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Patent 2933862 Summary

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Claims and Abstract availability

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(12) Patent Application: (11) CA 2933862
(54) English Title: MINERAL WOOL WALL SYSTEM COMPRISING A GAP AND EMBEDDED STUDS
(54) French Title: SYSTEME DE MUR DE LAINE MINERALE COMPRENANT UN ESPACE ET DES GOUJONS ENCASTRES
Status: Examination Requested
Bibliographic Data
(51) International Patent Classification (IPC):
  • E04B 2/82 (2006.01)
  • E04B 1/84 (2006.01)
(72) Inventors :
  • GRISOLIA, ANTHONY (United States of America)
(73) Owners :
  • IBACOS, INC. (United States of America)
(71) Applicants :
  • IBACOS, INC. (United States of America)
(74) Agent: SMART & BIGGAR LP
(74) Associate agent:
(45) Issued:
(22) Filed Date: 2016-06-23
(41) Open to Public Inspection: 2016-12-26
Examination requested: 2021-06-07
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data:
Application No. Country/Territory Date
62/185,075 United States of America 2015-06-26
15/190,671 United States of America 2016-06-23

Abstracts

English Abstract


A wall system for a building having a first room and a second room is
provided. The wall system includes: (a) a first panel having a first batting
material
positioned between a first board and a second board; and (b) a second panel
having a
second batting material positioned between a third board and a fourth board.
Further, at
least one of the second board and the fourth board is formed from at least one
mineral
wool board. A building having a first floor, a foundation, and a first floor
board area
positioned between the first floor and the foundation is also provided. The
first floor of
the building includes a first room, a second room, and a wall system
positioned between
the first room and the second room.


Claims

Note: Claims are shown in the official language in which they were submitted.


THE INVENTION CLAIMED IS
1. A wall system for a building having a first room and a second
room, comprising:
(a) a first panel comprising a first batting material positioned between a
first board and a second board; and
(b) a second panel comprising a second batting material positioned
between a third board and a fourth board,
wherein the fourth board of the second panel faces the second board of the
first panel, and
wherein at least one of the second board and the fourth board comprises at
least one mineral wool board.
2. The wall system according to claim 1, wherein the second board
and the fourth board both comprise mineral wool boards.
3. The wall system according to claim 1, wherein the mineral wool
board comprises a binder and inorganic fibers.
4. The wall system according to claim 3, wherein the inorganic fibers
are derived from stone, slag, glass, or a combination thereof.
5. The wall system according to claim 1, wherein the first board and
the third board comprise a drywall/gypsum board, a mineral wool board, or a
combination thereof.
6. The wall system according to claim 1, wherein at least one of the
first batting material and the second batting material comprises mineral wool
fibers.
7. The wall system according to claim 1, wherein a gap is located
between the first panel and the second panel.
8. The wall system according to claim 7, wherein an additional
mineral wool board is positioned within a portion of the gap.
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9. The wall system according to claim 1, wherein the first panel and
the second panel further comprise studs embedded within the first batting
material and
the second batting material, and wherein the first board, the second board,
the third
board, and the fourth board are attached to the studs.
10. The wall system according to claim 1, wherein at least one of the
second board and the fourth board independently comprises two or more mineral
wool
boards.
11. The wall system according to claim 1, wherein at least the first
panel comprises a first wood sheet positioned between the first batting
material and the
second board.
12. The wall system according to claim 11, wherein the first panel
further comprises a second wood sheet positioned on a side of the second board
opposite
the first wood sheet.
13. The wall system according to claim 11, wherein the wood sheet
comprises a fire-resistant coating layer.
14. The wall system according to claim 13, wherein the fire-resistant
coating layer comprises a binder comprising inorganic materials.
15. A building comprising a first floor, a foundation, and a first floor
board area positioned between the first floor and the foundation,
wherein the first floor comprises a first room, a second room, and a first
wall system positioned between the first room and the second room, the first
wall system
comprising:
(a) a first panel comprising a first batting material positioned
between a first board and a second board, the first board facing an interior
of the
first room; and
(b) a fourth panel comprising a second batting material positioned
between a third board and a second board, the third board facing an interior
of the
second room and the fourth board facing the second board of the first panel,
- 17 -

wherein at least one of the second board and the fourth board comprises at
least one mineral wool board, and
wherein the second board and the fourth board extend through the first
floor board area to the foundation of the building.
16. The building of claim 15, wherein a gap is located between the
first panel and the second panel.
17. The building of claim 15, wherein the first panel and the second
panel further comprise studs embedded within the first batting material and
the second
batting material, and wherein the first board, the second board, the third
board, and the
fourth board are attached to the studs.
18. The building of claim 15, wherein at least the first panel comprises
a first wood sheet positioned between the first batting material and the
second board, and
wherein the first wood sheet and the second board extend through the first
floor board area to the foundation of the building.
19. The building of claim 18, wherein the first panel further comprises
a second wood sheet positioned on a side of the second board opposite the
first wood
sheet, and
wherein the first wood sheet, the second board, and the second wood
sheet extend through the first floor board area to the foundation of the
building.
20. The building of claim 15, further comprising a second floor and a
second floor board area positioned between the first floor and the second
floor, and
wherein the second board and the fourth board extend through the second
floor board area to the second floor of the building.
21. The building of claim 20, wherein the second floor comprises a
second wall system that is the same as the first wall system.
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22. The building of claim 15, further comprising an attic comprising a
plurality of trusses, wherein an additional mineral wool board is attached to
at least one
side of each truss.
23. The building of claim 22, wherein a first wood sheet is positioned
between each truss and the additional mineral wool board.
24. The building of claim 23, wherein a second wood sheet is
positioned on a side of the additional mineral wool board opposite the first
wood sheet.
- 19 -

Description

Note: Descriptions are shown in the official language in which they were submitted.


