1. Field of the Invention
The present invention deals with the field of devices for sealing the joint gaps between substrate surfaces used structurally. These joint gaps normally occur between floors and walls or between ceilings and walls or between walls. However, such gaps can occur between any two construction substrates.
The primary problem here is that these individual substrates which are normally positioned at an angle with one another and normally at approximately a ninety degree angle with respect to one anther are capable of moving independently of one another. Thus the size of the joint gap can vary significantly as the wall, ceiling or floor flexes relative to the adjacently positioned similar surface. Heretofore the means for sealing such areas has been to insert an insulation batting or to spray foam into the joint gap. The problem is that as the two adjacent substrates move or otherwise flex with respect to one another the size of the gap becomes greater and becomes smaller at various times depending on the type of use and other conditions. When the joint gap widens with some materials the gap becomes too wide for the insulating or blocking material and sealing of the joint gap is compromised. On the other hand when the substrates flex toward one another the amount of this flexing is limited by the minimum width to which the batting or foam can be compressed without failure. Thus these unique conditions experienced by two movable substrates adjacently positioned to define a joint gap therebetween are greatly inhibited by the current means for sealing of the gap. The present invention provides a means for sealing of this gap without requiring the positioning of any component directly in the gap and in this way allows complete capability of flexible movement between the two substrates while maintaining an uncompromised seal extending over the joint gap therebetween.
2. Description of the Prior Art
Many patents have been granted on systems for providing interfacing structure between walls, ceilings and/or floors many of which are defined as “head-of-wall” control system. Other currently existing patents attempting to solve this problem or dealing peripherally with structures for sealing between structural substrates are shown in the following patents. See U.S. Pat. No. 1,357,713 patented Nov. 2, 1920 to A. M. Lane and assigned to Monarch Metal Products Company on a “Weather Strip For Expansion Joints”; and U.S. Pat. No. 3,331,294 patented Jul. 18, 1967 to R. A. Waller and assigned to Kins Developments Limited on a “Flexible Insert”; and U.S. Pat. No. 4,566,242 patented. Jan. 28, 1986 to C. L. Dunsworth and assigned to Metalines, Inc. on a “Smoke And Heat Barrier”; and U.S. Pat. No. 4,967,527 patented Nov. 6, 1990 to H. J. Gohlke and assigned to Metalines, Inc. on “Expansion Joint Fire Barrier Systems”; and U.S. Pat. No. 4,977,719 patented Dec. 18, 1990 to A. R. LaRoche et al on a “Fire Resistant Expansion Joint”; and U.S. Pat. No. 4,999,962 patented Mar. 19, 1991 to H. J. Gohlke et al and assigned to Metalines, INc. on “Expansion Joint Fire Barrier Systems”; and U.S. Pat. No. 5,029,423 patented Jul. 9, 1991 to A. T. Kornylak and assigned to Kornylak Corporation on a “Vibration Resistant Building Construction”; and U.S. Pat. No. 5,140,797 patented Aug. 25, 1992 to H. J. Gohlke et al and assigned to Balco, Inc. on “Expansion Joint Fire Barrier Systems”; and U.S. Pat. No. 5,259,162 patented Nov. 9, 1993 to J. D. Nicholas and assigned to Pawling Corporation on “Multi-Functional Wall Cover For Architectural Joints”; and U.S. Pat. No. 5,263,293 patented Nov. 23, 1993 to H. J. Gohlke et al and assigned to Balco, Inc. on “Expansion Joint Fire Barrier Systems”; and U.S. Pat. No. 5,297,372 patented Mar. 29, 1994 to J. D. Nicholas and assigned to Pawling Corporation on “Elastomeric Sealing System For Architectural Joints”; and U.S. Pat. No. 5,461,838 patented Oct. 31, 1995 to P. S. Heller on a “Fire