Granted Patent B2

US 12,428,836 · App. 18/411,488 · Granted Sep 30, 2025

Inventors: Donald Anthony Pilz (Livermore, CA); Eric Larson (City of Industry, CA)

Assignee: CEMCO, LLC

E04B2/7411E04B1/947E04B1/948E04B2/7453E04B2/7457E04B2/768E04B2/825

Abstract

Claims (40)

1. A wall assembly, comprising:

a ceiling structure;

a floor structure positioned opposite the ceiling structure;

a header track attached to the ceiling structure;

a bottom track attached to the floor structure, the bottom track including a first flange and a second flange extending from opposite edges of a web;

at least one stud extending in a vertical direction between the bottom track and the header track;

a wallboard attached to the at least one stud, the wallboard having a lower edge relatively closer to the floor structure and an upper edge relatively further from the floor structure, wherein a bottom wall gap is defined between the lower edge of the wallboard, the first flange of the bottom track, and the floor structure;

an elongate, compressible foam component received within the bottom wall gap to block passage of smoke or sound through the bottom wall gap, the elongate, compressible foam component comprising a rectangular cross-sectional profile extending between a first end and a second end, the rectangular cross-sectional profile having a first side and a second side, the first side and the second side meeting at a first edge, a third side opposite the first side, and a fourth side opposite the second side, the first side and the fourth side meeting at a second edge, the rectangular cross-sectional profile extending from the first end to the second end;

wherein the elongate, compressible foam component is positioned such that the first side faces the first flange of the bottom track;

wherein the second side of the elongate, compressible foam component contacts the lower edge of the wallboard; and

wherein the fourth side of the elongate, compressible foam component contacts the floor structure.

2. The wall assembly of claim 1 , wherein the elongate, compressible foam component comprises open cell or closed cell foam.

3. The wall assembly of claim 1 , wherein the elongate, compressible foam component is configured to create a fire rated joint and block passage of fire or heat through the bottom wall gap.

4. The wall assembly of claim 1 , wherein the elongate, compressible foam component is coated with intumescent material.

5. The wall assembly of claim 1 , wherein the third side is coated with sealant.

6. The wall assembly of claim 1 , wherein the first side comprises a same length as the second side.

7. The wall assembly of claim 1 , wherein the first side comprises a protective layer.

8. The wall assembly of claim 7 , wherein the protective layer comprises a tape layer, the tape layer having a width extending from the first edge to the second edge.

9. The wall assembly of claim 8 , wherein the tape layer is received by and bonded to the elongate, compressible foam component.

10. The wall assembly of claim 9 , wherein the tape layer covers at least a portion of a surface of the first side.

11. A wall assembly, comprising:

a floor structure;

a bottom track attached to the floor structure, the bottom track including a first flange and a second flange extending from opposite sides of a web;

at least one stud having a lower end attached to the bottom track, the lower end received between the first flange and the second flange;

a wallboard attached to the at least one stud, the wallboard having an upper edge and a lower edge;

a bottom wall gap located between the lower edge of the wallboard and the floor structure;

a compressible foam component having a rectangular cross section, the compressible foam component received within the bottom wall gap to block passage of smoke and/or sound, the compressible foam component comprising:

a compressible foam profile having a first end and a second end, the compressible foam profile comprising:

a first side;

a second side meeting the first side at a corner, wherein the second side faces the lower edge of the wallboard;

a third side opposite the first side;

a fourth side opposite the second side, wherein the fourth side contacts the floor structure.

12. The wall assembly of claim 11 , wherein the compressible foam component is configured to create a fire rated joint.

13. The wall assembly of claim 12 , wherein the compressible foam component has a moisture resistant outer skin.

14. The wall assembly of claim 11 , wherein the compressible foam component comprises a composite fire-resistant or fire-stopping compressible foam material.

15. The wall assembly of claim 11 , wherein a thickness of the wallboard is larger than a width of the second side or the fourth side.

16. The wall assembly of claim 11 , wherein the compressible foam component comprises polyurethane foam material.

17. The wall assembly of claim 11 , wherein the compressible foam component is coated with intumescent material.

18. The wall assembly of claim 11 , wherein the compressible foam component comprises open cell or closed-cell foam.

19. The wall assembly of claim 11 , wherein the compressible foam profile comprises a tape layer extending along the first side.

Assignments (2)

Continuity (11)

References Cited (400)