a more open position (such as the fully open position in  FIG. 2B ). The dynamic nature of the head-of-wall assembly  100  can accommodate seismic or thermal forces or other movements of the building within which the head-of-wall assembly  100  is included. 
     The head-of-wall assembly  100  can include a fire-rated composite component  10 . The composite component  10  can generally be configured to cover the deflection gap  101  to provide fire, smoke, heat and/or sound insulation and facilitate unencumbered movement of the joint. The component  10  can include an elongate metal profile  12  and a board member  14 . The board member  14  can comprise a fire-rated material, such as a gypsum drywall material. In certain implementations, the board member  14  can adhesively attached or otherwise mechanically secured with the metal profile  12  to form the composite component  10 . 
     The composite component  10  can be installed over the outer surface of the wall boards  111 ,  113  and/or the flanges  107   b ,  107   c  on the framed wall assembly once the drywall assembly is completed. The component  10  can be attached with the ceiling  105  by one or more fasteners  103 , such as metal screws, adhesives, staples or other fasteners. The fasteners  103  can extend through the metal profile  12 . The fire board member  14  can insulate the metal profile  12 , while the metal profile  12  provides a constant fire block as it will not melt during the fire test of UL 2079. The combination of these two materials provides long lasting fire protection. In addition, drywall used in the board member  14  is less expensive than other fire-resistant materials, such as intumescent materials, that are often used in head-of-wall assemblies or other gaps of a building construction joint. 
     The metal profile  12  can come in standard lengths (e.g., 10′, 12′, etc.). As shown further in the cross-section of  FIG. 3 , the metal profile  12  can include a single sheet of metal, such as steel. The metal profile  12  can include a plurality of bends to form the metal profile shape. The metal profile  12  can include, a vertical leg  16 , an upper leg  24 , and/or a lower leg  20 . The vertical leg  16  can have a length L extending from the upper leg  24  to the lower leg  20 . The length L can vary depending on the size of the head-of-wall deflection gap  101  and the overall dynamic movement needed. The length L can generally be between about 1″ and 6″. The vertical leg  16  can comprise a flattened portion of the metal profile  12 . Alternatively, the vertical leg  16  can comprise one or more strengthening features such as grooves or ribs. 
     The upper leg  24  can couple with the vertical leg  16  at a corner  34 . The upper leg  24  can generally form perpendicular angle with the vertical leg  16 . The upper leg  24  can extend from the corner  34  in a first (e.g., rightward) direction. The upper leg  24  can be a horizontal leg. The upper leg  24  can be approximately 1.5″-3.5″ in length. 
     The upper leg  24  can include a groove  22 . The groove  22  can be shaped as a v-groove, u-groove, or other form factor. The groove  22  can include an open end facing upwards and outwards. The groove  22  can provide structural strength to the metal profile  12  and to the upper leg  24 . Other retention features and/or strengthening features could also be used. The groove  22  can extend downwardly towards the lower leg  20 . The groove  22  can divide the upper leg into an inner portion  25  and an outer portion  26 . The inner portion  25  can be in-line with the outer portion  26 . The inner portion  25  can have a width W 1  from the corner to the groove  22  (e.g., approximately 0.625″). The outer portion  26  can include an attachment portion of the metal profile  12 . The outer portion  26  can have a width of approximately 1.25″. The attachment can include one or more holes or other mechanism to allow an installer to attach the metal profile  12  to the ceiling  105  (or other adjoining structure). 
     The lower leg  20  can couple with the vertical leg  16  at a corner  30 . The lower leg  20  can generally form perpendicular angle with the vertical leg  16 . The lower leg  20  can extend from the corner  30  in the first (e.g., rightward) direction. The lower leg  20  can extend in the same direction as the upper leg  24 . The lower leg  20  can be a horizontal leg. 
     The lower leg  20  can include a kick-out  32 . The kickout  32  can be on a free end of the lower leg  20 . The kickout  32  can include an upturned retention lip or portion of the lower leg  20  (e.g., towards the upper leg  24 ). The kick-out  32  can be angled upwardly towards the upper leg  24 . The lower leg  20  can include a width W 2  from the corner  30  to the free end or the kickout  32 . The width W 2  can optionally be the same as the width W 1 . 
     The lower leg  20 , the vertical leg  16 , and the upper leg  24  can form an inner, partially enclosed space. The inner space can receive and secure the board member  14 . The board member  14  can comprise a fire-rated drywall member. The board member  14  can comprise one or more layers of material. The board member  14  can be a rip of drywall comprising a gypsum material. The board member  14  can include a generally rectangular-shaped profile. The board member  14  can nest within the inner space between the upper leg  24 , the vertical leg  16 , and the lower leg  20 . Preferably, the width W 1  of the upper leg  24  and the width W 2  of the lower leg  20  can be sized to accommodate a width W 3  of the board member  14 . The kickout  32  and/or the groove  22  can exert an inward force on the board member  14  to help retain the board member  14  within the inner space and/or against the vertical leg  16 . In certain implementations, the width W 1  can be the same as width W 2  and correspond to the width W 3  of the board member  14 . The widths W 1 , W 2  can limit the W 3  of the board member  14  that can be used in the composite component  10 . 