Barrier”; and U.S. Pat. No. 5,560,165 patented Oct. 1, 1996 to L. Hoefsloot et al and assigned to KONE Oy on “Joint Between A Landing Door And Wall Structures”; and U.S. Pat. No. 5,560,166 patented Oct. 1, 1996 to J. Burke et al and assigned to Foster Wheeler Energia Oy on an “Expansion Joint With Protective Shielding”; and U.S. Pat. No. 5,755,066 patented May 26, 1998 to D. W. Becker on a “Slip Track Assembly”; and U.S. Pat. No. 5,765,332 patented Jun. 16, 1998 to H. V. Landin et al and assigned to Minnesota Mining and Manufacturing Company on a “Fire Barrier Protected Dynamic Joint”; and U.S. Pat. No. 5,887,400 patented Mar. 30, 1999 to D. J. Bratek et al and assigned to Watson Bowman Acme Corp. on an “Expansion Control System”; and U.S. Pat. No. 5,913,788 patented Jun. 22, 1999 to T. r. Herren on a “Fire Blocking And Seismic Resistant Wall Structure”; and U.S. Pat. No. 5,921,041 patented Jul. 13, 1999 to J. D. Egri, II on a “Bottom Track For Wall Assembly”; and U.S. Pat. No. 6,058,668 patented May 9, 2000 to t. R. Herren on a “Seismic And Fire-Resistant Head-Of-Wall Structure”; and U.S. Pat. No. 5,974,750 patented Nov. 2, 1999 to H. V. Landin et al and assigned to 3M Innovative Properties Company on a “Fire Barrier Protected Dynamic Joint”; and U.S. Pat. No. 6,112,488 patented Sep. 5, 2000 to J. R. Olson et al and assigned to Unifrax Corporation on “Fire Barrier Material And Gaskets Therefor”; and U.S. Pat. No. 6,128,874 patented Oct. 10, 2000 to J. R. Olson et al and assigned to Unifrax Corporation and Construction Specialties, Inc. on “Fire Resistant Barrier For Dynamic Expansion Joints”; and U.S. Pat. No. 6,131,352 patented Oct. 17, 2000 to V. Barnes et al on a “Fire Barrier”; and U.S. Pat. No. 6,176,053 patented Jan. 23, 2001 to R. C. A. St. Germain and assigned to roger C. A. St. Germain on a “Wall Track Assembly And Method For Installing The Same”.
The present invention provides a joint sealing means which can be positioned extending a joint gap defined between a first structural substrate and a second structural substrate which are independently movable with respect to one another and adjacently positioned. The joint sealing system includes a sealing member which is flexible and preferably flexibly resilient and is preformed into predetermined shape. This sealing member includes a mounting section adapted to be attached with respect to a first structural substrate for sealing engagement with it. The sealing member also includes a covering section attached to the mounting section and extending outwardly therefrom and formed integrally with the mounting section. The covering section is flexibly resilient and is preformed into a predetermined shape and is adapted to extend from the mounting section outwardly toward the second structural substrate to be urged into abutting engagement therewith to facilitate sealing engagement against it even during independent relative movement between the two substrates.
These two substrates normally comprise a wall and a floor or a ceiling and a floor or two walls which are adjacently positioned and normally angularly oriented with respect to one another and usually are approximately perpendicular with respect to one another. These common structural or construction substrates often are independently movable and need to have a flexible means for maintaining a seal therebetween at all times while allowing normal relative movement therebetween.
The joint sealing system preferably also includes a means of securement for fixedly securing the mounting section of the sealing member with respect to the first structural substrate. This can comprise an adhesive applied between the first substrate and the mounting section of the sealing member or can be nailed or staple driven through the covering section into the first substrate. Any means of securement which will hold the mounting section of the sealing member fixedly with respect to the first structural substrate would be usable.
