Patent Application
20190194955
Provided herein are modular curbs for transitioning between wall and floor. In particular, curbs are provided seal gaps between the wall and floor, protect walls against impact, are waterproof, and protect against bacteria/mold infiltration.
Protective guards for buildings and similar structures are well-known in the art. These protective guards include bollards, cement curbs, floor board bumpers, rubber-form structure bumpers, and layered cement wall construction. Current designs have deficiencies, such as being prone to damage when contacted by equipment and harboring sites for the growth of pathogenic microbes.
Provided herein are modular curbs for transitioning between wall and floor. In particular, curbs are provided seal gaps between the wall and floor, protect walls against impact, are waterproof, and protect against bacteria/mold infiltration.
In some embodiments, provided herein are devices (e.g., protective curbs) comprising a cross-sectional geometry comprising: a vertical engagement segment configured to contact a wall at a height above a floor and without contacting the floor; and a horizontal engagement segment configured to contact the floor at a distance from the wall and without contacting the wall; wherein, when the vertical engagement segment is placed in contact with the wall and the horizontal engagement segment is placed in contact with the floor, a cavity is formed between the device, the floor, and the wall. In some embodiments, the devices further comprise a central segment connecting the vertical engagement segment and the horizontal engagement segment. In some embodiments, the central segment, the vertical engagement segment, and the horizontal engagement segment comprise a single piece of material (e.g., FRP). In some embodiments, an internal angle between the vertical engagement segment and the central segment is 90° or less (e.g., 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°, 85°, 90%, or ranges therebetween). In some embodiments, an internal angle between the horizontal engagement segment and the central segment is 90° or less (e.g., 15°, 20°, 25°, 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, 70°, 75°, 80°, 85°, 90°, or ranges therebetween). In some embodiments, the central segment comprises one or more bends or folds. In some embodiments, one or more of the central segment, the vertical engagement segment, and the horizontal engagement segment comprise a locking segment (e.g., linear or L-shaped) that extends into the cavity formed between the device, the floor, and the wall. In some embodiments, the device is composed of a polymer or polymer composite material. In some embodiments, the device is composed of ultra-high-molecular-weight polyethylene (UHMW) or fiber reinforced plastic (FRP). In some embodiments, the cross-sectional geometry extends the entire longitudinal length of the device. In some embodiments, the vertical engagement segment is 0.25 to 6 inches in length (e.g., 0.25 inches, 0.5 inches, 0.75 inches, 1 inch, 1.5 inches, 2 inches, 3 inches, 4 inches, 5 inches, 6 inches, or lengths therebetween), the horizontal engagement segment is 0.25 to 3 inches in length (e.g., 0.25 inches, 0.5 inches, 0.75 inches, 1 inch, 1.5 inches, 2 inches, 3 inches, and lengths therebetween), and the central segment is 2 to 24 inches in length (e.g., 2 inches, 3 inches, 4 inches, 5 inches, 6 inches, 7 inches, 8 inches, 10 inches, 12 inches, 16 inches, 20 inches, 24 inches, or ranges therebetween). In some embodiments, the vertical engagement segment is configured to contact the wall at a height of 1.5 to 20 inches (e.g., 1.5 inches, 2 inches, 2.5 inches, 3 inches, 3.5 inches, 4 inches, 5 inches, 6 inches, 7 inches, 8 inches, 9 inches, 10 inches, 12 inches, 14 inches, 16 inches, 18 inches, 20 inches, or ranges therebetween) above the floor (e.g., lowest point of contact between the vertical engagement segment and the wall) and the horizontal engagement segment is configured to contact the floor at a distance of 0.5 to 4 inches (e.g., 0.5 inches, 0.75 inches, 1 inch, 1.25 inches, 1.5 inches, 1.75 inches, 2 inches, 2.5 inches, 3 inches, 3.5 inches, 4 inches, or ranges therebetween) from the wall (e.g., nearest point of contact to the wall between the horizontal engagement segment and the floor). In some embodiments, a device is 6 inches to 24 feet (e.g., 6 inches 1 foot, 2 feet, 3 feet, 4 feet, 6 feet, 8 feet, 12 feet, 16 feet, 20 feet, 24 feet, or ranges therebetween) in length longitudinally.
