U.S. patent application number 16/173823 was filed with the patent office on 2019-06-27 for helically-packaged expansion joint seal system with coiling, tear strips or secondary packaging.
This patent application is currently assigned to Schul International Company, LLC. The applicant listed for this patent is Schul International Company, LLC. Invention is credited to Steven R. Robinson.
Application Number | 20190194880 16/173823 |
Document ID | / |
Family ID | 64661240 |
Filed Date | 2019-06-27 |
United States Patent
Application |
20190194880 |
Kind Code |
A1 |
Robinson; Steven R. |
June 27, 2019 |
Helically-packaged expansion joint seal system with coiling, tear
strips or secondary packaging
Abstract
A foam-based expansion joint seal system packaging which
facilitates transport and reduces the need for internal
splices.
Inventors: |
Robinson; Steven R.;
(Windham, NH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Schul International Company, LLC |
Pelham |
NH |
US |
|
|
Assignee: |
Schul International Company,
LLC
Pelham
NH
|
Family ID: |
64661240 |
Appl. No.: |
16/173823 |
Filed: |
October 29, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15854152 |
Dec 26, 2017 |
10227734 |
|
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16173823 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 27/10 20130101;
B29D 99/001 20130101; E04C 2/284 20130101; B32B 5/32 20130101; B32B
7/12 20130101; E04B 1/948 20130101; B32B 3/14 20130101; E01C 11/10
20130101; B32B 27/065 20130101; B32B 2255/12 20130101; B32B 5/18
20130101; E04B 1/6812 20130101; E04B 1/6801 20130101; B29D 99/0053
20130101; B32B 3/04 20130101; E01C 11/106 20130101; B65D 65/00
20130101 |
International
Class: |
E01C 11/10 20060101
E01C011/10; B29D 99/00 20060101 B29D099/00; B32B 5/32 20060101
B32B005/32; E04B 1/68 20060101 E04B001/68; B32B 5/18 20060101
B32B005/18 |
Claims
1. An expansion joint seal system, comprising: a longitudinal body
of foam in compression; a water-resistant constituent, the
water-resistant constituent adhered to the longitudinal body of
foam on a first surface or contained within the longitudinal body
of foam in compression; and a casing in tension helically
compressively encircling the longitudinal body of foam in
compression and the water-resistant constituent, the longitudinal
body of loam in compression helically curved at a constant
radius.
2. The expansion joint seal system of claim 1, further comprising:
the casing having an internal surface, the internal surface
contacting the longitudinal body of foam, the internal surface
having a low friction coefficient.
3. The expansion joint seal system of claim 1, wherein a successive
section of the casing overlaps a prior section of the casing by
15%.
4. The expansion joint seal system of claim 1, further comprising:
a board intermediate the longitudinal body of foam in compression
and the casing at a first side of the casing, the board having a
board height, the longitudinal body of foam in compression having a
foam body height, the board height being greater than or equal to
the foam body height.
5. The expansion joint seal system of claim 4, further comprising:
a second board intermediate the longitudinal body of foam in
compression and the casing at a second side of the casing, the
second board having a second board height, the second board height
being greater than or equal to the foam body height.
6. The expansion joint seal system of claim 5, wherein the board
and the second board are in parallel planes.
7. The expansion joint seal system of claim 5, wherein the board
and the second board are askew, and wherein the board has a first
end adjacent a first end of the longitudinal body of foam in
compression, and the second board has a first end adjacent the
first end of the longitudinal body of foam in compression.
8. The expansion joint seal system of claim 1, wherein the casing
is paper.
9. The expansion joint seal system of claim 1, wherein the casing
is inelastic.
10. The expansion joint seal system of claim 1, wherein the
longitudinal body of foam in compression has a length greater than
ten feet.
11. The expansion joint seal of claim 1, wherein the casing bears a
distance indicator at regular intervals.
12. The expansion joint seal of claim 1, wherein the longitudinal
body of foam in compression is under compression laterally between
a first sidewall and a second sidewall.