A scrim material layer may be included extending over the mounting section and the covering section of the sealing member for aiding in the sealing of the joint gap. This scrim preferably is affixed to the mounting and the covering section of the sealing member preferably on the exposed surface thereof. The scrim preferably extends over the mounting section and beyond the covering section by the forming of an extended scrim section which will actually extend beyond the covering section and can lay over a portion of the second substrate. This scrim will significantly reinforce the mounting section and the covering section of the sealing member. Also, however, the scrim material layer can be used for facilitating the adhering of a seal enhancing coating applied thereover. This seal enhancing coating can have an intumescent component or can be a more conventional sealing material. Such a coating of seal enhancing material can be applied such as by spraying over the exposed outer surface of the mounting section as well as the covering section of the sealing member and also can extend over the adjacent areas of the first and second substrate for further facilitating sealing thereof. Adherence between the sealing member and the seal enhancing layer when sprayed can be significantly increased by the use of a scrim material layer secured to the sealing member, especially the extended scrim portion which can facilitate the interface between the area of engagement of the sealing member with respect to the first end or second substrate by allowing the sprayed coat to extend over this interface for maintaining engagement therebetween. A further smooth transition can be achieved by the more gradual contour provided by the inclusion of the extended scrim section. This seal enhancing layer can be any type of normal spray type caulking but could, optionally, include an intumescent component which would facilitate sealing of the joint gap in response to high heat conditions such as during a fire.
The system is utilized by initially providing of the sealing member with the mounting section and a flexibly resilient covering section adjacently secured thereto and then placing of this in abutment with respect to the second substrate. The flexibly resilient covering section is then compressed against the second substrate and the mounting section of the sealing member is affixed to the first substrate while in this flexed condition to thereby maintain firm securement between the first substrate and the mounting section and a biased or compressed engagement of the covering section with respect to the second substrate. Thereafter an intumescent or non-intumescent coating can be applied by spray or otherwise over the entire sealing member and the immediately adjacent sections of the first and second structural substrate.
It is an object of the present invention to provide a means for sealing of the joint gap between adjacently positioned walls, floors and/or ceilings and other structural substrates wherein independent movement of the adjacently positioned substrates is possible without compromising the seal.
It is an object of the present invention to provide a means for sealing of the joint gap between adjacently positioned walls, floors and/or ceilings and other structural substrates wherein changes in the size of the joint by movement of one or both of the substrates does not in any way compromise the integrity of the sealing system extending thereover.
It is an object of the present invention to provide a means for sealing of the joint gap between adjacently positioned walls, floors and/or ceilings and other structural substrates wherein ease of installation is a primary consideration.
It is an object of the present invention to provide a means for sealing of the joint gap between adjacently positioned walls, floors and/or ceilings and other structural substrates wherein repair is easy.
It is an object of the present invention to provide a means for sealing of the joint gap between adjacently positioned walls, floors and/or ceilings and other structural substrates wherein no insulating material need to be placed directly into the joint gap to thereby provide a more flexible interconnecting sealing mechanism.
It is an object of the present invention to provide a means for sealing of the joint gap between adjacently positioned walls, floors and/or ceilings and other structural substrates wherein initial cost capital outlay is minimized.
It is an object of the present invention to provide a means for sealing of the joint gap between adjacently positioned walls, floors and/or ceilings and other structural substrates wherein labor costs and time for installation are minimized.
It is an object of the present invention to provide a means for sealing of the joint gap between adjacently positioned walls, floors and/or ceilings and other structural substrates wherein maintenance is generally minimal.
It is an object of the present invention to provide a means for sealing of a joint gap between adjacently positioned walls, floors and/or ceilings and other structural substrates which is securable to one of the surfaces rather than being positioned in the joint itself and in this manner to allow for complete compression in the joint if needed.
While the invention is particularly pointed out and distinctly claimed in the concluding portions herein, a preferred embodiment is set forth in the following detailed description which may be best understood when read in connection with the accompanying drawings, in which:
The present invention provides a unique configuration for sealing of the joint gap often defined between walls, ceilings and floors. Such walls, ceiling and floors are referred to in the patent application as structural substrates since they define generally planar surfaces which are immediately adjacent to adjacent similar surfaces normally at an angular orientation with respect to one another while defining a gap in the joint therebetween. The present invention provides a means for sealing of these joint gaps 10 often found in such locations between the first substrates 12 and the second substrates 14. These designs have particular application to head-of-wall configurations wherein the top of a vertically extending wall will define a joint gap 10 between it and a ceiling thereabove. However the joint sealing system of the present invention is usable sealing any type of joint gap between any two structural substrates.