CA 02933862 2016-06-23
MINERAL WOOL WALL SYSTEM
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of United States Provisional
Application
No. 62/185,075, filed June 26, 2015 and United States Non-Provisional
Application No.
15/190,671, filed June 23, 2016, which are both incorporated herein by
reference in their
entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to partitions for buildings, and,
particularly, party
walls having a mineral wool barrier that provides improved fire and sound
protection in
buildings.
Description of Related Art
[0003] Buildings typically contain wall partitions that act as a divider
between
different rooms or areas in the building. Such partitions are particularly
important in
multi-unit buildings to divide different units disposed side-by-side. Adjacent
units,
therefore, share a wall that acts as a dividing partition. These walls are
commonly
referred to as party walls. In accordance with current building codes, party
walls must
possess a degree of fire resistance to prevent multiple units from catching
fire if a fire is
started in one of the units. In addition, party walls are also required to
provide a degree
of sound resistance. In order to meet these requirements, current party walls
are made
with gypsum wall panels, typically a panel of gypsum plaster sandwiched
between two
sheets of heavy paper, also referred to as dry wall.
[0004] Typically, party walls are incorporated into each unit during
construction of the
multi-unit building. As a result, party walls are often exposed to water
and/or moisture.
However, current party walls, such as party walls made with gypsum wall
panels, are
easily damaged due to exposure to water and/or moisture. In addition, current
party
walls also allow a significant amount of air to leak through, thereby reducing
the energy
efficiency of the building. Thus, it is desirable to provide improved party
walls that do
not absorb or deteriorate from water/moisture, that reduce the amount of air
flow, and
which also possess the required fire and sound resistant properties.
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CA 02933862 2016-06-23
SUMMARY OF THE INVENTION
[0005] The present invention is generally directed to a wall system for a
building.
[0006] In certain non-limiting embodiments, the wall system of the present
invention
includes: (a) a first panel comprising a first batting material positioned
between a first
board and a second board, the first board facing an interior of a first room
of the
building; and (b) a second panel comprising a second batting material
positioned
between a third board and a fourth board, the third board facing an interior
of a second
room in the building and the fourth board facing the second board of the first
panel.
Further, at least one of the second board and the fourth board comprises at
least one
mineral wool board.
[0007] In certain non-limiting embodiments, the second board and the fourth
board
both comprise mineral wool boards. In another non-limiting embodiment, at
least one of
the second board and the fourth board independently comprise two or more
mineral wool
boards. The mineral wool boards of the second board and/or the fourth board
can
comprise a binder and inorganic fibers. In some non-limiting embodiments, the
inorganic fibers are derived from stone, slag, glass, or a combination
thereof.
[0008] Moreover, in some non-limiting embodiments, the first board and third
board
comprise a drywall/gypsum board, a mineral wool board, or a combination
thereof. In
another non-limiting embodiment, at least one of the first batting material
and the second
batting material comprises mineral wool fibers.
[0009] As previously described, the wall system comprises a first panel and a
second
panel. In certain non-limiting embodiments, a gap is located between the first
panel and
the second panel. An additional mineral wool board can be positioned within a
portion of
the gap.
[0010] In certain non-limiting embodiments, the first panel and second
panel further
comprise studs embedded within the first batting material and the second
batting
material. The first board, second board, third board, and fourth board can be
attached to
the studs.
[0011] In one non-limiting embodiment, at least the first panel comprises a
first wood
sheet positioned between the first batting material and the second board. In
another non-
limiting embodiment, the first panel further comprises a second wood sheet
positioned
on a side of the second board opposite the first wood sheet, The wood sheet
can also
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=

