Sealing devices for use with wall configurations

Abstract

System and methods for sealing a joint between drywall and a deck panel. The methods may comprise: coupling a firestopping device to an end of the drywall (the firestopping device comprising a carrier structure having a channel into which at least a portion of the end of the drywall is received during the coupling); placing the drywall adjacent to the deck panel so as to cause a firestopping structure of the firestopping device to be compressed between the carrier structure and the deck panel for sealing the joint; and allowing, by the firestopping device, relative movement of the drywall and deck panel when the drywall is being used to provide a wall configuration.

We claim: 
     
         1 . A method for sealing a joint between drywall and a deck panel, comprising:
 coupling a firestopping device to an end of the drywall, the firestopping device comprising a carrier structure having a channel into which at least a portion of the end of the drywall is received during the coupling;   placing the drywall adjacent to the deck panel to cause a firestopping structure of the firestopping device to be compressed between the carrier structure and the deck panel for sealing the joint; and   allowing, by the firestopping device, relative movement of the drywall and deck panel when the drywall is being used to provide a wall configuration.   
     
     
         2 . The method according to  claim 1 , wherein said coupling comprises:
 expanding a distance between two opposing sidewalls of the carrier structure as the end of the drywall is being inserted into the channel; and   allowing the two opposing sidewalls of the carrier structure to automatically spring back to an unexpanded state when the end of the drywall is partially or fully inserted into to channel.   
     
     
         3 . The method according to  claim 1 , further comprising using a structural feature of the carrier structure to retain the firestopping device on the end of the drywall. 
     
     
         4 . The method according to  claim 2 , wherein the structural feature comprises an inward pointing protrusion, a slit, a mechanical fastener, or a surface texturing. 
     
     
         5 . The method according to  claim 2 , further comprising using the carrier structure to apply one or both of a compression force and a gripping force on the drywall. 
     
     
         6 . The method according to  claim 1 , wherein the end of the drywall is castle cut and the deck panel comprises a fluted metal deck. 
     
     
         7 . The method according to  claim 6 , wherein the firestopping device is configured to have a cross-sectional shape similar to a cross-sectional shape of the fluted metal deck. 
     
     
         8 . The method according to  claim 6 , further comprising:
 inserting a middle portion of the firestopping device into a wave portion of the fluted metal deck; and   receiving (a) at least a part of a trench portion of the fluted metal deck or (b) a side lap member of the fluted metal deck in each one of two opposing side portions of the firestopping device between which the middle portion resides.   
     
     
         9 . The method according to  claim 8 , wherein the middle portion has a substantially trapezoidal shape configured to allow the firestopping structure to be compressed between the carrier structure and the deck panel when the drywall is being used to provide a wall configuration. 
     
     
         10 . The method according to  claim 8 , further comprising:
 receiving an embossment of the fluted metal deck in an open area or a cut-out of the middle portion of the firestopping device;   wherein the open area or cut-out of the middle portion of the firestopping device is sized and shaped to allow for said relative movement of the drywall and deck panel while maintaining the sealing of the joint.   
     
     
         11 . The method according to  claim 8 , further comprising receiving a protruding portion of the firestopping structure in an embossment formed in the trench portion of the fluted metal deck. 
     
     
         12 . The method according to  claim 11 , wherein the protruding portion of the firestopping structure has a trapezoidal shape, or a curved shape. 
     
     
         13 . The method according to  claim 8 , further comprising using a protruding portion of the firestopping structure to seal a seam between the deck panel and another adjacent deck panel. 
     
     
         14 . The method according to  claim 12 , wherein the protruding portion is at least partially curved or rounded. 
     
     
         15 . The method according to  claim 6 , wherein the coupling comprises receiving, in a middle portion of the firestopping device, a merlon portion of the castle cut end of the drywall, the middle portion having a substantially trapezoidal shape configured to allow the merlon portion to snugly fit therein when the merlon portion is fully inserted into the channel. 
     
     
         16 . The method according to  claim 1 , wherein the at least one end of the drywall is cut straight. 
     
     
         17 . The method according to  claim 1 , wherein the firestopping structure is overmolded on the carrier structure. 
     
     
         18 . The method according to  claim 1 , wherein the firestopping structure comprises an intumescent material. 
     
     
         19 . The method according to  claim 1 , further comprising 3D printing or injection molding the firestopping device so that the firestopping structure is integral with the carrier structure to form a single modular part. 
     
     
         20 . The method according to  claim 19 , wherein the carrier structure is rigid or semi-rigid, while the firestopping structure is compressible. 
     
     
         21 . The method according to  claim 1 , further comprising coupling another firestopping device to the end of the drywall so that the another firestopping device abuts the firestopping device. 
     
     
         22 . The method according  claim 21 , wherein the firestopping device and the another firestopping device at least partially overlap when coupled to the end of the drywall. 
     
     
         23 . The method according to  claim 21 , wherein the firestopping device and the another firestopping device comprise modular parts that have a same overall structure. 
     
     
         24 . The method according to  claim 1 , further comprising coupling another firestopping device to the end of the drywall, wherein the firestopping device and the another firestopping device comprising modular parts have different overall structures. 
     
