Joint seal with body extensions

Abstract

A system for creating a durable water-resistant seal in the joint between adjacent panels. A durable foam-based expansion seal system provides contacting surfaces which are not planar by inclusion of extensions or second bodies and which therefore provide localized areas of higher density.

Claims

1. A joint seal system, comprising: a main body, the main body being resiliently compressible, the main body having a main body first surface, a main body second surface, the main body first surface opposite the main body second surface; a main body bottom surface, a main body top surface, a main body front surface, a main body rear surface, a main body height from the main body bottom surface to the main body top surface, a main body width from the main body first surface to the main body second surface, and a main body length along the main body first surface from the main body front surface to the main body rear surface, a second body, the second body having a second body first surface, a second body second surface, the second body first surface opposite the second body second surface, a second body bottom surface, a second body top surface, a second body front surface, a second body rear surface, a second body height from the second body bottom surface to the second body top surface, a second body width from the second body first surface to the second body second surface, and a second body length along the second body first surface from the second body front surface to the second body rear surface, the second body adhered at the second body first surface to the main body at the main body first surface, the second body height less than the main body height, the second body width not exceeding one third the main body width, and the second body length equal to the main body length, a third body, the third body having a third body first surface, a third body second surface, the third body first surface opposite the third body second surface, a third body bottom surface, a third body top surface, a third body front surface, a third body rear surface a third body height from the third body bottom surface to the third body top surface, a third body width from the third body first surface to the third body second surface, and a third body length along the third body first surface from the third body front surface to the third body rear surface, the third body adhered at the third body second surface to the main body at the main body second surface, the third body height less than the main body height, the third body width not exceeding one third the main body width, and the third body length equal to the main body length.

2. The joint seal system of claim 1, further comprising a packaging body, the packaging body having a packaging body height, a packaging body first surface, and a packaging body length, the packaging body height nearly equal to main body height and the packaging body length equal to the main body length, the packaging body first surface adapted to contact the main body first surface and the second body second surface.

3. The joint seal system of claim 2, further comprising a second packaging body, the second packaging body having a second packaging body height, a second packaging body first surface, and a second packaging body length, the second packaging body height nearly equal to main body height and the second packaging body length equal to the main body length, the second packaging body first surface adapted to contact the main body second surface and the third body first surface.

4. The joint seal system of claim 1, wherein the second body is of a shape selected from a triangular prism, a rectangular prism, a polygonal prism, and a cylindrical segment.

5. The joint seal system of claim 1, wherein the main body front surface, second body front surface, third body front surface, and a packaging body front surface are co-planar.

6. The joint seal system of claim 4, wherein the main body has a main body density and the second body has a second body density greater than the main body density.

7. The joint seal system of claim 6, wherein the main body includes internal voids in communication with at least one of the main body first surface, the main body second surface, the main body bottom surface, the main body top surface, the main body front surface, and the main body rear surface, at least one quarter of the internal voids having a fire retardant material therein.

8. The joint seal system of claim 4, wherein the main body has a main body compressibility and the second body has a second body compressibility less than the main body compressibility.

9. The joint seal system of claim 1, wherein the second body includes a fire retardant material.

10. The joint seal system of claim 1, wherein the second body is composed of a low durometer closed cell foam.

11. The joint seal system of claim 1, wherein the main body has a main body compressibility, the second body has a second body compressibility, and the third body has a third body compressibility, the main body compressibility less than the second body compressibility, and the main body compressibility less than the third body compressibility.

12. The joint seal system of claim 1, wherein the second body includes an intumescent, and the third body includes an intumescent.

13. The joint seal system of claim 1, wherein the main body comprises: a top layer, a central layer, and a bottom layer, the central layer having a central layer height, the central layer height equal to the greater of second body height and the third body height, the second body adhered to the main body at the central layer, the third body adhered to the main body at the central layer, the central layer having a lower permeability than the top layer.

14. The joint seal system of claim 14 wherein the central layer has a central interior layer width less than the main body width.

15. The joint seal system of claim 1 wherein the second body is an ovoid prism.

16. The joint seal system of claim 1 wherein the second body includes a first lamination body and a second lamination body.

17. The joint seal system of claim 1 wherein the packaging body is a cylindrical segment.

18. The joint seal system of claim 1 wherein the second body is formed as an extension of the main body and the third body is formed as an extension of the main body.

19. The joint seal system of claim 11, wherein second body is formed as an extension of the main body and includes a rigid additive and the third body is formed as an extension of the main body and includes a rigid additive.

20. A joint seal system, comprising: a body of resiliently compressible material having a main body, a second body and a third body, the main body having a main body first surface, a main body second surface, the main body first surface opposite the main body second surface; a main body bottom surface, a main body top surface, a main body front surface, a main body rear surface, a main body height from the main body bottom surface to the main body top surface, a main body width from the main body first surface to the main body second surface, and a main body length along the main body first surface from the main body front surface to the main body rear surface, the second body having a second body second surface, a second body bottom surface, a second body top surface, a second body front surface, a second body rear surface, a second body height from the second body bottom surface to the second body top surface, a second body width from the main body first surface to the second body second surface, and the second body formed at the main body first surface, the second body height less than the main body height, the second body width not exceeding one third the main body width, and the second body length equal to the main body length, the third body having a third body first surface, a third body bottom surface, a third body top surface, a third body front surface, a third body rear surface, a third body height from the third body bottom surface to the third body top surface, a third body width from the third body first surface to the main body second surface, and a third body length along the third body first surface from the third body front surface to the third body rear surface, the third body formed at the main body second surface, the third body height less than the main body height, the third body width not exceeding one third the main body width, and the third body length equal to the main body length, a packaging body, the packaging body having a packaging body height, a packaging body first surface, and a packaging body length, the packaging body height nearly equal to main body height and the packaging body length equal to the main body length, the packaging body first surface adapted to contact the main body first surface and the second body second surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] So that the manner in which the described features, advantages, and objects of the disclosure, as well as others which will become apparent, are attained and can be understood in detail; more particular description of the disclosure briefly summarized above may be had by referring to the embodiments thereof that are illustrated in the drawings, which drawings form a part of this specification. It is to be noted, however, that the appended drawings illustrate only typical preferred embodiments of the disclosure and are therefore not to be considered limiting of its scope as the disclosure may admit to other equally effective embodiments.