CA 02933862 2016-06-23
comprise a fire-resistant coating layer. For example, the wood sheet can have
a fire-
resistant coating layer that comprises a binder comprising inorganic
materials.
100121 The present invention is also directed to a building comprising a
first floor, a
foundation, and a first floor board area positioned between .the first floor
and the
foundation. Further, the first floor comprises a first wall system comprising:
(a) a first
panel comprising a first batting material positioned between a first board and
a second
board, the first board facing an interior of a first room in the building; and
(b) a fourth
panel comprising a second batting material positioned between a third board
and a
second board, the third board facing an interior of a second room in the
building and the
fourth board facing the second board of the first panel. In accordance with
one non-
limiting embodiment of the present invention, at least one of the second board
and the
fourth board comprises at least one mineral wool board. Further, the second
board and
the fourth board can extend through the first floor board area to the
foundation of the
building.
100131 As previously described, the wall system comprises a first panel and a
second
panel. In certain non-limiting embodiments, a gap is located between the first
panel and
the second panel. Moreover, the first panel and second panel can further
comprise studs
embedded within the first batting material and the second batting material,
and the first
board, second board, third board, and fourth board are attached to the studs.
100141 In certain non-limiting embodiments, at least the first panel
comprises a first
wood sheet positioned between the first batting material and the second board.
In such
embodiments, the first wood sheet and the second board extend through the
first floor
board area to the foundation of the building. In another non-limiting
embodiment, the
first panel further comprises a second wood sheet positioned on a side of the
second
board opposite the first wood sheet, and the first wood sheet, the second
board, and the
second wood sheet extend through the first floor board area to the foundation
of the
building.
100151 The building can also include additional floors. For instance, the
building can
further comprise a second floor and a second floor board area positioned
between the
first floor and the second floor. In such embodiments, the second board and
the fourth
board can extend through the second floor board area to the second floor of
the building.
The second floor can also comprise a second wall system that is the same as
the first wall
system.
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CA 02933862 2016-06-23
[0016] In another non-limiting embodiment, the building further includes an
attic
comprising a plurality of trusses with an additional mineral wool board
attached to at
least one side of each truss. In some non-limiting embodiments, a first wood
sheet is
positioned between each truss and the additional mineral wool board. In
another non-
limiting embodiment, a second wood sheet is positioned on a side of the
additional
mineral wool board opposite the first wood sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic front view of a party wall according to the
prior art;
100181 FIG. 2 is another schematic front view of a party wall according to the
prior
art;
[0019] FIG. 3 is a schematic partial cross-sectional view of a wall system
according to
the present invention;
[0020] FIG. 4 is a perspective cross-sectional view of a wall system according
to the
present invention;
[0021] FIG. 5 is a schematic partial cross-sectional view of a panel with
multiple
mineral wool boards according to the present invention;
[0022] FIG. 6 is a schematic partial cross-sectional view of a wall system
with wood
sheets according to the present invention;
[0023] FIG. 7 is a schematic partial cross-sectional view of a panel with
multiple
mineral wool boards and multiple wood sheets according to the present
invention;
[0024] FIG. 8 is a schematic partial cross-sectional view of a wall system
with
different layers of wood sheets according to the present invention;
[0025] FIG. 9 is a schematic partial cross-sectional view of a panel with
multiple
mineral wool boards and different layers of multiple wood sheets according to
the
present invention;
[0026] FIG. 10 is a schematic partial cross-sectional view of a building
with a wall
system that extends through different floors according to the present
invention;
100271 FIG. 11 is a schematic partial cross-sectional view of wood sheets
and mineral
wool boards attached to trusses according to the present invention; and
[0028] FIG. 12 is a schematic partial cross-sectional view of different layers
of wood
sheets and mineral wool boards attached to trusses according to the present
invention.
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CA 02933862 2016-06-23
DESCRIPTION OF THE INVENTION
[0029] For purposes
of the description hereinafter, the terms "end", "upper", "lower",
"right", "left", "vertical", "horizontal", "top", "bottom", "lateral",
"longitudinal", and
derivatives thereof shall relate to the invention as it is oriented in the
drawing figures.
However, it is to be understood that the invention may assume various
alternative
variations and step sequences, except where expressly specified to the
contrary. It is also
to be understood that the specific devices and processes illustrated in the
attached
drawings, and described in the following specification, are simply exemplary
embodiments of the invention. Hence, specific dimensions and other physical
characteristics related to the embodiments disclosed herein are not to be
considered as
limiting.
[0030] Notwithstanding that the numerical ranges and parameters setting forth
the
broad scope of the invention are approximations, the numerical values set
forth in the
specific examples are reported as precisely as possible. Any numerical value,
however,
inherently contains certain errors necessarily resulting from the standard
variation found
in their respective testing measurements.
[0031] Also, it should be understood that any numerical range recited herein
is
intended to include all sub-ranges subsumed therein. For example, a range of
"1 to 10"
is intended to include all sub-ranges between (and including) the recited
minimum value
of 1 and the recited maximum value of 10, that is, having a minimum value
equal to or
greater than 1 and a maximum value of equal to or less than 10.
[0032] In this
application, the use of the singular includes the plural and plural
encompasses singular, unless specifically stated otherwise. In addition,
in this
application, the use of "or" means "and/or" unless specifically stated
otherwise, even
though "and/or" may be explicitly used in certain instances.
[0033] As indicated, the present invention is directed to a wall system 100
(shown in
FIGS. 3 and 4), which can be used in a building. The term "building", as used
herein,
refers to a structure with at least a floor, a roof, and a plurality of walls.
Further, the term
"building" encompasses single unit residential and commercial buildings as
well as
multi-unit residential and commercial buildings such as, for example, multi-
unit
apartment complexes, multi-unit townhouses, and row houses. .
[0034] The wall system 100 of the present invention is particularly useful as
a
partition for buildings. As used herein, the term "partition" refers to a wall
or barrier that
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CA 02933862 2016-06-23
divides rooms or units of a building. In some non-limiting embodiments, the
wall
system 100 of the present invention is used as a party wall. A."party wall"
refers to a
division between separate units within a multi-unit building that are designed
to at least
provide a degree of fire and sound protection between adjacent units. Party
walls are
typically used in multi-unit apartment complexes, multi-unit townhouses, row
houses,
and the like.
[0035] A wall partition currently known in the art, and which is commonly used
as a
party wall, is shown in FIGS. 1 and 2. Referring to FIGS. 1 and 2, a wall
partition or
party wall 10 used in a multi-unit building typically includes a first panel
12 comprising
a first batting material 14 composed of, for example, mineral wool fibers,
positioned
between a first gypsum and/or drywall board 16 and a second gypsum and/or
drywall
board 18. The first drywall board 16 can face the interior of at least one of
the units (unit
A), while the second drywall board 18 can face a second panel 20 of the party
wall 10.
As further shown in FIGS. 1 and 2, the second panel 20 includes a second
batting
material 22 positioned between a third drywall board 24 and a fourth drywall
board 26.
The fourth drywall board 26 can face the interior of a second unit (unit B),
while the
third drywall board 24 can face the first panel 12 of the party wall 10, with
the panels 12,
20 being sandwiched by structural components 28 of the buildings, such as a
stud (e.g., a
2x4 board), joists, floor boards, and the like, typically made from lumber.
The drywall
boards 16, 18, 24, 26 can include single boards, two-layer glass faced boards,
and the
like. Further, the first and second panels 12, 20 are typically held in place
with clips,
channels, and similar fasteners.
[0036] As previously noted, drywall boards 16, 18, 24, 26 used in current
party walls
are easily damaged due to exposure to water and/or moisture. To overcome these

