U.S. patent application number 16/379238 was filed with the patent office on 2020-10-15 for composite joint seal.
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 | 20200325674 16/379238 |
Document ID | / |
Family ID | 1000005117843 |
Filed Date | 2020-10-15 |
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United States Patent
Application |
20200325674 |
Kind Code |
A1 |
Robinson; Steven R. |
October 15, 2020 |
Composite Joint Seal
Abstract
The present disclosure relates generally to systems for creating
a joint filler or seal in the gap between adjacent panels or
assemblies. The present disclosure is directed to providing an
expansion joint seal system which includes a foam associated with a
non-foam matrix.
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: |
1000005117843 |
Appl. No.: |
16/379238 |
Filed: |
April 9, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 15/02016 20130101;
E04B 1/61 20130101; E04B 2001/6818 20130101; E04B 1/948 20130101;
E04B 1/6801 20130101 |
International
Class: |
E04B 1/68 20060101
E04B001/68; E04B 1/94 20060101 E04B001/94; E04B 1/61 20060101
E04B001/61 |
Claims
1. An expansion joint seal comprising: an elastic and resilient
rectangular prism body having a rectangular prism body top surface,
a rectangular prism body bottom surface opposite the rectangular
prism body top surface, a rectangular prism height from the
rectangular prism body bottom surface to the rectangular prism body
top surface, a rectangular prism body first side surface, a
rectangular prism body second side surface opposite the rectangular
prism body first side surface, a rectangular prism body width from
the rectangular prism body second side surface to the rectangular
prism body first side surface, a rectangular prism body front
surface, a rectangular prism body rear surface opposite the
rectangular prism body front surface, a rectangular prism body
length from the rectangular prism body rear surface to the
rectangular prism body front surface, the rectangular prism body
having a plurality of prism members, each of the prism members
having a prism body length equal to the rectangular prism body
length, a prism body width less than the rectangular prism body
width; and a thin, flexible non-foam member intermediate each of
the plurality of nonrectangular prism members, the non-foam member
having a non-foam member length rectangular prism body, the
non-foam member adhered to each of the plurality of nonrectangular
prism members.
2. The expansion joint seal of claim 1, wherein one of the prism
members is not a rectangular prism.
3. The expansion joint seal of claim 1, wherein the non-foam member
has a non-foam member thickness not greater than 10 percent of the
rectangular prism body width.
4. The expansion joint seal of claim 1, wherein the non-foam member
is composed of material selected from the group consisting of a
permeable material, an impermeable material, a rubber material, a
hydrophilic, a hydrophobic material, a fire-retardant material.
5. The expansion joint seal of claim 1, wherein the plurality of
prism members includes a first triangular prism member and a second
triangular prism member.
6. The expansion joint seal of claim 5, wherein the plurality of
prism members includes a third prism member and the non-foam member
includes a v-shaped profile.
7. The expansion joint seal of claim 1, wherein the wherein the
plurality of prism members includes a first triangular prism member
and a second triangular prism member, and an irregular
quadrilateral polygonal prism member.
8. The expansion joint seal of claim 1, wherein the plurality of
prism members includes a quadrilateral prism member, a first
triangular prism member opposite the non-foam member from the
quadrilateral prism member, a second triangular prism member
opposite the non-foam member from the first triangular prism member
and opposite the non-foam member from the quadrilateral prism
member, a third triangular prism member opposite the non-foam
member from the first triangular prism member and opposite the
non-foam member from the quadrilateral prism member, a fourth
triangular prism member opposite the non-foam member from the
quadrilateral prism member, a fifth triangular prism member
opposite the non-foam member from the quadrilateral prism member,
and opposite the non-foam member from the fourth triangular prism
member, a sixth triangular prism member opposite the non-foam
member from the quadrilateral prism member, and opposite the
non-foam member from the fourth triangular prism member, and
opposite the non-foam member from the fifth triangular prism
member, and the non-foam member having a non-foam member internal
void at a center, two non-foam member legs at a non-foam member
first end and two non-foam member legs at a non-foam member second
end.
9. The expansion joint seal of claim 1, wherein a first prism
member of the plurality of prism members has a first prism member
density and a second prism member of the plurality of prism members
has a second prism member density, the first prism member density
and the second prism member density being unequal.
10. The expansion joint seal of claim 1, one of the plurality of
prism members having internal voids in communication with at least
one of a prism member first surface, a prism member second surface,
a prism member bottom surface, a prism member top surface, a prism
member front surface, and a prism member rear surface, at least one
quarter of the internal voids having a fire-retardant material
therein.
11. The expansion joint seal of claim 1, further comprising: a
packaging body, the packaging body having a packaging body length
from a packaging body front surface to a packaging body rear
surface, the packaging body length equal to the rectangular prism
body length, a packaging body having a packaging body height from a
packaging body top surface to a packaging body bottom surface, the
packaging body height equal to the rectangular prism height, a
packaging body first surface from the packaging body top surface to
the packaging body bottom surface and from the packaging body front
surface to the packaging body rear surface, the packaging body
first surface in contact with the rectangular prism body first side
surface.
12. The expansion joint seal of claim 1, wherein the non-foam
member has a spring force.
13. The expansion joint seal of claim 1, wherein the wherein the
plurality of prism members includes a first triangular prism
member, a second triangular prism member opposite the non-foam
member from the first triangular prism member, a third triangular
prism member opposite the non-foam member from the first triangular
prism member and opposite the on-foam member from the second
triangular prism member, a fourth triangular prism member opposite
the non-foam member from the second triangular prism member, a
fifth triangular prisms member opposite the non-foam member from
the quadrilateral prism member, and opposite the non-foam member
from the fourth triangular prism member, a sixth triangular prism
member opposite the non-foam member from the fourth triangular
prism member, and opposite the non-foam member from the filth
triangular prism member, and the non-foam member having a non-foam
member internal void at a center, two non-foam member legs at a
non-foam member first end and two non-foam member legs at a
non-foam member second end.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND
Field
[0003] The present disclosure relates generally to systems for
creating a joint filler or seal in the gap between adjacent panels
or assemblies. More particularly, the present disclosure is
directed to providing an expansion joint seal system which includes
a foam associated with a non-foam matrix.
Description of the Related Art
[0004] Construction panels and other assemblies come in many
different sizes and shapes and may be used for various purposes,
including curtain wall, aluminum and glass panels, roadways,
sideways, tunnels and other pre-cast structures. Because of the
effects of the co-efficient of thermal expansion between similar
and dissimilar materials, and external forces such as wind and
seismic movement, it is necessary to form a lateral gap or joint
between adjacent panels, buildings, or building sections to allow
for independent movement. These gaps are also used to permit
moisture to be collected and expelled. Cavity walls are common in
masonry construction, typically to allow for water or moisture to
condense or accumulate in the cavity or space between the two
exterior walls. Collecting and diverting moisture from the cavity
wall construction can be accomplished by numerous well-known
systems. The cavity wall is often ventilated, such as by brick
vents, to allow air flow into the cavity wall and to allow the
escape of moisture heat or humidity. In addition to thermal
movement or seismic joints in masonry walls, control joints are
often added to allow for the known dimensional changes in masonry
over time. Curtain wall or rain screen design is another common
form of exterior cladding similar to a masonry cavity wall. Curtain
walls can be designed to be primarily watertight but can also allow
for the collection and diversion of water to the exterior of the
structure. A cavity wall or curtain wall design cannot function as
intended if the water or moisture is allowed to accumulate or
condense in the cavity wall or behind a curtain wall or rain screen
design cannot be diverted or redirected back to the outside of the
wall. If moisture is not effectively removed it can cause damage
ranging from aesthetic in the form of white efflorescence buildup
on surface to mold and major structural damage from freeze/thaw
cycling.
[0005] Thus, expansion and movement joints are a necessary part of
all areas of construction. The size and location of the movement
depends on variables such as the amount of anticipated thermal
expansion, load deflection and any expected seismic activity. Joint
movement in a structure can be cyclical in design as in an
expansion joint or in as a control joint to allow for the shrinkage
of building components or structural settling. These movement
joints serve an important function by allowing a properly designed
structure to move and the joint to cycle over time and to allow for
the expected dimensional changes without damaging the structure.
