Composite joint seal

Abstract

The present invention relates generally to systems for creating a joint filler or seal in the gap between adjacent panels or assemblies. The present disclosure is directed to providing an expansion joint seal system which includes a foam associated with a non-foam matrix.

Claims

1. An expansion joint seal comprising: an elastic and resilient rectangular prism body having a rectangular prism body top surface, a rectangular prism body bottom surface opposite the rectangular prism body top surface, a rectangular prism height from the rectangular prism body bottom surface to the rectangular prism body top surface, a rectangular prism body first side surface, a rectangular prism body second side surface opposite the rectangular prism body first side surface, a rectangular prism body width from the rectangular prism body second side surface to the rectangular prism body first side surface, a rectangular prism body front surface, a rectangular prism body rear surface opposite the rectangular prism body front surface, a rectangular prism body length from the rectangular prism body rear surface to the rectangular prism body front surface, the rectangular prism body having a plurality of prism members, each of the prism members having a prism body length equal to the rectangular prism body length, a prism body width less than the rectangular prism body width; and a thin, flexible non-foam member intermediate each of the plurality of nonrectangular prism members, the non-foam member having a non-foam member length rectangular prism body, the non-foam member adhered to each of the plurality of nonrectangular prism members.

2. The expansion joint seal of claim 1, wherein one of the prism members is not a rectangular prism.

3. The expansion joint seal of claim 1, wherein the non-foam member has a non-foam member thickness not greater than 10 percent of the rectangular prism body width.

4. The expansion joint seal of claim 1, wherein the non-foam member is composed of material selected from the group consisting of a permeable material, an impermeable material, a rubber material, a hydrophilic, a hydrophobic material, a fire-retardant material.

5. The expansion joint seal of claim 1, wherein the plurality of prism members includes a first triangular prism member and a second triangular prism member.

6. The expansion joint seal of claim 5, wherein the plurality of prism members includes a third prism member and the non-foam member includes a v-shaped profile.

7. The expansion joint seal of claim 1, wherein the wherein the plurality of prism members includes a first triangular prism member and a second triangular prism member, and an irregular quadrilateral polygonal prism member.

8. The expansion joint seal of claim 1, wherein the plurality of prism members includes a quadrilateral prism member, a first triangular prism member opposite the non-foam member from the quadrilateral prism member, a second triangular prism member opposite the non-foam member from the first triangular prism member and opposite the non-foam member from the quadrilateral prism member, a third triangular prism member opposite the non-foam member from the first triangular prism member and opposite the non-foam member from the quadrilateral prism member, a fourth triangular prism member opposite the non-foam member from the quadrilateral prism member, a fifth triangular prism member opposite the non-foam member from the quadrilateral prism member, and opposite the non-foam member from the fourth triangular prism member, a sixth triangular prism member opposite the non-foam member from the quadrilateral prism member, and opposite the non-foam member from the fourth triangular prism member, and opposite the non-foam member from the fifth triangular prism member, and the non-foam member having a non-foam member internal void at a center, two non-foam member legs at a non-foam member first end and two non-foam member legs at a non-foam member second end.

9. The expansion joint seal of claim 1, wherein a first prism member of the plurality of prism members has a first prism member density and a second prism member of the plurality of prism members has a second prism member density, the first prism member density and the second prism member density being unequal.

10. The expansion joint seal of claim 1, one of the plurality of prism members having internal voids in communication with at least one of a prism member first surface, a prism member second surface, a prism member bottom surface, a prism member top surface, a prism member front surface, and a prism member rear surface, at least one quarter of the internal voids having a fire-retardant material therein.

11. The expansion joint seal of claim 1, further comprising: a packaging body, the packaging body having a packaging body length from a packaging body front surface to a packaging body rear surface, the packaging body length equal to the rectangular prism body length, a packaging body having a packaging body height from a packaging body top surface to a packaging body bottom surface, the packaging body height equal to the rectangular prism height, a packaging body first surface from the packaging body top surface to the packaging body bottom surface and from the packaging body front surface to the packaging body rear surface, the packaging body first surface in contact with the rectangular prism body first side surface.