drawbacks, the present invention provides an improved wall system 100 (shown
in FIGS.
3 and 4) that at least comprises mineral wool boards. As used herein, "mineral
wool"
refers to inorganic fibers derived from mineral materials. Non-limiting
examples of
mineral materials that can be used to form the inorganic fibers include rock
or stone such
as basalt (a volcanic rock), slag, glass, and combinations thereof. As used
herein, "slag"
refers to the by-product produced when a metal is separated or smelted from
its raw ore.
[0037] The mineral wool boards used with the present invention can also
include a
binder. As used herein, a "binder" can refer to organic materials that can
form a matrix
and which can help hold the inorganic fibers together. The binders used in the
mineral
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CA 02933862 2016-06-23
wool boards can comprise polymeric materials. The term
"polymer" includes
homopolymers, copolymers, and oligomers. Further, as used herein, the term
"resin" is
used interchangeably with the term "polymer". Non-limiting examples of
suitable
polymeric materials include polyurethanes, polyureas, polyamines, polyesters,
polyamides, and combinations thereof. In certain non-limiting embodiments, the
binder
is a thermosetting binder. The term "thermosetting binder" .refers to a binder
that
comprises resins or polymers that "set" irreversibly upon curing or
crosslinking in which
the polymer chains are joined together by covalent bonds. Typically,
thermosetting
binders also include a crosslinking agent. A "crosslinking agent" refers to a
compound
with two or more reactive functional groups that are capable of forming a
linkage
between two or more polymers. In another non-limiting embodiment, the binder
is a
thermoplastic-based binder which, in contrast to a thermosetting binder,
includes
polymeric materials that may be repeatedly heated to a softened or molten
state and
returned to their former state upon cooling. Suitable mineral wool boards are
also
commercially available from Roxul, Inc. under the tradename COMFORTBOARDTm.
[0038] As shown in FIG. 3, the wall system 100 according to the present
invention can
include a first panel 110 having a batting material 112 positioned between a
first board
114 and a second board 116. The first board 114, which is configured to face
in the
direction of the interior of a first room, such as the interior of a.room in a
first unit of a
multi-unit building, can comprise a drywall board, a mineral wool board, or a
combination thereof. The second board 116, which is configured to face the
opposite
direction from the first board 114, comprises a mineral wool board. As used
herein, by
being "configured to face" a particular direction in a building should be
understood to
mean that the component (e.g., the panel 110 or board 114) has a structure
suitable for
facing in the identified orientation.
[0039] As
indicated, the first panel 110 can include a batting material 112. As used
herein, "batting material" can refer to a material made of an assembly of non-
woven
fibers or foam. The batting material 112 can comprise, but is not limited to,
cotton,
polyester, wool, mineral wool, and combinations thereof. The batting material
112 can
also include a binder such as any of the binders previously described. Mineral
wool
batting materials are generally less dense and less rigid than mineral wool
boards.
Suitable mineral wool batting materials are also commercially available from
Roxul, Inc.
under the tradename COMFORTBATTO.
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CA 02933862 2016-06-23 =
[0040] The wall system 100 can also include a second panel 118. The second
panel
118 can be made of the same components as the first panel 110. Alternatively,
the
second panel 118 can be made of one or more different components. In certain
non-
limiting embodiments, the second panel 118 comprises a batting material 119
positioned
between a third board 120 and a fourth board 122. The third board 120, which
is
configured to face in the direction of the interior of a second room, such as
the interior of
a room in a second unit of a multi-unit building, can comprise a drywall
board, a mineral
wool board, or a combination thereof. The fourth board 122, which is
configured to face
the first panel 110 of the wall system 100, comprises a mineral wool board.
There can
also be a space or gap 130 between the first panel 110 and the second panel
118. An
additional mineral wool board 136 can be placed in at least a portion of the
gap 130, such
as in the area of the floor boards 138, to prevent fire from spreading to
additional floors
in a multi-level building. As used herein, by being "configured to" face a
direction in a
building should be understood to mean that the component has a structure
suitable
therefor.
[0041] FIG. 4 illustrates a perspective cross-sectional view of the
previously described
wall system 100. Particularly, FIG. 4 illustrates the wall system 100 with a
first panel
110 having a batting material 112, such as a mineral wool batting material,
that is
positioned between a first board 114 that is a drywall board and a second
board 116 that
is a mineral wool board. As further illustrated in FIG. 4, the wall system 100
includes a
second panel 118 having a batting material 119, such as a mineral wool batting
material,
that is positioned between a third board 120 that is a drywall board and a
fourth board
122 that is a mineral wool board.
[0042] As further shown in FIG. 4, studs 140 can be positioned adjacent to the
batting
material 112, 119. For instance, one or more studs 140 can be embedded within
the
batting material 112, 119 of the panel 110, 118 and can extend vertically
through at least
a portion of a building to provide structural support. During construction of
the wall
system 100, the first board 114, second board 116, third board 120, and fourth
board 122
can be attached to the studs 140 used in the framing of the wall system 100
such as with
fasteners 141 (shown in FIG. 3). The fasteners 141 can include, but are not
limited to,
screws, nails, adhesives, and the like.
[0043] In certain non-limiting embodiments, the second board 116 of the
first panel
110 and the fourth board 122 of the second panel 118 are independently formed
from
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CA 02933862 2016-06-23
multiple mineral wool boards. Referring to FIG. 5, in some instances, the
second board
116 of the first panel 110 and/or the fourth board 122 of the second panel 118
can be
formed from multiple pieces, sections, or segments of mineral wool boards 144,
146.
Different boards 144, 146 can be joined or connected together at a stud 140,
as shown in
FIG. 5. Particularly, and as shown in FIG. 5, one end 145 of a first mineral
wall board
144 can be attached to a portion of a stud 140 and one end 147 of a second
mineral wall
board 146 can be attached to another portion of the stud 140. This arrangement
can be
used to attach multiple mineral wall boards 144, 146 consecutively along a
horizontal or
vertical direction of a room or area of a building to form a portion of the
first panel 110
or the second panel 118.
[0044] The ends 145 and 147 of the consecutively placed mineral wool boards
144
and 146 can be aligned directly next to each other to form a continuous
barrier of mineral
wool boards 144 and 146. In certain non-limiting embodiments, the ends 145 and
147 of
the consecutively placed mineral wool boards 144 and 146 are cut at an angle
143 (see
FIG. 3) to join the ends 145 and 147 together. Alternatively, the ends 145 and
147 of the
consecutively placed mineral wool boards 144 and 146 can be configured to
allow for a
lapping connection such as a shiplap connection, as is known in the art. At
the lapped
configuration, the ends 145 and 147 of consecutively placed mineral wool
boards 144
and 146 can be directly adjacent to each other to form a continuous fire- and
sound-
resistance barrier.
[0045] As further shown in FIG. 5, a joint treatment 142 can be placed between
the
ends 145, 147 of the consecutive mineral wool boards 144, 146 to form a seal
between
the mineral wool boards 144, 146. Non-limiting examples of suitable joint
treatments
142 include, but are not limited to, cementitious materials, fire rated spray
foam, and
combinations thereof.
[0046] The batting
materials 112, 119, and boards 114, 116, 120, 122 of the first panel
110 and second panel 118 can be positioned directly next to each other in the
previously
described arrangements without any intervening components or layers.
Alternatively, in
certain non-limiting embodiments, the first panel 110 and/or the second panel
118
include additional components and layers. For example, and as shown in FIG. 6,
the first
panel 110 can further include a wood sheet 150 positioned between the batting
material
112 and the second board 116 that comprises a mineral wool board. Non-limiting