     
         25 . The method according to  claim 24 , wherein the different overall structures comprise a first structure configured to be used with a first number of wave portions of the deck panel, and a second structure configured to be used with a different second number of wave portions of the deck panel. 
     
     
         26 . A firestopping device, comprising:
 a carrier structure comprising a channel into which at least a portion of an end of drywall can be received during a coupling of the firestopping device to drywall; and   a firestopping structure coupled to the carrier structure and configured to be compressed between the carrier structure and a deck panel to seal a joint between the drywall and the deck panel;   wherein the firestopping device is configured to allow relative movement of the drywall and deck panel when the drywall is being used to provide a wall configuration.   
     
     
         27 . The firestopping device according to  claim 26 , wherein the carrier structure comprise two opposing sidewalls configured to bend away from each other as the portion of the end of the drywall is being inserted into the channel, and automatically spring back to an unexpanded state when the portion of the end of the drywall is partially or fully inserted into to channel. 
     
     
         28 . The firestopping device according to  claim 26 , wherein the carrier structure further comprises a structural feature configured to facilitate retention of the firestopping device on the end of the drywall. 
     
     
         29 . The firestopping device according to  claim 28 , wherein the structural feature comprises an inward pointing protrusion, a slit, a mechanical fastener, or a surface texturing. 
     
     
         30 . The firestopping device according to  claim 28 , wherein the carrier structure is configured to apply one or both of a compression force and a gripping force on the drywall. 
     
     
         31 . The firestopping device according to  claim 26 , wherein the end of the drywall is castle cut and the deck panel comprises a fluted metal deck. 
     
     
         32 . The firestopping device according to  claim 31 , wherein the firestopping device is configured to have a cross-sectional shape similar to a cross-sectional shape of the fluted metal deck. 
     
     
         33 . The firestopping device according to  claim 31 , wherein the firestopping device further comprises:
 a middle portion configured to have a wave portion of the fluted metal deck inserted therein; and   two opposing side portions, between which the middle portion resides, that are each configured to receive (a) at least a part of a trench portion of the fluted metal deck or (b) a side lap member of the fluted metal deck.   
     
     
         34 . The firestopping device according to  claim 33 , wherein the middle portion has a substantially trapezoidal shape configured to allow the firestopping structure to be compressed between the carrier structure and the deck panel when the drywall is being used to provide a wall configuration. 
     
     
         35 . The firestopping device according to  claim 33 , wherein the middle portion comprises an open area or a cut-out size and shaped to receive an embossment of the fluted metal deck and allow for said relative movement of the drywall and deck panel while the sealing of the joint is maintained. 
     
     
         36 . The firestopping device according to  claim 33 , wherein at least one of the two opposing side portions comprise a protruding member configured to be received in an embossment formed in the trench portion of the fluted metal deck. 
     
     
         37 . The firestopping device according to  claim 36 , wherein the protruding member has a trapezoidal shape, or a curved shape. 
     
     
         38 . The firestopping device according to  claim 33 , wherein at least one of the two opposing side portions comprise a protruding member configured to seal a seam between the deck panel and another adjacent deck panel. 
     
     
         39 . The firestopping device according to  claim 38 , wherein the protruding member is at least partially curved or rounded. 
     
     
         40 . The firestopping device according to  claim 31 , wherein the firestopping device further comprises a middle portion configured to receive a merlon portion of the castle cut end of the drywall, the middle portion having a substantially trapezoidal shape configured to allow the merlon portion to snugly fit therein when the merlon portion is fully inserted into the channel. 
     
     
         41 . The firestopping device according to  claim 26 , wherein the at least one end of the drywall is cut straight. 
     
     
         42 . The firestopping device according to  claim 26 , wherein the firestopping structure is overmolded on the carrier structure. 
     
     
         43 . The firestopping device according to  claim 26 , wherein the firestopping structure comprises an intumescent material. 
     
     
         44 . The firestopping device according to  claim 26 , wherein the firestopping device is 3D printed or injection molded so that the firestopping structure is integral with the carrier structure to form a single modular part. 
     
     
         45 . The firestopping device according to  claim 44 , wherein the carrier structure is rigid or semi-rigid, while the firestopping structure is compressible. 
     
     
         46 . The firestopping device according to  claim 26 , wherein the firestopping device is configured to abut another firestopping device when coupled to the end of the drywall. 
     
     
         47 . The firestopping device according  claim 46 , wherein the firestopping device and the another firestopping device are configured to at least partially overlap when coupled to the end of the drywall. 
     
     
         48 . The firestopping device according to  claim 46 , wherein the firestopping device and the another firestopping device comprise modular parts that have a same overall structure. 
     
     
         49 . The firestopping device according to  claim 46 , wherein the firestopping device and the another firestopping device comprise modular parts have different overall structures. 
     
     
         50 . The firestopping device according to  claim 49 , wherein the different overall structures comprise a first structure configured to be used with a first number of wave portions of the deck panel, and a second structure configured to be used with a different second number of wave portions of the deck panel.