[0028] In the drawings:

[0029] FIG. 1 illustrates an isometric view of a joint seal system.

[0030] FIG. 2 illustrates an end view of a joint seal system with packaging bodies prior to compression.

[0031] FIG. 3 illustrates a top view of a joint seal system with packaging bodies prior to compression.

[0032] FIG. 4 illustrates an isometric view of the rear of a packaging body.

[0033] FIG. 5 illustrates an isometric view of an alternative embodiment of the joint seal system.

[0034] FIG. 6 illustrates an isometric view of an alternative embodiment of a packaging body.

DETAILED DESCRIPTION

[0035] The present disclosure provides an expansion joint seal system. As can be appreciated, sealants, coatings, functional membranes, adhesives and other functional materials may be applied to or included within the components of the disclosure. The present disclosure enables the design of a hybrid type joint sealant that uses less impregnated or un-impregnated foam and less surface sealant or coating while providing the same or superior sealing capabilities using less materials which is beneficial for the environment and provides for a more economical system.

[0036] Referring to FIG. 1, an isometric view of one embodiment of a joint seal system 100 is illustrated, where the second body 120 and the third body 130 are separate from and adhered to the main body 110. The joint seal system 100 includes a main body 110, a second body 120, and a third body 130. The main body 110 is resiliently compressible and has a main body first surface 111, a main body second surface 112, a main body bottom surface 113, a main body top surface 114, and a main body front surface 117. The main body top surface 114 may be flat or may be shaped to facilitate compression, such as by a sinusoidal shape to promote formation of a bellows profile upon compression. The main body first surface 111 is opposite the main body second surface 112. The main body 110 further has a main body height 115 from the main body bottom surface 113 to the main body top surface 114, a main body width 116 from the main body first surface 111 to the main body second surface 112. The second body 120 has a second body first surface 121, a second body second surface 122, a second body bottom surface 127, a second body top surface 126, a second body front surface 125. The second body first surface 121 is opposite the second body second surface 122. The second body 120 further has a second body height 123 from the second body bottom surface 127 to the second body top surface 126, a second body width 124 from the second body first surface 121 to the second body second surface 122. The third body 130 has a third body first surface 131, a third body second surface 132, a third body bottom surface 137, a third body top surface 136, a third body front surface 135. The third body first surface 131 is opposite the third body second surface 132. The third body 130 further has a third body height 133 from the third body bottom surface 137 to the third body top surface 136, and a third body width 134 from the third body first surface 131 to the third body second surface 132. While the main body 110 generally provides a rectangular prism profile, the second body 120 and the third body 130 may be shaped as desired, such as a triangular prism, a rectangular prism, a polygonal prism, or a cylindrical segment.

[0037] When desired a plurality of second bodies 120s and third bodies 130s may be employed. Each of the plurality of second bodies 120s and third bodies 130s may be rigid or semi-rigid based on selection of density, compressibility and composition. When desired, rigidity may be side or depth specific, such that the second bodies 120 and third bodies 130 at a particular horizontal plane may be more or less rigid that those above or below or the second bodies 120 may be more or less rigid than the third bodies 130 on the other side of the main body 110.

[0038] There is a size relationship between the main body 110 and the second body 120 and between the main body 110 and the third body 130. The second body height 123 is less than the main body height 115, the second body width 124 does not exceeding one third the main body width 116. The third body height 133 is less than the main body height 115 and the third body width 134 does not exceed one third the main body width 116.

[0039] The main body 110, the second body 120, and the third body 130 are made one integral unit such as by forming each body separately or by modifying a single body. When separate bodies are provided, the second body 120 is adhered at the second body first surface 121 to the main body 110 at the main body first surface 111 and the third body 130 is adhered at the third body second surface 132 to the main body 110 at the main body second surface 112. When desired, the need for adhesion among the main body 110, the second body 120, and the third body 130 may be avoided by forming all three from a single piece of foam. This, the second body 120 may be formed as an extension of the main body 110 and the third body 130 formed as an extension of the main body 110.

[0040] When desired, the main body 110 may have a main body density and the second body 120 may have a second body density greater than the main body density. Similarly, the third body 130 may have a third body density greater than the main body density, which may be equal to the second body density. Likewise, the main body 110 may have a main body compressibility and the second body 120 may have a second body compressibility less than the main body compressibility. Similarly, the third body 130 may have a third body compressibility less than the main body compressibility, which may be equal to the second body compressibility. The greater density of the second body 120 and/or of the third body 130, or the lower compressibility of each, causes the areas of localized greater compression in the main body 110 within the joint seal system 100 when compressed. When separate bodies are used for the main body 110, the second body 120, and the third body 130, each may be selected from a separate material. When one body is used and the second body 120 and the third body 130 are formed from the main body, the density and compressibility of each of the second body 120, and the third body 130 may be altered by providing additives or binders, such as rigid or solidifying additive, into the second body 120 and the third body 130 but not into the main body 110.

[0041] When desired, the compositions of the main body 110, of the second body 120, and/or of the third body 130 may be selected to performance characteristics and may be the same or different from one another. One or more of the main body 110, of the second body 120, and/or of the third body 130 may include a first retardant material, such as by a coating, or by infusion, by injection, or by including the material in the body when forming. One or more of the main body 110, of the second body 120, and/or of the third body 130 may be composed of a low durometer closed cell foam. Similarly, one or more of the main body 110, of the second body 120, and/or of the third body 130 may include an intumescent on its surface or within, such as by inserted pellets or rods.

[0042] In operation, the joint seal system 100 is positioned between substrates in compression and maintains compression to seal against external solids and liquids. The second body 120 and the third body 130 each introduce a localized area of higher density in the main body 110 due to the space necessary, even when compressed, for the second body 120 and the third body 130. To enable installation of the joint seal system 100 between the substrates, the joint seal system is compressed below the joint size. During operation, the joint seal system 100 is often in compression at one-third to one-sixth its original size. A greater compression for delivery permits the product to be removed from packaging and installed before the joint seal system 100 relaxes to a width greater than the expansion joint gap size between substrate walls.