In some embodiments, provided herein are systems (e.g., protective systems) comprising: a device described herein (e.g., protective cub), a wall, and a floor; wherein the vertical engagement segment is in contact with the wall at a height above a floor and without contacting the floor; wherein the horizontal engagement segment is in contact with the floor at a distance from the wall and without contacting the wall. In some embodiments, the vertical engagement segment and the horizontal engagement segment are adhered to the wall and the floor, respectively, by an adhesive or chemical weld. In some embodiments, a gap between the vertical engagement segment and the wall and/or the horizontal engagement segment and the floor is filled and/or sealed with a sealant and/or chemical weld. In some embodiments, the cavity formed between the device, the floor, and the wall is filled with a filler material. In some embodiments, the filler material is selected from cement, concrete, foam, a polymeric material, and composites thereof. In some embodiments, the cavity is filled along the entire longitudinal length of the device. In some embodiments, systems further comprise one or more anchors attached to the floor or wall and extending into the filled cavity. In some embodiments, the anchor is a pin or screw. In some embodiments, the wall comprises or is covered with a panel comprising a polymer or polymer composite material (e.g., ultra-high-molecular-weight polyethylene (UHMW) or fiber reinforced plastic (FRP)). In some embodiments, the floor comprises concrete. In some embodiments, the floor is covered with a urethane flooring material. In some embodiments, a system comprises multiple devices aligned longitudinally end-to-end.
In some embodiments, provided herein are methods of installing a system described herein and/or preventing water damage, bacteria/mold growth, and/or damage from impact comprising: (a) placing a device of one of claims 1-15 at the junction of a wall and a floor such that: (i) the vertical engagement segment contacts the wall at a height above the floor and without contacting the floor, (ii) the horizontal engagement segment contacts the floor at a distance from the wall and without contacting the wall, and (iii) a cavity is formed between the device, the floor, and the wall; (b) adhering the vertical engagement segment to the wall and the horizontal engagement segment to the floor with an adhesive or chemical weld; (c) sealing a gap between the vertical engagement segment and the wall and/or the horizontal engagement segment and the floor with a sealant and/or chemical weld; and (d) filling the cavity with a filler material.
Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments described herein, some preferred methods, compositions, devices, and materials are described herein. However, before the present materials and methods are described, it is to be understood that this invention is not limited to the particular molecules, compositions, methodologies or protocols herein described, as these may vary in accordance with routine experimentation and optimization. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the embodiments described herein.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. However, in case of conflict, the present specification, including definitions, will control. Accordingly, in the context of the embodiments described herein, the following definitions apply.
As used herein and in the appended claims, the singular forms “a”, “an” and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “a curb” is a reference to one or more curbs and equivalents thereof known to those skilled in the art, and so forth.
As used herein, the term “and/or” includes any and all combinations of listed items, including any of the listed items individually. For example, “A, B, and/or C” encompasses A, B, C, AB, AC, BC, and ABC, each of which is to be considered separately described by the statement “A, B, and/or C.”
As used herein, the term “comprise” and linguistic variations thereof denote the presence of recited feature(s), element(s), method step(s), etc. without the exclusion of the presence of additional feature(s), element(s), method step(s), etc. Conversely, the term “consisting of” and linguistic variations thereof, denotes the presence of recited feature(s), element(s), method step(s), etc. and excludes any unrecited feature(s), element(s), method step(s), etc., except for ordinarily-associated impurities. The phrase “consisting essentially of” denotes the recited feature(s), element(s), method step(s), etc. and any additional feature(s), element(s), method step(s), etc. that do not materially affect the basic nature of the composition, system, or method. Many embodiments herein are described using open “comprising” language. Such embodiments encompass multiple closed “consisting of” and/or “consisting essentially of” embodiments, which may alternatively be claimed or described using such language.
As used herein, the term “substantially all,” “substantially complete” and similar terms refer to greater than 99%; and the terms “substantially none,” “substantially free of,” and similar terms refer to less than 1%.
The term “about” allows for a degree of variability in a value or range. As used herein, the term “about: refers to values within 10% of the recited value or range (e.g., about 50 is the equivalent of 45-55).
As used herein, the terms “off-vertical” and “off-horizontal” may refer to devices or structures that are substantially vertical or horizontal, about vertical or horizontal, or not vertical or horizontal. Any uses of “off-vertical” and “off-horizontal” herein may be substituted with one of the aforementioned.
As used herein, the term “acutely oriented” refers to the relationship between two segments of a device or structure that have an internal angle between them that is less than 90°.
