Top track seal, assembly and method for installing a wall configuration

Abstract

A top track seal is useful for sealing a movement joint between a fluted metal deck and an adjacent wall configuration. The top track seal includes a pre-formed sealing strip adapted to seal the movement joint and a first set of two or more sealing elements for sealing corrugations of the fluted metal deck. The sealing elements are spaced apart in the longitudinal direction of the sealing strip and the distance between two consecutive sealing elements corresponds to the distance between two consecutive corrugations of the metal deck. Each sealing element is moldable and has a predefined geometry. Also, an assembly includes this top track seal. Furthermore, a method is useful for installing a wall configuration to a fluted metal deck with corrugations.

Claims

1. A top track seal for sealing a movement joint between a fluted metal deck and an adjacent wall configuration, the top track seal comprising; a pre-formed sealing strip adapted to seal the movement joint, and a first set of two or more sealing elements for sealing corrugations of the fluted metal deck, wherein the pre-formed sealing strip comprises a seat for a top track, wherein the two or more sealing elements protrude from a side of the pre-formed sealing strip designed to face the fluted metal deck in a mounted state, wherein the two or more sealing elements are spaced apart in the longitudinal direction of the pre-formed sealing strip and the distance between two consecutive sealing elements corresponds to the distance between two consecutive corrugations of the fluted metal deck, and wherein each of the two or more sealing elements is moldable and has a predefined geometry adapted to seal the corrugation between adjacent fluted deck elements or in one of the fluted deck elements.

2. The top track seal according to claim 1, wherein the top track seal further comprises; a second set of sealing elements which is designed identical to the first set of two or more sealing elements, wherein the first set and the second set are spaced apart crosswise to the longitudinal direction of the pre-formed sealing strip.

3. The top track seal according to claim 2, wherein the distance between the first set and the second set crosswise to the longitudinal direction of the pre-formed sealing strip correlates to the width of the top track.

4. The top track seal according to claim 1, wherein the shape of the cross section of each of the two or more sealing element corresponds to the shape of the cross section of the corrugation and/or wherein the orientation of each of the two or more sealing elements is adapted to seal the corrugation.

5. The top track seal according to claim 1, wherein the two or more sealing elements are made from a material which is at least air-tight, sound-attenuating or sound-proof, fire-resistant, smoke-proof, and/or thermally isolating.

6. The top track seal according to claim 1, wherein the two or more sealing elements are self-adhesive.

7. An assembly, comprising: the top track seal according to claim 1, and a top track.

8. The assembly according to claim 7, wherein the top track seal is longer in longitudinal direction than the top track.

9. A method for installing a wall configuration to a fluted metal deck with corrugations, wherein a wall plane of the wall configuration is positioned substantially perpendicular to a flute axis, wherein the wall configuration comprises the assembly according to claim 7 being mounted on a lower side of the fluted metal deck, the method comprising: a) positioning the assembly on the lower side of the fluted metal deck, wherein the two or more sealing elements are positioned in the corrugations of the fluted metal deck, and b) fixing the top track to the fluted metal deck, whereby the two or more sealing elements are pressed into the corrugations.

10. A method for installing a wall configuration to a fluted metal deck with corrugations, wherein a wall plane of the wall configuration is positioned substantially perpendicular to a flute axis, wherein the wall configuration comprises the assembly according to claim 8 being mounted on a lower side of the fluted metal deck, the method comprising: a) positioning the assembly on the lower side of the fluted metal deck, wherein the two or more sealing elements are positioned in the corrugations of the fluted metal deck, b) positioning the top track within the seat of the pre-formed sealing strip, and c) fixing the top track to the fluted metal deck, whereby the two or more sealing elements are pressed into the corrugations.