[0043] To prepare the joint seal system 100 for delivery, it is often desirable to compress the joint seal system 100 to an even smaller portion of its original size and then to include one or more packaging members to provide rigidity and/or non-stick surface against the surrounding packaging, such as shrink wrap. Referring to FIG. 2, an end view of a joint seal system 100 with two packaging bodies 240, 250 is illustrated prior to compression. The packaging body 240, 250 may be a board of any durable material, including wood and plastic, or may be a thin plastic liner. The packaging body 240 has a packaging body height 241, a packaging body first surface 244. The packaging body height 241 is nearly equal to main body height 115. The packaging body first surface 244 is adapted to contact the main body first surface 111 and the second body second surface 121. The second packaging body 250 has a second packaging body height 251 and a second packaging body first surface 253. The second packaging body height 251 is nearly equal to main body height 115. The second packaging body first surface 253 is adapted to contact the main body second surface 112 and the third body first surface 131. When desired, the main body front surface 117, second body front surface 125, third body front surface 135, and a packaging body front surface 243 may be co-planar. The packaging body 240 may be adhered to the joint seal system 100 or may be resistant to any adhesive on the joint seal system 100. The packaging body 240 may be provided with a surface facing the joint seal system 100 which deters adhesion to facilitate later removal from the packaging for installation between substrates.

[0044] Referring to FIG. 3, a top view of a joint seal system with packaging bodies prior to compression is illustrated. The main body 110 has a main body rear surface 317 and a main body length 311 along the main body first surface 111 from the main body front surface 117 to the main body rear surface 317. The second body 120 has a second body rear surface 322 and a second body length 321 along the second body first surface 121 from the second body front surface 125 to the second body rear surface 322. The second body length 321 is equal to the main body length 311. The third body 130 has a third body rear surface 332 and a third body length 331 along the third body first surface 131 from the third body front surface 135 to the third body rear surface 332. The third body length 331 is equal to the main body length 311. The packaging body length 341 is equal to the main body length 311 and the second packaging body length 351 is equal to the main body length 311. As the main body 110, like the second body 120 and the third body 130, may be selected to have compositions, binders, and additives to enhance or accomplish specific performance. The main body 110, for example, may have internal voids in communication with at least one of the main body first surface 111, the main body second surface 112, the main body bottom surface 113, the main body top surface 114, the main body front surface 117, and the main body rear surface 312, at least one quarter of the internal voids having a fire retardant material therein. The second body 120 and/or the third body 130 may likewise have such internal voids and a fire retardant material. Other materials, such as hydrophobic, hydrophilic and intumescent materials, may be used.

[0045] Referring to FIG. 4, an isometric view of the rear of a packaging body is provided. The packaging body 240 includes a packaging body first surface 244 and has a packaging body rear surface 443. As illustrated in FIG. 3, the packaging body length 351 from the packaging body front surface 243 to the packaging body rear surface 443. The packaging body 240 may be a rectangular prism as illustrated in FIGS. 2, 3, and 4 or may, when desired, be of a different shape. For example, the packaging body 240 may have a conic or cylindrical shape, which may be beneficial in reducing areas of stress concentration in any tensioned packaging, such as shrink wrap.

[0046] Referring to FIG. 5, an isometric view of an alternative embodiment of the joint seal system is provided. The main body 110 may be a non-rectangular prism of multiple layers, either by lamination or by layering of additives and binders. The main body 110 therefore includes a top layer 511, a central layer 512, and a bottom layer 513, the central layer 512 having a central layer height 513, where the central layer height 513 may be equal to the greater of second body height 123 and the third body height 133. When the second body is externally formed from the main body 110, it may be adhered to the main body 110 at the central layer 512, with the third body 130 adhered to the main body 110 at the central layer 512. When desired, the central layer 512 may have a lower permeability than the top layer 511, functioning as a barrier. A barrier may be imposed between the layers when desired. Moreover, when desired, the second body 120 and the third body 130 may be adhered to the main body 110 so as to be partially surrounded by part of the main body 110. In such an instance, the central layer 512 may have a central layer internal width 515 less than the main body width 116. When desired, the second body 120 and/or the third body 130 may be an ovoid prism, which may be partially surrounded by the main body 120, such as illustrated for the second body 120 in FIG. 5. Moreover, as with the main body 110, one or both of the second body 120 and the third body 130 may be constructed of laminations. The second body 120 may include a first lamination body 516 and a laterally-adjacent second lamination body 517 and thus have a central layer width 525 greater than the main body width 116, as illustrated in FIG. 6. The third body 130 may include a first lamination body 519 and a vertically-adjacent second lamination body 520.

[0047] Each of the main body 110, the second body 120 and the third body 130 may be a foam member or may be a non-foam material which exhibits similar properties of compressibility, expansion, resiliency, and to support liquid-based additives, such a fire retardants and fillers. The main body 110, the second body 120 and the third body 130 may be a core, such as rubber or cellulose or other material, or may be composed of a foam, such as an open-celled polyurethane foam. The main body 110, the second body 120 and the third body 130 may have an overall length sufficient for use on site, eliminating any need for a splice to join to an adjacent joint seal system 100. The main body 110 is sized to fit between two panels or substrates and may be adjusted in width and height to accommodate the intended lateral movement and provide sufficient benefits. When desired, the main body 110 may be generally square, or may be greater in a lateral plane or may be greater in a vertical plane, i.e. the plane parallel to the surfaces of the adjacent substrates or panels contacted by the body 102.

[0048] Each of the main body 110, the second body 120 and the third body 130 may be composed of an elastically compressible, though materials which are not elastic and/or not compressible may be used. Each of the main body 110, the second body 120 and the third body 130 therefore has body specific properties, including a body density and a body spring force.

[0049] When any of the main body 110, the second body 120 and the third body 130 is to be constructed of foam, any of various types of foam known in the art may be, including compositions such as polyurethane and polystyrene, and may be open or closed cell. The uncompressed density of the main body 110, the second body 120 and the third body 130 may also be altered for performance, depending on local weather conditions. The density of any of the main body 110, the second body 120 and the third body 130 when relaxed and prior to any compression may be less 400 kg/m.sup.3. The composition of any of the main body 110, the second body 120 and the third body 130 may be selected of a composition which is fire retardant or water resistant.