As used herein, the term “obtusely oriented” refers to the relationship between two segments of a device or structure that have an internal angle between them that is greater than 90°.
As used herein, the term “orthogonally oriented” refers to the relationship between two segments of a device or structure that have an internal angle between them that is equal to 90°.
As used herein, the term “parallel” refers to the relationship between to segments of a device or structure that have a constant distance between the segment over their length (e.g., 0° angle between the segments).
As used herein, the term “antiparallel” refers to the relationship between two segments of a device or structure that have a constant distance between the segment over their length (e.g., 0° angle between the segments), but are oriented in opposite directions.
Provided herein are modular curbs for transitioning between wall and floor. In particular, curbs are provided seal gaps between the wall and floor, protect walls against impact, are waterproof, and protect against bacteria/mold infiltration.
Provided herein are curbs for the protection of structural surfaces, equipment, machinery, and users thereof. In some embodiments, curbs are secured to a structural surface, such as a wall, divider, or door opening frame, as well as to a floor (or ceiling) and bridge the gap therebetween. In some embodiments, the curbs provide a transition between a vertical structural surface (e.g., wall, wall panel, etc.) and a horizontal floor surface. In some embodiments, the curb prevents collection and/or invasion of water, mold/bacteria, etc. at the intersection (or a gap) between the vertical structural surface and the horizontal floor surface. In some embodiments, the curb is impregnated or back-filled with a filler material (e.g., concrete, cement, foam, etc.). In some embodiments, the curb is sealed to the floor (e.g., with silicone, with glue, with sealant, with a chemical weld, etc.). In some embodiments, the curb is sealed to a vertical structure (e.g., wall, door frame, wall liner, panel, etc.) by any suitable material (e.g., with silicone, with glue, with sealant, with a chemical weld, etc.). In some embodiments, the filler (e.g., behind and/or within the curb) is sealed to the floor and/or vertical structure (e.g., wall, door frame, wall liner, panel, etc.) by any suitable material (e.g., with silicone, with glue, with sealant, with a chemical weld, etc.). In some embodiments, the filler (e.g., behind and/or within the curb) is anchored to the floor and/or vertical structure (e.g., wall, door frame, wall liner, panel, etc.) by a mechanical anchoring element (e.g., screw, pin, etc.). In some embodiments, gaps between the curb and the floor are sealed/filled/closed by a sealant or chemical weld. In some embodiments, gaps between the curb and the vertical structure (e.g., wall, door frame, wall liner, panel, etc.) are sealed/filled/closed by a sealant or chemical weld.
In some embodiments, a curb is a structural component configured to sit at the intersection of a vertical structure (e.g., wall, door frame, wall liner, panel, etc.) and the floor. In some embodiments, a curb comprises a head 10, a face 20, and a foot 30 (
In some embodiments,
In some embodiments, the head 10 comprises a vertical engagement segment 12, angled segment 15, and head joint 18 (
In some embodiments, a curb comprises a face 20 that extends from the head 10 to the foot 30. The face may be vertical or slope outward from the vertical (e.g., 0-30° (e.g., 0°, 1°, 2°, 3°, 4°, 5°, 10°, 15°, 20°, 25° 30°, or ranges therebetween). In some embodiments, the face 20 and the vertical engagement segment 12 are antiparallel. In some embodiments, the angled segment 15 provides a transition between the head 10 and the face 20 of the curb 1.
In some embodiments, the foot 30 is the bottommost portion of the curb 1 and comprises a floor engagement segment 32 and a bottom locking segment 34 (
In some embodiments (See
In some embodiments (
In some embodiments (
The curbs described herein find use in providing a protective transition (e.g., protection from impact, from water damage, from bacteria/mold, etc.) between a vertical structure (e.g., wall, door frame, wall panel, etc.) and the floor. In some embodiments, provided herein are systems comprising the curbs described herein, a vertical structure, and a floor. Exemplary systems are depicted in
In the embodiment depicted in
In some embodiments, a gap between the curb and the wall and/or floor is filled and/or sealed with a chemical weld (See, e.g., U.S. Pub No. 2016/0222263; U.S. Pub No. 2002/0114914, U.S. Pat. No. 5,810,956; each of which is herein incorporated by reference in its entirety; for examples of chemical welds and materials and methods suitable for making such welds; other technologies of chemical welding are understood in the art). In some embodiments, the top gap between the curb and the wall is chemically welded. In some embodiments, the bottom gap between the curb and the floor is chemically welded.