Expansion, control and movement joints are found throughout a
structure from the roof to the basement, and in transitions between
horizontal and vertical planes. It is an important function of
these expansion joints to not only move as intended but to remain
in place through their useful lifespan. This is often accomplished
by extending the length and/or width of the expansion joint system
over or past the edge of the gap or joint opening to attach to the
joint substrate or another building component. Examples of building
components that would ideal to integrally join an expansion joint
with and seal would be, although not limited to, waterproofing
membranes, air barrier systems, roofing systems and transitions
requiring the watertight diversion of rain water. Although these
joints represent only a small percentage of the building surface
area and initial cost, they often account for a large percentage of
waterproofing, heat loss, moisture/mold problems and other serious
interior and exterior damage during the life of the building.
[0006] Conventional joint sealants like gunnable sealants and most
foam seals are designed to hold the water out of the structure or
expansion joint. However, water can penetrate the joint substrate
in many ways such as cracks, poor sealant installation, roofing
details and a porous substrate or wall component. When water or
moisture enters the wall the normal sealing function of joint
sealant may undesirably retain the moisture in the wall. Foam joint
seals known in the art typically rely on the application of an
elastomer sealant on the primary or exposed face of foam to provide
the water-resistant function. Such joint seals are not waterproof,
but retard the penetration of water into the joint by providing a
seal between adjacent substrates for a time and under a maximum
pressure. Particularly, such joint seals are not waterproof--they
do not preclude water penetration under all circumstances. While
this is helpful initially to keep water out of the joint and
structure it does not allow for this penetrating water or moisture
to escape.
[0007] Further complicating operation, some wall designs, such as
cavity walls, allow for moisture to enter a first wall layer where
it collects and is then directed to the outside of the building by
flashing and weep holes. In these systems, water can sometimes be
undesirably trapped in the cavity wall, such as at a mortar bridge
in the wall, or other impediment caused by poor flashing selection,
design or installation. When a cavity wall drainage system fails,
water is retained within the structure, leading to moisture
accumulating within in tire wall, and to an efflorescence buildup
on the exterior of the wall. This can also result in freeze-thaw
damage, among other known problems.
[0008] To be effective in this environment, fully functional,
foam-based joint seals require a minimum compression ratio. It is
known that higher densities and ratios can provide addition sealing
benefits. Cost, however, also tends to increase with overall
density. There is ultimately a trade-off between compression
ratio/density range and reasonable movement capabilities at about
750 kg/m.sup.3. As can be appreciated, this compressed density is a
product of the uncompressed density of the material and the desired
compression ratio to obtain other benefits, such as water
resistance. For example, a foam having an uncompressed density of
150 kg/m.sup.3 uncompressed and compressed at a 5:1 ratio results
in a compressed density of 750 kg/m.sup.3. Alternative uncompressed
densities and compression ratios may reach that compressed density
of 750 kg/m.sup.3 while producing different mechanical properties.
It has been long known in the art that a functional foam expansion
joint sealant can be constructed using a foam having an
impregnation which, when uncompressed, has a density range of about
80 kg/m.sup.3, which is used at a 5:1 compression ratio, resulting
in a compressed density of 400 kg/m.sup.3. Various impregnations
are known in the art, including binders, fillers, fire-retardant
impregnations, water retarding impregnations, and water reactive
impregnations. Alternatively, materials may be introduced by
infusion, being put into, or being included in foe foam. As a
further alternative, foe materials may be provided as a coating.
This functional foam expansion joint sealant is capable of
maintaining position within a joint and its profile, while
accommodating thermal and seismic cycling, while providing
effective sealing, resiliency and recovery. Such joint seals are
not fireproof, but retard the penetration of lire into foe joint by
providing a seal which protects the adjacent substrates or the base
of the joint for a time and under a maximum temperature.
Particularly, such joint seals are not fireproof--they do not
preclude the burning and decomposition of the foam when exposed to
flame.
[0009] Another alternative known in the art for increasing
performance is to provide a foam impregnated with a water-resistant
material at a density in the range of 120-160 kg/m.sup.3, ideally
at 150 kg/m.sup.3 for some products, with a mean joint size
compression ratio of about 3:1 with a compressed density in a range
of about 400-450 kg/m.sup.3, although densities in a broader range,
such as 45-710 kg/m.sup.3 uncompressed and installed densities,
after compression and installation in the joint of 45 kg/m.sup.3
and 1500 kg/m.sup.3 may also be used. These criteria ensure
excellent movement and cycling while providing for lire resistance
according to DIN 4112-2 F120, meeting the Conditions of Allowance
under UL 2079 for a two-hour endurance, for conventional depth,
without loading, with one or more movement classifications, for a
joint not greater than six inches and having a movement rating as
great as 100%, without a hose stream test, and an ASTM E-84 test
result with a Flame Spread of 0 and a Smoke Index of 5. This
density range is well known in the art, whether it is achieved by
lower impregnation density and higher foam compression or higher
impregnation density and a lower compression ratio, as the average
functional density required for an impregnated open cell foam to
provide sealing and other functional properties while allowing for
adequate joint movement up to +/-50% or greater. Foams having a
higher uncompressed density may be used in conjunction with a lower
compression ratio, but resiliency may be sacrificed. As the
compressed density increases, the foam tends to retard water more
effectively and provides an improved seal against the adjacent
substrates. Additives that increase the hydrophobic properties or
inexpensive fillers such as calcium carbonate, silica or alumina
hydroxide (ATH) provided in the foam can likewise be provided in a
greater density and become more effective. Combustion modified
foams such as a combustion modified flexible polyurethane foam,
combustion modified ether (CME) foam, combustion modified high
resilience (CMHR) foam or combustion modified Viscoelastic foam
(CMVE) can be utilized in the preferred embodiments to add
significant fire resistance to the impregnated foam seal or
expansion joint without adding additional fire-retardant additives.
Foam that is inherently fire resistant or is modified when it
manufactured to be combustion or fire-resistant reduces the cost of
adding and binding a fire retardant into the foam. This method has
been found to be advantageous in allowing fire resistance in foam
seals configured in very high compression ratios such 5:1 and
higher.
[0010] By selecting the appropriate additional component, the type
of foam, the uncompressed foam density and the compression ratio,
the majority of the cell network will be sufficiently closed to
impede the flow of water into or through the compressed foam seal
thereby acting like a closed cell foam. Beneficially, an
impregnated or infused open cell foam can be supplied to the end
user in a pre-compressed state in rolls/reels or sticks that allows
for an extended release time sufficient to install it into the
joint gap. To further the sealing operation, additional components
may be included. For example, additives may be fully or partially
impregnated, infused or otherwise introduced into die foam such
that at least some portion of the foam cells are effectively
closed, or a hydrophobic or water-resistant coating is applied.
However, foe availability of additional components may be
restricted by the type of foam selected. Closed cell foams which
are inherently impermeable for example, are often restricted to a
lower joint movement range such as +/-25% rather than the +/-50% of
open celled foams. Additionally, the use of closed cell foams
restricts the method by which any additive or fillers can be added
after manufacture. Functional features such as fire resistance to
the Cellulosic time-temperature curve for two hours or greater can
be however be achieved in a closed cell foam seal without impacting
the movement properties. Intumescent graphite powder added to a
polyethylene (PE), ethylene vinyl (EVA) acetate or other closed
cell foam during processing in a ratio of about 10% by weight has
been found to be a highly effective in providing flexible and
durable water-and-fire-resistant foam seal. While intumescent
graphite is preferred, other fire retardants added during the
manufacture of the closed cell foam are anticipated and the ratio
of known fire retardants, added to the formulation prior to
creating the closed cell foam, is dependent on the required lire
resistance and type of fire retardant. Open celled foams, however,
present difficulties in providing water-resistance and typically
require impregnation, infusion or other methods for introducing
functional additives into the foam. The thickness of a foam core or
sheet, its resiliency, and its porosity directly affect the extent
of diffusion of the additive throughout the foam. The thicker the
foam core or sheet, the lower its resiliency, and the lower its
porosity, the greater the difficulty in introducing the additive.
Moreover, even with each of these at optimum, the additive will
likely not be equally distributed throughout the foam, but will be
at increased density at the inner or outer portions depending on
the impregnation technique.
[0011] A known solution in tire art is the use of foam segments
bonded together laterally to provide a lamination. However, such
lateral laminations can separate from one another, creating
fissures and openings for contaminates. Moreover, because the
laminations are laterally positioned, the resulting pressure
exerted by the joint seal against, the adjacent substrates is a
function of the combined densities and thicknesses and is constant
at all heights of the substrate wall.
[0012] It is also known that the thin built-up lateral laminations
must be adhesively bonded to avoid separation, and therefore
failure, under thermal shock, rapid cycling or longitudinal shear.