[0050] Each of the main body 110, the second body 120 and the third body 130 may be a foam, such as an open cell foam, a lamination of open cell foam and closed cell foam, and closed cell foam. When desired, any of the main body 110, the second body 120 and the third body 130 may have a treatment, such as impregnation, to increase desirable properties, such as fire resistance or water resistance, by, respectively, the introduction of a fire retardant into the foam or the introduction of a water inhibitor into the foam. Further, any of the main body 110, the second body 120 and the third body 130 may be composed of a hydrophilic material, a hydrophobic material, a fire-retardant material, or a sintering material.

[0051] Moreover, the material for the main body 110, the second body 120 or the third body 130 may be selected from partially closed cell or viscoelastic foams. Most prior art foams seals have been designed as soft foam pre-compressed foam seals utilizing low to medium density foam (about 16-30 kg/m.sup.3) and softer foam (ILD range of about 10-20). It has been surprisingly found through extensive testing of variations of foam densities and foam hardness, fillers and elastic impregnation compounds that higher density hard foams with high ILD's can provide an effective foam seal meeting the required waterproofing (600 Pa minimum and ideally 1000 Pa or greater) and movement and cycling requirements such as ASTM E-1399 Standard Test Method for Cyclic Movement and Measuring the Minimum and Maximum Joint Widths of Architectural Joint Systems as well as long term joint cycling testing. An advantage has been found in using higher density and higher hardness (higher ILD) foams particularly in horizontal applications. While at first this might seem obvious it is known in the art that higher density foams that are about 32-50 kg/m.sup.3 with an ILD rating of about 40 and greater tend to have other undesirable properties such as a long term decrease in fatigue resistance. Desirable properties such as elongation, ability to resist compression set, foam resiliency and fatigue resistance typically decline relative to an increase in density and ILD. These undesirable characteristics are often more pronounced when fillers such as calcium carbonate, melamine and others are utilized to increase the foam density yet the cost advantage of the filled foam is beneficial and desirable. Similarly, when graft polyols are used in the manufacture of the base foam to increase the hardness or load carrying capabilities, other desirable characteristics of the base foam such as resiliency and resistance to compression set can be diminished. Through the testing of non-conventional impregnation binders and elastomers for pre-compressed foam sealants such as silicones, urethanes, polyureas, epoxies, and the like, it has been found that materials that have reduced tack or adhesive properties after cure and which provide a high internal recovery force can be used to counteract the long term fatigue resistance of the high density, high ILD foams. Further, it has been found that by first impregnating and curing the foam with the injected or impregnated silicone, acrylic, urethane or other low tack polymers and, ideally, elastomers with about 100-199% elongation or greater providing a sufficient internal recovery force, that it was additionally advantageous to re-impregnate the foam with another elastomer or binder to provide a timed expansion recovery at specific temperatures. The impregnation materials with higher long-term recovery capabilities imparted to the high density, high ILD base foams, such as a silicone or urethane elastomers, can be used to impart color to the foam seal or be a clear or translucent color to retain the base foam color. If desirable a second impregnation, partial impregnation or coating can be applied to or into the foam seal to add additional functional characteristics such as UV stability, mold and mildew resistance, color, fire-resistance or fire-ratings or other properties deemed desirable to functionality to the foam.

[0052] Viscoelastic foams have not typically been commercially available or used for foam seals due to perceived shortcomings. Commonly used formulations, ratios and methods do not provide a commercially viable foam seal using viscoelastic foam when compared to standard polyurethane foams. Open cell viscoelastic foams are more expensive than polyester or polyether polyurethane foams commonly used in foam seals. Any impregnation process on a viscoelastic foam tends to proceed slower than on a traditional foam due to the fine cell structure of viscoelastic foam. This can be particularly frustrating as the impregnation materials and the impregnation process are typically the most expensive component of a foam seal. However, because of their higher initial density viscoelastic foams can provide better load carrying or pressure resistant foam seal. Both properties are desirable but not fully provided for in the current art for use in applications such as load carrying horizontal joints or expansion joints for secondary containment. Common densities found in viscoelastic foams are 64-80 kg/m.sup.3 or greater. Additionally, viscoelastic foams have four functional properties (density, ILD rating, temperature and time) compared to flexible polyurethane foams, which have two primary properties (density and an ILD rating).

[0053] However, the speed of recovery of viscoelastic foams following compression may be increased by reducing or eliminating any impregnation, surface impregnation or low adhesive strength impregnation compound. Incorporating fillers into the impregnation compound is known to be effective in controlling the adhesive strength of the impregnation binder and therefore the re-expansion rate of the impregnated foam. By surface impregnating or coating the outside surface of one or both sides of viscoelastic foam to approximately 10% of the foam thickness, such as about 3-8 mm deep for conventional joint seals, the release time can be controlled and predicted based on ambient temperature. Alternatively, the foam can be infused, partially impregnated or impregnated with a functional or non-functional filler without a using binder but rather only a solvent or water as the impregnation carrier where the carrier evaporates leaving only the filler in the foam.

[0054] The re-expansion rate of a seal using viscoelastic foam may be controlled by using un-impregnated viscoelastic foam strips and re-adhering them with a pressure sensitive adhesive or hot melt adhesive. When the seal is compressed, the laminating adhesive serves as a temporary restriction to re-expansion allowing time to install the foam seal. Viscoelastic foam may be advantageously used, rather than standard polyurethane foam, for joints requiring additional softness and flexibility due to higher foam seal compression in hot climates or exposure or increased stiffness in cold temperatures when a foam seal is at its minimum compressed density. Additionally, closed cell, partially closed cell and other foams can be used as in combination with the viscoelastic foams to reduce the overall cost.

[0055] This second group of body materials, the non-foam members, may include, for example, corrugated cardboards, natural and man-made batting materials, and natural, synthetic and man-made sponge material. When desired, such materials may be selected for properties, such as water leakage, air leakage, resilience in face of one or more cycling regimes, compressibility, relaxation rate, compression set, and elasticity.

[0056] The material for the main body 110, the second body 120 and/or the third body 130 may be altered to provide additional functional characteristics. It may be infused, impregnated, partially impregnated or coated with an impregnation material or binder that is designed specifically to provide state of the art seal water-resistance properties with a uniform and consistent distribution of the waterproofing binder. The body 102 may also, or alternatively, be infused or impregnated or otherwise altered to retain a fire retardant, dependent on function. Where the body 102 is foam, any suitable open cell foam type with a density of 16-45 kg/m.sup.3 or higher can provide an effective water-resistant foam-based seal by varying the impregnation density or the final compression ratio. Where a sound resistant seal is desired, the density or the variable densities provide a sound resistant seal in a similarly-rated wall from a Sound Transmission Class value from 42-63 and/or a sound reduction between 12 and 50 decibels.

