U.S. patent application number 11/320882 was filed with the patent office on 2007-07-05 for method and device for resilient seal system.
Invention is credited to Steven Richard Robinson.
Application Number | 20070151185 11/320882 |
Document ID | / |
Family ID | 38222893 |
Filed Date | 2007-07-05 |
United States Patent
Application |
20070151185 |
Kind Code |
A1 |
Robinson; Steven Richard |
July 5, 2007 |
Method and device for resilient seal system
Abstract
A method and structure for providing a resilient seal system in
the gap or joint between adjacent construction panels utilizing a
foaming expansive elastic closed-cell liquid-impermeable sealant, a
backer rod and a seal. The foaming expansive elastic closed-cell
liquid-impermeable sealant is first introduced to the gap or joint
between the adjacent construction panels. A seal is introduced into
or over the gap after the foaming expansive elastic closed-cell
liquid-impermeable sealant has sufficiently cured. In alternative
embodiment a backer rod is located intermediate the sealant and
seal as a spacing member.
Inventors: |
Robinson; Steven Richard;
(Windham, NH) |
Correspondence
Address: |
CRAIN, CATON & JAMES
FIVE HOUSTON CENTER
1401 MCKINNEY, 17TH FLOOR
HOUSTON
TX
77010
US
|
Family ID: |
38222893 |
Appl. No.: |
11/320882 |
Filed: |
December 29, 2005 |
Current U.S.
Class: |
52/396.04 ;
404/67 |
Current CPC
Class: |
E01C 11/10 20130101;
E04B 1/6801 20130101 |
Class at
Publication: |
052/396.04 ;
404/067 |
International
Class: |
E01C 11/08 20060101
E01C011/08; E04B 1/68 20060101 E04B001/68 |
Claims
1. A method of providing a resilient barrier between a first
construction panel and a second construction panel, said first
construction panel being adjacent said second construction panel,
said first construction panel having a first edge, said second
construction panel having a first edge, said first construction
panel having thickness, said second construction panel having
thickness, said first edge of said first construction panel being
distant said first edge of said second construction panel,
comprising: a. introducing a foaming expansive elastic closed-cell
liquid-impermeable sealant adjacent said first edge of said first
construction panel and adjacent said first edge of said second
construction panel; b. introducing a seal above said expansive
elastic closed-cell liquid-impermeable sealant and adjacent said
first construction panel and adjacent said second construction
panel.
2. The method of providing a resilient barrier of claim 1, wherein
said seal is an application of one or more from the group of
acrylic-latex-based caulk, polysulfide-based caulk, urethane-based
caulk, poly-urea-based caulk, and silicone-based caulk.
3. The method of providing a resilient barrier of claim 2, further
comprising a. introducing a spacing member intermediate said
expansive elastic closed-cell liquid-impermeable sealant and said
seal.
4. The method of providing a resilient barrier of claim 1 wherein
said seal comprises an resilient member adhered in place, said
resilient member is one or more from the group of neoprene,
santoprene, silicone, and urethane.
5. The method of providing a resilient barrier of claim 4, further
comprising a. introducing a spacing member intermediate said
expansive elastic closed-cell liquid-impermeable sealant and said
seal.
6. A resilient interface intermediate a first construction panel
and a second construction panel, said first construction panel
having a first edge, said second construction panel having a first
edge, said first construction panel having thickness, said second
construction panel having thickness, said first edge of said first
construction panel being distant said first edge of said second
construction panel comprising: a. a first sealant, said first
sealant being a foaming expansive elastic closed-cell
liquid-impermeable sealant, said first sealant being adjacent said
first edge of said first construction panel and adjacent said first
edge of said second construction panel; b. a seal, said seal being
above said expansive elastic closed-cell liquid-impermeable sealant
and adjacent said first construction panel and adjacent said second
construction panel
7. The resilient interface of claim 6, wherein said seal is an
application of one or more from the group of acrylic-latex-based
caulk, polysulfide-based caulk, urethane-based caulk,
poly-urea-based caulk, and silicone-based caulk.
8. The resilient interface of claim 7, further comprising a. a
spacing member intermediate said expansive elastic closed-cell
liquid-impermeable sealant and said seal.
9. The resilient interface of claim 6 wherein said seal comprises
an resilient member adhered in place, said resilient member is one
or more from the group of neoprene, santoprene, silicone, and
urethane.
10. The resilient interface of claim 9, further comprising a. a
spacing member intermediate said expansive elastic closed-cell
liquid-impermeable sealant and said seal.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates generally to systems and
methods for creating a seal system between adjacent panels subject
to temperature expansion and contraction. More particularly, the
present invention is directed to providing seals in construction
joints that are resilient, and ideally waterproof, over relatively
long periods of time.
[0005] 2. Description of the Related Art
[0006] Construction panels come in many different sizes and shapes
and may be used for various purposes, including roadways, sideways,
and pre-cast structures. In many situations it is necessary to form
a lateral gap or joint in the structure to allow for independent
movement of the adjacent sections. Such movement is caused by many
factors including expansion and contraction of the adjacent
sections due to changes in temperature.