Because of the cost to effectively bond the lateral laminations, a
cost/performance assessment sometimes produces laminations loosely
held together by the foam compression rather than by an adhesive.
While this is known in the art to be somewhat effective in low
performance applications and OHM assembly uses, it also known that
it cannot meet the demands of high movement seismic, shear,
deflection joints or where fail-safe performance is required. In
light of these issues, the preferred embodiment for a high movement
impregnated foam expansion joint has been found to instead be a
monolithic foam design comprised of a single impregnated foam core.
However, lamination systems may be desirable when the structure
includes a functional component between the laminations such as a
water-resistant membrane or a fire-resistant layer.
[0013] Construction of lamination systems have typically been
lateral composites considered undesirable or inferior for a high
movement or rapid cycling fire-resistant expansion joint sealant.
The higher compression ratios and greater volumes of fire-retardant
additives are likely to cause the foam to fatigue more rapidly and
to lose much of its internal recovery force. This proves
problematic over time due to the anticipated exposure to movement
and cycling as the impregnated foam will lend to lose its recovery
force and rely more on the push-pull connection to the joint
substrate. When foam laminations are vertically-oriented, the
laminations can de-bond or de-laminate and separate from one
another, leading to only the outer most lamination remaining
attached to the joint substrate, resulting in the laminated foam
joint sealant ceasing to provide either water, air or fire
resistance.
[0014] A known alternative or functional supplement to the use of
various impregnation densities and compression ratios is the
application of functional surface coatings such as water-resistant
elastomers or fire-resistant intumescents, so that the impregnated
foam merely serves as a "resilient backer". Almost any physical
property available in a sealant or coating can be added to an
already impregnated foam sealant layering the functional sealant or
coating material. Examples would include hut not limited to, fire
ratings, waterproofing, color, UV resistance, mold and mildew
resistance, soundproofing, impact resistance, load carrying
capacity, faster or slower expansion rates, insect resistance,
conductivity, chemical resistance, pick-resistance and others known
to those skilled in the art. For example, a sealant or coating
having a rating or listing for Underwriters Laboratories 2079 may
be applied to an impregnated compressed foam to create a
fire-resistant foam sealant.
[0015] One approach to addressing the shortcomings has been the
creation of composite materials, where the loam core--whether solid
or composed of laminations of the same or differing
compositions--is coated or surface impregnated with a functional
layer, so that the foam is merely a resilient backer for the
sealant, intumescent or coating, such that the composition and
density become less important. These coatings, and the associated
properties, may be adhered to the surface of each layer of a core
or layered thereon to provide multiple functional properties. As
can be appreciated, the composite material may have different
coatings applied the different sides to provide desired property or
properties consistent with its position. Functional coatings such
as a water-resistant sealant can protect the foam core from
absorbing moisture even if the foam or foam impregnation is
hydrophilic. Similarly, a functional coating such as a fire-rated
sealant added to the foam core or lamination with protect a foam or
foam impregnation that is flammable. A biocide may even be
included. This could be layered, or on opposing surfaces, or--in
the case of a laminate body--on perpendicular surfaces.
[0016] Additionally, it has become desirable, and in some
situations required, for the joint sealant system to provide not
only water resistance, but also fire resistance. A high degree of
fire resistance in foams and impregnated foam sealants is well
known in the art and has been a building code requirement for foam
expansion joints in Europe for more than a decade. Fire ratings
such as UL 2079, DIN 4112-2, BS 476. EN1399, AS1503.4 have been
used to assess performance of expansion joint seals, as have other
fire resistance tests and building codes and as the basis for
further tire resistance assessments, the DIN 4112 standard, for
example, is incorporated into the DIN 18542 standard for "Sealing
of outside wall joints with impregnated sealing tapes made of
cellular plastics--Impregnated sealing tapes". While each testing
regime utilizes its own requirements for specimen preparation and
tests (water test, hose stream tests, cycling tests), the 2008
version of UL 2079, the ISO 834, BS 476: Part 20, DIN 4112, and AS
1530.4-2005 use the Cellulosic time/temperature curve, based on the
burning rate of materials found in general building materials and
contents, which can be described by the equation
T=20+345*LOG(8*t+1), where t is time in minutes and T is
temperature in C While differing somewhat, each of these testing
regimes addresses cycling and water resistance, as these are
inherent in a fire-resistant expansion joint. The tire resistance
of a foam sealant or expansion has been sometimes partially or
fully met by infusing, impregnating or otherwise putting into the
foam a liquid-based tire retardant, such as aluminum tri-hydrate or
other tire retardants commonly used to add fire resistance to foam.
Unfortunately, this increases weight, alters the foam's
compressibility, and may not provide the desired result without
additional fire-resistant coatings or additives if a binder, such
as acrylic or polyurethane, is selected to treat the foam for fire
and water resistance. Doing so while maintaining movement
properties may affect the foam's compressibility at densities
greater than 750 kg/m.sup.3. Ultimately, these specialty
impregnates and infused compositions increase product cost.
[0017] It has further become desirable or functionally required to
apply a fire-resistant coating to the foam joint systems to
increase fire and water resistance, but often at tire sacrifice of
movement Historically, fire-resistant foam sealant products that
use an additional fire-resistant surface coating to obtain the life
safely fire properties have been limited to only +/-25% movement
capability, especially when required to meet longer
time-temperature requirements such as UL2079'S 2 hour or longer
testing. This +/-25% movement range is too limited for most
movement joints and would not meet most seismic movement and
expansion joint requirements. One well-known method for utilizing
these low movement fire-resistant joint sealants is to increase the
width or size of the joint opening, an undesirable and expensive
alternative, to allow for a commonly required +/-50% joint movement
rating.
[0018] It would be an improvement to the art to provide an
expansion joint seal which provides full or variable levels of
resistance to water, air, sound, impact and potentially to flame,
retains compressibility over time, provided separate body members
which may provide different or a combination of properties and
which each maintain a density value across the joint, and which may
only optionally include impregnating, infusing or compression
forcing a large amount of solid fillers into the foam
structure.
SUMMARY
[0019] The present disclosure therefore meets the above needs and
overcomes one or more deficiencies in the prior art. The disclosure
provides an expansion joint seal with an elastic and resilient
rectangular prism body and a thin, flexible non-foam member. The
elastic and resilient rectangular prism body has a rectangular
prism body top surface, a rectangular prism body bottom surface
opposite the rectangular prism body top surface, a rectangular
prism height from the rectangular prism body bottom surface to foe
rectangular prism body top surface, a rectangular prism body first
side surface, a rectangular prism body second side surface opposite
the rectangular prism body first side surface, a rectangular prism
body width from the rectangular prism body second side surface to
the rectangular prism body first side surface, a rectangular prism
body front surface, a rectangular prism body rear surface opposite
the rectangular prism body front surface, and a rectangular prism
body length from the rectangular prism body rear surface to the
rectangular prism body front surface. The rectangular prism body
may have a plurality of prism members where each of the prism
members may have a prism body length equal to the rectangular prism
body length, a prism body width less than the rectangular prism
body width, and a thin, flexible non-foam member intermediate each
of the plurality of nonrectangular prism members. The non-foam
member may have a non-foam member length rectangular prism body,
the non-foam member adhered to each of the plurality of
nonrectangular prism members. The thin, flexible non-foam member is
intermediate each of the plurality of nonrectangular prism
members.
[0020] 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
[0021] 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 part 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.
[0022] In the drawings:
[0023] FIG. 1 illustrates an end view of a joint seal system
according to the present disclosure.
[0024] FIG. 2 illustrates an end view of an alternative joint seal
system according to the present disclosure with packaging body,
[0025] FIG. 3 illustrates an end view of another alternative joint
seal system according to the present disclosure.
[0026] FIG. 4 illustrates a packaging body according to the present
disclosure.
[0027] FIG. 5 illustrates an isometric view of the expansion joint
seal from the tear and side according to the present
disclosure.
DETAILED DESCRIPTION
[0028] The present disclosure provides an expansion joint system.
As can be appreciated, sealants, coatings, functional membranes,
adhesives and other functional materials may be applied to or
included within the components of the disclosure.
[0029] Referring to FIG. 1, an illustration is provided of an end
view of a joint seal system according to the present disclosure.
The expansion joint seal 100 includes an elastic and resilient,
rectangular prism body 102 which may have a plurality of prism
members 114, 116, 118, and a thin, flexible non-foam member 124
intermediate each of the plurality of nonrectangular prism members
114, 116, 118.