     An interior side of the board member  14  can be glued to the vertical leg  16  with an adhesive or secured with a mechanical fastener. The adhesive can secure the board member  14  within the inner space of the metal profile  12 . The kickout  32  and/or groove  22  can also retain the board member in place within the metal profile and ensure it will not fall out during a fire that may compromise the adhesive. The groove  22  and/or kickout  32  can be shaped in any suitable shape for retention of the board member  14  and/or strengthening of the composite  10 . 
     The corner  30  can include an inward facing protrusion (e.g., towards the wall boards  111 ,  113 ) that sticks out further than the interior surface of the vertical leg  16  (e.g., approximately 0.125″). The inward facing protrusion can be formed of a bend in the metal of the metal profile  12 . In the installed position with the head-of-wall assembly  100 , the protrusion can provide a sealing point against one of the board members  111 ,  113  of the framed wall assembly. This protrusion can also allow the wall to cycle up and down, as is needed in order to pass the UL-2079 “Test For Fire-rated Building Joints” without causing any damage to the drywall on the framed wall assembly. In other configurations, one or both of the protrusion of the corner  30  and kickout  32  can be omitted. 
     In the installed configuration within the head-of-wall assembly  100 , the board member  14  can be nested within the inner space of the metal profile  12 . The upper leg  24  can abut against and attached with the ceiling  105  (e.g., by fastener  103 ). The vertical leg  16  can abut an upper end of the wall board  113  and cover the deflection gap  101 . The protrusion of the corner  30  can abut the outer face of the wall board  113  to provide a seal therewith. The wall board  113  can cycle behind the installed composite component  10  between open and closed configurations. 
       FIG. 4  illustrates an alternative metal profile  12 . The metal profile  12  can include a vertical leg  16 , an upper leg  24 , and a lower leg  20 , like the metal profile  12  previously described. An upward facing protrusion can be formed of a bent portion of the material of the metal profile  12  on the upper leg  24  (e.g., approximately 0.125″). The upward facing protrusion can be directed or extend generally upwardly. In the installed configuration, the protrusion can contact and provide a sealing point against the ceiling  105  of the assembly  100 . In the installed configuration within the head-of-wall assembly  100 , the upper leg  24  can abut against and attached with the ceiling  105 . The upward facing protrusion of the corner  30  can abut the ceiling  105  to provide a seal therewith. The wall board  113  can cycle behind the installed composite component  10  between open and closed configurations. 
     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 example. 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 examples 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 examples. 
     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 examples 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 examples, 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 examples, 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. All ranges are inclusive of endpoints. 
     SUMMARY 
     Several illustrative examples of construction joints have been disclosed. Although this disclosure has been described in terms of certain illustrative examples and uses, other examples and other uses, including examples and uses which do not provide all of the features and advantages set forth herein, are also within the scope of this disclosure. 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 examples. All possible combinations and subcombinations 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. 
     Any portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in one example in this disclosure can be combined or used with (or instead of) any other portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in a different example or flowchart. The examples described herein are not intended to be discrete and separate from each other. Combinations, variations, and some implementations of the disclosed features are within the scope of this disclosure. 
     While operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Additionally, the operations may be rearranged or reordered in some implementations. Also, the separation of various components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. Additionally, some implementations are within the scope of this disclosure. 
     Further, while illustrative examples have been described, any examples having equivalent elements, modifications, omissions, and/or combinations are also within the scope of this disclosure. Moreover, although certain aspects, advantages, and novel features are described herein, not necessarily all such advantages may be achieved in accordance with any particular example. For example, some examples within the scope of this disclosure achieve one advantage, or a group of advantages, as taught herein without necessarily achieving other advantages taught or suggested herein. Further, some examples may achieve different advantages than those taught or suggested herein. 
     Some examples 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 examples can be used in all other examples 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 example of the inventions disclosed herein. No aspects of this disclosure are essential or indispensable. In many examples, 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 implementations, additional or different processors or modules may perform some or all of the functionalities described with reference to the examples 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 example. 
     In summary, various examples of construction joints and related methods have been disclosed. This disclosure extends beyond the specifically disclosed examples to other alternative examples and/or other uses of the examples, as well as to certain modifications and equivalents thereof. Moreover, this disclosure expressly contemplates that various features and aspects of the disclosed examples can be combined with, or substituted for, one another. Accordingly, the scope of this disclosure should not be limited by the particular disclosed examples described above, but should be determined only by a fair reading of the claims.