Abstract:
A method and apparatus for forming a sealed joint comprises a joint member having at least one elongate component that comprises a top surface, a bottom surface, a first component side and a second component side, wherein at least a portion of the top surface has a contour which is curved. In forming a joint a first member is formed on a substrate. The joint member is positioned against the first member and the substrate. A second member is formed on the substrate immediately adjacent to the joint member. In some embodiments the joint member comprises two components, one of which is removed following formation of the second member.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
         [0001]    Not Applicable  
         STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH  
         [0002]    Not Applicable  
         BACKGROUND OF THE INVENTION  
         [0003]    1. Field of the Invention  
           [0004]    Various embodiments of the present invention are directed to systems for maintaining and/or at least partially filling a space between two materials, particularly materials such as concrete, brick, stucco, plastic, wood, metal, and other somewhat rigid materials associated with construction and manufacturing. In some embodiments the invention is directed to joints, such as expansion joints, and more specifically to backings, fillers, forms, stand-offs, spacers and other devices suitable for insertion into the space between materials to form a joint, hereinafter referred to cumulatively as a spacer or joint spacer. In those embodiments directed to a joint spacer, the spacer comprises one or more components that are configured for placement into and/or removal from a joint space.  
           [0005]    2. Brief Description of Related Technology  
           [0006]    Expansion joints and joints in general are present in many industrial applications. Typically a joint comprises a groove, trough or other space of selected shape and size between two surfaces or materials. Often the materials that define the space, such as concrete, wood, metal, plastic, etc. are often quite rigid. The space between these more rigid materials is at least partially filled with a joint spacer. The material of the joint spacer is typically less rigid than the surrounding materials. The joint spacer acts to maintain a space between the materials.  
           [0007]    In many applications joint spaces are known to be formed by cutting into rigid materials or by forming the space through the utilization of rigid forming materials or standoffs. Once the joint space has been cut, or the forms removed, a flexible backer rod or other form is inserted into the space to a predetermined depth in order to obtain the desired joint shape and depth. After the backer rod is inserted, sealant is applied to finish the joint.  
           [0008]    There are numerous disadvantages to cutting joint spaces in preparation for receiving a sealant. For example, in applications involving walls, it is difficult, if not impossible, to cut joint spaces adjacent to fenestrations or other wall penetrations in order to seal them to the surrounding material without damaging the frame or finish of the penetrating fixture in the cutting process. In addition, the cutting of joint spaces is expensive and difficult to do on vertical surfaces or from scaffolding. Furthermore, dust resulting from the cutting process may settle in the formed joint space. The dust may hinder sealant adhesion.  
           [0009]    As mentioned above, as an alternative to cutting a joint space from the material, standoff type devices may be used to create the joint space. However, processes using forms and other standoff devices are also known to include drawbacks. For example, because standoffs are typically constructed of fairly rigid material that are put in place prior to the application of plastic construction materials, the forms often cannot be readily removed from the resulting joint space between the cured material without the destructive use of power tools or other equipment.  
           [0010]    Often time standoffs are simply left in place within the joint space, however, because the standoff is made of rigid material that does not fill a substantial portion of the space, the standoff will not provide an insulating effect. Moreover, a standoff left in place may prevent the joint from opening and closing as intended, and may potentially lead to damage of the adjoining materials.  
           [0011]    Known components that are inserted into the formed joint space, such as joint backer rods and other foam or semi-rigid materials are inserted into the joint space in order to establish a joint bottom and to provide a convex contour to the bottom of the joint space. As currently used however, backer rods and similar devices must be inserted into the joint space following placement of the materials adjacent to the space, or cutting of the space into the materials, but prior to the application of sealant. Almost without exception the backer rod or similar device is inserted into the space by the sealant contractor prior to application of the sealant. Often times during the insertion process the backer rod is punctured by the rough edges of the space or by the tools used to insert the rod. A punctured foam backer rod may emit gas causing bubbling in the plastic sealant. Another drawback to the use of backer rod is that it may be inserted at an inconsistent depth within the joint space. If this occurs, the joint sealant may fail prematurely because it was not placed at the desired depth to width ratio. In addition, expensive sealants may be wasted as a result of filling the joint space to a depth further than desired.  