[0030] The rectangular prism body 102 has a height, width and
length. The rectangular prism body 102 has a rectangular prism body
top surface 104, a rectangular prism body bottom surface 106
opposite the rectangular prism body top surface 104, and a
rectangular prism height 120 from the rectangular prism body bottom
surface 106 to the rectangular prism body top surface 104. The
rectangular prism body 102 further has a rectangular prism body
first side surface 108, a rectangular prism body second side
surface 110 opposite the rectangular prism body first side surface
108, and a rectangular prism body width 122 from the rectangular
prism body second side surface 110 to the rectangular prism body
first side surface 108. Referring to Fig. and to FIG. 5, an
isometric illustration of the expansion joint seal 100 from the
rear and side, the rectangular prism body 102 also has a
rectangular prism body front surface 112, a rectangular prism body
rear surface 512 opposite the rectangular prism body front surface
112, and a rectangular prism body length 522 from the rectangular
prism body rear surface 512 to the rectangular prism body front
surface 112.
[0031] Similarly, each of the prism members 114, 116, 118 has a
length, width and height, constrained by inclusion in the
rectangular prism body 102. The prism members may be of any shape
and may be a rectangular prism. Referring to FIG. 1, the plurality
of prism members 114, 116, 118 includes a first triangular prism
member 114, a second triangular prism member 116 and a third prism
member 118. The prism members 114, 116, 118 fit to the non-foam
member 124 and may have a v-shaped profile to form the rectangular
prism body 102. Each of the prism members 114, 116, 118 has a prism
body length 524 equal to rectangular prism body length 522, a prism
body width less than the rectangular prism body width 122, the
non-foam member 124 may have a non-foam member length rectangular
prism body, the non-foam member 124 adhered to each of the
plurality of nonrectangular prism members 114, 116, 118.
[0032] The prism members 114, 116, 118 may be a foam member or may
be a non-foam material which exhibits similar properties of
compressibility, expansion, resiliency, and to support liquid-based
additives, such a fire retardants and fillers, each of which may
have its own spring force. This may be a foam, a corn starch-based
material, cellulose or other compressible material. Each prism
member should preferably be composed of an elastically
compressible, though materials which are not elastic and/or not
compressible may be used. Each of the prism members 114, 116, 118
has body specific properties, including density and spring force,
which may be common or dissimilar. Each of the prism members 114,
116, 118 may have common or dissimilar or unequal properties which
affect sound damping, including cell size, tortuosity, and
porosity. Similarly, each prism member has a density, where the
prism member densities may be unequal.
[0033] One or more of the prism members 114, 116, 118 may have one
or more internal voids in communication with at least one of a
prism member first surface, a prism member second surface, a prism
member bottom surface, a prism member top surface, a prism member
front surface, and a prism member rear surface, where at least one
quarter of the internal voids have a fire-retardant material
therein.
[0034] The intended compression, a reduction in a width, of a prism
member 114, 116, 118 may be coupled with the spring force of that
particular core body and the thickness of that body to provide a
force to be applied by that body to packaging for shipment and to
substrates after installation. The resulting force by each of the
prism members 114, 116, 118 may be equal, nearly equal or of
different values as desired.
[0035] The expansion joint seal 100 may be provided with end
profiles intended to provide interlocking faces so a plurality of
expansion joint seal 100 may be installed in abutment.
[0036] The expansion joint seal 100 includes rectangular prism body
front surface 112 which may have a joint first end profile and a
rectangular prism body rear surface 512 which may have a joint seal
second end profile, where die joint seal first end profile and the
joint seal second end profile are complementary, such as where one
of the prism members 114, 116, 118 is offset from the others, and
thereby provides a key which interlocks with the adjacent expansion
joint seal 100. Alternatively, the joint seal first end profile may
be aFlatt end.
[0037] The thin, flexible non-foam member 124 may be composed of
any non-foam material including plastics, rubber, and similar
materials which provide resiliency, structural support, and
flexibility, and therefore may have its own spring force. The thin,
flexible non-foam member 124 may be constructed in any shape, but
preferably so the thin, flexible non-foam member 124 extends from
the rectangular prism body first side surface 108 to, the
rectangular prism body second side surface 110 with a deflection or
change of direction within to facilitate a change in shape as the
extent of compression of the expansion joint seal 100 by the
adjacent substrates changes. As illustrated in FIG. 1, the thin,
flexible non-foam member 124 may be a simple vee shape, oriented
downward, but may also be oriented upwards.
[0038] The non-foam member 124 may have a non-foam member thickness
not greater than 10 percent of the rectangular prism body width.
The non-foam member 124 is composed of a material selected from the
group consisting of a permeable material, an impermeable material,
a rubber material, a hydrophilic material, a hydrophobic material,
a fire-retardant material.
[0039] A first fire-retardant coating 130 may be applied adjacent
the rectangular prism body top surface 104. The first
fire-retardant coating 330 is selected to provide a substance that
slows the spread of fire. The first fire-retardant coating 130 may
undergo chemical reaction when heated to reduce flammability or
delay combustion or cool through physical action or endothermic
reactions, the first fire-retardant coating 130 may provide
retardancy through endothermic degradation, such as by use of
aluminum hydroxide. The first fire-retardant coating 130 may
provide retardancy through thermal shielding, such as by use of an
intumescent, which chars over when burned, separating the flame
from the material and slowing heat transfer. The first
fire-retardant coating 130 may provide retardancy by gas phase
radical quenching, such as when chlorinated paraffin undergoes
thermal degradation and releases hydrogen chloride to lower
potential propagation of combustion reactions. The first
fire-retardant coating 130 may extend to one or more of the
rectangular prism body first side surface 108, the rectangular
prism body second side surface 110, the rectangular prism body
front surface 112, and die rectangular prism body rear surface
512.
[0040] Referring to FIG. 2, an illustration is provided of an end
view of an alternative joint seal system according to the present
disclosure with packaging body. The thin, flexible non-foam member
232 may include one or more extensions 228 and need not be a single
vee shape. The extension 228 provides a knee or other capturing
shape for one of the prism members 214, 216, 218. The plurality of
prism members includes a first triangular prism member 214 and a
second triangular prism member 216, and an irregular quadrilateral
polygonal prism member 218. A packaging body 220 may be included
with the expansion joint seal 100, such as against the rectangular
prism body first side surface 108 and/or the rectangular prism body
second side surface 110. Referring to Fig. and to FIG. 4, an
isometric illustration of a packaging body according to the present
disclosure, the packaging body 220 may have a packaging body length
402 and a packaging body height 404. The packaging body 220 may
have a packaging body length 402 from a packaging body front
surface 222 to a packaging body rear surface 406, the packaging
body length 402 equal to the first body length 522. The packaging
body 220 may have a packaging body height 404 from a packaging body
top surface 224 to a packaging body bottom surface 226, the
packaging body height 404 equal to the first body height 120. The
packaging body may have a packaging body first surface 408 from the
packaging body top surface 224 to the packaging body bottom surface
226 and from the packaging body front surface 222 to the packaging
body rear surface 406, the packaging body first surface 408 in
contact with the rectangular prism body first side surface 10.
[0041] The packaging body 220 may be adhered to the rectangular
prism body 102 and the thin, flexible non-foam member 232 or may be
resistant to any adhesive on the rectangular prism body 102. The
packaging body 220 may be provided with a surface the prism members
214, 216, 218 and the thin, flexible non-foam member 232 which
deters adhesion to facilitate later removal from the packaging for
installation between substrates.
[0042] The expansion joint seal 100 is provided in pre-compressed
form for installation. The packaging body 220, the rectangular
prism body 102 and the thin, flexible non-foam member 232 are
subjected to laterally compression, such that the rectangular prism
body width 122 is reduced. The expansion joint seal 100 is then
packaged, such as m shrink wrap, to remain in compression. The
packaging body 220 provides a rigid surface against which the the
rectangular prism body 102 is maintained in compression. Prior to
compression, the rectangular prism body 102 is wider than the
nominal size of the expansion joint. After the expansion joint seal
100 is removed from packaging and separated from the packaging body
220, it Is imposed between the first substrate and the second
substrate before the rectangular prism body 102 relaxes to a width
greater than the expansion joint. The rectangular prism body 102
continues to relax and contacts the substrate walls and is
maintained in compression in the joint, and, by virtue of its
nature, inhibits the transmission of water or other contaminants
further into the expansion joint. The rectangular prism body 102
may be adhered to the substrate walls by an adhesive on the sides
of the core bodies. Thus, the joint system may include the first
substrate and the second substrate.