[0007] Various seal systems and configurations have been used to
seal such gaps or joints. One popular technique involves pressing a
flexible rod or tube into the gap or joint. The rods or tubes are
typically made from some type of foam material and are commonly
referred to as "backer rods". The remainder of the gap or joint
above the tube is then filled in with a sealant. The backer rod
does not add any waterproofing value, as it is only used to control
the depth of the sealant. Another method is to use pre-compressed
saturated, foam tapes. Pre-compressed foam tapes can require
additional time to be sized to the particular distance between any
two panels, which may vary slightly or significantly. Such
variations also require a variety of sizings to be readily
accessible for the particulars of any single gap. Such
pre-compressed tapes are expensive. Another method is to combine
the sealant and the pre-compressed foam tape; however such a method
may require additional time because each joint must be coated with
the sealant along its entire length, which may be five to seven
feet, allowed to cure, then be compressed into the "precompressed"
state for installation.
[0008] The seal system is intended to deter water and other
contaminants from entering the gap or joint. It is important that
the seal be effective over relatively long periods of time and that
it function properly even when exposed to extreme weather
conditions. Major problems with seals include water penetration and
contaminant penetration. Water penetration may result in exposure
of unsealed surfaces or in freezing expansion. In the case of a
seal where at least one panel contains wood, water penetration of
the seal may result in rotting, particularly as the water may
become trapped within the seal or gap. In the case of a seal where
at least one panel contains masonry, the water may penetrate into
the masonry and expand when cooled below its freezing point,
creating internal stresses on the masonry and potentially
fracturing the masonry. In all instances, penetration of water may
result in further destruction of the seal should the water cool
below its freezing point. Contaminant penetration may also have
detrimental effects on the gap or seal. As the gap or seal is
intended to permit expansion of the panels into the gap or seal,
the presence of non-flexible contaminants may prevent such
expansion and contribute to the increase of stresses and strains
within the panels.
[0009] It is known that such flexing and conditions may have a
detrimental effect on the seal between the panels. Flexing may
fatigue the sealant, which has limited flexibility and elasticity.
Weather conditions may alter the flexibility and elasticity of the
sealant so as to result in cracking. It is known to introduce the
sealant into the space between the adjacent construction panels in
two applications, forming two seals, so that if one seal fails, the
other may remain waterproof. However the conditions which cause
failure of the first seal layer may also cause the second
substantially identical seal layer to fail.
[0010] Another difficulty in applying such sealants is to ensure
that the sealant completely fills the gap or joint as it then
exists and adequately attaches to the adjacent panels. This may be
accomplished by increasing the nozzle size, by slowing the rate at
which the applicator is moved while increasing the rate of
application, or by hand tooling. Increasing the nozzle size creates
problems as the optimum nozzle size is the approximate width of the
distance between adjacent panels at the lowermost portion of the
gap or joint, which becomes difficult to reach with a full width
nozzle. Slowing the rate of application, while effective, slows the
construction process, increases manpower requirements, and may
require additional time for staging and scaffolding use, all of
which are undesirable.
[0011] A further difficulty in apply such seals is that time
necessary to apply multiple seal layers. The second seal cannot be
applied before the first seal has sufficiently cured as to prevent
the seals from becoming intertwined or not allowing air required to
cure and therefore transferring destructive forces between
themselves. Moreover conventional seals require each seal to be
applied and worked by hand to ensure adherence to the adjacent
panels and sufficient penetration into the gap or joint. Such
conventional seals may require skilled labor, further consuming
additional time.
[0012] It would be an improvement to the art to have a seal system,
and a method for application of such seal system, which would
provide a seal having a longer duration of use, which would better
seal adjacent panels regardless of distance and which could be
rapidly applied without the need multiple sized backer rods. It
would be a further improvement to increase the speed of
application, and to reduce costs, labor requirements, and material
needs. It would be a further improvement to have a second seal
which would not fail due to the same conditions as a first
seal.
BRIEF SUMMARY OF THE INVENTION
[0013] In accordance with the present invention, a seal system and
method are provided for slowing deterioration at joints or gaps and
for providing a second seal having physical properties different
from the first seal.
[0014] The method for creating a resilient interface to deter water
and contaminants from entering the joint or gap adjacent
construction panels in accordance with the present invention
includes introducing a foaming liquid expansive elastic closed-cell
liquid-impermeable sealant between the two adjacent panels with
sufficient volume to fill the distance between the two panels and
adhere to each. A seal is then introduced above the foamed liquid
expansive elastic closed-cell liquid-impermeable sealant with
sufficient volume to also fill the distance between the two panels
and adhere to each. The seal may be by application of one or more
gunnable sealants, which are well known in the art, typically being
sold in a tube form for use with a caulking gun. Alternatively, the
seal may comprise an extruded resilient member affixed in gap with
adhesive sealant on each side. The extruded resilient member may be
one or more from the group of neoprene, santoprene, silicone, and
urethane. A backer rod may be inserted in the seal between the
layering of sealant and the seal to control sealant application
depth and to contour the first sealant.
