Patent Publication Number: US-6991400-B1

Title: Cap sealer for caulked joints

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   Not applicable 
   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not applicable 
   REFERENCE TO A “MICROFICHE APPENDIX” 
   Not applicable 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The apparatus of the present invention relates to sealing caulked joints. More particularly, the present invention relates to an improved cap for sealing a joint filled with sealant or caulking compound which adheres more firmly to the hard surfaces adjacent the joint. 
   2. General Background of the Invention 
   In the art of working with stone in order to construct a building or the like structure, it is imperative that the space between adjacent blocks of stone be filled with a caulking or sealant material so that there is a proper seal between the surfaces of the two adjacent stone or the like members. The use of caulking or sealant material for this purpose is well known in the art and has had a long history. In fact, there have been additional sealing procedures which are utilized in order to more effectively seal the joint. U.S. Pat. No. 5,211,506 discloses a backer rod tool which is utilized to insert material to a proper depth within the joint prior to placing the sealing or caulking material into the joint. In addition to this process, there has been in use for years a product known as Weathercap, which is a trademark owned by Weathercap, Inc., wherein following the cleaning, priming and placement of sealant or caulking into the joint, and the Weathercap is installed. The Weathercap is a flexible material, preferably, but not necessarily made of lead or other material having the same properties of lead which is inserted along the joint with edges of the cap resting on adjacent surfaces of the stone. The cap historically has been used to assist in maintaining the integrity of the joint preventing the intrusion of moisture. 
   One of the problems in the Weathercap which has been used over the years is the fact that the cap member was substantially a flexible material which simply rested on the top of the stones with little means for adherence in any manner to the edge of the block (stones) which it rested upon. Therefore, historically this Weathercap, although a marketable product, did not solve all of the problems, since it itself did not have sufficient means for securing it firmly to the stone in its own right, and therefore, did not fully protect the caulking or sealant compound. Therefore, there is a need in the art for a product which would greatly improve the ability of a sealed joint to withstand movement and prevent the capping member from separating from the stone as it has done in the past. 
   BRIEF SUMMARY OF THE INVENTION 
   The apparatus of the present invention solves the problems in a simple and straight forward manner. What is provided is an improved sealant cap which is comprised of a flexible material, preferably, but not necessarily made of lead or other material having the same properties of lead, having a first arm member which is inserted downward into the caulking material after the caulking material has been in place within the joint. The downward depending arm portion extends from a cap portion downward, so that as the arm member is pushed into the caulking material, the upper cap portion spans across the joint and rests on the adjoining stone members. There is further provided a plurality of ridges formed on the undersurface of the improved cap cover, these ridges increase (by 50%) the area of the underside of the cap for the sealant to adhere to and the surface of the stone in such a manner as to prevent the cap from separating from the stone and insuring an elastic protection for the joints. A second embodiment of the flat cap member includes an embodiment which is used as a “cove cap” to seal the surfaces of adjacent stones which have both a horizontal and vertical surface, with likewise the cove cap having the undersurface of the cap including a plurality of ridges for adhering to the stone in a similar manner. 