13. The expansion joint seal of claim 1 wherein the longitudinal
body of foam in compression is under compression laterally between
a first sidewall and a second sidewall and is under compression
longitudinally.
14. The expansion joint seal of claim 1 wherein the longitudinal
body of foam in compression is under compression laterally between
a first sidewall and a second sidewall and the longitudinal body of
foam in compression is under compression between a longitudinal
body of foam top and a longitudinal body of foam bottom.
15. The expansion joint seal of claim 1 wherein the longitudinal
body of foam in compression is under compression laterally between
a first sidewall and a second sidewall, the longitudinal body of
foam in compression is under compression longitudinally and the
longitudinal body of foam in compression is under compression
between a longitudinal body of foam top and a longitudinal body of
foam bottom.
16. The expansion joint seal system of claim 1, wherein the casing
includes an external adhesive surface.
17. The expansion joint seal system of claim 1, wherein the casing
includes a heat sensitive coating.
18. The expansion joint seal system of claim 1, wherein the casing
includes a first chemically sensitive coating on a first surface
and a second chemically sensitive coating on a second surface, the
first chemically sensitive coating reactive to the second
chemically sensitive coating bonding the first surface to the
second surface.
19. An expansion joint seal system, comprising: a longitudinal body
of foam in compression; a water-resistant constituent, the
water-resistant constituent adhered to the longitudinal body of
foam on a first surface or contained within the longitudinal body
of foam in compression; and a casing in tension helically
compressively encircling the longitudinal body of foam in
compression and the water-resistant constituent, and a plurality of
internal tear strips, each of the plurality of internal tear strips
affixed to the casing at regular intervals.
20. An expansion joint seal system, comprising: a longitudinal body
of foam in compression; a water-resistant constituent, the
water-resistant constituent adhered to the longitudinal body of
foam on a first surface or contained within the longitudinal body
of foam in compression; and a casing in tension helically
compressively encircling the longitudinal body of foam in
compression and the water-resistant constituent, and a second
casing in tension helically compressively encircling the casing.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/854,152 for Helically-packaged expansion
joint seal system, filed Dec. 26, 2017, which is incorporated
herein by reference. The benefit of and priority to are hereby
claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND
Field
[0003] The present disclosure relates generally to packaging of
systems for creating a durable seal between adjacent panels,
including those which may be subject to seismic or temperature
expansion and contraction and/or mechanical shear. More
particularly, the present disclosure is directed to a design for
packaging and shaping/forming such expansion joint seal systems
which facilitates transport, reduces material damage, the need for
internal splices and waste.
Description of the Related Art
[0004] Construction panels come in many different sizes and shapes
and may be used for various purposes, including roadways, sideways,
and pre-cast structures, particularly buildings. Use of precast
concrete panels for interior and exterior walls, ceilings and
floors, for example, has become more prevalent. As precast panels
are often aligned in generally abutting relationship, forming a
lateral gap or joint between adjacent panels to allow for
independent movement, such in response to ambient temperature
variations within standard operating ranges, building settling or
shrinkage and seismic activity. Moreover, these joints are subject
to damage over time. Most damage is from vandalism, wear,
environmental factors and when the joint movement is greater, the
seal may become inflexible, fragile or experience adhesive or
cohesive failure. As a result, "long lasting" in the industry
refers to a joint likely to be usable for a period greater than the
typical lifespan of five (5) years. Various seals have been created
in the field.
[0005] Various seal systems and configurations have been developed
for imposition between these panels to provide seals which provide
one or more of fire protection, waterproofing, sound and air
insulation. This typically is accomplished with a seal created by
imposition of multiple constituents in the joint, such as silicone
application, backer bars, and compressible foams.
[0006] Foam-based expansion joint seal systems are typically
shipped in sticks, which often is a six-to-ten fool straight
segment, or in rolls wherein the external layer is adhered to a
release tape to permit the wrapping around a reel. Providing the
joint seal system in a stick permits the product, in particular
joint seals having a final width greater than one inch, to be
compressed at the factory, i.e. pre-compressed, laterally, so the
installer on site may remove the packaging and install the
expansion joint seal system before it expands beyond the gap of the
expansion joint. Higher compression ratios, coupled with slower
release lime, facilitate the installation and function of such
precompressed, stick-based expansion joint seal systems.