           [0012]    In light of the above, it is clear that a need exists to provide a joint formation process and joint insertion material which avoids the drawbacks associated with those previously utilized.  
           [0013]    All US patents and applications and all other published documents mentioned anywhere in this application are incorporated herein by reference in their entirety.  
           [0014]    Without limiting the scope of the invention a brief summary of some of the claimed embodiments of the invention is set forth below. Additional details of the summarized embodiments of the invention and/or additional embodiments of the invention may be found in the Detailed Description of the Invention below.  
           [0015]    A brief abstract of the technical disclosure in the specification is provided as well only for the purposes of complying with 37 C.F.R. 1.72. The abstract is not intended to be used for interpreting the scope of the claims.  
         BRIEF SUMMARY OF THE INVENTION  
         [0016]    The present invention is directed to a variety of embodiments. In at least one embodiment, the invention is directed to one or more joint spacer components having at least one curved surface which is positioned to at least partially define the bottom of the joint space. At least one of the joint spacer components is constructed and arranged to be capable of expanding and contracting within the joint space.  
           [0017]    In at least one embodiment the component is a substantially flexible, elongate member.  
           [0018]    In at least one embodiment the component has a cross-sectional shape that is substantially flat on at least two sides, and curved on at least one side.  
           [0019]    In some embodiments a plastic or flowable material such as preset terrazzo concrete or stucco at least partially defines the joint space. Where the joint space is defined by a plastic material the joint spacer is a member comprised of at least two components in a stacked configuration that are removably engaged to one another. Subsequent to the plastic material being made substantially rigid, the component positioned at the top or nearest to the opening of the joint space may be removed from the space. The lower or bottom component remains in place within the joint space. Alternatively, where the joint space is to be at least partially defined by rigid materials, such as wood, metal, synthetic or similar materials, the joint spacer may comprise a single component.  
           [0020]    Where the joint spacer comprises a multi-component member the components are engaged to one another to form an elongated, sheet or member. In at least one method of use the member is constructed and arranged to be inserted within a joint space or to be position adjacent to a surface defined by a substantially rigid material.  
           [0021]    Regardless of whether the joint spacer is inserted during or following the formation of a joint space, the joint spacer acts to define the joint space between two sections of material, such as concrete, wooden members, molding, etc. As the sections contract, expand, flex, and otherwise move as a result of changes in the environment such as temperature, humidity, etc., the space between the sections is maintained by the joint spacer. As a result the joint spacer is constructed to be capable of expanding and contracting to a substantial extent.  
           [0022]    In some embodiments at least one side of the member is adhesively and removably engaged to at least one surface of a substantially rigid material. After the member is placed against a single surface of a substantially rigid first material a second material may be placed against the side of the member opposite the adhesively engaged side of the member. The member maintains a space between the materials. Where the member comprises multiple components, one or more top components of the member may then be removed from the bottom component and withdrawn from the joint space to complete the formation of the joint.  
           [0023]    In at least one embodiment a sealant or other material may be placed over the component that remains within the joint space.  
           [0024]    In at least one embodiment at least the bottom component defines a convex, surface that extends into the joint space.  
           [0025]    In at least one embodiment the bottom component is constructed and arranged to provide the joint space with a width to depth ratio of about 2 to 1.  
           [0026]    In at least one embodiment the height and width of the member may respectively range between about ⅛ th  of an inch to about four inches or more.  
           [0027]    In at least one embodiment of the invention, at least one of the components is constructed from closed and/or open cell foam.  
           [0028]    In at least one embodiment the invention is directed to a building or structure such as a residential or commercial dwelling having a joints formed with a component and/or component members as described herein.  
           [0029]    These and other embodiments which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages and objectives obtained by its use, reference should be made to the drawings which form a further part hereof and the accompanying descriptive matter, in which there is illustrated and described a embodiments of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)  
       [0030]    A detailed description of the invention is hereafter described with specific reference being made to the drawings.  