In some embodiments, an anchor (e.g., screw, pin, etc.) stabilizes the filler material (and the associated curb) to the floor (as depicted in
In some embodiments, the protective curbs herein are secured to structural surfaces (e.g., horizontal surface (e.g., floor, flooring, etc.), vertical surface (e.g., wall, wall panel, door frame, etc.)) by the compositions and methods described herein. In some embodiments, the void or cavity formed behind the curb is filled with a filler material (e.g., concrete, cement, insulation, foam, etc.). In some embodiments, the void behind the curb is filled after securing the curb to the structural surfaces. In other embodiments, all or a portion of the void behind the curb is filled with filler material (e.g., concrete, cement, insulation, foam, etc.) prior to placement of the curb.
In one embodiment, the curbs described herein transversely extend the length of the structural surface. Alternatively, in some embodiments one or more sections of curbs terminate at a desired distance for adequate protection. For example, a curb is configured along a door frame, ramp, or hallway and terminates at the end thereof. In some embodiments, the termination point of a curb is sharp, abrupt, gradual, sloped, or rounded. In some embodiments, a curb is configured to fit to an inside (e.g., 90°) or outside (e.g., 270°) corner of a wall. In some embodiment, one or more curbs (e.g., linked (e.g., sealed, welded, etc.) end to end) transversely extend a wall length (e.g., 2 feet, 4 feet, 6 feet, 8 feet, 10 feet, 15 feet, 20 feet, 25 feet, 30 feet, 40 feet, 50 feet, 60 feet, 70 feet, 80 feet, 90 feet, 100 feet, or more, or ranges therebetween). Other lengths and distances are contemplated beyond those disclosed herein in order to accommodate various wall and door way sizes and configurations. In many embodiments herein, the curbs are placed against the floor, although curbs may alternatively be configured for placement at the junction of any two structural surfaces. Curbs may be placed near the floor, on the middle of a structural surface, at the junction between a wall and the ceiling, or any other position along a structural surface. The structural surface may be an internal or external wall, a wall to wall corner, a door, a door frame, or like structure requiring impact protection. The structural surface can be made of cement, wood, glass, ceramics, metals, stone or aggregate concrete. In some embodiments, the curb is secured to the structural surface by one or more attachment members (e.g., pins, screws, etc.) or substances (e.g., chemical welds, sealants, glues, caulk, silicone, etc.).
In some embodiments, a curb comprises a plurality of protrusions extending into the cavity therein that facilitate tight interaction between the curb and the filler material. Alternatively, a curb may comprise grooves that receive the filler material and facilitate interaction. In some embodiments, protrusions and/or grooves form dovetails or ball shaped.
The dimensions of the curbs may be of any suitable size/dimensions to facilitate protection of the transition point between structural surfaces. In some embodiments, a curb is between 2 inches and 24 inches in height (e.g., 2 inches, 3 inches, 4 inches, 5 inches, 6 inches, 7 inches, 8 inches, 9 inches 10 inches, 11 inches, 12 inches, 13 inches, 14 inches, 15 inches, 16 inches, 17 inches, 18 inches, 19 inches, 20 inches, 21 inches, 22 inches, 23 inches, 24 inches, or ranges therebetween (e.g., 8-16 inches). In some embodiments, a curb is between 0.5 inches and 10 inches in depth (e.g., 0.5 inches, 0.75 inches, 1 inch, 1.25 inches, 1.5 inches, 1.75 inches, 2 inches, 2.25 inches, 2.5 inches, 2.75 inches, 3 inches, 3.5 inches, 4 inches, 4.5 inches, 5 inches, 5.5 inches, 6 inches, 7 inches, 8 inches, 9 inches, 10 inches, or ranges therebetween (e.g., 1-4 inches). In some embodiments, a curb is between 0.5 feet and 24 feet in length (e.g., 6 inches, 12 inches, 2 feet, 3 feet, 4 feet, 5 feet 6 feet, 7 feet, 8 feet, 9 feet 10 feet, 11 feet, 12 feet, 13 feet, 14 feet, 15 feet, 16 feet, 17 feet, 18 feet, 19 feet, 20 feet, 21 feet, 22 feet, 23 feet, 24 feet, or ranges therebetween (e.g., 2-12 feet). In some embodiments, the various segments of the curbs herein are of any suitable dimensions (e.g., lengths, widths, angles, etc.) to produce the protective curbs described herein. For example, the face angled head segment, and/or angled foot segments may be, independently, between 1 inch and 24 inches in length (e.g., 1 inch, 2 inches, 3 inches, 4 inches, 5 inches, 6 inches, 7 inches, 8 inches, 9 inches 10 inches, 11 inches, 12 inches, 13 inches, 14 inches, 15 inches, 16 inches, 17 inches, 18 inches, 19 inches, 20 inches, 21 inches, 22 inches, 23 inches, 24 inches, or ranges therebetween). In some embodiments, the vertical engagement segments, locking segments, floor engagement segments, etc. may be, independently, between 0.25 inches and 8 inches in length (e.g., 0.25 inches, 0.5 inches, 0.75 inches, 1 inch, 2 inches, 3 inches, 4 inches, 5 inches, 6 inches, 7 inches, 8 inches, or ranges therebetween). As described herein, the transition angles between segments may be of any suitable angle to provide the proper dimensions for a particular application.