11. A method for installing a wall configuration, to a fluted metal deck with corrugations, wherein a wall plane of the wall configuration is positioned substantially perpendicular to a flute axis, wherein the wall configuration comprises the assembly according to claim 7 being mounted on a lower side of the fluted metal deck, the method comprising: a) positioning the top track seal on the lower side of the fluted metal deck, wherein the two or more sealing elements are positioned in the corrugations of the fluted metal deck, b) inserting the top track into the seat of the pre-formed sealing strip. and c) fixing the top track to the fluted metal deck, whereby the two or more sealing elements are pressed into the corrugations.

12. The top track seal according to claim 5, wherein the material is a putty or a butyl.

13. The method according to claim 9, wherein fixed wall configuration is a drywall configuration.

14. The method according to claim 10, wherein the wall configuration is a drywall configuration.

15. The method according to claim 11, wherein the wall configuration is a drywall configuration.

Description

[0035] Different embodiments of the invention are shown in the attached drawings.

[0036] FIG. 1 shows a top view of a top track seal according to an embodiment of the invention comprising multiple sealing elements,

[0037] FIG. 2 shows a cross sectional view I-I of the top track seal of FIG. 1.

[0038] FIG. 3 shows a cross sectional view of a top track seal according to another embodiment of the invention.

[0039] FIG. 4 shows a cross sectional view of a section of a fluted metal deck with a corrugation.

[0040] FIG. 5 shows a cross sectional view of a sealing element of FIG. 1 designed to seal the corrugation of FIG. 4.

[0041] FIG. 6 shows a top view of the sealing element of FIG. 5.

[0042] FIG. 7 shows a method according to an embodiment of the invention for installing a wall configuration comprising an assembly according to an embodiment of the invention to a fluted metal deck with corrugations.

[0043] FIG. 8 shows a cross sectional view II-II of the wall configuration of FIG. 7.

[0044] FIG. 9 shows a first step of a method according to a further embodiment of the invention for installing a wall configuration to a fluted metal deck with corrugations.

[0045] FIG. 10 shows a second step of the method of FIG. 9, and

[0046] FIG. 11 shows a third step of the method of FIG. 9.

[0047] FIG. 1 shows a section of a top track seal 10 comprising a sealing strip 12 and multiple sealing elements 14, 16.

[0048] The sealing strip 12 is pre-formed and has a seat 18 for a top track 20 (see FIG. 8) on its bottom side 22 that runs in longitudinal direction X.

[0049] The sealing strip 12 can be produced as one integral part, for example from polyurethane foam.

[0050] The sealing strip 12 can also be produced from any other air-tight, sound-attenuating or even sound-proof, fire-resistant, smoke-proof and/or thermally isolating material.

[0051] The material, the sealing strip 12 is made of, is generally resilient.

[0052] On the top side 24 of the sealing strip 12 which is located opposite to the bottom side 22 (see FIG. 2), the sealing elements 14, 16 are attached to the sealing strip 12 and protrude from the top side 24.

[0053] The sealing elements 14, 16 are arranged in two identical sets 26, 28 which are spaced apart, end to end, a distance B in direction A that runs perpendicular to the longitudinal direction X.

[0054] The distance B corresponds to the width T of the top track 20 in direction A (see FIG. 8).

[0055] The top track seal 10 is designed to seal a movement joint 31 between a metal deck 30 and an adjacent wall configuration 32 (see FIG. 8). The metal deck 30 comprises one or more fluted metal deck elements 34 with parallel corrugations 36. The sealing elements 14, 16 are designed to seal these corrugations 36 when the top track seal 10 is mounted on the lower side 38 of the fluted metal deck 30.

[0056] To this end, each set 26, 28 comprises multiple sealing elements 14, 16 which are arranged in a line in longitudinal direction X with a distance C between two consecutive sealing elements 14, 16. The distance C between two consecutive sealing elements 14, 16 corresponds to the distance D between two consecutive corrugations 36 of the metal deck 30.