         [0031]    [0031]FIG. 1 is a perspective view of an embodiment of the invention.  
         [0032]    [0032]FIG. 2 is a perspective view of an embodiment of the invention.  
         [0033]    [0033]FIG. 3 is a schematic drawing of an embodiment of the invention as shown in an environment of use.  
         [0034]    [0034]FIG. 4 is a schematic drawing of the embodiment shown in FIG. 3 after the removal of the top component.  
         [0035]    [0035]FIG. 5 is a schematic drawing of an embodiment of the invention as shown in an environment of use.  
         [0036]    [0036]FIG. 6 is a schematic drawing of the embodiment shown in FIG. 5 after the removal of the top component.  
         [0037]    [0037]FIG. 7 is a schematic drawing of the embodiment shown in FIG. 6 after a sealant or other substance has been inserted into the joint space.  
         [0038]    [0038]FIG. 8 is a perspective view of an embodiment of the invention.  
         [0039]    FIGS.  9 - 11  show an embodiment of the invention as used in the formation of a sealed joint. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0040]    While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.  
         [0041]    For the purposes of this disclosure, like reference numerals in the figures shall refer to like features unless otherwise indicated.  
         [0042]    As indicated above, the present invention is directed to a variety of embodiments. A first embodiment is shown in FIG. 1 wherein a joint member, indicated generally at  10 , is shown. Joint member  10  is comprised of at least one component  12 , and in alternative embodiments is comprised of at least two components  12  and  14 . Where the member  10  comprises more than one component the multiple components such as, components  12  and  14  are removably engaged to one another so that subsequent to the placement of the member  10  into a pre-existing joint space or the creation of a joint space with the use of member  10 , the upper component  14  may be readily removed from the bottom component  12  without damaging the bottom component.  
         [0043]    In the various embodiments described herein, the member  10  and any of its components, such as components  12  and  14 , are capable of expanding and contracting when acted upon by an outside force. In some embodiments the components of member  10  are preferably light weight and flexible enough to be easily manipulated such as by being bent, folded to an angle of at least 90 degrees or more without damaging or detrimentally affecting the structure of the components  12  and  14  or member  10 . Some examples of material suitable for use in manufacturing the member  10  and its components  12  and  14  are: foam, foam-rubber, and/or similar materials including but not limited to closed cell polyethylene foam and open cell polyurethane foam.  
         [0044]    Foam and similar materials gain some of their desired characteristics by forming a matrix of cells. Often the cells of the foam contain various gasses. As is mentioned above, it is known that when foam is torn or otherwise disrupted, cells of the foam are ruptured and thus release any gas contained therein. In joint applications release of such gas may be particularly bothersome in that the released gas may interfere with the performance of the joint filler by forming bubbles in the sealant or other material placed upon the joint filler. Not only is the presence of bubbles in the sealant unsightly but the bubbles may also compromise the weatherproofing effectiveness of the sealant.  
         [0045]    The present invention avoids potential gas release and its affects by avoiding the need to tear or cut the member  10  or its components  12  and  14  by removably engaging the components  12  and  14  through the use of an adhesive and/or mechanical engagement interface.  
         [0046]    In the embodiment shown in FIG. 1, the bottom component  12  may be adhesively engaged to the upper component  14 . Where an adhesive or other chemical  16  is used to engage the components, when the components  12  and  14  are separated, the adhesive or other coating is removed along with the upper component  14 , leaving the exposed surface  18  of the bottom component  12  clean and free of debris. Suitable adhesives may include removable pressure sensitive adhesives including those that are both thermoplastic and water based. A more specific example of an adhesive that may be suitable for use in the embodiment shown is described in U.S. Pat. No. 5,194,299, the entire content of which is incorporated herein by reference.  
         [0047]    In some embodiments of the invention, an example of which is shown in FIG. 2, the use of adhesives to engage the components  12  and  14  together prior to use may be avoided by providing the components  12  and  14  with complimentary surfaces  18  and  20  that engage one another by a mechanical interface.  