12. The expansion joint seal of claim 1, wherein the non-foam member has a spring force.

13. The expansion joint seal of claim 1, wherein the plurality of prism members includes a first triangular prism member, a second triangular prism member opposite the non-foam member from the first triangular prism ember, a third triangular prism member opposite the non-foam member from the first triangular prism member and opposite the non-foam member from the second triangular prism member, a fourth triangular prism member opposite the non-foam member from the second triangular prism member, a fifth triangular prism member opposite the non-foam member from the quadrilateral prism member, and opposite the non-foam member from the fourth triangular prism member, a sixth triangular prism member opposite the non-foam member from the fourth triangular prism member, and opposite the non-foam member from the fifth triangular prism member, and the non-foam member having a non-foam member internal void at a center, two non-foam member legs at a non-foam member first end and two non-foam member legs at a non-foam member second end.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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.

(2) In the drawings:

(3) FIG. 1 illustrates an end view of a joint seal system according to the present disclosure.

(4) FIG. 2 illustrates an end view of an alternative joint seal system according to the present disclosure with packaging body.

(5) FIG. 3 illustrates an end view of another alternative joint seal system according to the present disclosure.

(6) FIG. 4 illustrates a packaging body according to the present disclosure.

(7) FIG. 5 illustrates an isometric view of the expansion joint seal from the rear and side according to the present disclosure.

DETAILED DESCRIPTION

(8) The present disclosure provides an expansion joint 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.

(9) Referring to FIG. 1, an illustration is provided of an end view of a joint seal system according to the present disclosure. The expansion joint seal 100 includes an elastic and resilient, rectangular prism body 102 which may have plurality of prism members 114, 116, 118, and a thin, flexible non-foam member 124 intermediate each of the plurality of nonrectangular prism members 114, 116, 118.

(10) The rectangular prism body 102 has a height, width and length. The rectangular prism body 102 has a rectangular prism body top surface 104, a rectangular prism body bottom surface 106 opposite the rectangular prism body top surface 104, and a rectangular prism height 120 from the rectangular prism body bottom surface 106 to the rectangular prism body top surface 104. The rectangular prism body 102 further has a rectangular prism body first side surface 108, a rectangular prism body second side surface 110 opposite the rectangular prism body first side surface 108, and a rectangular prism body width 122 from the rectangular prism body second side surface 110 to the rectangular prism body first side surface 108. Referring to Fig. and to FIG. 5, an isometric illustration of the expansion joint seal 100 from the rear and side, the rectangular prism body 102 also has a rectangular prism body front surface 112, a rectangular prism body rear surface 512 opposite the rectangular prism body front surface 112, and a rectangular prism body length 522 from the rectangular prism body rear surface 512 to the rectangular prism body front surface 112.

(11) Similarly, each of the prism members 114, 116, 118 has a length, width and height, constrained by inclusion in the rectangular prism body 102. The prism members may be of any shape and may be a rectangular prism. Referring to FIG. 1, the plurality of prism members 114, 116, 118 includes a first triangular prism member 114, a second triangular prism member 116 and a third prism member 118. The prism members 114, 116, 118 fit to the non-foam member 124 and may have a v-shaped profile to form the rectangular prism body 102. Each of the prism members 114, 116, 118 has a prism body length 524 equal to rectangular prism body length 522, a prism body width less than the rectangular prism body width 122, the non-foam member 124 may have a non-foam member length rectangular prism body, the non-foam member 124 adhered to each of the plurality of nonrectangular prism members 114, 116, 118.

(12) The prism members 114, 116, 118 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, each of which may have its own spring force. This may be a foam, a corn starch-based material, cellulose or other compressible material. Each prism member should preferably be composed of an elastically compressible, though materials which are not elastic and/or not compressible may be used. Each of the prism members 114, 116, 118 has body specific properties, including density and spring force, which may be common or dissimilar. Each of the prism members 114, 116, 118 may have common or dissimilar or unequal properties which affect sound damping, including cell size, tortuosity, and porosity. Similarly, each prism member has a density, where the prism member densities may be unequal.

(13) One or more of the prism members 114, 116, 118 may have one or more internal voids in communication with at least one of a prism member first surface, a prism member second surface, a prism member bottom surface, a prism member top surface, a prism member front surface, and a prism member rear surface, where at least one quarter of the internal voids have a fire-retardant material therein.

(14) The intended compression, a reduction in a width, of a prism member 114, 116, 118 may be coupled with the spring force of that particular core body and the thickness of that body to provide a force to be applied by that body to packaging for shipment and to substrates after installation. The resulting force by each of the prism members 114, 116, 118 may be equal, nearly equal or of different values as desired.

