Fire-rated wall construction product

Patent metadata

Field	Value
Publication number	US-9683364-B2
Application number	US-201614996502-A
Country	US
Kind code	B2
Filing date	Jan 15, 2016
Priority date	Apr 8, 2010
Publication date	Jun 20, 2017
Grant date	Jun 20, 2017

Abstract

Fire-rated wall construction components and wall systems for use in building construction. Embodiments can include tracks for holding studs which incorporate various geometries capable of receiving fire-retardant material, including but not limited to intumescent material. The fire-retardant material can be attached to compressible backer rods inserted within deflection gaps in the wall systems such that the fire-retardant material expands and seals gaps and/or areas between the tracks and wall components such as ceilings, floors, and drywall. Various assemblies and methods can be used to cover the deflection gap.

First claim

What is claimed is:

1. A fire-rated assembly for a linear wall gap, comprising:
a header track attached to a horizontal ceiling element;
a plurality of vertical wall studs extending in a vertical direction from the header track;
at least a wall board supported by the plurality of wall studs, wherein the wall studs and the wall board are movable relative to the header track, wherein the wall board is spaced from the horizontal ceiling element to define a deflection gap having an opening;
a compressible backer rod positioned within the deflection gap between an upper edge of the wall board and the horizontal ceiling element, wherein less than one-half of an outer surface of the compressible backer rod is comprised of intumescent material; and
a sealant material contactingly adhered to the wall board, the sealant material covering the opening of the deflection gap to enclose the compressible backer rod between the header track and the sealant material;
wherein the compressible backer rod is inserted into the deflection gap at least a portion of the intumescent material facing towards the horizontal ceiling element or towards the wall board and at least a portion of the compressible backer rod without the intumescent material facing towards the opening of the deflection gap, and
wherein the sealant material engages the portion of the compressible backer rod without the intumescent material.

2. The fire-rated assembly of claim 1 , wherein the compressible backer rod contacts the horizontal ceiling element and a top surface of the wall board.

3. The fire-rated assembly of claim 1 , wherein the compressible backer rod has a cross-sectional profile that is circular, square, rectangular, or half circular.

4. The fire-rated assembly of claim 3 , wherein the sealant material is a combination of joint compound and joint tape applied to the wall board and the backer rod.

5. The fire-rated assembly of claim 1 , wherein the sealant material is an elastomeric spray applied to the wall board and the compressible backer rod.

6. The fire-rated assembly of claim 1 , wherein a melt temperature of the compressible backer rod is greater than an activation temperature of the intumescent material.

7. A fire-rated assembly for a linear wall gap, comprising:
a header track;
a plurality of vertical wall studs extending in a vertical direction from the header track;
at least a wall board supported by the plurality of wall studs;
wherein the header track is attached to a horizontal ceiling element, wherein the wall studs and the wall board are movable relative to the header track, and wherein the wall board is spaced from the horizontal ceiling element to define a deflection gap having an opening;
a rectangular compressible open cell backer rod formed from an open cell material and positioned within the deflection gap between the upper edge of the wall board and the horizontal ceiling element;
a sealant material contactingly adhered to the wall board and covering the opening of the deflection gap to enclose the rectangular compressible open cell backer rod between the header track and the flexible sealant material;
a fire-retardant material contactingly adhered to less than one-half of an outer surface of the rectangular compressible open cell backer rod;
wherein the rectangular compressible open cell backer rod is inserted into the deflection gap with at least a portion of the fire-retardant material facing towards the horizontal ceiling element or towards the wall board and at least a portion of the rectangular compressible open cell backer rod without the fire-retardant material facing towards the opening of the deflection gap, and
wherein the sealant material engages open cells of the portion of the rectangular compressible open cell backer rod without the fire-retardant material facing the opening of the deflection gap.

8. The fire-rated assembly of claim 7 , wherein the sealant material is a combination of joint compound and joint tape contactingly applied to the wall board and the rectangular compressible open cell backer rod.

9. The fire-rated assembly of claim 7 , wherein the sealant material is an elastomeric spray applied to the wall board and the rectangular compressible open cell backer rod.

10. The fire-rated assembly of claim 7 , wherein a melt temperature of the rectangular compressible open cell backer rod is greater than an activation temperature of the fire-retardant material.

11. The fire-rated assembly of claim 1 , wherein the compressible backer rod is formed from an open cell polyurethane foam material.

12. The fire-rated assembly of claim 7 , wherein the rectangular compressible open cell backer rod is formed from an open cell polyurethane foam material.

13. A fire-rated assembly for a linear wall gap, comprising:
a header track attached to a horizontal ceiling element;
a plurality of vertical wall studs extending in a vertical direction from the header track;
at least a wall board supported by the plurality of wall studs, wherein the wall studs and the wall board are movable relative to the header track, wherein the wall board is spaced from the horizontal ceiling element to define a deflection gap having an opening;
a compressible backer rod positioned within the deflection gap between an upper edge of the wall board and the horizontal ceiling element, an outer surface of the compressible backer rod at least partially coated with an intumescent material; and
a sealant material applied to the wall board and covering the opening of the deflection gap to enclose the compressible backer rod between the header track and the sealant material,
wherein the compressible backer rod is sized to contact the horizontal ceiling element and a top surface of the wall board,
wherein less than one-half of the outer surface of the compressible backer rod is coated in intumescent material, and
wherein the compressible backer rod is inserted into the deflection gap with at least part of the coated outer surface of the compressible backer rod facing towards the horizontal ceiling element and at least part of an uncoated surface of the compressible backer rod facing an opening of the deflection gap, wherein the sealant material engages the uncoated surface of the compressible backer rod.

14. A fire-rated assembly for a linear wall gap, comprising:
a header track;
a plurality of vertical wall studs extending in a vertical direction from the header track;
at least a wall board supported by the plurality of wall studs;
wherein the header track is attached to a horizontal ceiling element, wherein the wall studs and the wall board are movable relative to the header track, and wherein the wall board is spaced from the horizontal ceiling element to define a deflection gap having an opening;
a square compressible open cell backer rod formed from an open cell material and positioned within the deflection gap between the upper edge of the wall board and the horizontal ceiling element;
a sealant material applied to the wall board and covering the opening of the deflection gap to enclose the square compressible open cell backer rod between the header track and the sealant material; and
a fire-retardant material at least partially coating an outer surface of the square compressible open cell backer rod,
wherein less than one-half of an outer surface of the square compressible open cell backer rod is coated in the fire-retardant material, and
wherein the square compressible open cell backer rod is inserted into the deflection gap with at least part of the coated outer surface of the square compressible open cell backer rod facing towards the h

Assignees

• California Expanded Metal Products Co

Inventors

• Pilz Donald A

Classifications

• E04B2/7411 Primary

  Details for fire protection · CPC title

• E04B2/768

  allowing vertical movement of upper rail with respect to the stud, e.g. by using slots in the rail or stud · CPC title

• E04B2/7457

  with wallboards attached to the outer faces of the posts, parallel to the partition (E04B2/7459 takes precedence) · CPC title

• E04B2/825

  the connection between the floor and the ceiling being achieved without any restraining forces acting in the plane of the partition · CPC title

• E04B1/948 Primary

  Fire-proof sealings or joints (for doors or windows E06B5/164) · CPC title