In some embodiments, combination of the curb, the filler material, and the seals/welds creates a barrier between the structural surface and an outside object. The outside object may be equipment, machinery, or vehicles operated by an individual such as forklifts, tractors, trucks, haulers, and the like.
In some embodiments, curbs are provided that are composed of a damage resistant material (e.g., impact resistant, abrasion resistant, low coefficient of friction, etc.), such as a polymer, metal, alloy, combinations thereof, etc.
In some embodiments, one or more elements of the curb systems described herein (e.g., curb, wall panel, etc.) comprise and/or are manufactured from a composite material, such as, a polymer matrix (e.g., vinylester, polyester, etc.), epoxy, phenol formaldehyde, polyester thermosetting plastic (e.g., PEEK, PEKK, PPS), etc., reinforced with fibers, such as carbon, aramid, glass, Kevlar, boron, basalt, Hybor, quartz, asbestos, etc. In some embodiments, the composite materials comprise additional components, such as, metal, metal foil (e.g., TiGr), or fiber metal laminate. In some embodiments, the composite materials are generally are “cured” into a stronger form through an endothermic chemical reaction, which requires the addition of energy, for example, by way of heating or irradiation. Examples of composite materials used in various embodiments of this herein include graphite fiber reinforced epoxy, fiber reinforced plastic (FRP), glass-fiber reinforced plastic (GRP), carbon-fiber reinforced plastic (CRP), metal matrix composites (MMC), and reinforced carbon-carbon (carbon fiber in a graphite matrix).
In some embodiments, one or more elements of the curb systems described herein (e.g., curb, wall panel, etc.) comprise and/or are manufactured from a fiber reinforced plastic (FRP). FRPs are a category of composite plastics that use elongated fibrous materials to alter and/or enhance characteristics of the plastic, such as mechanical characteristics (e.g., strength, elasticity, rigidity, etc.). FRP manufacturing typically involves two distinct processes: (1) the fibrous material is manufactured and formed, and (2) the fibrous material is bonded with the polymer matrix during molding. The fibers may be manufactured in two- or three-dimensional orientations (e.g., aligned along a plane x- and y-directions, fibers incorporated in the x-, y- and z-directions). Fiber preforms may be manufactured in sheets, continuous mats, or as continuous filaments for spray applications. The four major ways to manufacture the fiber preform is through the textile processing techniques of weaving, knitting, braiding and stitching. A rigid structure is usually used to establish the shape of FRP components. In some embodiments, parts are laid up on a flat surface referred to as a “caul plate”” or on a cylindrical structure referred to as a “mandrel.” However, most fiber-reinforced plastic parts are created with a mold or “tool.” In some embodiments, the molding process of FRP begins by placing a fiber preform on or in a mold. The fiber preform may be dry fiber, or fiber that already contains a measured amount of resin (“prepreg”). Dry fibers are “wetted” with resin either by hand or the resin is injected into a closed mold. The part is then cured, leaving the matrix and fibers in the shape created by the mold. Heat and/or pressure are sometimes used to cure the resin and improve the quality of the final part. Different methods of forming include bladder molding, compression molding, autoclave and vacuum bag, mandrel wrapping, chopper gun, filament winding, pultrusion, and resin transfer molding. In some embodiments, any suitable materials sand methods for the production of one or more elements of the curb systems described herein (e.g., curb, wall panel, etc.) out of FRP materials find use in embodiments herein.