Alternatively, the expansion joint seal may be provided on a roll,
where successive layers are wrapped around a center, permitting
immediate compression during wrapping.
[0007] Each shipping system has shortcomings. Willi the slick, the
compressed product is typically encased in a shrink wrap sleeve,
which shrinks when heated. Unfortunately, this is applied to each
stick, which is limited in length due to shipping sizes, typically
to six to ten foot sections. As a result, during shipping, the
stick may be subjected to bending forces, such as when loaded on a
truck over other materials, which causes the shrink wrap to crack
or fail along a seal, permitting the compressed product to expand
through the resultant opening and rendering the product unusable.
Because the packaging is sized for conventional shipment, the
sticks are typically limited to not more than ten (10) feet. Even
with the size limitation the sticks are too long for easy handling
which can result in damage in transit or added delivery fees. As a
result, the resulting sections must be joined with a splice to fit
within the actual expansion joint. Moreover, because each stick is
individually packaged, when the packaging is opened, the entire
stick begins to expand. That portion which exceeds the required
length is often lost as it is cut off because it expands to size
greater than the intended gap, therefore is discarded. With the
roll, because any compression is generally radially as each
successive layer is deposited, compression is possible in only one
direction, but difficult to control over time due to the varying
radius of the material and the potential for localized areas of
higher or lower compression.
SUMMARY
[0008] The present disclosure therefore meets the above needs and
overcomes one or more deficiencies In the prior art by providing a
packaging of systems for creating a durable seal between adjacent
panels. In particular, the present disclosure provides a foam-based
expansion joint seal system which can be of longer length, shipped
conventionally, facilitates constant and equal compression
throughout the system, and precludes loss of large segments of
material.
[0009] The disclosure provides an expansion joint seal system which
includes a longitudinal body of foam in compression; a
water-resistant constituent, the water-resistant constituent
adhered to the longitudinal body of foam on a first surface or
contained within the longitudinal body of foam in compression; and
a casing helically encircling the longitudinal body of foam in
compression and the water-resistant constituent.
[0010] Additional aspects, advantages, and embodiments of the
disclosure will become apparent to those skilled in the art from
the following description of the various embodiments and related
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] So that the manner in which the described features,
advantages, and objects of the disclosure, as well as others which
will become apparent, are attained and can be understood in detail;
more particular description of the disclosure briefly summarized
above may be had by referring to the embodiments thereof that are
illustrated in the drawings, which drawings form a pan of this
specification. It is to be noted, however, that the appended
drawings illustrate only typical preferred embodiments of the
disclosure and are therefore not to be considered limiting of its
scope as the disclosure may admit to other equally effective
embodiments.
[0012] In the drawings;
[0013] FIG. 1 provides an end view of one embodiment of the present
disclosure.
[0014] FIG. 2 provides a side view of one embodiment of the present
disclosure.
[0015] FIG. 3 provides an end view of one embodiment of the present
disclosure after imposition between substrates.
[0016] FIG. 4 provides an illustration of a coiled embodiment of
the present disclosure.
[0017] FIG. 5 provides an illustration of one embodiment with
internal tear strips.
[0018] FIG. 6 provides an illustration of a structure for
processing one embodiment of the present disclosure.
[0019] FIG. 7 providers an illustration of an alternative structure
for processing one embodiment of the present disclosure.