examples of a wood sheet 150 include an oriented strand board or OSB and
plywood. As
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CA 02933862 2016-06-23
used herein, "oriented strand board" or "OSB" refers to an engineered
structural-use
board typically manufactured from thin wood strands bonded together with resin
under
heat and pressure.
[0047] The wood sheet 150 can also have a fire-resistant coating layer 151
formed
over at least a portion of one side of the wood sheet 150. The fire-resistant
coating layer
151 can be formed from a binder component comprising inorganic materials. Non-
limiting examples of inorganic materials include magnesium oxide, alumina
calcium,
aluminate cement, and combinations thereof. The fire-resistant coating layer
151 can
also comprise a gauging component that comprises, but is not limited to, an
aqueous
solution of magnesium chloride, magnesium sulfate, and combinations thereof.
Suitable
fire-resistant coatings are also described in United States Patent Nos.
4,572,862;
4,818,595; and 5,039,454, which are incorporated herein by reference in their
entireties.
Suitable fire-resistant coatings are also commercially available from
International Barrier
Technology, Inc. under the tradenames PYROTITE and BLAZEGUARD .
[0048] As
indicated, the fire-resistant coating layer 151 can be applied over at least a
portion of one side of the wood sheet 150. The fire-resistant coating layer
151 can also
be applied over an entire side of the wood sheet 150. In some non-
limiting
embodiments, the fire-resistant coating layer 151 is applied over at least a
portion of both
sides of the wood sheet 150 or, alternatively, over the entirety of both sides
of the wood
sheet 150.
[0049] Referring to FIG. 7, two separate wood sheets 152 and 154 can be
attached to
the same stud 140 that extends vertically in a room of a building.
Particularly, and as
shown in FIG. 7, one end 153 of a first wood sheet 152 can be attached to a
portion of a
stud 140 and one end 155 of a second wood sheet 154 can be attached to another
portion
of the stud 140. This arrangement can be used to attach multiple wood sheets
152, 154
consecutively along a horizontal or vertical direction of a room or area of a
building.
[0050] The ends 153 and 155 of the consecutively placed wood sheets 152 and
154
can be aligned directly next to each other to form a continuous barrier of
wood sheets
152 and 154. A joint treatment 142 can be placed between the ends 153, 155 of
the
consecutive wood sheets 152, 154 to form a seal between the wood sheets 152,
154.
Non-limiting examples of suitable joint treatments include any of the joint
treatments
previously described.
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CA 02933862 2016-06-23
[0051] In certain non-limiting embodiments, mineral wool boards 144, 146 are
placed
over the wood sheets 152, 154 such that two separate mineral wool boards 144,
146 are
aligned over the same stud 140. For instance, and as shown in FIG. 7, two
separate
mineral wool boards 144, 146 can be positioned over two separate wood sheets
152, 154,
respectively, such that one end 145 of a first mineral wool board 144 is
aligned over a
portion of the stud 140, and one end 147 of a second mineral wool board 146 is
aligned
over another portion of the stud 140. The end 145 of the first mineral wool
board 144
and the end 147 of the second mineral wool board 146 can therefore be attached
to the
wood sheets 152, 154 as well as the stud 140. A joint treatment 142 can be
placed
between the ends 145, 147 of the consecutive mineral wool boards 144, 146 and
between
the ends 153, 155 of the consecutively placed wood sheets 152, 154.
[0052] With reference again to FIG. 6, as previously described, the first
panel 110 can
include the wood sheet 150 with the fire-resistant coating layer 151,
positioned between
the batting material 112 and the second board 116, which comprises a mineral
wool
board. In certain non-limiting embodiments, the wall system 100 also includes
the
second panel 118, which comprises the batting material 119 positioned between
the third
board 120, which comprise a drywall board, and the fourth board 122, which
comprises a
mineral wool board. As shown in FIG. 6, the second panel 118 further comprises
a wood
sheet 160 positioned between the batting material 119 and the fourth board 122
(e.g., the
mineral wool board). The wood sheet 160 can include any of the wood sheets
previously
described, such as a fire-resistant coated OSB. Separate wood sheets 160 can
also be
used in the second panel 118 and aligned over the same stud 140 as previously
described
with respect to the first panel 110. Multiple mineral wool boards that can be
used to
form the fourth board 122 can be placed over the wood sheets 160 such that
separate
mineral wool boards are aligned over the same stud 140 as previously
described.
[0053] In certain non-limiting embodiments, at least one of the first panel
110 and the
second panel 118 have at least two wood sheets positioned between different
components of the first and/or second panel 110, 118. For example, and as
shown in
FIG. 8, the first panel 110 can include (i) a first wood sheet 164 positioned
between the
batting material 112 and the second board 116, and (ii) a second wood sheet
166
positioned on the opposite side of the second board 116. The first wood sheet
164 and
the second wood sheet 166 can include any of the wood sheets previously
described such
as an OSB with a fire-resistant coating. Thus, in some non-limiting
embodiments, the
- 11 -
=