[0043] Because the rectangular prism body 102 is in compression
between the substrates of an expansion joint, it is well-known to
pre-compress the rectangular prism body 102 at the factory and
provide the rectangular prism body 102 in compression.
[0044] When desired, a second packaging body 230, sized the same or
similar to the first packaging body 220 may be used, and may
provide benefit in compression and packaging of the joint seal 101.
The second packaging body 230 abuts the rectangular prism body 102
at the rectangular prism body second side surface 110. The second
packaging body 230 may be provided with a surface facing the
rectangular prism body 102 which deters adhesion to facilitate
later removal from the packaging for installation between
substrate.
[0045] Referring to FIG. 3, an end view of another alternative
joint seal system according to the present disclosure is
illustrated. When desired, the thin, flexible non-foam member 326
may include one or more internal openings, m which a prism member
may be imposed, and may include a number of triangular openings in
which prism members may be imposed. Alternatively, any shapes may
be provided, including polygons, cylindrical sections and even
conic sections. As illustrated in FIG. 3, the plurality of prism
members includes a quadrilateral prism member 324, a first
triangular prism member 312 opposite the non-foam member 326 from
the quadrilateral prism member 324, a second triangular prism
member 314 opposite the non-foam member 326 from the first
triangular prism member 212 and opposite the non-foam member 326
from the quadrilateral prism member 324, a third triangular prism
member 316 opposite the non-foam member 326 from the first
triangular prism member 212 and opposite the non-foam member 326
from the quadrilateral prism member 324, a fourth triangular prism
member 318 opposite the non-foam member 326 from the quadrilateral
prism member 324, a fifth triangular prism member 320 opposite the
non-foam member 326 from the quadrilateral prism member 324, and
opposite the non-foam member 326 from the fourth triangular prism
member 318, a sixth triangular prism member 322 opposite the
non-foam member 326 from the quadrilateral prism member 324, and
opposite the non-foam member 326 from the fourth triangular prism
member 318, and opposite the non-foam member 326 from the fifth
triangular prism member 320, and the non-foam member 326 may have a
non-foam member internal void at a center, two non-foam member legs
at a non-foam member first end and two non-foam member legs at a
non-foam member second end.
[0046] Alternatively, one or more openings in the non-foam member
326 may remain open. When desired, the expansion joint seal 100
includes a first triangular prism member 312, a second triangular
prism member 314 opposite the non-foam member 326 from the first
triangular prism member 212, a third triangular prism member 316
opposite the non-foam member 326 from the first triangular prism
member 212 and opposite the non-foam member 326 from the second
triangular prism member 314, a fourth triangular prism member 318
opposite the non-foam member 326 from the second triangular prism
member 314, a fifth triangular prism member 320 opposite the
non-foam member 326 from the quadrilateral prism member 324, and
opposite the non-foam member 326 from the fourth triangular prism
member 318, a sixth triangular prism member 322 opposite the
non-foam member 326 from the fourth triangular prism member 318,
and opposite the non-foam member 326 from the fifth triangular
prism member 320, and the non-foam member 326 may have a non-foam
member internal void at a center, two non-foam member legs at a
non-foam member first end and two non-foam member legs at a
non-foam member second end.
[0047] When the prism members 114, 116, 118, 214, 216, 218, 312,
314, 318, 320, 322, 324 are constructed of foam, any of various
types of foam known in the art may be used, including compositions
such as polyurethane and polystyrene, and may be open or closed
cell. The uncompressed density of a prism member 114, 116, 118,
214, 216, 218, 312, 314, 318, 320, 322, 324 may also be altered for
performance, depending on local weather conditions. The composition
of each prism member 114, 116, 118, 214, 216, 218, 312, 314, 318,
320, 322, 324 need not be identical to another. A prism member 114,
116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324, for example,
may be selected of a composition which is fire retardant or
water-resistant. Moreover, when the prism members 114, 116, 118,
214, 216, 218, 312, 314, 318, 320, 322, 324 are constructed of
foam(s), these may be any of an open cell foam, a lamination of
open cell foam and dosed cell foam, and closed cell foam. Further
any of the prism members 114, 116, 118, 214, 216, 218, 312, 314,
318, 320, 322, 324 may have a treatment such as impregnation, to
increase desirable properties, such as fire resistance or water
resistance, by, respectively, the introduction of a fire retardant
into the foam or the introduction of a water inhibitor into the
foam. Additionally, any of the prism members 114, 116, 118, 214,
216, 218, 312, 314, 318, 320, 322, 324 may fee composed of or may
include a hydrophilic material, a hydrophobic material, a
fire-retardant material, or a sintering material.
[0048] Moreover, the material for the prism members 114, 116, 118,
214, 216, 218, 312, 314, 318, 320, 322, 324 may be selected from
partially closed cell or viscoelastic foams. Most prior art foams
seals have been designed as "soft foam" pre-compressed foam seals
utilizing low to medium density foam (about 16-30 kg/m.sup.3) and
softer foam (ILD range of about 10-20). It has been surprisingly
found through extensive testing of variations of foam densities and
foam hardness, fillers and elastic impregnation compounds that
higher density "hard" foams with high ILD's can provide an
effective foam seat meeting the required waterproofing (600 Pa
minimum and ideally 1000 Pa or greater) and movement and cycling
requirements such as ASTM E-1399 Standard Test Method for Cyclic
Movement and Measuring the Minimum and Maximum Joint Widths of
Architectural Joint Systems as well as long term joint cycling
testing. An advantage has been found in using higher density and
higher hardness (higher ILD) foams particularly in horizontal
applications. While at first this might seem obvious it is known in
the art that higher density foams that are about 32-50 kg/m.sup.3
with an ILD rating of about 40 and greater tend to have other
undesirable properties such as a long term decrease in fatigue
resistance. Desirable properties such as elongation, ability to
resist compression set, foam resiliency and fatigue resistance
typically decline relative to an increase in density and ILD. These
undesirable characteristics are often more pronounced when tillers
such as calcium carbonate, melamine and others are utilized to
increase the foam density yet the cost advantage of the filled foam
is beneficial and desirable. Similarly, when graft polyols are used
in the manufacture of the base foam to increase the hardness or
load carrying capabilities, other desirable characteristics of the
base foam such as resiliency and resistance to compression set can
be diminished. Through the testing of non-conventional impregnation
binders and elastomers for pre-compressed foam sealants such as
silicones, urethanes, polyureas, epoxies, and the like, it has been
found that materials that have reduced tack or adhesive properties
after cure and which provide a high internal recovery force can be
used to counteract the long term fatigue resistance of the high
density, high ILD foams. Further, it has been found that by first
impregnating and curing the foam with the injected or impregnated
silicone, acrylic, urethane or other low tack polymers and,
ideally, elastomers with about 100-200% elongation or greater
providing a sufficient internal recovery force, that it was
additionally advantageous to re-impregnate the foam with another
elastomer or binder to provide a timed expansion recovery at
specific temperatures. The impregnation materials with higher
long-term recovery capabilities imparted to the high density, high
ILD base foams, such as a silicone or urethane elastomers, can be
used to impart color to the foam seal or be a clear or translucent
color to retain the base foam color. If desirable a second
impregnation, partial impregnation or coating can be applied to or
into the foam seal, to add additional functional characteristics
such as UV stability, mold and mildew resistance, color,
fire-resistance or fire-ratings or other properties deemed
desirable to functionality to the foam.
[0049] Viscoelastic foams have not typically been commercially
available or used for foam seals due to perceived shortcomings.
Commonly used formulations, ratios and methods do not provide a
commercially viable foam seal using viscoelastic foam when compared
to standard polyurethane foams. Open cell viscoelastic foams are
more expensive than polyester or polyether polyurethane foams
commonly used in foam seals. Any impregnation process on a
viscoelastic foam tends to proceed slower than ort a traditional
foam due to the fine cell structure of viscoelastic foam. This can
be particularly frustrating as the impregnation materials and the
impregnation process are typically the most expensive component of
a foam seal. However, because of their higher initial density
viscoelastic foams can provide better load carrying or pressure
resistant foam seal. Roth properties are desirable but not fully
provided for in the current art for use in applications such as
load carrying horizontal joints or expansion joints for secondary
containment. Common densities found in viscoelastic foams are 64-80
kg/m.sup.3 or greater. Additionally, viscoelastic foams have four
functional properties (density, ILD rating, temperature and time)
compared to flexible polyurethane foams, which have two primary
properties (density and an ILD rating).