[0057] The main body 110, the second body 120 and/or the third body 130 may be selected from an inherently hydrophilic material or have a hydrophilic component such as a hydrophilic polymer that is uniformly distributed throughout. The main body 110, the second body 120 and/or the third body 130 may include strategically-placed surface impregnation or partially impregnate with a hydroactive polymer. Because the primary function of the main body 110 is waterproofing, the addition of a hydrophilic function does not negatively impact any desired fire-resistant properties, as an increased moisture content, and may increase fire resistive properties.

[0058] Any of the main body 110, the second body 120 and/or the third body 130 may be formed of commercially available vapor permeable foam products or by forming specialty foams. Commercial available products which provide vapor permeable and excellent fire resistant properties are well known, such as Sealtite VP or Willseal 600. It is well known that a vapor permeable but water resistant foam joint sealant may be produced leaving at least a portion of the cell structure open while in compression such that water vapor can escape through the impregnated foam sealant. Water is then ejected on the exterior of the main body 110 because the foam, and/or any impregnation, is hydrophobic and therefore repels water. Water can escape from the foam sealant or wall cavity through water vapor pressure by virtue of the difference in humidity creating unequal pressure between the two areas. Because the cell structure is still partially open the vapor pressure drive is sufficient to allow moisture to return to equalization or the exterior of the structure. By a combination of compression ratio and impregnation density of a hydrophobic component the water resistance capacity can be increased to provide resistance to various levels of pressure or driving rain.

[0059] Other variations may be employed. The joint seal system 100 may be constructed to withstand a hydrostatic pressure equal to or greater than 29.39 psi. Environmentally friendly foam, fillers, binders, elastomer and other components may be selected to meet environmental, green and energy efficiency standards. The main body 110 may exhibit auxetic properties to provide support or stability for the joint seal system 100 as it thermally cycles or to provide additional transfer loading capacity. Auxetic properties may be provided by the body material, the internal components such as the members/membrane or by an external mechanical mechanism.

[0060] The main body 110, the second body 120 and the third body 130 may include an impregnate, such as a fire retardant such as aluminum trihydroxide, which may be throughout its entirety or which may be only about ten percent of it from one surface to the opposing surface. Additional function properties can be added by surface impregnating the exposed or outside surfaces of the foam as well as the inside portion if additional properties are desirable. Any of the main body 110, the second body 120 and/or the third body 130 may contain, such as by impregnation or infusion, a sintering material, wherein the particles in the impregnate move past one another with minimal effort at ambient temperature but form a solid upon heating. Once such sintering material is clay or a nano-clay. Such a sintering impregnate would provide an increased overall insulation value and permit a lower density at installation than conventional foams while still having a fire endurance capacity of at least one hour, such as in connection with the UL 2079 standard for horizontal and vertical joints. While the cell structure, particularly, but not solely, when compressed, of any of the main body 110, the second body 120 and/or the third body 130, preferably inhibits the flow of water, the presence of an inhibitant or a fire retardant may prove additionally beneficial. The fire retardant may be introduced as part of the foaming process, or by impregnating, coating, infusing, or laminating, or by other processes known in the art. The joint seal system 100 may be provided with end profiles intended to provide interlocking faces so a plurality of joint seal systems 100 may be installed in abutment.

[0061] Each of the main body 110, the second body 120, and third body 130 may be simple rectangular shapes and may constructed to mate to an adjacent joint seal system 100.

[0062] The coating 202 may be applied at the main body 110 at the main body top surface 114. Where the coating 202 provides fire resistance, the body main body 110 may be provided without a fire retardant. The coating 202 may further include an insulating layer, such as a silicate, to add a refractory of insulating function. However, such a layer, unless otherwise selected, would not be a fire-retardant liquid glass formulation. The coating 202 may include a flexible or semi-rigid elastomer to increase load carrying capability which is further enhanced by the supporting intumescent members. These, or other coatings, may be used to provide waterproofing, fire resistance, or additional functional benefits. Such coatings are known in the art, such as Dow 790.

[0063] When desired, the main body 110 may be structured to aid in installation by beveling its bottom. The main body 110 may include main body beveled surface 160 intermediate the main body extension bottom surface 113 and the second body 120. Additionally or alternatively, the main body 110 may further include one or more openings 162 at the main body bottom surface 113, each of which penetrate upward into the main body 102 and may become wider as it becomes more distant from the main body bottom surface 113, such as by an initially rectangular prism opening coupled with a cylindrical opening, which permits movement and compression of the main body 110 but limits, particularly at the main body bottom surface 113, the extent of such movement. When desired, a structural member, such as a load transfer member or an intumescent rod or other shape may be imposed in each opening 162.

[0064] Further structural elements may be incorporated to increase the fire resistance of the joint seal system 100. Thus, the joint seal system 100 may include an intumescent member 164 in any of the main body 110, the second body 120, and/or the third body 130. Additionally, or alternatively, one or more the main body 110, the second body 120, and/or the third body 130 may include a channel 166 in a side surface and an intumescent body 168 imposed in the channel 166. The intumescent body 168 may provide both fire retardancy and may extend beyond the joint seal system 100 to overlap and join and adjacent joint seal system 100. Further, the joint seal system 100 may include a spring member 170, the spring member 170 presenting a wave-like profile and having a spring member spring force. When desired, the spring member 170 may have a spring member first end 172 proximate the main body top surface 114 and the first spring member having a spring member second end 174 proximate the body bottom surface 113. When desired, the spring member 170 may have an intumescent or fire retarding coating or composition.