[0057] The top track seal 10 is pre-manufactured to seal the regular distanced corrugations 36 of a metal deck 30. In the case that not all corrugations 36 are spaced equally apart, the distances between two consecutive sealing elements 14, 16 of each set 26, 28 can mirror the distances of the corresponding corrugations 36 in the metal deck 30. In this way, the top track seal 10 is adapted to seal the movement joint 31, wherein the sealing elements 14, 16 tightly seal the respective corrugations 36 of the fluted metal deck 30 adjacent to the wall configuration.

[0058] FIG. 4 shows a cross sectional view of a section of a metal deck element 34 with two flutes 40 and a corrugation 36 extending in direction A (see also FIG. 8) that runs perpendicular to the drawing plane in FIG. 4.

[0059] The corrugation 36 has a generally triangular cross section with a depth h and a width w when seen in mounted state in direction A, which is the perspective taken in FIG. 4.

[0060] FIGS. 5 and 6 show one of the sealing elements 14, 16 of the top track seal 10.

[0061] The sealing element 14, 16 has a generally triangular cross section with a height H and a width W when seen in mounted state in direction A, which is the perspective taken in FIG. 5, as well as a length L the sealing element 14, 16 extends in perpendicular to its cross section in direction A.

[0062] The height H of the sealing element 14, 16 is larger than the depth h of the corrugation 36. In this way, the sealing element 14, 16 protrudes from the corrugation 36 when inserted in the corrugation 36 so that it can be pressed more easily into the corrugation 36 to ensure a tight fit.

[0063] Further the maximum width W of the sealing element 14, 16 is larger than the maximum width w of the corrugation 36, ensuring a tight seal.

[0064] As a result of the, the cross sectional area of the sealing element 14, 16 is larger than the cross sectional area of the corrugation 36. This ensures that enough sealing material is provided to securely seal the corrugation.

[0065] The length L of the sealing element 14, 16 is defined by firestop requirements. Usually the length L of a sealing element 14, 16 less than half of the track width T (see FIG. 2).

[0066] The sealing element 14, 16 is made of a moldable and self-adhesive putty that is air-tight, sound-attenuating, fire-resistant, smoke-proof and thermally isolating.

[0067] In a different embodiment the sealing element 14, 16 can be made of a different material, for example a butyl.

[0068] In an alternative embodiment the sealing element 14, 16 can be non-adhesive.

[0069] In a further embodiment, the sealing element 14, 16 can comprise at least one of the following properties: self-adhesive, air-tight, sound-attenuating, sound-proof, fire-resistant, smoke-proof and thermally isolating.

[0070] Furthermore, the sealing element 14, 16 can be elastic to better adapt its shape to the shape of the corrugation 36 when applied to the corrugation 36. Thus, the sealing properties of the sealing element 14, 16 are improved. Also, an elastic sealing element 14, 16 keeps its shape before being applied, thereby ensuring its geometry is perfectly adapted to seal a corresponding corrugation 36, even when the sealing element 14, 16 was deformed prior to the application.

[0071] The sealing element 14, 16 is pre-portioned so that it comprises enough material to ensure a tight seal of the corrugation 36 it is designed to seal.

[0072] In this way, the sealing element 14, 16 is adapted to seal the corrugation 36 by its predefined shape and size.

[0073] The embodiment of the sealing element 14, 16 shown in FIGS. 5 and 6 has a cross section with a shape that corresponds to the shape of the cross section of the corrugation 36 as both cross sections are triangular with a similar shape.

[0074] Because the sealing element 14, 16 is moldable, its cross section can also be rectangular, round shaped or can have any other shape as long as its cross section guarantees a secure seal of the corrugation 36. This is the case if the cross sectional area of the sealing element 14, 16 is at least as large as the cross sectional area of the corrugation 36. Also, for corrugations 36 with no or minimal undercuts a tight seal can be ensured if the height H and the width W of the sealing element 14, 16 are larger than the height h and the width w of the corresponding corrugation 36 respectively.