DETAILED DESCRIPTION
[0020] Referring to FIG. 1, the packaging 100 of the present
invention is illustrated An expansion joint seal system 102,
composed of a longitudinal body of foam 104 in compression and a
water-resistant constituent 106, is surrounded by a casing 108
helically encircling the compressed longitudinal body of foam 104,
typically laterally compressed, and the water-resistant constituent
106. The water-resistant constituent 106 may be adhered to the
compressed longitudinal body of foam 104 on a first surface or
contained within the compressed longitudinal body of foam 104, such
as the elastomer coating depicted in U.S. Pat. No. 9,745,738 for
Expansion Joint for Longitudinal Load Transfer, issued to Schul
International Company, LLC. Because the casing 108 helically
encircles the compressed longitudinal body of foam 104 and can
accommodate flexing by the overlapping casing 108. the compressed
longitudinal body of foam 104 may be cut to length without fear of
a shrink-wrap seam failing due to flexion.
[0021] The system is particularly beneficial in connection with
foam-based expansion joint seal systems, which are often supplied
pre-compressed. Pre-compression of such expansion joint seal
systems is desirable as installation of the uncompressed expansion
joint system can be problematic given the length, often in multiple
meters, resulting in long sections above the expansion joint while
working in sections on centimeter basis. As the expansion joint
seal system may be compressed al installation between one-fifth to
one-half the original width to a final density in excess of 300
kg/ml, such installation of uncompressed product can be difficult.
It is therefore desirable in the industry to provide the expansion
joint seal systems compressed to a size less than the nominal
expansion joint size, so the expansion joint seal can be removed
from the packaging and rapidly installed before the expansion joint
seal system can being to relax and thereby contact the adjacent
substrate walls. The present disclosure maintains, and may
provides, such precompression with additional benefits.
[0022] To facilitate removal of the casing 108, the casing may have
a casing internal surface 110 which may have a low friction
coefficient. The casing internal surface 110 may be a layer of the
casing 108 or may be applied to die casing 108. A casing internal
surface 110 having a low coefficient of friction may be
particularly beneficial when the associated expansion joint seal
system 102 and its compressed longitudinal body of foam 104
includes an adhesive at expansion joint seal system first and
second sidewalls 150, 152.
[0023] The casing 108 may be overlapped as little as 15% of its
width, or as great at 85%, though more or less is possible. As the
overlap approaches 15%, the casing 108 provides beneficial
tensioning and resilience against external damage.
[0024] To maintain the casing 108 in position, the casing may
include an external surface with clinginess, such as a polyvinyl
chloride or low density polyethylene, or adhesive, preferably an
external adhesive surface, such that the successive layering of the
casing 108 provides a bond to the prior layer, and, where desired,
to the expansion joint seal system 102 or any boards or other
materials abutting the expansion joint seal system 102, which may
also have adhesive surfaces. Such materials may be applied to only
the exterior to-be-overlapped portion, such that the ultimate
exposed surface has no such properly while bonding to the
successive overlap. The casing 108, for example, may overlap 50% of
itself with each successive application, where the overlapped
exterior surface has an adhesive to bond to the successive
application and for further retard any propagation of a tear in the
resultant packaging 100.
[0025] Because the longitudinal body of foam 104 provides
elasticity and compressibility in the packaging 100, the casing 108
may be constructed of an inelastic material. Alternatively, the
casing 108 may be constructed of a material which is elastic.
Regardless of the material from which the casing 108 is
constructed, the easing 108 is applied under tension to maintain,
and to impart at the level desired, compression to the longitudinal
body of foam 104. Moreover, because the casing 108 includes
multiple layers of the casing 108 along the expansion joint seal
system 102, the failure at any point of the casing 108 does not
result in the expansion joint seal system 102 being permitted to
expand significantly and reduces the potential for unusable
material. This marks a substantial departure from the prior art,
wherein the shrink wrap packaging would fail due to impact or
flexing, often initially splitting along a seam, and then further
failing as the now-permitted expansion of the expansion joint seal
system 102 further split the packaging and rendered the product
unusable due to the force needed to recompress to the necessary
width. The casing 108 may be an inelastic paper of sufficient
strength to resist tearing and may be coated externally with a
water-resistant layer to ensure maintenance of the packaging 100 in
case of precipitation. When desired, conventional bandings can be
applied about the packaging 100.