CA 02933862 2016-06-23
first panel 110 can include a first board 114 that comprises a drywall board,
a batting
material 112, a first wood sheet 164, a second board 116 that comprise a
mineral wool
board, and a second wood sheet 166 as shown in FIG. 8.
[0054] In some non-limiting embodiments, as shown in FIG. 9, a first layer of
wood
sheets 170, which includes at least two separate wood sheets 172, 174, can be
attached to
the same stud 140, which extends vertically in a room of a building. For
example, one
end 173 of a first wood sheet 172 can be attached to a portion of a stud 140
and one end
175 of a second wood sheet 174 can be attached to another portion of the stud
140.
Mineral wool boards 144, 146 are positioned adjacent to the wood sheets 172,
174, such
that one end 145 of a first mineral wool board 144 is aligned over a portion
of the stud
140 and one end 147 of a second mineral wool board 146 is aligned over another
portion
of the stud 140. A second layer of wood sheets 180, which includes at least
two separate
wood sheets 182, 184, are positioned adjacent to the mineral wool boards 144,
146, such
that one end 183 of a third wood sheet 182 is aligned over a portion of the
stud 140, and
one end 185 of a fourth wood sheet 184 is aligned over another portion of the
stud 140.
The end 183 of the third wood sheet 182 and the end 185 of the fourth wood
sheet 184
can therefore be attached to the mineral wool boards 144, 146. Optionally, the
ends 183,
185 can also be attached to the first layer of wood sheets 170 and/or the stud
140. A
joint treatment 142 can be placed between the ends 183 and 1.85 of the
consecutively
placed wood sheets 182 and 184, the ends 145 and 147 of the consecutively
placed
mineral wool boards 144 and 146, and/or the ends 173 and 175 of the
consecutively
placed wood sheets 172 and 174 for mounting the respective ends to the stud
140.
[0055] In certain non-limiting embodiments, referring again to FIG. 8, the
second
panel 118 of the wall system 100 also comprises at least two wood sheets 190,
192 as
previously described with respect to the first panel 110. In particular, the
second panel
118 can comprise (i) a first wood sheet wood sheet 190 positioned between the
batting
material 119 and the fourth board 122, and (ii) a second wood sheet 192
positioned on
the opposite side of the fourth board 122. Multiple wood sheets 190, 192 can
also be
arranged over the same stud 140 as previously described with respect to the
first panel
110.
[0056] It is
appreciated that the first panel 110 and the second panel 118 can also
include additional components and layers. For example, the first panel 110 and
second
panel 118 can each independently include an additional drywall board attached
to the
-12-