Such substrates are often movable independently of one another. For example, a floor will flex while a wall substrate therebelow or thereabove may remain stationary. Thus the size of the joint gap 10 between the two substrates 12 and 14 can vary significantly over time as the individual substrates separately or independently move, flex and/or expand.
The joint sealing means 16 of the present invention includes a sealing member having two sections. The first portion is a mounting section 20 designed to be fixedly secured with respect to the first substrate 12. It also includes a covering section 22 which is preferably formed integrally with the mounting section and can have various preformed shapes as shown in the present invention such as the U-shaped covering section 36 or the V-shaped covering section 42 or the bellows covering section 50 or any other usable design.
Either the shape or the material of which the covering section 22 is made will preferably define it to be in some manner flexibly resilient such that it can be biased into contact in engagement with respect to the second substrate 14. Once the covering member 22 is biased or forced into contact with second substrate 14 the mounting section 20 of the sealing member 18 can be secured to the first substrate 12 securely. Thus the sealing member 18 in this position will be flexibly biased into sealing engagement with the second substrate 14 while being fixedly secured in its attachment or mounting of the mounting section 20 thereof upon the first substrate 12. In this manner as the joint flexes the sealing member 18 will move with the first substrate 12 and the covering section 22 thereof will be maintained in contact with respect to the second substrate 14 despite the fact that the joint gap 10 itself may become wider or narrower due to the independent movement between the two substrates. It should be appreciated that the first substrate could be a floor, wall or ceiling and the second substrate could also be a floor, wall or ceiling. However the most common situation addressed by this type of sealing system would be where the first substrate 12 is a vertically extending wall and the second substrate 14 is the ceiling portion of horizontally extending floor area.
A securement means 24 will be included for attaching of the mounting section 20 with respect to the first substrate 12. The securement means 24 can include any type of an attaching mechanism but preferably will comprise a mechanical attachment means 34 such as nails or staples driven through the mounting section 20 into the first substrate 12 for affixing them together. Alternatively an adhesive means 32 may be positioned in between the first substrate 12 and the mounting section 20 of sealing member 18 for adhering them together as desired.
In the configuration shown in
In a similar manner the U-shaped covering section 36 includes a first leg member 38 and a second leg member 40 extending outwardly away from one another in the form of a U-shape. This design is best shown in
A third configuration is shown in
In a preferred configuration as shown in
It should be appreciated that the material of the sealing member 18 can be of any chosen configuration. It needs to be in some manner flexibly resilient which can be achieved through the choice of a material or the structure of the sealing member 18 itself and in particular in the material or structure of the covering section 22 of sealing member 18. For example, the sealing member 18 could be chosen of a galvanized steel construction which has some flexible resilience and can have a mounting section 20 defined thereon which is fixedly secured by a mechanical securement means 34 such as nails or staples for affixing thereof with respect to the first substrate 12. Also the present invention can be usable along with a batting of sealing or insulation material placed in the joint gap 10. However, such material would only be an added supplement and would not be the primary means of maintaining a seal over the joint gap 10.
It should be appreciated that the present invention provides a predetermined shaped molded product which, although being flexibly resilient, has a predetermined molded shape designed specifically to allow sealing of the joint gap 10 while allowing fixed securement of the sealing system to only one of the two adjacent substrates and not both. The present invention also is designed for fire rated situations or non-fire related standard applications which are often required in areas such as head-of-wall sealing wherein fire sealing is not something specifically required. This type of requirement is often experienced, however of course, the present invention could be used in any fire rated joint sealing application.