[0065] Referring to FIG. 2, the joint seal system 100 may include, within and across the main body 110, a membrane 246 intermediate the main body top surface 114 and the main body bottom surface 113, the membrane 191 parallel to the main body top surface 114. The membrane 246 may be vapor impermeable layer. The membrane 246 may provide a barrier to foreign matter penetrating through the joint seal system 100 and to opposing surface of the joint, thus ensuring some portion of the core bodies are not susceptible to contaminants and therefore continue to function. As one or more core bodies may be composed of a vapor permeable foam, such a composition becomes particularly beneficial when a barrier or membrane 246 is present. The membrane 246 may thus may retain and then expel moisture, preventing moisture from penetrating in an adjacent substrate. As can be appreciated, to be effective, the membrane 246 is preferably sized to be no smaller in any dimension than the adjacent core body. Alternatively, the membrane 246 may extend beyond the core bodies to provide a surface which may contact an adjacent substrate and even overlap its top. The membrane 246 may be intumescent or may otherwise provide fire retardancy in the joint seal system 100. Consistent with uses known in the art, the present disclosure may be associated with a central non-conductive spine and cover plate assembly for those uses wherein high traffic is anticipated, as well as for compliance with Department of Transportation requirements. The present invention may be adapted for use with other expansion joint systems, such those that incorporate a rib or spline within or connection to a body such as core bodies and attached or associated, permanently or detachably with a cover plate.

[0066] Referring to FIG. 2, other mechanical benefits can be incorporated into the joint seal system 100, such as a load transfer member 248 positioned on or below, i.e. adjacent, the main body top surface 114 of the main body 110 which distributes any load applied to the main body top surface 114 of the main body 110 across a greater surface area of the body main body 110.

[0067] The load transfer member 248 may composed of any durable material, including plastics, metals, or composites with its own spring force. The load transfer member 248 may be provided with mechanical properties, such as fire resistance, and may be intumescent. Such a load transfer member 248 may be logistically aligned as to be parallel to the main body first surface 111. Alternatively, a rib 252 may be positioned into the main body 110 through the main body top surface 114 and extending toward the main body bottom surface 113, but which does not contact the main body bottom surface 113. The rib 252 may resist any internal lateral shear force and may provide a point of attachment for a metal cover plate. In a further alternative, the coating 202 may an elastomeric gland. Finally, to ensure an anchor to the substrate, an adhesive may be applied to one or more of main body first surface 111 and the main body second surface 112. Moreover, an intumescent rod 164 or other shape may be imposed within the joint seal system 100 and may also provide a key for splicing to an adjacent joint seal system 100. Beneficially, where the intumescent rod 164 extends beyond a first end of the joint seal system 100, it may be used to provide a splice connection to an adjacent joint seal system 100.

[0068] Additionally, when desired, a sensor 183 may be included and may contact one of more of the component of the joint seal system 100. The sensor 183 may be a radio frequency identification device (RFID) or other wirelessly transmitting sensor. A sensor may be beneficial to assess the health of a joint seal system 100 without accessing the interior of the expansion joint, otherwise accomplished by removal of the cover plate. Such sensors are known in the art, and which may provide identification of circumstances such as moisture penetration and accumulation. The inclusion of a sensor 183 in the joint seal system 100 may be particularly advantageous in circumstances where the joint seal system 100 is concealed after installation, particularly as moisture sources and penetration may not be visually detected. Thus, by including a low cost, moisture-activated or sensitive sensor, the user can scan the joint seal system 100 for any points of weakness due to water penetration. A heat sensitive sensor may also be positioned within the joint seal system 100, thus permitting identification of actual internal temperature, or identification of temperature conditions requiring attention, such as increased temperature due to the presence of fire, external to the joint or even behind it, such as within a wall. Such data may be particularly beneficial in roof and below grade installations where water penetration is to be detected as soon as possible.

[0069] Inclusion of a sensor 183 in the joint seal system 100 may provide substantial benefit for information feedback and potentially activating alarms or other functions within the joint seal system 100 or external systems. Fires that start in curtain walls are catastrophic. High and low-pressure changes have deleterious effects on the long-term structure and the connecting features. Providing real time feedback and potential for data collection from sensors, particularly given the inexpensive cost of such sensors, in those areas and particularly where the wind, rain and pressure will have their greatest impact would provide benefit. While the pressure on the wall is difficult to measure, for example, the deflection in a pre-compressed sealant is quite rapid and linear. Additionally, joint seals are used in interior structures including but not limited to bio-safety and cleanrooms. Additionally, a sensor 183 could be selected which would provide details pertinent to the state of the Leadership in Energy and Environmental Design (LEED) efficiency of the building. Additionally, such a sensor, which could identify and transmit air pressure differential data, could be used in connection with masonry wall designs that have cavity walls or in the curtain wall application, where the air pressure differential inside the cavity wall or behind the cavity wall is critical to maintaining the function of the system. A sensor 183 may be positioned in other locations within the joint seal system 100 to provide beneficial data. A sensor 183 may be positioned to provide prompt notice of detection of heat outside typical operating parameters, so as to indicate potential fire or safety issues. Such a positioning would be advantageous in horizontal of confined areas. A sensor 183 so positioned might alternatively be selected to provide moisture penetration data, beneficial in cases of failure or conditions beyond design parameters. The sensor 183 may provide data on moisture content, heat or temperature, moisture penetration, and manufacturing details. A sensor 183 may provide notice of exposure from the surface of the joint seal system 100 most distant from the base of the joint. A sensor 183 may further provide real time data. Using a moisture sensitive sensor in the joint seal system 100 and at critical junctions/connections would allow for active feedback on the waterproofing performance of the joint seal system 100. It can also allow for routine verification of the watertightness with a hand-held sensor reader to find leaks before the reach occupied space and to find the source of an existing leak. Often water appears in a location much different than it originates making it difficult to isolate the area causing the leak. A positive reading from the sensor alerts the property owner to the exact location(s) that have water penetration without or before destructive means of finding the source. The use of a sensor 183 in the joint seal system 100 is not limited to identifying water intrusion but also fire, heat loss, air loss, break in joint continuity and other functions that cannot be checked by non-destructive means. Use of a sensor 183 within the joint seal system 100 may provide a benefit over the prior art. Impregnated foam materials, which may be used for the main body 110 are known to cure fastest at exposed surfaces, encapsulating moisture remaining inside the body, and creating difficulties in permitting the removal of moisture from within the body. While heating is a known method to addressing these differences in the natural rate of cooling, it unfortunately may cause degradation of the foam in response. Similarly, while forcing air through the foam bodies may be used to address the curing issues, the potential random cell size and structure impedes airflow and impedes predictable results. Addressing the variation in curing is desirable as variations affect quality and performance properties. The use of a sensor 183 within the joint seal system 100 may permit use of the heating method while minimizing negative effects. The data from the sensors, such as real-time feedback from the heat, moisture and air pressure sensors, aids in production of a consistent product. Moisture and heat sensitive sensors aid in determining and/or maintaining optimal impregnation densities, airflow properties of the foam during the curing cycle of the foam impregnation. Placement of the sensors 183 into foam at the pre-determined different levels allows for optimum curing allowing for real time changes to temperature, speed and airflow resulting in increased production rates, product quality and traceability of the input variables to that are used to accommodate environmental and raw material changes for each product lots.