         [0048]    In the example shown in FIG. 2, each component  12  and  14  have a first surface  18  and a second surface  20  which are removably engaged to adjacent surfaces by way of flange or lip  22  that is a shaped to correspondingly fit into groove  24 . By providing each component  12  and  14  with the same corresponding features on the surfaces  18  and  20 , a plurality of adjacent components may be stacked upon one another to provide a member  10  that may be comprised of two, three, four, five, or nearly any other number of components as may be required for a specific joint space. Because joint spaces may have a wide range of depths, a member  10  having multiple components allows a space to be filled to a desired depth in a highly efficient and inexpensive manner.  
         [0049]    In the various embodiments of the invention, the surface of the component  12  be provided with a surface  18  that has an area that is greater than what a more substantially flat or planar surface would otherwise have. In the embodiments shown herein for example, sides  70  and  72  have substantially flat surfaces when compared to the convex shape of surface  18 . The increased surface area of surface  18  provides for improved performance of the member  10  with sealants or other materials placed thereon. The convex surfaces  18  encourages sealants to bond to the material  34  surrounding the member  10  as is discussed in greater detail below.  
         [0050]    The member  10  may be used in a variety of applications. In at least one embodiment member  10  is suitable for use as a joint filler as part of an joint or other construction application. In the embodiments shown, the member  10  has a size and shape to fittingly engage the sides of the joint space, and in some embodiments the bottom of the space as well. To this end, at least one component of the member  10 , such as component  12 , has a shape corresponding to the desired shape of the joint space.  
         [0051]    An example of one type of joint and the manner it which member  10  may be utilized therewith is shown in FIGS. 3 and 4.  
         [0052]    In FIG. 3 a wall or other form  30  has an exterior portion  32  constructed of concrete, stone, wood or other substantially rigid material  34 . The material  34  defines one or more joint spaces  36  which separate sections  38  and  40  of the material  34 .  
         [0053]    In practice, after the first section  38  is put into place or otherwise formed upon the wall interior portion  42 , the member  10  is placed against the surface  44  of the section  38  and the exposed wall interior portion  42 .  
         [0054]    To ensure that the member  10  is held in place against the section  38 , the surface of the member  10  in contact with the section  38  may include an adhesive coating  46 . In embodiments where member  10  is comprised of multiple components, the adhesive coating  46  may be present on one or both the upper component  14  and lower component  12 . Where coating  46  is present on both components  12  and  14 , the coating  46  may aid in retaining the upper component  14  to the lower component  12  prior to removal of the upper component  14 . The adhesive  46  may be pressure sensitive to allow ready removal of the upper component  14  from the joint space  36  without drawing out the lower component  12 .  
         [0055]    Once the member  10  is positioned against the first section  38  the second section  40  is put into place. Where the second section  40  is a flowable material when initially put in to position adjacent to the member  10 , the member  10  comprises at least two components such as components  12  and  14 .  
         [0056]    In some embodiments, sections  38  and  40  may already be present on wall  30 . In this case a singe component member  10  may be inserted directly into the space  36  defined by the exterior sections  38  and  40 . In such a case, the use of an adhesive  46  is not required as the frictional interface of the sections  38  and  40  against the member  10  may be sufficient to retain the member  10  within the space  36 .  
         [0057]    In a two component member  10 , once the space  36  has been formed and member  10  is in place, the upper component is removed from the space  36 , as is shown in FIG. 4. The lower component  12  remains within the space  36 . Component  12  may be sufficiently water proof and/or weather resistant to be left in place without additional sealants or fillers. If desired however, a sealant or other material may be placed on top of surface  18 .  