[0050] However, the speed of recovery of viscoelastic foams
following compression may be increased by reducing or eliminating
any impregnation, surface impregnation or low adhesive strength
impregnation compound. Incorporating fillers into the impregnation
compound is known to be effective in controlling the adhesive
strength of the impregnation binder and therefore the re-expansion
rate of the impregnated foam. By surface impregnating or coating
the outside surface of one or both sides of viscoelastic foam to
approximately 10% of the foam thickness, such as about 3-8 mm deep
for conventional joint seals, the release time can be controlled
and predicted based on ambient temperature. Alternatively, the foam
can be infused, partially impregnated or impregnated with a
functional or non-functional filler without a using binder but
rather only a solvent or water as the impregnation carrier where
the carrier evaporates leaving only the filler in the foam.
[0051] The re-expansion rate of a seal using viscoelastic foam may
be controlled by using un-impregnated viscoelastic foam strips and
re-adhering them with a pressure sensitive adhesive or hot melt
adhesive. When the seal is compressed, the laminating adhesive
serves as a temporary restriction to re-expansion allowing time to
install the foam seal. Viscoelastic foam may be advantageously
used, rather than standard polyurethane foam, for joints requiring
additional softness and flexibility due to higher foam seal
compression in hot climates or exposure or increased stiffness in
cold temperatures when a foam seal is at its minimum compressed
density. Additionally, closed cell, partially closed cell and other
foams can be used as in combination with the viscoelastic foams to
reduce the overall cost.
[0052] This second group of body materials, the non-foam members,
may include, for example, corrugated cardboards, natural and
man-made batting materials, and natural, synthetic and man-made
sponge material. When desired, such materials may be selected for
properties, such as water leakage, air leakage, resilience in face
of one or more cycling regimes, compressibility, relaxation rate,
compression set, and elasticity.
[0053] The material for one or more of the prism members 114, 116,
118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may be altered to
provide additional functional characteristics. It may be infused,
impregnated, partially impregnated or coated with an impregnation
material or binder that is designed specifically to provide state
of the art seal water-resistance properties with a uniform and
consistent, distribution of the waterproofing binder. One or more
of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318,
320, 322, 324 may also, or alternatively, be infused or impregnated
or otherwise altered to retain a fire retardant, dependent on
function. Where the any of the prism members 114, 116, 118, 214,
216, 218, 312, 314, 318, 320, 322, 324 is foam, any suitable open
cell foam type with a density of 16-45 kg/m.sup.5 or higher can
provide an effective water-resistant foam-based seal by varying the
impregnation density or the final compression ratio. Where a sound
resistant seal is desired, the density or the variable densities
provide a sound resistant seal in a similarly-rated wall from a
Sound Transmission Class value from 42-63 and/or a sound reduction
between 12 and 50 decibels.
[0054] One or more of the prism members 114, 116, 118, 214, 216,
218, 312, 314, 318, 320, 322, 324 may be selected from an
inherently hydrophilic material or have a hydrophilic component
such as a hydrophilic polymer that is uniformly distributed
throughout One or more of the prism members 114, 116, 118, 214,
216, 218, 312, 314, 318, 320, 322, 324 are constructed of foam may
include strategically-placed surface impregnation or partially
impregnate with a hydroactive polymer. Because the primary function
of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318,
320, 322, 324 is waterproofing, the addition of a hydrophilic
function does not negatively impact any desired fire-resistant
properties, as an increased moisture content, in any of the prism
members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324
are constructed of foam may increase fire resistive properties.
[0055] One or more of the prism members 114, 116, 118, 214, 216,
218, 312, 314, 318, 320, 322, 324 could be formed of commercially
available vapor permeable foam products or by forming specialty
foams. Commercial available products which provide vapor permeable
and excellent fire-resistant properties are well known, such as
Sealtite VP or Willseal 600. It is well known that a vapor
permeable but water-resistant foam joint sealant may be produced
leaving at least a portion of the cell structure open while in
compression such that water vapor can escape through the
impregnated foam sealant. Water is then ejected on the exterior of
the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320,
322, 324 because the foam, and/or any impregnation, is hydrophobic
and therefore repels water. Water can escape from the foam sealant
or wall cavity through water vapor pressure by virtue of the
difference in humidity creating unequal pressure between the two
areas. Because live cell structure is still partially open the
vapor pressure drive is sufficient to allow moisture to return to
equalization or the exterior of the structure. By a combination of
compression ratio and impregnation density of a hydrophobic
component the water resistance capacity can be increased to provide
resistance to various levels of pressure or driving rain.
[0056] One or more of the prism members 114, 116, 118, 214, 216,
218, 312, 314, 318, 320, 322, 324 may include an impregnate, such
as a fire retardant such as aluminum trihydroxide, which may be
throughout its entirety or for a desired depth from the surface.
Additional function properties can be added by surface impregnating
the exposed or outside surfaces of the foam as well as the inside
portion if additional properties axe desirable.
[0057] Beneficially, where fire retardancy is provided by first
fire-retardant coating 130 and/or non-foam member 124, 232, 326,
the present disclosure provides for an expansion joint sealant
without the need to impregnate one or all of the prism members 114,
116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 with a fire
retardan.
[0058] An adhesive may be applied to the rectangular prism body
first side surface 108 and/or rectangular prism body second side
surface 110.
[0059] The one or all of the prism members 114, 116, 118, 214, 216,
218, 312, 314, 318, 320, 322, 324 may contain, such as by
impregnation or infusion, a sintering material, wherein the
particles in the impregnate move past one another with minimal
effort at ambient temperature but form a solid upon heating. Once
such sintering material is clay or a nano-clay. Such a sintering
impregnate would provide an increased overall insulation value and
permit a lower density at installation than conventional foams
while still having a fire endurance capacity of at least one hour,
such as in connection with the UL2079 standard for horizontal and
vertical joints. While the cell structure, particularly, but not
solely, when compressed, of one or all of the prism members 114,
116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 preferably
inhibits the flow of water, the presence of an inhibitant or a fire
retardant may prove additionally beneficial. The fire retardant may
be introduced as part of the foaming process, or by impregnating,
coating, infusing, or laminating, or by other processes known in
the art.
[0060] The expansion joint seal 100 may further include an
insulating layer 132, such as a silicate, atop the first
fire-retardant coating 130 to add a refractory of insulating
function. However, such a layer, unless otherwise selected, would
not be a fire-retardant liquid glass formulation.
[0061] The exposed top surface may be coated or partially coated
with a flexible or semi-rigid elastomer to increase load carrying
capability which is further enhanced by the supporting intumescent
members. These, or other coatings, may be used to provide
waterproofing, fire resistance, or additional functional
benefits.
[0062] Other variations may be employed. Referring to FIG. 3, the
present disclosure may further incorporate a membrane 330, such as
vapor impermeable layer, for further benefits. The membrane 330 may
be positioned at the top or bottom surface of the rectangular prism
body 102 are not susceptible to contaminants and therefore continue
to function. As one or more prism members 114, 116, 118, 214, 216,
218, 312, 314, 318, 320, 322, 324 may be composed of a vapor
permeable foam, such a composition becomes particularly beneficial
when a barrier or membrane 330 is present. The membrane 330 may
thus may retain and then expel moisture, preventing moisture from
penetrating in an adjacent substrate. As can be appreciated, to be
effective, the membrane 330 is preferably sized to be no smaller in
any dimension than the adjacent core body. Alternatively, the
membrane 330 may extend beyond the core bodies to provide a surface
which may contact an adjacent substrate and even overlap its top.
The membrane 330 may be intumescent or may otherwise provide fire
retardancy in the expansion joint seal 100. Consistent with uses
known in the art, the present disclosure may be associated with a
central non-conductive spine and cover plate assembly for those
uses wherein high traffic is anticipated, as well as for compliance
with Department of Transportation requirements. The present
invention may be adapted for use with other expansion joint
systems, such those that incorporate a rib or spline within or
connection to a body such as core bodies and attached or
associated, permanently or detachably with a co ver plate.
[0063] The expansion joint seal 100 may be constructed to withstand
a hydrostatic pressure equal to or greater than 29.39 psi.