   Therefore, it is the principal object of the present invention to increase the area available for the sealant to adhere to, creating an improved cover for a joint which has been filled with sealant or caulking material adhering more firmly to the surface upon which it is placed, protecting it from moisture intrusion, puncture and vandalism, ultraviolet rays, chemicals, abrasion, extreme weather and dirt; 
   It is a further object of the present invention to provide an improved Weathercap product which can be used both on flat joints and on joints comprised of horizontal vertical surfaces, having an underside which has a plurality of ridges for adhering to the surface upon which it is placed and for improving the contact between the surface and the cap over a prolonged period of time; 
   It is a further object of the present invention to provide a Weathercap apparatus which includes a downward depending leg member, so that the masonry joint is reduced by one half when the Weathercap is inner posed in a joint between sealants; 
   It is a further object of the present invention to provide an improved Weathercap which remains flexible and will not tear or shear; 
   It is a further object of the present invention to provide a Weathercap which covers sealant, thereby prolonging life and preventing margin checking, and which is not a conductor of heat or cold; 
   It is a further object of the present invention to provide a Weathercap which resists corrosion, accepts paint thereupon, and resists mold attack on covered sealant in high humidity areas; 
   It is a further object of the present invention to provide a Weathercap which is made of a material which is low in tensile strength, hardness, elastic modulus and increased strength. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
       FIG. 1  is an overall view of the preferred embodiment of the apparatus of the present invention as utilized on a flat surface; 
       FIG. 2  is an overall view of the apparatus of the present invention as utilized on mating horizontal and vertical surfaces; 
       FIGS. 3 and 4  are views of the preferred embodiment of the apparatus of the present invention as utilized on flat and vertical arid horizontal surfaces respectively; 
       FIGS. 5A–5D  illustrate sequential steps of the installation of the apparatus of the present invention during the caulking process. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIGS. 1–5D  illustrate the preferred embodiment of the apparatus of the present invention by the numeral  10  and the method of installation thereof. As illustrated, for example, in  FIG. 1 , there is illustrated apparatus  10  which comprises a substantially flexible material  12  having an overall cap portion  14  with a leg portion  16  extending from the underside  18  of the cap portion  14 . As illustrated in side view in  FIG. 1 , this embodiment of the apparatus would be used primarily for sealing flat surfaces between two stone components utilizing the present invention. As illustrated in  FIG. 1 , leg portion  16  extends from substantially a center point on the undersurface  18  of the cap portion  14  of apparatus  10 . Wherein the upper face  20  of the cap  14  is flat, the undersurface  18  includes a plurality of ridges  22  which define a plurality of semicircular channels  24  there between, the purpose of which will be described further. As further illustrated, the leg member  16  also includes a terminating end portion  26  which is shaped substantially in an arrowhead shape having a lower depending point portion  28  and a pair of outward extending shoulders  29  and  30 . 
   Turning now to  FIG. 2 , the cap apparatus  10  would be substantially the same type of apparatus as illustrated in  FIG. 1  but for the fact that in this particular embodiment, the cap apparatus would be entitled a “cove” cap, which would be the type of cap utilized for mating of vertical and horizontal surfaces, as is more clearly seen in  FIG. 4 . Again, the components of the apparatus are identical and as seen by the view in  FIG. 2 . The cap apparatus  10  is flexible since it is comprised of high modulus type material such as lead or other type of material with similar characteristics, the cap is able to flex to allow movement while maintaining the integrity of the joint. 
   Turning now to  FIG. 3 , there is illustrated a view of the apparatus  10  as being positioned on a sealed joint. As illustrated, there is a pair of, for example, stones  30 ,  32  which are abutted against one another, forming a space  34  which must be sealed. This sealing of the space is normally accomplished with the first use of a backer rod or bond breaker tape  36  pushed down within the space  34  as seen in the process in  FIGS. 5A–5B , leaving an upper portion  37  which must be sealed. This is normally done with the use of a sealing or caulking material  38  which as seen in  FIG. 3 , has been placed within the space  37  and filled. After the caulking material is in place and is still quite soft, the cap  10  would then be inserted down onto the space with the downward depending leg portion  16  of cap  10  being forced downward into the caulk so that the arrowhead portion  26  of the leg is embedded within the caulk and the plurality of ridges  22  are likewise forced into the caulk with the caulk also filling the semicircular channels  24  on the under face  18  of the cap portion  14 . As also illustrated, the cap portion  14  is such a width that the end portions of the cap extend beyond the opening  37  and make contact with the upper surface of each of the stones  30 ,  32  wherein caulk would have been forced out of the space as the cap member is pushed on. Therefore, as the extra caulk  38  is being removed by a tool  40 , the caulk would then be allowed to substantially dry so that the caulk would hold the cap  10  in place via the leg member  16  and the plurality of under ridges  22 . 