[0075] In this way, the sealing element 14, 16 is adapted to seal the corrugation 36 in the fluted metal deck element 34. Further, the sealing element 14, 16 is adapted to seal a corrugation between adjacent fluted metal deck elements 34, wherein the corrugation corresponds in size and shape to the corrugation 36 in the fluted metal deck element 34.

[0076] Further, by being moldable, the sealing element 14, 16 is adapted to seal corrugations 36 between adjacent fluted metal deck elements 34, even if the shape of a corrugation 36 between adjacent fluted metal deck elements 34 differs from the shape of a corrugation 36 in the fluted metal deck element 34.

[0077] All sealing elements 14, 16 are identical and are oriented in the same direction (see FIG. 1).

[0078] In an alternative embodiment, one or more of the sealing elements 14, 16 can have a different geometry and/or orientation than other sealing elements 14, 16. In an extreme form, the top track seal 10 can comprise sealing elements 14, 16 wherein each sealing element 14,16 has an individual geometry and/or orientation.

[0079] As shown in FIG. 1, the sealing elements 14 of the first set 26 and the sealing elements 16 of the second set 28 are aligned in such a way that the sealing elements 14, 16 form a grid, i.e. each sealing element 14 of the first set 26 has a corresponding sealing element 16 of the second set 28, wherein both are aligned in direction A. In this way, the top track seal 10 provides two sealing elements 14, 16 for each corrugation 36. So when the top track seal 10 is mounted to the fluted metal deck 30 (see FIG. 8), each corrugation 36 is sealed by two sealing elements 14, 16, one of each set 26, 28.

[0080] In an alternative embodiment, the top track seal 10 can only comprise a single set 26 of two or more sealing elements 14 (see FIG. 3). In this case, there is only a single sealing element 14 provided to seal each corrugation 36.

[0081] The set 26 of sealing elements 14 is preferably positioned equally distanced to the sides 42, 43 of the sealing strip.

[0082] FIG. 7 shows an assembly 50 comprising the top track seal 10 and a corresponding top track 20.

[0083] The top track seal 10 has arrow shaped markings 52 on its sides 42, 43 which correspond to the positions of the sealing elements 14, 16. This has the effect, that the positions of the sealing elements 14, 16 can be identified more easily from different directions. Thus, the installation of the top track seal 10 is facilitated as the sealing elements 14, 16 can be aligned more easily to the respective corrugations 36 of the metal deck 30.

[0084] The assembly 50 is part of the wall configuration 32 (see FIG. 8) and is designed to be mounted on a lower side 38 of the fluted metal deck 30 to seal the corrugations 36.

[0085] Further, the top track seal 10 is adapted to seal the movement joint 31.

[0086] The wall configuration 32 is a drywall configuration.

[0087] In the example shown, the wall configuration 32 further comprises two gypsum boards 54.

[0088] The wall plane of the wall configuration 32 is defined by the longitudinal direction X and the vertical direction V in which both the wall plane extends in.

[0089] In the embodiment, the wall plane of the wall configuration 32 is positioned substantially perpendicular to the direction A in which the flutes 40 and corrugations 36 of the fluted metal deck 30 extend in as well as substantially perpendicular to the plane defined by the fluted metal deck 30.

[0090] The axis of the flutes 40 extends in direction A.

[0091] To install the wall configuration 32 to the fluted metal deck 30 the following method is used.

[0092] The top track seal 10 is positioned on the lower side 38 of the fluted metal deck 30 (see FIG. 7), in a way that the sealing elements 14, 16 are positioned in the respective corrugations 36 of the fluted metal deck 30.

[0093] The sealing elements 14, 16 are inserted in the corrugation 36 with enough pressure in direction V, so that the top track seal 10 adheres to the metal deck 30. Due to the self-adhesive properties of the sealing elements 14, 16, the top track seal 10 remains temporally in place without the need of additional fixing elements.