Environmentally friendly foam, fillers, binders, elastomer and
other components may be selected to meet environmental, green and
energy efficiency standards. One or more of the prism members 114,
116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may exhibit
auxetic properties to provide support or stability for the
expansion joint seal 100 as it thermally cycles or to provide
additional transfer loading capacity. Auxetic properties may be
provided by the body material, the internal components such as the
members/membrane or by an external mechanical mechanism. One or
more of prism members 114, 116, 118, 214, 216, 218, 312, 314, 318,
320, 322, 324 may have a rigid or semi-rigid central core equal to
5-65% of rectangular prism body width 122. One or more of the prism
members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324
may have a central core rigid through normal joint cycling,
typically +/-25%, but collapsible under seismic (+/-50%) joint
cycling. One or more of the prism members 114, 116, 118, 214, 216,
218, 312, 314, 318, 320, 322, 324 may have a central core both
rigid and collapsible and coupled with a data feedback system where
sensors collect data and supplies information to be stored
internally or externally.
[0064] Additionally, when desired, a sensor 332 may be included and
may contact one of more of the component of the expansion joint
seal 100. The sensor may be a radio frequency identification device
(RFID), transponder, or other wirelessly transmitting sensor. A
sensor may be beneficial to assess the health of an expansion joint
seal 100 without accessing the interior of the expansion joint,
otherwise accomplished by removal of the cover plate. It may
identify when a failure occurs and thus provide an integral failure
detection system. The failure detection system may be continuously
or intermittently monitored and may provide feedback by powered,
radio or inductive methods which may have an active or passive
feedback system. It may alternatively provide environmental data,
including air or water contamination. Such sensors are known m the
art, and which may provide identification of circumstances such as
moisture penetration and accumulation. The inclusion of a sensor in
the expansion joint seal 100 may be particularly advantageous in
circumstances where the expansion joint seal 100 is concealed after
installation, particularly as moisture sources and penetration may
not be visually detected. Thus, by including a low cost,
moisture-activated or sensitive sensor at the rectangular prism
body bottom surface 106, the user can scan the expansion joint seal
100 for any points of weakness due to water penetration. A heat
sensitive sensor may also be positioned within the expansion joint
seal 100, thus permitting identification of actual internal
temperature, or identification of temperature conditions requiring
attention, such as increased temperature due to the presence of
fire, external to the joint or even behind it, such as within a
wall. Such data may be particularly beneficial in roof and below
grade installations where water penetration is to be detected as
soon as possible.
[0065] Inclusion of a sensor in rectangular prism body 102 may
provide substantial benefit for information feedback and
potentially activating alarms or other functions within the joint
seal 101 or external systems. Fires that start in curtain walls are
catastrophic. High and low-pressure changes have deleterious
effects on the long-term structure and the connecting features.
Providing real time feedback and potential for data collection from
sensors, particularly given the inexpensive cost of such sensors,
in those areas and particularly where the wind, rain and pressure
will have their greatest impact would provide benefit. While the
pressure on the wall is difficult to measure, for example, the
deflection in a pre-compressed sealant is quite rapid and linear.
Additionally, joint seals are used in interior structures including
but not limited to bio-safety and cleanrooms. Additionally, a
sensor could be selected which would provide details pertinent to
the state of the Leadership in Energy and Environmental Design
(LEED) efficiency of the building. Additionally, such a sensor,
which could identify and transmit air pressure differential data,
could be used in connection with masonry wall designs that have
cavity walls or in the curtain wall application, where the air
pressure differential inside the cavity wall or behind the cavity
wall is critical to maintaining the function of the system. A
sensor may be positioned in other locations within the joint seal
101 to provide beneficial data. A sensor may be positioned within
the rectangular prism body 102 to provide prompt notice of
detection of heat outside typical operating parameters, so as to
indicate potential fire or safety issues. Such a positioning would
be advantageous in horizontal of confined areas. A sensor so
positioned might alternatively be selected to provide moisture
penetration data, beneficial in cases of failure or conditions
beyond design parameters. The sensor may provide data on moisture
content, heat or temperature, moisture penetration, and
manufacturing details. A sensor may provide notice of exposure from
the surface of the expansion joint seal 100 most distant from the
base of the joint. A sensor may further provide real time data.
Using a moisture sensitive sensor in the expansion joint seal 100
and at critical junctions/connections would allow for active
feedback on the waterproofing performance of the expansion joint
seal 100. It can also allow for routine verification of the
watertightness with a band-held sensor reader to find leaks before
the reach occupied space and to find the source of an existing
leak. Often water appears in a location much different than it
originates making it difficult to isolate the area causing the
leak. A positive reading from the sensor alerts the property owner
to the exact locations) that have water penetration without or
before destructive means of finding the source. The use of a sensor
in the expansion joint seal 100 is not limited to identifying water
intrusion but also fire, heat loss, air loss, break in joint
continuity and other functions that cannot be checked by
non-destructive means. Use of a sensor within expansion joint seal
100 may provide a benefit over the prior art. Impregnated foam
materials are known to cure fastest at exposed surfaces,
encapsulating moisture remaining inside the body, and creating
difficulties in permitting the removal of moisture from within the
body. While heating is a known method to addressing these
differences in the natural rate of cooling, it unfortunately may
cause degradation of the foam in response. Similarly, while forcing
air through the foam bodies may be used to address the curing
issues, the potential random cell size and structure impedes
airflow and impedes predictable results. Addressing the variation
in curing is desirable as variations affect quality and performance
properties. The use of a sensor within expansion joint seal 100 may
permit use of the heating method while minimizing negative effects.
The data from the sensors, such as real-time feedback from the
heal, moisture and air pressure sensors, aids in production of a
consistent product. Moisture and heat sensitive sensors aid in
determining and/or maintaining optimal impregnation densities,
airflow properties of the foam during the curing cycle of the foam
impregnation. Placement of the sensors into foam at the
pre-determined different levels allows for optimum curing allowing
for real time changes to temperature, speed and airflow resulting
in increased production rates, product qualify and traceability of
the input variables to that are used to accommodate environmental
and raw material changes for each product lots.
[0066] The selection of components providing resiliency,
compressibility, water-resistance and fire resistance, the joint
seal 101 may be constructed to provide sufficient characteristics
to obtain fire certification under any of the many standards
available, in the United States, these include ASTM international's
E 814 and its parallel Underwriter Laboratories UL 1379 "Fire Tests
of Through-penetration Fires tops," ASTM International's E1966 and
its parallel Underwriter laboratories UL 2079 "Tests for
Fire-Resistance Joint Systems," ASTM International's E 2307
"Standard Test Method for Determining Fire Resistance of Perimeter
Fire Barrier Systems Using Intermediate-Scale, Multi-story Test
Apparatus, the tests known as ASTM E 84, UL 723 and NFPA 255
"Surface Burning Characteristics of Building Materials," ASTM E 90
"Standard Practice for Use of Sealants in Acoustical Applications,"
ASTM E 119 and its parallel UL 263 "Fire Tests of Building
Construction and Materials," ASTM E 136 "Behavior of Materials in a
Vertical Tube furnace at 750.degree. C." (Combustibility), ASTM E
1399 "Tests for Cyclic Movement of Joints." ASTM E 595 "Tests for
Outgassing in a Vacuum Environment." ASTM G 21 "Determining
Resistance of Synthetic Polymeric Materials to Fungi." Some of
these test standards are used in particular applications where
firestop is to be installed.
[0067] Most of these, use the Cellulosic time/temperature curve,
described by the known equation T=20+345*LOG(8*t+1) where t is
time, in minutes, and T is temperature in degrees Celsius including
E814/UL 1379 and E 1966/UL 2079.
[0068] E 814/UL 1379 tests a fire-retardant system for fire
exposure, temperature change, and resilience and structural
integrity after fire exposure (foe latter is generally identified
as "the Hose Stream test"). Fire exposure, resulting in an F [Time]
rating, identifies the time duration--rounded down to foe last
completed hour, along foe Cellulosic curve before flame penetrates
through foe body of foe system, provided the system also passes foe
hose stream test. Common F ratings include 1, 2, 3 and 4 hours but
up to 8 hours may be required. Temperature change, resulting in a T
[Time] rating, identifies the time for the temperature of the
unexposed surface of the system, or any penetrating object, to rise
181.degree. C. above its initial temperature, as measured at the
beginning of the test. The rating is intended to represent how long
it will take before a combustible item on the non-fireside will
catch on lire from heat transfer. In order for a system to obtain a
UL 1379 listing, it must pass both the fire endurance (P rating)
and the Hose Stream test. The temperature data is only relevant
where building codes require the T to equal the F-rating.