   One feature of the improved Weathercap of the present invention is its ability to decrease the size of a joint by one half when the Weathercap is inserted into a joint filled with sealant. For example, if there were a joint between blocks, which may be ¾ inch in width, if one would simply attempt to seal such a joint, because the joint is more than ½ in width, the results would be “out of code”. However, because the Weathercap of the present invention includes the downward depending leg portion  16 , when the Weathercap is placed into the joint ¾ inch in width, the leg member  16  in effect transforms the single ¾ inch joint to two ⅜ inch joints separated by the leg member  16 . Therefore, each “joint” being now ⅜ inches in diameter, is able to be sealed with conventional material. This feature, therefore, allows the improved Weathercap to seal a larger joint, and because of the plurality of ridges and channels on the underside, enables it to adhere to the sealant and seal the joints for a longer period of time. 
   Turning now to  FIG. 4 , there is substantially the same type of process that is taken place in relation to  FIG. 3 , however the cap  10  which is utilized in this particular embodiment is the “cove cap” because it is sealing a joint or an opening  37  between a vertical surface of block  30  and the horizontal surface of a lower block  32 . As seen in this embodiment, the backer rod or bond breaker tape  36  has been placed within the opening  37 . Caulking or sealant material  38  is then forced within the opening to extend outward beyond or along the vertical and horizontal surfaces out of the opening. The cap  10  is then inserted into the caulking with the leg  16  extending therein so that the caulking completely surrounds the leg  16 , in particular the end portion  26  and the caulking fills the various semicircular channels  24  and is held in place via the ridges  22  of the cap member. The cap surface  14  is able to form a seal along between the vertical and horizontal surfaces. Also, because of the under ridges  22  and the channels  24  formed thereby, the cap will accomplish the same results of these joints as does the flat cap on joints formed by stones adjacent to one another. 
   Reference is now made to  FIGS. 5A–5D  wherein there is seen a series of sequential steps for the process of sealing a joint between building blocks such as concrete or the like material. There is first included a pair of blocks  30 ,  32  forming a flat surface  31  and channel  37  there between. The joint is marked and masked for guidance. Next, a backer rod or bond breaker  36  is inserted down into the opening  37  via a tool  50  to a particular point as seen in  FIG. 5B . The tool  50  is then removed, and the Weathercap  10  is prefit thereupon. The cap  10  is then primed and both top and sides of the joint are primed. Next, the caulking or sealant material  38  is placed within the opening  37  between the upper surface  31  of the blocks and the rod or tape member  36 . In this particular embodiment, the caulking is being inserted from a caulking gun  52 , as illustrated. After the caulking has been placed into the opening  37  to a point where there is excess caulking along the top surface of block  30 ,  32 , the cap member  10  is then pressed downward into the position as was illustrated in  FIG. 1 . The excess caulking  38  would then be removed, and the caulking has filled the space around the leg members  16  and the various ridges  22  and semicircular channels  24 . Therefore, the cap member would adhere to the caulk within the channel  37  and the overlapping edges of the cap  10 , as the cap rests on the stones  30 ,  32  would also adhere to the caulking on the upper surface of the stones. This would form a strong and flexible protective seal between the outer ambient atmosphere and the sealed space  37 . The joint is allowed to set for two days before the masking tape is removed. If the cap is to be painted, the masking tape is left in place and metal which is rubbed with vinegar (10% volume concentration), and primed with Sherwin &amp; Williams galvite primer 631–5191 (or equivalent) which is then covered with latex flat paint. 
   Primarily because of the feature of the plurality of ridges which define a plurality of channels there between on the underside of the cap portion, this improved sealing cap for joints enables this improved product to adhere more firmly to the surfaces of the stone and the caulking there between. These features solve a problem which heretofore was plaguing the industry in that the inability of the old Weathercap product to maintain a seal between itself and the underlying surface caused by movement, resulting in loss of integrity of the joint and ultimately its failure, allowing seepage of moisture into the building. 
   Because of the properties of the Weathercap being constructed of material such as lead or other material having similar characteristics, if there is building movement, the low creep strength causes the lead or other suitable material to creep into the new configuration. Temperature change accelerates this creep movement. The low elastic modulus allows this process to continue indefinitely within the joint designed limits. Other metals would retain their original shape and permit moisture into the joints. 
   The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.