[0070] The selection of components providing resiliency, compressibility, water-resistance and fire resistance, the joint seal system 100 may be constructed to provide sufficient characteristics to obtain fire certification under any of the many standards available. In the United States, these include ASTM International's E 814 and its parallel Underwriter Laboratories UL 1379 Fire Tests of Through-penetration Firestops, ASTM International's E1966 and its parallel Underwriter Laboratories UL 2079 Tests for Fire-Resistance Joint Systems, ASTM International's E 2307 Standard Test Method for Determining Fire Resistance of Perimeter Fire Barrier Systems Using Intermediate-Scale, Multi-story Test Apparatus, the tests known as ASTM E 84, UL 723 and NFPA 255 Surface Burning Characteristics of Building Materials, ASTM E 90 Standard Practice for Use of Sealants in Acoustical Applications, ASTM E 119 and its parallel UL 263 Fire Tests of Building Construction and Materials, ASTM E 136 Behavior of Materials in a Vertical Tube Furnace at 750 C. (Combustibility), ASTM E 1399 Tests for Cyclic Movement of Joints, ASTM E 595 Tests for Outgassing in a Vacuum Environment, ASTM G 21 Determining Resistance of Synthetic Polymeric Materials to Fungi. Some of these test standards are used in particular applications where firestop is to be installed.

[0071] Most of these use the Cellulosic time/temperature curve, described by the known equation T=20+345*LOG(8*t+1) where t is time, in minutes, and T is temperature in degrees Celsius including E 814/UL 1379 and E 1966/UL 2079.

[0072] E 814/UL 1379 tests a fire retardant system for fire exposure, temperature change, and resilience and structural integrity after fire exposure (the latter is generally identified as the Hose Stream test). Fire exposure, resulting in an F [Time] rating, identifies the time durationrounded down to the last completed hour, along the Cellulosic curve before flame penetrates through the body of the system, provided the system also passes the hose stream test. Common F ratings include 1, 2, 3 and 4 hours Temperature change, resulting in a T [Time] rating, identifies the time for the temperature of the unexposed surface of the system, or any penetrating object, to rise 181 C. above its initial temperature, as measured at the beginning of the test. The rating is intended to represent how long it will take before a combustible item on the non-fireside will catch on fire from heat transfer. In order for a system to obtain a UL 1379 listing, it must pass both the fire endurance (F rating) and the Hose Stream test. The temperature data is only relevant where building codes require the T to equal the F-rating.

[0073] When required, the Hose Steam test is performed after the fire exposure test is completed. In some tests, such as UL 2079, the Hose Stream test is required with wall-to-wall and head-of-wall joints, but not others. This test assesses structural stability following fire exposure as fire exposure may affect air pressure and debris striking the fire resistant system. The Hose Stream uses a stream of water. The stream is to be delivered through a 64 mm hose and discharged through a National Standard playpipe of corresponding size equipped with a 29 mm discharge tip of the standard-taper, smooth-bore pattern without a shoulder at the orifice consistent with a fixed set of requirements:

TABLE-US-00001 Hourly Fire Rating Water Pressure Duration of Hose Stream Test Time in Minutes (kPa) (sec./m.sup.2) 240 time < 480 310 32 120 time < 240 210 16 90 time < 120 210 9.7 time < 90 210 6.5

[0074] The nozzle orifice is to be 6.1 m from the center of the exposed surface of the joint system if the nozzle is so located that, when directed at the center, its axis is normal to the surface of the joint system. If the nozzle is unable to be so located, it shall be on a line deviating not more than 30 from the line normal to the center of the joint system. When so located its distance from the center of the joint system is to be less than 6.1 m by an amount equal to 305 mm for each 10 of deviation from the normal. Some test systems, including UL 1379 and UL 2079 also provide for air leakage and water leakage tests, where the rating is made in conjunction with a L and W standard. These further ratings, while optional, are intended to better identify the performance of the system under fire conditions.

[0075] When desired, the Air Leakage Test, which produces an L rating and which represents the measure of air leakage through a system prior to fire endurance testing, may be conducted. The L rating is not pass/fail, but rather merely a system property. For Leakage Rating test, air movement through the system at ambient temperature is measured. A second measurement is made after the air temperature in the chamber is increased so that it reaches 177 C. within 15 minutes and 204 C. within 30 minutes. When stabilized at the prescribed air temperature of 2045 C., the air flow through the air flow metering system and the test pressure difference are to be measured and recorded. The barometric pressure, temperature and relative humidity of the supply air are also measured and recorded. The air supply flow values are corrected to standard temperature and pressure (STP) conditions for calculation and reporting purposes. The air leakage through the joint system at each temperature exposure is then expressed as the difference between the total metered air flow and the extraneous chamber leakage. The air leakage rate through the joint system is the quotient of the air leakage divided by the overall length of the joint system in the test assembly.

[0076] When desired, the Water Leakage Test produces a W pass-fail rating and which represents an assessment of the watertightness of the system, can be conducted. The test chamber for or the test consists of a well-sealed vessel sufficient to maintain pressure with one open side against which the system is sealed and wherein water can be placed in the container. Since the system will be placed in the test container, its width must be equal to or greater than the exposed length of the system. For the test, the test fixture is within a range of 10 to 32 C. and chamber is sealed to the test sample. Nonhardening mastic compounds, pressure-sensitive tape or rubber gaskets with clamping devices may be used to seal the water leakage test chamber to the test assembly. Thereafter, water, with a permanent dye, is placed in the water leakage test chamber sufficient to cover the systems to a minimum depth of 152 mm. The top of the joint system is sealed by whatever means necessary when the top of the joint system is immersed under water and to prevent passage of water into the joint system. The minimum pressure within the water leakage test chamber shall be 1.3 psi applied for a minimum of 72 hours. The pressure head is measured at the horizontal plane at the top of the water seal. When the test method requires a pressure head greater than that provided by the water inside the water leakage test chamber, the water leakage test chamber is pressurized using pneumatic or hydrostatic pressure. Below the system, a white indicating medium is placed immediately below the system. The leakage of water through the system is denoted by the presence of water or dye on the indicating media or on the underside of the test sample. The system passes if the dyed water does not contact the white medium or the underside of the system during the 72-hour assessment.