[0026] The easing 108 may be formed of a material of sufficient
durability to withstand exposure to any additive such as a fire
retardant, a hydrophobic additive, or a hydrophilic additive, which
may be associated with the expansion joint seal system 102, such as
by a coating, infusion or impregnation. Such fire retardants, in
amounts sufficient to obtain a desired fire endurance rating under
any of the various tests, such as E-119, UL 2079, UL 84, DIN 4102,
etc., may otherwise adversely react with the casing 108.
[0027] The interior surface of easing 108 may be selected to ensure
other materials do not adhere, or may be impermeable to ensure no
leakage of additives. Water and airflow resistant constituents 106,
may be additives 132 introduced before foaming such as by mixing
into the isocyanate or polyol, or after such by infusion and/or
impregnation, or may, instead be a layer 134 subsequently applied
externally, such as an elastomer or may be internal membranes,
force compensating and/or recovery spring members, or other systems
known in the art. Notably, such water-resistant constituents 106
may have adhesive surfaces to which the casing 108 may a pressure
but to which the casing 108 should not adhere.
[0028] The casing 108 may further include compositions on some or
all of its inner and outer surface which react when brought in
contact, when the casing 108 is overlapped, and which may therefore
provide a more durable chemical bond. The casing 108 may include a
first chemically sensitive coating on a first surface and a second
chemically sensitive coating a second surface, where the first
chemically sensitive coating is reactive to the second chemically
sensitive coating. Likewise, the casing 108 may include heat
reactive compositions on one or both surfaces or itself may be
heat-reactive, such that the packaging 100 may be subjected to some
degree of heating to increase the adhesion between layers of the
casing 108, to cause further constriction by shrinking, or to alter
other properties, such as permeability or ductility. Similarly, the
casing 108 may be an insulating material, precluding, substantial
heat transfer to the expansion joint system 102. The casing 108 may
therefore include cellulose, soy or carob oil derivatives.
[0029] Because the compression of the compressed longitudinal body
of foam 104 of the expansion joint seal system 102 is maintained
by, and may be provided by, the casing 108, the packaging 100
permits the compression ratio of the compressed longitudinal body
of foam 104 to be adjusted as needed, such as higher compression Or
lower compression, even in the same stick or coil. Similarly,
because the compression around a transition, a change in direction
of the material, varies according to the length of each successive
section 114, the tension maintained the casing 108 during
application may be reduced for those sections surrounding a
transition. Beneficially, because the casing 108 is continually
encapsulating, the expansion joint system 102 may include
longitudinal bodies of foam 104 of different seal sizes, i.e, a
continuation expansion joint 102 intended for use across a span
which includes a section of narrower expansion joint width,
avoiding the need for a field splice to accommodate the varying
sizes. As a result, the easing 108 may be applied at varying
radius, whether as a result of varying compression ratio upon
application of the coating or due to the application of a common
compression ratio as the expansion joint system 102 varies in
dimension.
[0030] To ensure sufficient binding of the expansion joint seal
system 102, the casing 108 may be overlapped such that a successive
section 114 overlaps a prior section 112 by a quarter, 25%, of its
width 116. Increased overlaps ensure the casing 108 remains tight
against the compressed longitudinal body of foam 104 of the
expansion joint seal system 102, but consumes a substantially
greater length of casing 108 and results in a thicker casing 108
which must be cut through prior to installation. The interior
surface 110 of the casing 108 may include an adhesive edge 111, or
may adhere by virtue of an electrostatic charge, or by a high
friction surface, preferably on the exterior of the casing 108, or
other systems known ins the art to maintain the overlap.
[0031] The resulting packaging 100 permits dispatch of an expansion
joint seal system 102 sized to, or above, the necessary length,
avoiding the need for any field splice.
[0032] To aid cutting the expansion joint seal system 102 to the
desired length, the casing 108 may include a distance indicator 146
at regular intervals, such as feet, yards, or meters. The presence
of the distance indicator 146 outside the packaging 100 permits the
packaging 100 to be cut to the needed length prior to cutting the
casing 108 to open the packaging 100. The use of the casing 108
and, where desired, the distance indicator 146, permits a packaging
100 where the compressed longitudinal body of foam 104 may have a
length greater than ten feet.
