System, method and apparatus for substantially airtight area separation wall

Patent metadata

Field	Value
Publication number	US-2017191258-A1
Application number	US-201615382525-A
Country	US
Kind code	A1
Filing date	Dec 16, 2016
Priority date	Dec 18, 2015
Publication date	Jul 6, 2017
Grant date	—

Abstract

An area separation wall (ASW) may include gypsum liner panels and structural elements located between adjacent ones of the gypsum liner panels. A sealing material may be located between the gypsum liner panels and the structural elements, and between adjacent ones of the structural elements. The sealing material may form seals therebetween, such that the ASW is substantially airtight when assembled. In addition, the ASW may include a fire rating of at least 2 hours in compliance with ANSI/UL 263.

First claim

What is claimed is:

1 . An area separation wall (ASW), comprising:
a plurality of gypsum liner panels; a plurality of structural elements located between at least some of adjacent ones of the gypsum liner panels; sealing material located between the gypsum liner panels and the structural elements, and between adjacent ones of the structural elements, wherein the sealing material forms seals therebetween such that the ASW is substantially airtight when assembled; and the ASW comprises: a fire rating of at least 2 hours in compliance with ANSI/UL 263; and an air permeance of not greater than 0.44 cfm/ft 2 under a pressure differential of 0.3 in water (1.57 psf) (2.25 L/s·m 2 @ 75 Pa).

2 . The ASW of claim 1 , wherein the air permeance is not greater than 0.38 cfm/ft 2 , under a pressure differential of 0.3 in water (1.57 psf), when tested with the method prescribed by ASTM E2357.

3 . The ASW of claim 1 , wherein the sealing material comprises an air permeance of not greater than 0.004 cfm/ft 2 under a pressure differential of 0.3 in water (1.57 psf) (0.02 L/s·m 2 @ 75 Pa) when tested with the method prescribed by ASTM E2178.

4 . The ASW of claim 1 , wherein the structural elements comprise elongated tracks with at least one of a generally C-shaped sectional profile or a generally H-shaped sectional profile.

5 . The ASW of claim 1 , wherein the sealing material is oriented in both a vertical direction and a horizontal direction.

6 . The ASW of claim 1 , wherein sealing material has a thickness in a range of about 0.05 mm to about 13 mm.

7 . The ASW of claim 1 , wherein the sealing material is secured to at least one of the gypsum liner panels or the structural elements at a manufacturing facility prior to assembly of the ASW.

8 . The ASW of claim 1 , wherein the sealing material is secured to at least one of the gypsum liner panels or the structural elements during assembly of the ASW.

9 . The ASW of claim 1 , wherein the sealing material comprises at least one of a sealant, caulk, tape, gasket, foam, coating, water activated adhesive or mastic.

10 . The ASW of claim 1 , wherein the structural elements have an interior perimeter dimension, and the sealing material comprises sheets that are flexible and have a width that exceeds the interior perimeter dimension of the structural elements.

11 . The ASW of claim 1 , wherein the sealing material is located on at least one of interiors of the structural elements or exteriors of the structural elements.

12 . The ASW of claim 1 , wherein, when the ASW is assembled adjacent to one or between two adjacent interior finish walls to form a construction, the construction comprising a sound transmission classification (per ASTM E90) of at least about 50.

13 . The ASW of claim 1 , wherein the gypsum liner panels comprise a surface treatment comprising at least one of a film, coating, laminate or primer configured to provide improved adherence thereof; and
the surface treatment has a thickness in a range of about 0.025 mm to about 1 mm.

14 . The ASW of claim 1 , wherein each gypsum liner panel comprises a facing surface having a major axis along a length of the gypsum liner panel, a minor axis perpendicular to the major axis along a width of the gypsum liner panel, a thickness that is transverse to the length and width;
interfaces are defined between the facing surfaces of the gypsum liner panels and the structural elements; joints are defined between adjacent ones of the structural elements; and the ASW further comprises tape applied over at least one of the interfaces or the joints to further seal the ASW.

15 . The ASW of claim 1 , wherein at least some of the structural elements comprise a track having a base and flanges extending from the base, each flange comprises a lip that protrudes away and outward therefrom, such that when the gypsum liner panels are installed in the track, the lip provides a rut between the track and the gypsum liner panels; and further comprising:
a second sealing material in the ruts between the track and the gypsum liner panels.

16 . The ASW of claim 1 , wherein at least some of the structural elements comprise a spring stud track having a generally C-shaped sectional profile including a base and flanges extending from the base, each flange comprises a lip that protrudes inward therefrom and toward the base, such that when the gypsum liner panels are installed in the spring stud track, the lips provide a spring force bias against the gypsum liner panels to further seal the ASW.

17 . The ASW of claim 1 , wherein at least some of the structural elements comprise a one-sided track having a base with only three walls, wherein a first wall and a second wall extend in a same direction, and a third wall extends opposite to the first and second walls; and
a face piece secured adjacent the one-sided track to form a fourth wall across from the third wall.

18 . The ASW of claim 1 , wherein at least some of the structural elements comprise a one-sided track having a generally J-shaped sectional profile including a base, a first side having first flange extending from the base, the first flange having a first lip folded adjacent an interior of the first flange toward the base, a second side having a second flange extending from the base, the second flange having a second lip folded adjacent an exterior of the second flange, the second lip extending beyond the base for approximately a same distance as the second flange extends from the base, and the second lip having a third lip folded adjacent an interior of the second lip, wherein the first flange, first lip, second flange, second lip and third lip are substantially parallel to each other; and
a first set of the gypsum liner panels is installed on the base between the first and second flanges and are captured between the first and second sides, a second set of the gypsum liner panels are installed on the base opposite the first and second flanges and are captured only by the second and third lips on the second side of the one-sided track but are exposed on the first side of the one-sided track across from the second and third lips.

19 . A structural element, comprising:
a one-sided track having a base with only three walls, wherein a first wall and a second wall extend in a same direction, and a third wall extends in a direction opposite to the first and second walls; a face piece configured to be secured adjacent the one-sided track to form a fourth wall across from the third wall; and the structural element is configured, with gypsum liner panels, to form part of an area separation wall (ASW) having a fire rating of at least 2 hours in compliance with ANSI/UL 263, and an air permeance of not greater than 0.44 cfm/ft 2 under a pressure differential of 0.3 in water (1.57 psf) (2.25 L/s·m 2 @ 75 Pa).

20 . A gypsum liner panel, comprising:
a gypsum liner panel body having perimeter edges; a sealing material secured only adjacent to at least some of the perimeter edges of the gypsum liner panel body; and the gypsum liner panel is configured to form part of an area separation wall (ASW) having a fire rating of at least 2 hours in compliance with ANSI/UL 263, and an air permeance of not greater than 0.44 cfm/ft 2 under a pressure differential of 0.3 in water (1.57 psf) (2.25 L/s·m 2 @ 75 Pa).

Assignees

• Certainteed Gypsum Inc

Inventors

• Gatland Stanley D
• Dinoia Todd P
• Mcdonald Conor Patrick

Classifications

• E04B1/6108

  the frontal surfaces of the slabs connected together · CPC title

• E04B1/24

  the supporting parts consisting of metal · CPC title

• E04B2/723

  constituted of gypsum elements · CPC title

• E04B2002/0202

  Details of connections · CPC title

• E04B2001/2481

  Details of wall panels · CPC title