CA 02933862 2016-06-23
first board 114 and third board 120 that are drywall boards, thereby providing
two layers
of drywall boards on the first panel 110 and the second panel 118. Other
additional
components and layers can be added to the first panel 110 and second panel 118
based
on the building structure and desired properties in the wall system 100.
[0057] The wall systems 100 of the present invention can also be prepared off-
site at a
wall panelization facility remote or away from a building construction site.
As such, the
wall systems 100 can be pre-formed at a manufacturing plant and shipped to a
construction site where they can be directly installed.
[0058] As indicated, the previously-described wall systems 100 can be used to
form a
wall partition in a building. For example, referring to FIG. 10, the wall
system 100 can
extend from a floor 200 to a ceiling 202 in at least one room, such as in the
first level
210, of a building. In certain non-limiting embodiments, the second board 116
of the
first panel 110 and/or the fourth board 122 of the second panel 118 can extend
through a
floor board area 212. For example, and as shown in FIG. 10, the second board
116 and
the fourth board 122 can comprise mineral wool boards that extend through the
floor
board area 212 of a multi-level building. This arrangement provides fire and
sound
protection around the floor board areas 212 of the building. In some examples,
an
additional board 117, such as a mineral wool board, can be mounted between the
second
board 116 and the fourth board 122 in the floor board area 212 to provide an
added fire
protection barrier between the floor board area 212 and foundation 250.
[0059] In certain non-limiting embodiments, when the wall system 100 includes
one
or more of the previously described wood sheets 150, 160 (shown in FIG. 6),
the wood
sheets 150, 160 can also extend through the floor board area 212 of the
building. For
instance, the first panel 110 can include a wood sheet 150 and a second board
116 that
comprises a mineral wool board. Both the wood sheet 150 and the second board
116
extend through a floor board area 212 of a multi-level building. The second
panel 118
can also include a wood sheet 160 and a fourth board 122 that comprises a
mineral wool
board that extends through the floor board area 212 of the multi-level
building. As such,
the wall system 100 can include wood sheets 150, 160 and mineral wool boards
116, 122
that extend through the floor board area 212 of a building.
[0060] In another
non-limiting embodiment, the first panel 110 and the second panel
118 of the wall system 100 both independently include two separate wood sheets
164,
166 and 190, 192 (shown in FIG. 8). In such embodiments, the second board 116
that
- 13-

CA 02933862 2016-06-23
comprises a mineral wool board and the two wood sheets 164, 166 of the first
panel 110,
and the fourth board 122 that comprises a mineral wool board and the two wood
sheets
190, 192 of the second panel 118 can all extend through the floor board area
212 of a
building. Thus, the wall system 100 can include multiple wood sheets 164, 166
and 190,
192 on each panel 110, 118 that extend through the floor board area 212 of a
building
along with the mineral wool boards.
[0061] As shown in FIG. 10, the second board 116, which comprises a mineral
wool
board, and the fourth board 122, which also comprises a mineral wool board,
extend
through the floor board area 212 to the foundation 250 of the building. In
certain non-
limiting embodiments, the first panel 110 and second panel 118 of the wall
system 100
also include the wood sheets 150, 160 (shown in FIG. 6) or wood sheets 164,
166, 190,
192 (shown in FIG. 8), respectively, that extend through the floor board area
212 to the
foundation 250 of the building. This arrangement provides a fire and sound
protective
barrier that extends from the first level 210 to the foundation 250.of a
building.
[0062] Referring again to FIG. 10, the second board 116 and the fourth board
122 can
also extend through a second floor board area 258 to the second floor 260 of
the
building. In some non-limiting embodiments, the first panel 110 and second
panel 118
of the wall system 100 also include wood sheets 150, 160 (shown in FIG. 6) or
wood
sheets 164, 166, 190, 192 (shown in FIG. 8), respectively, that extend through
the second
floor board area 258 to the second floor 260 of the building. This arrangement
provides
a fire and sound protective barrier between different levels 210 and 260 of a
building. In
some examples, an additional board 117 can be mounted between the second board
116
and the fourth board 122 in the floor board area(s) 212, 258 to provide an
added fire
protection barrier between levels 210, 260 or between the level 260 and an
attic 280.
[0063] In certain non-limiting embodiments shown in FIG. 10, the second
floor 260 of
the building includes a second wall system 270. The second wall system 270 can

comprise any of the previously-described wall systems 100. The.second wall
system 270
can be the same as the first wall system 100 or, alternatively, the second
wall system 270
can be different from the first wall system 100. It is appreciated that
additional wall
systems 100, 270 can be used to form partitions on additional floors that are
found in a
larger building.
[0064] As further shown in FIG. 10, the building can also include the attic
280. In
order to provide fire and sound protection to the attic 280, mineral wool
boards 282 can
-14-