In some embodiments, one or more elements of the curb systems described herein (e.g., curb, wall panel, etc.) comprise and/or are manufactured from a polymer material. Some non-limiting examples of suitable nondegradable materials include polymeric materials, for example, polyolefins such as polyethylene (e.g., ultra-high molecular weight polyethylene (UHMWPE or UHMW)) and polypropylene including atactic, isotactic, syndiotactic, and blends thereof; polyethylene glycols; polyethylene glycol (PEG) coated polyethylene terephthalate (PET), polyethylene oxides; polyisobutylene and ethylene-alpha olefin copolymers; fluorinated polyolefins such as fluoroethylenes, fluoropropylenes, fluoroPEGSs, and polytetrafluoroethylene; polyamides such as nylon, Nylon 6, Nylon 6,6, Nylon 6,10, Nylon 11, Nylon 12, and polycaprolactam; polyimines; polyesters such as polyethylene terephthalate, polyethylene naphthalate, polytrimethylene terephthalate, and polybutylene terephthalate; polyethers; polybutester; polytetramethylene ether glycol; 1,4-butanediol; polyurethanes; acrylic polymers; methacrylics; vinyl halide polymers such as polyvinyl chloride; polyvinyl alcohols; polyvinyl ethers such as polyvinyl methyl ether; polyvinylidene halides such as polyvinylidene fluoride and polyvinylidene chloride; polychlorofluoroethylene; polyacrylonitrile; polyaryletherketones; polyvinyl ketones; polyvinyl aromatics such as polystyrene; polyvinyl esters such as polyvinyl acetate; etheylene-methyl methacrylate copolymers; acrylonitrile-styrene copolymers; ABS resins; ethylene-vinyl acetate copolymers; alkyd resins; polycarbonates; polyoxymethylenes; polyphosphazine; epoxy resins; aramids; rayon; rayon-triacetate; spandex; silicones; and copolymers and combinations thereof.
In some embodiments, one or more elements of the curb systems described herein (e.g., curb, wall panel, etc.) comprise and/or are manufactured from ultra-high-molecular-weight polyethylene (UHMW), or high-modulus polyethylene as is it also known, which is a subset of thermoplastic polyethylene. UHMW is well-known in the art of plastics by having high impact strength and abrasion resistance (Stein, H. L., Ultra High Molecular Weight Polyethylene, Engineered Material Handbook, Vol. 2, 167-171 (1998); herein incorporated by reference in its entirety). UHMW is 15 times more resistant to abrasion than carbon steel and its coefficient of friction is significantly lower than that of nylon and acetyl. UHMW has superior abrasion resistance than Teflon. The combination of high impact strength, coefficient of friction, and abrasion resistance of UHMW makes well-suited for applications where lower molecular weight grades fail. UHMW has been used in medical devices, cables, wire, and fibers for personal armor, cut-resistant gloves, bow strings, fishing line, climbing gear, and industrial webbing. UHMW is both FDA and USDA approved for use in food processing and medical applications. UHMW cannot be transformed and molded by conventional plastic processing techniques such as injection molding, blow molding or thermoforming. Rod tubing and profiles of UHMW are typically created by compression molding or ram extrusion processing. During ram extrusion, UHMW powder is gravity fed into a chamber and a hydraulic ram pushes the powder from this chamber into a die. The die is the shape of the desired plastic, a certain diameter rod, a certain tube, or a profile shape. Heaters are employed on the outside of the die to heat the plastic and make it form into the shape of the die. The hydraulic ram moves back and forth continuously feeding the powder into the die. As the material comes out of the die, it travels the length of the conveyor after which it is cut to length. Ram extrusion does not shear the material that is being manufactured as does single screw extrusion which employs a rotating screw to move the material. It moves the material by hydraulically pushing it through the die which is the desired shape of the end product.
In some embodiments, curbs herein are shaped/formed by any suitable technique, such as ram extrusion, compression molding, gel spinning, sintering, 3D printing, etc. The curb may be formed into a profile configured for particular structural surfaces (e.g., vertical/horizontal, off-vertical/horizontal, vertical/off-horizontal, off-vertical/off-horizontal, corner, ramp, doorway, un-even surface, etc.). In some embodiments, any embodiments described herein for the junctions of orthogonal structures (e.g., vertical wall meeting a horizontal floor) will also find use in non-orthogonal junctions.