[0015] The resulting structure of the seal system provides a
resilient interface intermediate a first construction panel and a
second construction panel including a first seal composed of a
foaming, expansive elastic closed-cell liquid-impermeable sealant,
potentially a backer rod, and finally a second seal.
[0016] The above described and many other features and attendant
advantages of the present invention will become better understood
by reference to the following detailed description when taken in
conjunction with the accompanying drawings.
[0017] Accordingly, the objects of my invention are to provide,
inter alia, a seal system that: [0018] extends the lifespan of the
seal; [0019] extends the lifespan of the adjacent panels; [0020]
utilizes at least two different seals to increase longevity; [0021]
can include a backer rod to absorb some of the load and to provide
further impediments to external articles invading the lower
seal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a cross sectional view of the seal without the
backer rod.
[0023] FIG. 2 is a cross-sectional view of the seal with the backer
rod.
DESCRIPTION OF THE INVENTION
[0024] As shown in FIG. 1, the seal system 10 comprises of a
foaming sealant 20 and a seal 40 applied between adjacent first
panel 110 and second panel 120.
[0025] Foaming sealant 20 is a sprayed-in-place, elastic closed
cell hydrophilic/phobic sealant that expands when exposed to air,
is impermeable to water and cures rapidly. Because the foaming
sealant 20 expands and fills the joint when dispensed, seal 40 may
be applied almost immediately thereafter. In one embodiment foaming
sealant 20 may be a polyurethane-based sealant. No hand working of
foaming sealant 20 by the applicator is necessary once applied.
Foaming sealant 20 expands upon contact with air/moisture and is
applied in sufficient volume to expand to completely cover the
distance between first panel 110 and second panel 120 and to adhere
to first panel surface 111 and to second panel surface 121, forming
a first resilient seal. Foaming sealant 20 is elastic, therefore
not detaching from first panel surface 111 or from second panel
surface 121 during expansive cycling. Moreover the elastic property
of foaming sealant 20 permits foaming sealant 20 not to internally
shear or fail between first panel surface 111 and to second panel
surface 121 during expansive cycling.
[0026] Seal 40 is seal of any material known in the art. In the
preferred embodiment, seal 40 is a standard gunnable sealant,
including acrylic-latex-based caulk, polysulfide-based caulk,
urethane-based caulk, poly-urea-based caulk, and silicone-based
caulk. As is known in the art seal 40 is not foaming or expansive,
but is instead applied with a compressing "gun," such as a caulking
gun, as a highly viscous liquid, which may be worked in place,
including by increasing the nozzle size, by slowing the rate at
which the applicator is moved while increasing the rate of
application, or by hand tooling. Such adjustments may be necessary
to ensure seal 40 adheres to both first panel surface 111 and
second panel surface 121. In an alternative embodiment (not shown),
seal 40 may comprise an extruded resilient member affixed about gap
50 with adhesive sealant. The extruded resilient member may be one
or more from the group of neoprene, santoprene, silicone, and
urethane.
[0027] In operation, foaming sealant 20 is applied to gap 50 in
sufficient volume to expand to adhere to both first panel surface
111 and second panel surface 121. After time for outer surface 21
of foaming sealant to cure sufficiently to become semi-rigid, seal
40 is applied into gap 50 above foaming sealant 20 in sufficient
volume to contact or be worked into contact with panel surface 111
and second panel surface 121.
[0028] In the alternative embodiment depicted in FIG. 2, a backer
rod 30 may be located between foaming sealant 20 and seal 40.
Backer rod 30 is constructed of a foam or other material, which is
cut to length on site and which is intended as a spacing member.
Backer rod 30 provides additional support for the forces exerted on
foaming sealant 20 and on seal 40 from contact with panel surface
111 and/or second panel surface 121. Moreover backer rod 30 serves
to prevent contaminants that may pass seal 40 from reaching foaming
sealant 20. Finally, backer rod 30 may be inserted immediately
after application of foaming sealant 20, including at times prior
to the sufficient curing of foaming sealant 20 for outer surface 21
to become semi-rigid. Seal 40 may therefore be applied nearly
immediately after application of foaming sealant 20.
[0029] In operation for the alternative embodiment depicted in FIG.
2, foaming sealant 20 is applied to gap 50 in sufficient volume to
expand to adhere to both first panel surface 111 and second panel
surface 121. Backer road 30 is inserted into gap 50 atop foaming
sealant 20. Seal 40 is then applied into gap 50 above backer rod 30
in sufficient volume to contact or be worked into contact with
panel surface 111 and second panel surface 121.
[0030] The foregoing disclosure and description of the invention is
illustrative and explanatory thereof. Various changes in the
details of the illustrated construction may be made within the
scope of the appended claims without departing from the spirit of
the invention. The present invention should only be limited by the
following claims and their legal equivalents.
* * * * *