[0094] Afterwards, the top track 20 is inserted into the seat 18 of the sealing strip 12 and then fixed to the fluted metal deck 30. Thereby, the top track seal 10 is fixed to the metal deck 30 and the sealing elements 14, 16 are pressed in direction V into the corrugations 36 sealing them tight in the process.

[0095] The top track 20 can be fixed to the fluted metal deck 30 with fastening means, like anchors, bolts and/or nails.

[0096] In an alternative embodiment, the assembly 50 is positioned as a whole on the lower side 38 of the fluted metal deck 30, in a way that the sealing elements 14, 16 are positioned in the respective corrugations 36 of the fluted metal deck 30. This means that the top track 20 is already arranged in the seat 18 and thus does not have to be inserted after the top track seal 10 is positioned to the fluted metal deck 30.

[0097] In a different embodiment, the length N of the top track seal 10 is larger than the length M of the top track 20 in the longitudinal direction X (see FIG. 9). This has the advantage that the top track 20 can be positioned within the sealing strip 12 independently from the top track seal 10 relative to the metal deck 30.

[0098] To mount the assembly 50 to the fluted metal deck 30, the sealing elements 14, 16 are inserted in the corrugation 36 with enough pressure in direction V, so that the top track seal 10 adheres to the metal deck 30. Due to the self-adhesive properties of the sealing elements 14, 16, the top track seal 10 remains temporally in place with no need for additional fixing elements.

[0099] Because the height H of the sealing elements 14, 16 is larger than the depth h of the corrugations 36, the sealing elements 14, 16 protrude from the plane defined by the fluted metal deck 30 out of the corrugation 36 (see FIGS. 9 and 10).

[0100] As shown in FIG. 10, after the top track seal 10 is temporally attached to the metal deck 30, the top track 20 can be slid inside the seat 18 in longitudinal direction X into a desired position relative to the top track seal 10 and the metal deck 30 while the top track seal 10 stays substantially in its place. This staying in place is achieved solely by the adhesive properties of the sealing elements 14, 16.

[0101] In an alternative embodiment, where the friction between the top track 20 and the top track seal 10 is higher than the adhesive forces between the sealing elements 14, 16 and the metal deck 30, the position of the top track seal 10 relative to the metal deck 30 can be kept by manually holding the top track seal 10 in place during these events.

[0102] After the top track seal 10 and the top track 20 are in position, the top track is fixed to the fluted metal deck 30. Thereby, the top track seal 10 is fixed to the metal deck 30 and the protruding sealing elements 14, 16 are pressed in direction V towards the corrugation 36 which results in the sealing elements 14, 16 completely filing the cross section of the corrugations 36 and sealing the corrugations 36 tight.

[0103] All methods described above can also be executed with top track seals 10 with non-adhesive sealing elements 14, 16. In this case, the position of the top track seal 10 relative to the metal deck 30 has to be kept steady by other means, for example by manually holding the top track seal 10 or by fixing it with fastening means.

[0104] The top track seal 10 and the assembly 50 as well as the method described above improve the sealing of corrugations 36 of a flute metal deck 30 in the following ways:

[0105] The corrugations 36 can be tightly sealed in a short amount of time without the need of additional tools.

[0106] The sealing elements 14, 16 are installed with the installation of the top track seal 10. In this way, the corrugations 36 are easily accessible and no additional ladder climbing is required.

[0107] The sealing of the corrugations 36 is failure proof as the pre-manufactured top track seal 10 with pre-proportioned sealing elements 14, 16 ensure that the necessary material required for a tight seal is installed.

[0108] Further, the sealing of the corrugations 36 requires no curing time because the material, the sealing elements 14, 16 are made of, is already cured.

[0109] The invention is not limited to the embodiments shown. In particular, individual features of an embodiment can be contained in a further inventive embodiment independently of the other features of the corresponding embodiment, i.e. the described features can be freely combined.