In some embodiments, curb systems herein comprise the filler material. In some embodiments, filler is any suitable material to fill the void between the curb and the structural surfaces, such as, for example, concrete, a concrete-filler mixture, a cement-filler mixture, a concrete-polymer mixture, industrial foams, polymers, insulation, plastics, and the like. In some embodiments, the filler material fills the cavity behind the curb, prevents damage to the curb, seals the area behind the curb, prevents infestation, prevents bacterial/mold growth, prevents water invasion, and/or structurally reinforces the structural surfaces and/or curb. Similarly, the interior and/or surface of walls, panels, doors, floors, etc. may comprise similar materials to the fillers above.
In some embodiments, the curb systems herein interact with floor/flooring materials (e.g., are adhered to). Suitable floor/flooring materials include, but are not limited to: ceramic (e.g., tile), wood, concrete, cement, glass, natural or synthetic stone, urethane, sheet vinyl, vinyl composite, rubber, laminate, linoleum, polyaspartics, epoxies, etc. In some embodiments, curb systems are tailored (e.g., appropriate adhesives/sealants/chemical welds are selected) to the floor/flooring material present.
In some embodiments, adhesives, glues, and/or sealants are provided in the systems herein to adhere two or more components together (e.g., curb to floor, curb to wall, filler to wall, filler to floor, etc.). In some embodiments, adhesives, glues, and/or sealants are provided in the systems herein to seal a gap between to components. Exemplary adhesives, glues, and/or sealants that find use in some embodiments herein include, but are not limited to: epoxies, silicone-based, cyanoacrylates, urethanes adhesives, acrylic adhesives, rubber cements, pressure sensitive adhesives, heat sensitive adhesives, thermosetting structural adhesives, UV-curing adhesives, acrylic, foam, latex sealants, polysulfide sealants, polyurethane sealants, etc. In some embodiments, the type of adhesives, glues, and/or sealants is selected based on the materials to be adhered/sealed and/or the desired characteristics of the adhesion/seal (e.g., strength, durability, lifetime, waterproof, bacteria/mold resistance, etc.).
In some embodiments, a chemical weld is provided in the systems herein to adhere two or more components together (e.g., curb to floor, curb to wall, filler to wall, filler to floor, etc. and/or to seal a gap between to components. Compared to glues and sealants, a chemical weld is a more permanent method for bonding two materials. Chemical welding involves the application of one or more materials (e.g., solvents, reactants, components, etc.) on a surface or between two surfaces; a chemical reaction within the applied materials and/or between the applied materials and the surfaces results in chemical bonding of the surfaces (e.g., to each other, to the weld materials, etc.). Exemplary chemical components of chemical weld systems that may find use in embodiments herein include, but are not limited to: an aromatic polyisocyanate such as 1,3-phenylenediisocyanate, 4,4′-diphenyldiisocyanate, 1,4-phenylenediisocyanate, 4,4′-diphenylmethanediisocyanate, 2,4-tolylenediisocyanate, 2,6-tolylenediisocyanate, 4,4′-toluidinediisocyanate, 2,4,6-triisocyanatetoluene, 1,3,5-triisocyanatebenzene, dianisidine diisocyanate, 4,4′-diphenyletherdiisocyanate, 4,4′,4″-triphenylmethanetriisocyanate or xylene diisocyanate; an aromatic polyisocyanate such as tri-methylene diisocyanate, tetra-methylene diisocyanate, hexa-methylene diisocyanate, penta-methylene diisocyanate 1,2-propylenediisocyanate, 2,3-butylenediisocyanate, 1,3-butalenediisocyanate, dodeca-methylene diisocyanate or 2,4,4-trimethylhexamethylenediisocyanate; an aliphatic polyisocyanate such as omega,omega-diisocyanate-1,3-dimethylbenzene, omega,omega-diisocyanate-1,4-dimethylbenzene, omega,omega-diisocyanate-1,4-diethylbenzene, 1,4-tetramethylxylylenediisocyanate, 1,3-tetramethylxylenediisocyanate; an alicyclic polyisocyanate such as 3-isocyanatemethyl-3,5,5-trimethylcyclohexylisocyanate, 1,3-cyclopentanediisocyanate, 1,3-cyclohexanediisocyanate, 1,4-cyclohexanediisocyanate, methyl-2,4-cyclohexanediisocyanate, methyl-2,6-cyclohexanediisocyanate, 