The present invention is particularly adaptable for sealing various types of joint gaps since when utilizing the V or U-shaped configuration the angle between the outwardly extending legs or struts can be varied in order to vary the size of gap with which the sealing system is usable. The size needs to be increased sufficiently that the portion of the covering section 22 in abutment with the second substrate 14 will be biased thereagainst when the mounting section 22 is fixedly secured to the first substrate 12 thereadjacent.
One of the important objects of the present invention is to avoid the situation where the first and second substrates are firmly bonded to one another. This type of firm bonding does sometimes occur even when merely a sealing mechanism is placed extending therebetween. This problem is commonly referred to as “three-sided adhesion” or “three-point adhesion”. When a sealing mechanism is placed in the joint gap 10 and is firmly secured to both sides it is basically restricting the capability of the first and second substrates 12 and 14 moving independently of one another. This independent movement is sometimes very important to allow for thermal or other expansion or contraction as well as normal flexing of the walls, ceilings and floors of conventional building structures. The avoidance of such three-sided adhesion is an important advantage of the present invention.
These types of systems often require the use of very elastic caulking or coating compounds and the forces causing the joint to become larger and smaller over time force these caulking or coating materials to elongate. In this manner these elongated materials often cannot handle the amount of movement required on a regular basis. As such, this lack of flexibility tends to become more critical over time because of the tendency of such elastic caulking and coating materials to continue to cure over extensive periods of time.
While particular embodiments of this invention have been shown in the drawings and described above, it will be apparent, that many changes may be made in the form, arrangement and positioning of the various elements of the combination. In consideration thereof it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention.
Number | Name | Date | Kind |
---|---|---|---|
378604 | Kramer | Feb 1888 | A |
1357713 | Lane | Nov 1920 | A |
3286422 | Pangerl | Nov 1966 | A |
3331294 | Waller | Jul 1967 | A |
3435574 | Hallock | Apr 1969 | A |
3447273 | Thom | Jun 1969 | A |
3694976 | Warshaw | Oct 1972 | A |
3919820 | Green | Nov 1975 | A |
4566242 | Dunsworth | Jan 1986 | A |
4601475 | Nicholson | Jul 1986 | A |
4616460 | Nicholas | Oct 1986 | A |
4746129 | Puccio | May 1988 | A |
4811529 | Harris et al. | Mar 1989 | A |
4967527 | Gohlke | Nov 1990 | A |
4977719 | LaRoche et al. | Dec 1990 | A |
4999962 | Gohlke et al. | Mar 1991 | A |
5029423 | Kornylak | Jul 1991 | A |
5140797 | Gohlke et al. | Aug 1992 | A |
5251917 | Chee et al. | Oct 1993 | A |
5259162 | Nicholas | Nov 1993 | A |
5263293 | Gohlke et al. | Nov 1993 | A |
5269624 | Kramer | Dec 1993 | A |
5297372 | Nicholas | Mar 1994 | A |
5365713 | Nicholas et al. | Nov 1994 | A |
5461838 | Heller | Oct 1995 | A |
5560165 | Hoefsloot et al. | Oct 1996 | A |
5560166 | Burke et al. | Oct 1996 | A |
5755066 | Becker | May 1998 | A |
5765332 | Landin et al. | Jun 1998 | A |
5887400 | Bratek et al. | Mar 1999 | A |
5913788 | Herren | Jun 1999 | A |
5921041 | Egri, II | Jul 1999 | A |
5974750 | Landin et al. | Nov 1999 | A |
6058668 | Herren | May 2000 | A |
6112488 | Olson et al. | Sep 2000 | A |
6128874 | Olson et al. | Oct 2000 | A |
6131352 | Barnes et al. | Oct 2000 | A |
6176053 | St. Germain | Jan 2001 | B1 |
6183575 | Embelton | Feb 2001 | B1 |
6345480 | Kemper et al. | Feb 2002 | B1 |
6751919 | Calixto | Jun 2004 | B2 |