[0033] Referring to FIG. 1 and to FIG. 2, an end view of the
packaging 100, consistent with pre-compressed foam-based expansion
joint seals, the expansion joint seal system 102 may be positioned,
while in--or prior to--compression against a board 118 or between a
board 118 and a second board 120 prior to be encased within the
easing 108. The board 118 is positioned intermediate the compressed
longitudinal body of foam 104 and the casing 108 at the interior
surface 110 of the casing 108. Preferably the board 118 has a
height 224 equivalent to a height 226 of the compressed
longitudinal body of foam 104, the foam body height 226.
Alternatively, the board height 224 may be equivalent to the height
228 of the expansion joint seal system 102, particularly where an
external layer 134 of water-resistant constituent 106 is provided.
Thus, the board 118 is positioned intermediate the compressed
longitudinal body of foam 104 and the easing 108 in contact with
the casing internal surface 110. A second board 120 may be
positioned intermediate the compressed longitudinal body of foam
104 and the casing internal surface 110. Preferably the second
board 120 also has a second board height 240 equivalent to the
height 226 of the compressed longitudinal body of foam 104. Use of
one of more boards 118, 120 permits the expansion joint seal system
102 to be laterally compressed so the expansion joint seal system
width 222 is maintained in compression at a distance less than the
width of the expansion joint into which the expansion joint seal
system 102 is be imposed after removal from the casing 108.
Beneficially, because the casing 108 is provided as a single,
continuous helical wrap around the expansion joint seal system 102,
the boards 118 and 120 need to be of great length of even
co-terminal. Shorter board 118, 120 might be used and positioned so
the ends are not co-terminal, reducing the potential for deflection
at any single point. Such boards 118, 120 may even be spliced when
appropriate, particularly when the expansion joint seal system 102
includes a transition, such as that the product is in more than one
plane. The boards 118, 120 array be of wood, or plastic, or high
density paper, any may be constructed from recyclable materials.
The boards 118, 120 may be positioned on any surface of the
expansion joint system 102, and may be of any size, any may only
provide a longitudinal strut to control flexing prior to use.
[0034] Referring to FIGS. 2 and 3, while the first board 118 and
the second board 120 are typically aligned in parallel planes, such
that the distances between the tops 230, 232 of the first board 118
and the second board 120 and bottoms 234, 236 of each of the first
board 118 and the second board 120 are equal, the first board 118
and the second board 120 may be skewed, such that the distance
between the first board top 230 and the second board top 232 of the
second board is greater than the distance between the first board
bottom 234 and the second board bottom 236, such as illustrated in
FIG. 3. Such a skewed construction may be advantageous where the
expansion joint seal system 102 incorporates a chambered base. To
ensure the compression introduced into the longitudinal body of
foam 104 is maintained along the length of a stick of the expansion
joint seal system 102, one or both of the board 118 and the second
board 120 may have a board first end 142 and a second board first
end 144 to which the casing 108 reaches.
[0035] Beneficially, because the casing 108 may be applied after
the expansion joint seal system 102 is in lateral compression,
maintaining compression of the expansion joint system system 102 in
other planes is possible. The expansion joint seal system 102 may
be subjected to a longitudinal compression in a section immediately
subject to the helical encircling by the casing 108, such that the
longitudinal compression is retained by the successive layering of
the casing 108. Longitudinal compression may be desirable to ensure
that, upon release in the expansion joint, the expansion joint seal
system 102 is maintained in abutment with the end of the expansion
joint and to ensure that any joint is maintained in position.
Further, the expansion joint seal system 102 may be subjected to a
vertical compression such that the expansion joint scat system
height 228 is less than its operational height. Vertical
compression may be desirable, particularly in connection with any
surface cover over the expansion joint, such as a cover plate, to
ensure the expansion joint seal system 102 abuts the cover plate
after installation and, when desired, transfers any load front the
cover plate to adjacent substrate. Further because the expansion
joint seal system 102 is maintained in compression by the packaging
100, the compressed longitudinal body of foam 101 may be provided
with different shapes and profiles, such as chamfering at the lower
sides, to facilitate compression and installation.