(15) The expansion joint seal 100 may be provided with end profiles intended to provide interlocking faces so a plurality of expansion joint seal 100 may be installed in abutment.

(16) The expansion joint seal 100 includes rectangular prism body front surface 112 which may have a joint first end profile and a rectangular prism body rear surface 512 which may have a joint seal second end profile, where the joint seal first end profile and the joint seal second end profile are complementary, such as where one of the prism members 114, 116, 118 is offset from the others, and thereby provides a key which interlocks with the adjacent expansion joint seal 100. Alternatively, the joint seal first end profile may be a flat end.

(17) The thin, flexible non-foam member 124 may be composed of any non-foam material including plastics, rubber, and similar materials which provide resiliency, structural support, and flexibility, and therefore may have its own spring force. The thin, flexible non-foam member 124 may be constructed in any shape, but preferably so the thin, flexible non-foam member 124 extends from the rectangular prism body first side surface 108 to, the rectangular prism body second side surface 110 with a deflection or change of direction within to facilitate a change in shape as the extent of compression of the expansion joint seal 100 by the adjacent substrates changes. As illustrated in FIG. 1, the thin, flexible non-foam member 124 may be a simple vee shape, oriented downward, but may also be oriented upwards.

(18) The non-foam member 124 may have a non-foam member thickness not greater than 10 percent of the rectangular prism body width. The non-foam member 124 is composed of a material selected from the group consisting of a permeable material, an impermeable material, a rubber material, a hydrophilic material, a hydrophobic material, a fire-retardant material.

(19) A first fire-retardant coating 130 may be applied adjacent the rectangular prism body top surface 104. The first fire-retardant coating 130 is selected to provide a substance that slows the spread of fire. The first fire-retardant coating 130 may undergo chemical reaction when heated to reduce flammability or delay combustion or cool through physical action or endothermic reactions. The first fire-retardant coating 130 may provide retardancy through endothermic degradation, such as by use of aluminum hydroxide. The first fire-retardant coating 130 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 first fire-retardant coating 130 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 first fire-retardant coating 130 may extend to one or more of the rectangular prism body first side surface 108, the rectangular prism body second side surface 110, the rectangular prism body front surface 112, and the rectangular prism body rear surface 512.

(20) Referring to FIG. 2, an illustration is provided of an end view of an alternative joint seal system according to the present disclosure with packaging body. The thin, flexible non-foam member 232 may include one or more extensions 228 and need not be a single vee shape. The extension 228 provides a knee or other capturing shape for one of the prism members 214, 216, 218. The plurality of prism members includes a first triangular prism member 214 and a second triangular prism member 216, and an irregular quadrilateral polygonal prism member 218. A packaging body 220 may be included with the expansion joint seal 100, such as against the rectangular prism body first side surface 108 and/or the rectangular prism body second side surface 110. Referring to Fig. and to FIG. 4, an isometric illustration of a packaging body according to the present disclosure, the packaging body 220 may have a packaging body length 402 and a packaging body height 404. The packaging body 220 may have a packaging body length 402 from a packaging body front surface 222 to a packaging body rear surface 406, the packaging body length 402 equal to the first body length 522. The packaging body 220 may have a packaging body height 404 from a packaging body top surface 224 to a packaging body bottom surface 226, the packaging body height 404 equal to the first body height 120. The packaging body may have a packaging body first surface 408 from the packaging body top surface 224 to the packaging body bottom surface 226 and from the packaging body front surface 222 to the packaging body rear surface 406, the packaging body first surface 408 in contact with the rectangular prism body first side surface 108.

(21) The packaging body 220 may be adhered to the rectangular prism body 102 and the thin, flexible non-foam member 232 or may be resistant to any adhesive on the rectangular prism body 102. The packaging body 220 may be provided with a surface the prism members 214, 216, 218 and the thin, flexible non-foam member 232 which deters adhesion to facilitate later removal from the packaging for installation between substrates.