[0069] When required, the Hose Steam test is performed after the
fire exposure test is completed. In some tests, such as UL 2079,
the Hose Stream test is required with wall-to-wall and head-of-wall
joints, but not others. This test assesses structural stability
following fire exposure as fire exposure may affect air pressure
and debris striking the fire-resistant system. The Hose Stream uses
a stream of water. The stream is to be delivered through a 64 mm
hose and discharged through a National Standard playpipe of
corresponding size equipped with a 29 mm discharge tip of the
standard-taper, smooth-bore pattern without a shoulder at the
orifice consistent with a fixed set of
TABLE-US-00001 Hourly Fire Rating Water Pressure Duration of Hose
Time in Minutes (kPa) Stream Test (sec./m.sup.2) 240 .ltoreq. time
< 480 310 32 120 .ltoreq. time < 240 210 16 90 .ltoreq. time
< 120 210 9.7 time < 90 210 6.5
The nozzle orifice is to be 6.1 m from the center of the exposed
surface of the joint system if the nozzle is so located that, when
directed at the center, Its axis is normal to the surface of the
joint system. If the nozzle is unable to be so located, it shall be
on a line deviating not more than 30.degree. from the line normal
to the center of the joint system. When so located its distance
from the center of the joint system is to be less than 6.1 m by an
amount equal to 305 mm for each 10.degree. of deviation from the
normal. Some test systems, including UL 1379 and UL 2079 also
provide for air leakage and water leakage tests, where the rating
is made in conjunction With a L and W standard. These further
ratings, while optional, are intended to better identify the
performance of the system under fire conditions.
[0070] When desired, the Air Leakage Test which produces an L
rating and which represents the measure of air leakage through a
system prior to fire endurance testing, may be conducted. Hie L
rating is not pass/fail, but rather merely a system property. For
Leakage Rating test, air movement through the system at ambient
temperature is measured. A second measurement is made after the air
temperature in the chamber is increased so that it reaches
177.degree. C. within 15 minutes and 204.degree. C. within 30
minutes. When stabilized at the prescribed air temperature of 204
.+-.5.degree. C., the air flow through the air flow metering system
and the test pressure difference are to be measured and recorded.
The barometric pressure, temperature and relative humidity of the
supply air are also measured and recorded. The air supply flow
values are corrected to standard temperature and pressure (STP)
conditions for calculation and reporting purposes. The air leakage
through the joint system at each temperature exposure is then
expressed as the difference between the total metered air flow and
the extraneous chamber leakage. The air leakage rate through the
joint system is the quotient of the air leakage divided by the
overall length of the joint system in the test assembly.
[0071] When desired, the Water Leakage Test produces a W pass-fail
rating and which represents an assessment of the watertightness of
the system, can be conducted. The test chamber for or the test
consists of a well-sealed vessel sufficient to maintain pressure
with one open side against which the system is sealed and wherein
water can be placed in the container. Since the system will be
placed in the test container, its width must be equal to or greater
than the exposed length of the system. For the test, the test
fixture is within a range of 10 to 32.degree. C. and chamber is
sealed to the test sample. Nonhardening mastic compounds,
pressure-sensitive tape or rubber gaskets with clamping devices may
be used to seal the water leakage test chamber to the test
assembly. Thereafter, water, with a permanent dye, is placed in the
water leakage test chamber sufficient to cover the systems to a
minimum depth of 152 mm. The top of the joint system is sealed by
whatever means necessary when the top of the joint system is
immersed under water and to prevent passage of water into the joint
system. The minimum pressure within the water leakage test chamber
shall be 1.3 psi applied for a minimum of 72 hours. The pressure
head is measured at the horizontal plane at the top of the water
seal. When the test method requires a pressure head greater than
that provided by the water inside the water leakage test chamber,
the water leakage test chamber is pressurized using pneumatic or
hydrostatic pressure. Below the system, a white indicating medium
is placed immediately below the system. The leakage of water
through the system is denoted by the presence of water or dye on
the indicating media or on the underside of the rest sample. The
system passes if the dyed water does not contact the white medium
or the underside of the system during the 72-hour assessment.
[0072] Another frequently encountered classification is ASTM E-84
(also found as UL 723 and NFPA 255), Surface Burning
Characteristics of Burning Materials, A surface burn test
identifies the flame spread and smoke development within the
classification system. The lower a rating classification, the
better fire protection afforded by the system. These
classifications are
TABLE-US-00002 Classfication Flame Spread Smoke Development A 0-25
0-450 B 26-75 0-450 C 76-200 0-450
[0073] UL 2079, Tests for Fire Resistant of Budding Joint Systems,
comprises a series of tests for assessment for fire resistive
building joint system that do not contain other unprotected
openings, such as windows and incorporates four different cycling
test standards, a fire endurance lest for the system, the Hose
Stream test for certain systems and the optional air leakage and
water leakage tests. This standard is used to evaluate
floor-to-floor, floor-to-wall, wall-to-wall and top-of-wall
(head-of-wall) joints for fire-rated construction. As with ASTM
E-814, UL 2079 and E-1966 provide, in connection with the fire
endurance tests, use of the Cellulosic Curve. UL 2079/E-1966
provides for a rating to the assembly, rather than the convention F
and T ratings. Before being subject to the Fire Endurance Test, the
same as provided above, the system is subjected to its
TABLE-US-00003 Movement Minimum Minimum cycling Classification
number of rate Joint Type/ (if used) cycles (cycles per minute) (if
used) No Classification 0 0 Static Class I 500 1 Thermal Expansion/
Contraction Class II 500 10 Wind Sway Class III 100 30 Seismic 400
10 Combination
[0074] ASTM E 2307. Standard Test Method for Determining Fire
Resistance of Perimeter Fire Barrier Systems Using
Intermediate-Scale, Multi-story Test Apparatus, is intended to test
for a systems ability to impede vertical spread of fire from a
floor of origin to that above through the perimeter joint, the
joint installed between the exterior wall assembly and the floor
assembly. A two-story test structure U used wherein the perimeter
joint and wall assembly are exposed to an interior compartment fire
and a flame plume from an exterior burner. Test results are
generated in F-rating and T-rating. Cycling of the joint may be
tested prior to the fire endurance test and an Air Leakage test may
also be incorporated.
[0075] The expansion joint seal 100 may therefore perform wherein
the bottom surface the rectangular prism body bottom surface 106 at
a maximum joint width increases no more than 181.degree. C. after
sixty minutes when the body member 111 is exposed to heating
according to the equation T=20+345*LOG(8*t+1), where t may be time
in minutes and T may be temperature in C.
[0076] The expansion joint seal 100 may also perform wherein the
rectangular prism body bottom surface 106, mid may have a maximum
joint width of more than six (6), increases no more than
139.degree. C. after sixty minutes when the expansion joint seal
100 is exposed to heating according to the equation
T=20+345*LOG(8*t+1), where t may be time in minutes and T may be
temperature in C.
[0077] The expansion joint seal 100 may be adapted to be cycled one
of 500 times at 1 cycle per minute, 500 times at 10 cycles per
minute and 100 cycles at 30 times per minute, without indication of
stress, deformation or fatigue.
[0078] In other embodiments, the expansion joint seal 100 is
configured to pass hurricane force testing to TAS 202/203. Further
the expansion joint seal 100 may be designed or configured to pass
ASTM E-282, E-331, E-330, E-547 or similar testing to meet the
pressure cycling and water resistance requirements up to 5000 Pa or
more.
[0079] As can be appreciated, the foregoing disclosure may
incorporate or be incorporated into other expansion joint systems,
such as those with fire-retardant members in a side of any of
expansion joint seal 100 adjacent the substrate, the inclusion of a
separate barrier Within the expansion joint seal 100 and which may
extend beyond the rectangular prism body first side surface 108 and
the rectangular prism body second side surface 110 of the expansion
joint seal 100 or remain encapsulated within, one or more
longitudinal load transfer members atop or within any of the prism
members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324,
without or without support members, a cover plate, a spline or ribs
tied to the cover plate whether fixedly or detachably, use of
auxetic materials, or constructed to obtain a fire endurance rating
or approval according to any of the tests known in the United
States and Europe for use with expansion joint systems, including
lire endurance, movement classification(s), load bearing capacity,
air penetration and water penetration.
[0080] 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 without departing from the spirit of the invention.
The present invention should only be limited by the following
claims and their legal equivalents.
* * * * *