4,4′-methylenebis(cyclohexylisocyanate) or 1,4-bis(isocyanatomethyl)cyclohexane; an aromatic dicarboxylic acid such as sigma-phthalic acid, isophthalic acid, terephthalic acid, 1,4-dimethylterephthalic acid, 1,3-dimethylisophthalic acid, 5-sulfo-1,3-dimethylisophthalic acid, 4,4-bidphenyldicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, norbornene dicarboxylic acid, diphenylmethane-4,4′-dicarboxylic acid or phenylindandicarboxylic acid; an aromatic dicarboxylic acid anhydride such as phthalic anhydride, 1,8-naphthalenedicarboxylic acid anhydride or 2,3-naphthalenedicarboxylic acid anhydride; an alicyclic dicarboxylic acid such as hexahydrophthalic acid; an alicyclic dicarboxylic acid anhydride such as hexahydrophthalic anhydride, 3-methyl-hexahydrophthalic anhydride, 4-methyl-hexahydrophthalic anhydride or 1,2-cyclohexanedicarboxylic acid anhydride; an aliphatic dicarboxylic acid such as oxalic acid, malonic acid, succinic acid, adipic acid, sebacic acid, azelaic acid, suberic acid, maleic acid, chloromaleic acid, fumaric acid, dodecanoic acid, pimellic acid, citraconic acid, glutaric acid or itaconic acid; an epoxy group such as ethyleneglycoldiglycidylether, triglycidylether, trimethylolpropanetriglycidylether, N,N,N′,N′-tetraglycidylethylenediamine, or glycerin diglycidylether; an acid anhydride group such as pyromellitic anhydride, benzophenonetetracarboxylic acid dianhydride, biphenyltetracarboxylic acid dianhydride, oxydiphthalic acid dianhydride, diphenyl sulfone tetracarboxylic acid dianhydride, diphenyl sulfide tetracarboxylic acid dianhydride, butanetetracarboxylic acid dianhydride, perylene tetracarboxylic acid dianhydride, or naphthalenetetracarboxylic acid dianhydride; an aziridinyl group such as N,N′-toluene-2,4-bis(1-aziridinecarboxide), N,N′-diphenylmethane-4,4′-bis(1-aziridinecarboxide), triethylenemelamine, or tri-1-aziridinylphosphineoxide; an aliphatic diamine such as ethylenediamine or hexamethylenediamine; an alicyclic diamine such as 4,4′-diamino-3,3′-dimethyldicyclohexylmethane, 4,4′-diamino-3,3′-dimethyldicyclohexyl, diaminocyclohexane or isophoronediamine; or an aromatic diamine such as xylenediamine. Chemical welding agents that find use in embodiments herein may be others known in the field. Exemplary chemical weld systems are described, for example, in U.S. Pub No. 2016/0222263; U.S. Pub No. 2002/0114914, and U.S. Pat. No. 5,810,956; each of which is herein incorporated by reference in its entirety.
In some embodiments, one or more components of the curb systems herein comprise or exhibit antimicrobial (e.g., anti-mold, antibacterial) and/or antiseptic characteristics. In some embodiments, one or more materials of the curb systems herein comprise, are coated in, and/or are impregnated with an antimicrobial (e.g., anti-mold, antibacterial) and/or antiseptic agent. Suitable agents for rendering such materials antimicrobial (e.g., anti-mold, antibacterial) and/or antiseptic are understood in the field.
In some embodiments, one or more components of the curb systems herein comprise or exhibit waterproof and/or water resistant characteristics. In some embodiments, one or more materials of the curb systems herein comprise, are coated in, and/or are impregnated with a waterproof and/or water resistance agent. Suitable agents for rendering such materials waterproof and/or water resistant are understood in the field.
In some embodiments, the curbs and systems described herein find use in a variety of fields and facilities, including, but not limited to the meat processing industry, the fruit and vegetable industry, catering facilities, slaughter houses, the confectionary industry, retail shops, the fish processing industry, supermarkets, restaurants, the bakery industry, walk-in freezers, pharmaceutical manufacturing facilities, the dairy industry, logistics, hospitals, the beverage industry, etc.
Any publications or patents mentioned in the present application are herein incorporated by reference. Various modification and variation of the described methods, compositions, and system described herein will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention that are obvious to those skilled in the relevant fields are intended to be within the scope of the following claims.