[0036] Unlike any packaging 100 known in the art, use of the casing
108 helically encircling the compressed longitudinal body of foam
104 permits the longitudinal body of foam 104 to itself be
helically curved, such that the longitudinal body of foam 104 is
bent or curved into a different plane, off a central axis 402, and,
while deflected or bent, helically bound with the casing 108, such
that each successive section 114 of casing 108 is bound and a
constant radius is provided to result in the application of a
coiling from a casing 108 provided at the constant radius about
that central axis, as illustrated in FIG. 4. The packaging 100 may
therefore be directed and coiled in any direction--laterally,
vertically or in any combination thereof. Eliminating the
conventional stick format permits the storage and shipping of
expansion joint seal systems 102 of lengths substantially greater
than available in a stick form, potentially eliminates the need for
internal field splices, and permits conventional shipping. On the
job site, the coil 400 of the packaging 100 can be released by
cutting the casing 108, unrolling the coil 400, and opening the
packaging 100 and inserting the expansion joint seal system 102 in
the expansion joint. Cutting the packaging 100 to the appropriate
length using the distance indicators 146 permits the packaging 100
to be maintained as the coil 400 until needed. Alternatively, the
coil 400 may be constructed in a vertical plane, inducing the
deflection and associated coiling in a plane perpendicular to the
longitudinal and lateral axes.
[0037] Additional components may be incorporated into the expansion
joint seal system 102 and included in the coil 400. One such
component may include one or more longitudinal flexible members
bonded to the compressed longitudinal body of foam 104 at the
longitudinal body of foam top 154 opposite the longitudinal body of
foam bottom 156 and capable of transferring a load to the
compressed longitudinal body of foam 104, which would have
sufficient flexibility in the horizontal plane to permit the
coiling if desired. Another component may one or more membranes,
which may be permeable or impermeable, which may extend from one
side of the compressed longitudinal body of foam 104 to the other,
or some portion thereof, which may be in the horizontal plane and
which may permit coiling as well. Such membranes may be used to
provide an air barrier, vapor permeability, hydrostatic head
resistance, electromagnetic frequency/radio frequency interference
insulators, or other functions known for association with expansion
joint seal systems. Another component may be an elastomeric gland,
wherein the compressed longitudinal body of foam 104 may surround
the gland, be incorporated in it, or some combination thereof. The
packaging 100 provides the potential for lengths far in excess of
conventional lengths and, where the gland permits coiling of the
expansion joint seal system, the expansion joint seal system 102
may be coiled. Another component may be a combination of one or
more flexible members, one or more cover plates, and one or more
ribs, where the flexible member is attached to the cover plate and
to the rib, such that the ribs extends into the compressed
longitudinal body of foam 104. An increased number of cover plates,
functional as a series of overlapping shields, may permit the
expansion joint seal system 102 to be coiled vertically when
packaged and facilitates constant and equal compression throughout
the expansion joint seal system 102. Beneficially, the compressed
longitudinal body of foam 104 may be offset with respect to these
additional components, or extend past the end of the compressed
longitudinal body of foam 104, such that the additional component
provides a mating surface for another expansion joint seal system
100, to serve as a splice when desired. While a splice is ideally
avoided in a run of the expansion joint seal system 102 by the
present invention, should a second expansion joint seal system
intersect the first, such as in a T or angled joint, such
additional components may provide the splice.
[0038] Referring to FIG. 5, to further aid in installation,
internal tear strips 502 may be affixed to the casing 108 at
regular intervals associated with the circumference of the
expansion joint seal system 102 and any boards 118, 120, such that
the tear strips are commonly positioned along the length of the
packaging 100 and may tear the casing 108 for a desired distance,
such as in two-foot sections. Other tools may be used to separate
the casing, such as box knives, particularly those with depth
control and automatic retracing systems.