CA 02933862 2016-06-23
be attached to the trusses 284 found in the attic 280. As used herein, a
"truss" refers to
the framework or structure that supports the roof of a building. A truss is
typically
formed with rafters or posts. Thus, mineral wool boards 282 can be attached to
the
components that form the trusses in order to provide a fire and sound barrier
in the attic
280 of a building. The mineral wool boards 282 can be attached to both sides
of each
truss 284 found in an attic 280. Alternatively, the mineral wool boards 282
can be
attached to only one side of each truss 284.
[0065] In certain non-limiting embodiments, as shown in FIG. 11, a combination
of
mineral wool boards 282 and wood sheets 286 can be attached to one or both
sides of
each truss 284. In some examples, additional boards (e.g., 2x4 boards) can be
mounted
to the truss(es) 284 to form a wood frame wall extending into the attic. In
some
examples, a wood sheet 286, such as a wood sheet 286 with a fire-resistant
coating as
previously described, is positioned between the truss(es) 284 and/or wood
frame wall
and the mineral wool board 282. In another non-limiting embodiment shown in
FIG. 12,
a second wood sheet 286 is positioned on the opposite side of the mineral wool
board
282 such that the mineral wool board 282 is positioned between two wood sheets
286.
The mineral wool boards 282 and wood sheets 286 can also be placed in other
areas of
the attic 280. For instance, wood sheets 286 with fire-resistant Coatings can
placed over
the ceiling of the attic 280 to provide additional fire and sound protection.
[0066] Thus, the previously described wall systems 100, 270, mineral wool
boards
282, and optional wood sheets 286 with fire-resistant coatings can be placed
throughout
a building to form a continuous fire and sound resistance barrier that extends
from the
foundation 250 to the attic 280 of the building. In addition to possessing the
superior fire
and sound resistant properties, the wall systems 100, 270 according to the
present
invention do not absorb or deteriorate from water/moisture and, therefore,
overcome the
drawbacks typically encountered with currently known wall systems. Further,
the
combination of mineral wool boards 282 and batting material 112, 119 help slow
down
air movement, thereby increasing the energy efficiency of a building.
[0067] Whereas particular embodiments of this invention have been described
above
for purposes of illustration, it will be evident to those skilled in the art
that numerous
variations of the details of the present invention may be made without
departing from the
invention.
- 15 -

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date Unavailable
(22) Filed 2016-06-23
(41) Open to Public Inspection 2016-12-26
Examination Requested 2021-06-07

Abandonment History

There is no abandonment history.

Maintenance Fee

Last Payment of $203.59 was received on 2022-12-23


 Upcoming maintenance fee amounts

Description Date Amount
Next Payment if small entity fee 2024-06-25 $100.00
Next Payment if standard fee 2024-06-25 $277.00

Note : If the full payment has not been received on or before the date indicated, a further fee may be required which may be one of the following

  • the reinstatement fee;
  • the late payment fee; or
  • additional fee to reverse deemed expiry.

Patent fees are adjusted on the 1st of January every year. The amounts above are the current amounts if received by December 31 of the current year.
Please refer to the CIPO Patent Fees web page to see all current fee amounts.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $400.00 2016-06-23
Maintenance Fee - Application - New Act 2 2018-06-26 $100.00 2018-05-23
Maintenance Fee - Application - New Act 3 2019-06-25 $100.00 2019-05-28
Maintenance Fee - Application - New Act 4 2020-06-23 $100.00 2020-08-24
Maintenance Fee - Application - New Act 5 2021-06-23 $204.00 2021-05-25
Request for Examination 2021-06-23 $816.00 2021-06-07
Maintenance Fee - Application - New Act 6 2022-06-23 $203.59 2022-07-13
Late Fee for failure to pay Application Maintenance Fee 2022-07-13 $150.00 2022-07-13
Maintenance Fee - Application - New Act 7 2023-06-23 $203.59 2022-12-23
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
IBACOS, INC.
Past Owners on Record
None
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Amendment 2023-01-16 18 980
Request for Examination 2021-06-07 4 123
Examiner Requisition 2022-09-16 6 375
Description 2023-01-16 15 1,059
Claims 2023-01-16 2 112
Representative Drawing 2016-11-29 1 14
Abstract 2016-06-23 1 17
Description 2016-06-23 15 772
Claims 2016-06-23 4 108
Drawings 2016-06-23 11 210
Cover Page 2016-12-28 2 48
Amendment 2023-12-11 16 585
Abstract 2023-12-11 1 24
Description 2023-12-11 15 1,212
Claims 2023-12-11 2 110
New Application 2016-06-23 8 131
Examiner Requisition 2023-08-11 3 157