[0077] Another frequently encountered classification is ASTM E-84 (also found as UL 723 and NFPA 255), Surface Burning Characteristics of Burning Materials. A surface burn test identifies the flame spread and smoke development within the classification system. The lower a rating classification, the better fire protection afforded by the system. These classifications are determined as follows:

TABLE-US-00002 Classification Flame Spread Smoke Development A 0-25 0-450 B 26-75 0-450 C 76-199 0-450

[0078] UL 2079, Tests for Fire Resistant of Building Joint Systems, comprises a series of tests for assessment for fire resistive building joint system that do not contain other unprotected openings, such as windows and incorporates four different cycling test standards, a fire endurance test for the system, the Hose Stream test for certain systems and the optional air leakage and water leakage tests. This standard is used to evaluate floor-to-floor, floor-to-wall, wall-to-wall and top-of-wall (head-of-wall) joints for fire-rated construction. As with ASTM E-814, UL 2079 and E-1966 provide, in connection with the fire endurance tests, use of the Cellulosic Curve. UL 2079/E-1966 provides for a rating to the assembly, rather than the convention F and T ratings. Before being subject to the Fire Endurance Test, the same as provided above, the system is subjected to its intended range of movement, which may be none. These classifications are:

TABLE-US-00003 Movement Minimum Minimum cycling Classification number of rate (cycles per (if used) cycles minute) Joint Type (if used) No Classification 0 0 Static Class I 500 1 Thermal Expansion/ Contraction Class II 500 10 Wind Sway Class III 100 30 Seismic 400 10 Combination

[0079] ASTM E 2307, Standard Test Method for Determining Fire Resistance of Perimeter Fire Barrier Systems Using Intermediate-Scale, Multi-story Test Apparatus, is intended to test for a systems ability to impede vertical spread of fire from a floor of origin to that above through the perimeter joint, the joint installed between the exterior wall assembly and the floor assembly. A two-story test structure is used wherein the perimeter joint and wall assembly are exposed to an interior compartment fire and a flame plume from an exterior burner. Test results are generated in F-rating and T-rating. Cycling of the joint may be tested prior to the fire endurance test and an Air Leakage test may also be incorporated.

[0080] The joint seal system 100 may therefore perform wherein the body bottom surface 110 at a maximum joint width increases no more than 181 C. after sixty minutes when the body 102 is exposed to heating according to the equation T=20+345*LOG(8*t+1), where t may be time in minutes and T may be temperature in C.

[0081] The joint seal system 100 may also perform wherein the body bottom surface 110, having a maximum joint width of more than six (6), increases no more than 139 C. after sixty minutes when the joint seal system 100 is exposed to heating according to the equation T=20+345*LOG(8*t+1), where t may be time in minutes and T may be temperature in C.

[0082] The joint seal system 100 may be adapted to be cycled one of 500 times at 1 cycle per minute, 500 times at 10 cycles per minute and 100 cycles at 30 times per minute, without indication of stress, deformation or fatigue.

[0083] In other embodiments, the joint seal system 100 is configured to pass hurricane force testing to TAS 202/203. Further the joint seal system 100 may be designed or configured to pass ASTM E-282, E-331, E-330, E-547 or similar testing to meet the pressure cycling and water resistance requirements up to 5000 Pa or more.

[0084] The coating 202 may undergo chemical reaction when heated to reduce flammability or delay combustion or cool through physical action or endothermic reactions. The coating 202 may provide retardancy through endothermic degradation, such as by use of aluminum hydroxide. Coating 202 may provide retardancy through thermal shielding, such as by use of an intumescent, which chars over when burned, separating the flame from the material and slowing heat transfer. The coating 202 may provide retardancy by gas phase radical quenching, such as when chlorinated paraffin undergoes thermal degradation and releases hydrogen chloride to lower potential propagation of combustion reactions. The coating 202 may extend to one or more of the main body first surface 111, the main body second surface 112, a main body front surface 117, and a main body rear surface 317.

[0085] Because the joint seal system 100 is in compression between the substrates of an expansion joint, it is well-known to pre-compress the joint seal system 100 at the factory and provide the joint seal system 100 in compression.

[0086] The joint seal system 100 is provided in precompressed form for installation. The packaging body 240, the main body 110, the second body 120, and the third body 130 are laterally compressed. The joint seal system 100 is then packaged, such as in shrink wrap, to remain in compression. The packaging body 240 provides a rigid surface against which the joint seal system 100 is maintained in compression. After the joint seal system 100 is removed from packaging and separated from the packaging body 240, it is imposed between the first substrate and the second substrate before relaxing to a width greater than the expansion joint. The joint seal system 100 continues to relax and contacts the substrate walls and is maintained in compression in the joint, and, by virtue of its nature, inhibits the transmission of water or other contaminants further into the expansion joint. The joint seal system 100 may be adhered to the substrate walls by an adhesive on the sides of the core bodies. When desired a second packaging body may be provided on the opposing side of the joint seal system 100.

[0087] The present disclosure thus provides a dimensional stability, as a result of the reduction of main foam, while requiring less silicone as the width of the main body, defining the size of the top to be coated, is less than that of the convention joint. Additionally, no fixture is required for anchorage. In operation, less strain is imparted to the foam of the main body, while a higher compression is generated, resulting in a tighter seal. Additionally, at the top and bottom of the main body, less strain is introduced in light of the lack of the secondary bodies at those positions. The construction of the present invention further results in the top and bottom being pulled inward against any bowing. This construction results in better recovery as areas of lower compression expand faster than those under higher compression.

[0088] The foregoing disclosure and description is illustrative and explanatory thereof. Various changes in the details of the illustrated construction may be made within the scope of the appended claims without departing from the spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.