[0039] The expansion joint seal system 102 may be compressed prior
to or during the application of the casing 108. For example, the
expansion joint system 102 may be processed through one or more
sets of rollers, such as depicted in FIG. 6, wherein each roller
set 602, 604 provides an increased compression during which any
external layer 134 of water-resistant constituent 106 is applied by
an applicator 608, and after which the compressed longitudinal body
of foam 104 is subsequently maintained by a final roller set 606
until the application of the casing 108, which may be after the
imposition of the board 118, 120 about the expansion joint seal
system 102.
[0040] Alternatively, the boards 118, 320 may be applied to the
sides of the expansion joint seal system 102 prior to the
imposition of compression, such as by the rollers 602, 604 as
previously described, or by a lateral press 702 as illustrated in
FIG. 7. The boards 118, 120 may facilitate the compression in both
systems by resisting any problematic necking of the expansion joint
seal system 102 when passing between rollers 620, 604 or by
providing a working surface for the application of force by a
lateral press 702. The roller system 610 depicted in FIG. 6 permits
a longer run of the expansion joint seal system 102 as the board
118, 120 limit the length which can be readily transported in
packaging. The roller system 610 depicted in FIG. 6 facilitates the
forming of the coil 400 at the final set of rollers 606, such as by
a guide offsetting the expansion joint seal system 102 after exit
from the final set of rollers 606, or by one roller 606a, 606b of
the final set of rollers 606b introducing a greater amount of
compression on one side than the other.
[0041] Alternatively, the casing 108 may itself be applied to
introduce the compression of the longitudinal body of foam 104 in
the expansion joint seal system 102 during encirclement. The casing
108 therefore provides a packaging 100 which may be provided
without the structural support of boards 118, 120, which must be
disposed after unpackaging. The casing 108 may be tensioned, such
that once a first end of the casing 108 is affixed or bound to the
expansion joint seal system 102, the casing 108 under tension may
be wrapped about the expansion joint seal system 102, while the
expansion joint seal system 102 is maintained in position,
permitting the necessary amount of casing 108 to be released while
the supply of the casing 108 revolves about the expansion joint
seal system 102 or while the expansion joint seal system 102 is
rotated about a central axis. Where the first board 118 and the
second board 120 are used, the resultant compression would be
limited to lateral compression. Where the expansion joint seal
system 102 is directly encircled by the casing 108 with any board,
the expansion joint seal system 102 may be compressed laterally and
vertically (under compression between a longitudinal body of foam
top and a longitudinal body of foam bottom). Where the rate of
advance of the expansion joint seal system 102 is decreased
immediately prior to the encirclement by the casing 108, the
expansion joint seal system 102 may also be compressed
longitudinally. Alternatively, where the rate of advance of the
expansion joint seal system 102 is increased, the opposite
occurs.
[0042] Beneficially, the casing 108 may be used in connection with
expansion joint seal systems 102 which incorporate other components
beyond a longitudinal body of foam 104, such as one or more
membranes, such as disclosed in U.S. Pat. No. 9,803,357 and by U.S.
Patent Application Publication 2017-0159817, both by Schul
International Company, LLC, each of which teach a membrane
extending to or beyond the sides of the foam, which may therefore
be positioned against one or more of the external surfaces for
packaging. The casing 108 may thus contact the winged membranes or
extensions, which may serve as the bond breaker or support for the
now-compressed expansion joint seal systems 102, such that only the
wrapping material is required reducing weight and waste.
[0043] A second layer of casing 108 may be applied about some or
all of the expansion joint seat system 102 when encircled in the
casing 108 to provide a second compression ratio in the applied
area. When a second layer of casing 108 is used, the overlap may be
reduced to less than 15% and may be entirely eliminated.
[0044] The foregoing disclosure and description is illustrative and
explanatory thereof. Various changes in the details of the
illustrated construction may be made within the scope of the
appended claims departing from the spirit of the invention. The
present invention should only be limited by the following claims
and their legal equivalents.
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