         [0058]    In another embodiment, shown in FIGS.  5 - 7 , the member  10  is shown as it may be used in the construction of a wall exterior finish adjacent to a window or other structure  52 . Such an exterior finish, window, door, vents, or other structure  52 , utilizing member  10  may be constructed within any commercial or residential dwelling such as building  100  shown in FIG. 8  
         [0059]    In constructing a window  52  into a wall  30 , the window frame  54  is put into place prior to completion or formation of the wall exterior  32 . Where wall exterior  32  is stucco, concrete or other plastic material when initially applied, member  10  will be comprised of at least two components as described above. Where exterior  32  is a rigid member or members when applied, such as vinyl or wood siding, a member  10  comprised of a single component may be used. In FIG. 5 a member  10  is shown having an upper component  14  and a bottom component  12 . FIG. 6 illustrates a member  10  shown comprised of only a single bottom component  12  while any upper component has been removed.  
         [0060]    Once the window frame  54  is appropriately positioned and installed member  10  is placed against the frame  54  and the exposed wall interior or other complimentary surfaces  42 . The exterior  32  is then put into place or completed leaving a joint space  36  within which member  10  is positioned.  
         [0061]    Subsequently following completion of the wall exterior  32 , the upper component of the member  10  is removed to expose surface  18  such as is shown in FIG. 6. A sealant  56  may then be placed over bottom component  12  to complete the formation of the joint, as is shown in FIG. 7.  
         [0062]    Joints utilizing member  10  and/or joint formed according to the methods described herein are useful in many applications including but not limited to: the soundproof of walls; in ceiling and floor penetrations; in wall, ceiling and floor interfaces, both exterior and interior; in joints between rigid flooring materials such as tile, marble and terrazzo; in the production of door frames; in ventilation ducts, plumbing, conduit passages, and other penetrations of interior and/or exterior walls, floors and/or ceilings; in the formation of joints located at structural steel brick ledges used in constructing multi-story brick masonry facade structures, as well as others.  
         [0063]    In some embodiments, such as in the examples shown in FIGS. 3 and 5, the upper component  14  corresponds to an area of the space  36  having a predetermined depth  60  and a predetermined width  62 . This area  64 , has a ratio of width to depth of approximately two to one (2:1).  
         [0064]    It should be noted however, that while a 2:1 width to depth ratio is considered the optimum under the guide lines of the American Society for Testing Materials (ASTM), area  64  may be provided with any ratio desired.  
         [0065]    As indicated above, member  10  is particularly useful in encouraging a sealant  56  to bond with the material  34  of the joint walls  38  and  40  as opposed to the member  10  itself. In some embodiments such as are shown in FIGS.  9 - 11 , the ability of the member  10  to encourage sealant bonding to the material  34  is further enhanced. In the embodiment shown the member  10  is provided with a bonding agent  80 , which is at least partially transferred to the material  34  by the member  10 . Bonding agent  80  is a layer of material such as a coating that is placed on the member  10  prior to placement of the member within the joint space  36 .  
         [0066]    Bonding agent  80  may be used in place of or in addition to an adhesive coating such as is described above. The bonding agent may be placed on any surface of the member  10  but is preferably placed on sides  70  and  72 .  
         [0067]    Preferably, the bonding agent  80  may be any sort of agent that encourages a sealant  56  to bond to the walls  38  and  40  of the material  34 . In at least one embodiment the bonding agent  80  reacts with the moisture of the material  34  in the plastic state causing at least a portion of the bonding agent to adhere or migrate to the walls  38  and  40 . As a result, when the upper component  14  is removed from the joint space  36 , as is shown in FIG. 10, at least a portion of the bonding agent  80  remains in place, incorporated into the walls  38  and  40 .  
         [0068]    Such a bonding agent  80  may be any sort of moisture cure adhesive or coating. In some embodiments the bonding agent  80  includes one or more epoxy functionalities. In at least one embodiment the bonding agent  80  includes one or more bonding enhancers.  
         [0069]    As is shown in FIG. 11, once the walls  38  and  40  solidify, the sealant  56  is applied to the joint space  36 . The presence of the bonding agent  80  in the material  34  encourages the sealant to bond to the walls  38  and  40 .  
         [0070]    The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.  
         [0071]    Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below.  
         [0072]    This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.