(22) The expansion joint seal 100 is provided in pre-compressed form for installation. The packaging body 220, the rectangular prism body 102 and the thin, flexible non-foam member 232 are subjected to laterally compression, such that the rectangular prism body width 122 is reduced. The expansion joint seal 100 is then packaged, such as in shrink wrap, to remain in compression. The packaging body 220 provides a rigid surface against which the the rectangular prism body 102 is maintained in compression. Prior to compression, the rectangular prism body 102 is wider than the nominal size of the expansion joint. After the expansion joint seal 100 is removed from packaging and separated from the packaging body 220, it is imposed between the first substrate and the second substrate before the rectangular prism body 102 relaxes to a width greater than the expansion joint. The rectangular prism body 102 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 rectangular prism body 102 may be adhered to the substrate walls by an adhesive on the sides of the core bodies. Thus, the joint system may include the first substrate and the second substrate.

(23) Because the rectangular prism body 102 is in compression between the substrates of an expansion joint, it is well-known to pre-compress the rectangular prism body 102 at the factory and provide the rectangular prism body 102 in compression.

(24) When desired, a second packaging body 230, sized the same or similar to the first packaging body 220 may be used, and may provide benefit in compression and packaging of the joint seal 101. The second packaging body 230 abuts the rectangular prism body 102 at the rectangular prism body second side surface 110. The second packaging body 230 may be provided with a surface facing the rectangular prism body 102 which deters adhesion to facilitate later removal from the packaging for installation between substrates.

(25) Referring to FIG. 3, an end view of another alternative joint seal system according to the present disclosure is illustrated. When desired, the thin, flexible non-foam member 326 may include one or more internal openings, in which a prism member may be imposed, and may include a number of triangular openings in which prism members may be imposed. Alternatively, any shapes may be provided, including polygons, cylindrical sections and even conic sections. As illustrated in FIG. 3, the plurality of prism members includes a quadrilateral prism member 324, a first triangular prism member 312 opposite the non-foam member 326 from the quadrilateral prism member 324, a second triangular prism member 314 opposite the non-foam member 326 from the first triangular prism member 212 and opposite the non-foam member 326 from the quadrilateral prism member 324, a third triangular prism member 316 opposite the non-foam member 326 from the first triangular prism member 212 and opposite the non-foam member 326 from the quadrilateral prism member 324, a fourth triangular prism member 318 opposite the non-foam member 326 from the quadrilateral prism member 324, a fifth triangular prism member 320 opposite the non-foam member 326 from the quadrilateral prism member 324, and opposite the non-foam member 326 from the fourth triangular prism member 318, a sixth triangular prism member 322 opposite the non-foam member 326 from the quadrilateral prism member 324, and opposite the non-foam member 326 from the fourth triangular prism member 318, and opposite the non-foam member 326 from the fifth triangular prism member 320, and the non-foam member 326 may have a non-foam member internal void at a center, two non-foam member legs at a non-foam member first end and two non-foam member legs at a non-foam member second end.

(26) Alternatively, one or more openings in the non-foam member 326 may remain open. When desired, the expansion joint seal 100 includes a first triangular prism member 312, a second triangular prism member 314 opposite the non-foam member 326 from the first triangular prism member 212, a third triangular prism member 316 opposite the non-foam member 326 from the first triangular prism member 212 and opposite the non-foam member 326 from the second triangular prism member 314, a fourth triangular prism member 318 opposite the non-foam member 326 from the second triangular prism member 314, a fifth triangular prism member 320 opposite the non-foam member 326 from the quadrilateral prism member 324, and opposite the non-foam member 326 from the fourth triangular prism member 318, a sixth triangular prism member 322 opposite the non-foam member 326 from the fourth triangular prism member 318, and opposite the non-foam member 326 from the fifth triangular prism member 320, and the non-foam member 326 may have a non-foam member internal void at a center, two non-foam member legs at a non-foam member first end and two non-foam member legs at a non-foam member second end.

(27) When the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 are constructed of foam, any of various types of foam known in the art may be used, including compositions such as polyurethane and polystyrene, and may be open or closed cell. The uncompressed density of a prism member 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may also be altered for performance, depending on local weather conditions. The composition of each prism member 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 need not be identical to another. A prism member 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324, for example, may be selected of a composition which is fire retardant or water-resistant. Moreover, when the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 are constructed of foam(s), these may be any of an open cell foam, a lamination of open cell foam and closed cell foam, and closed cell foam. Further any of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 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. Additionally, any of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may be composed of or may include a hydrophilic material, a hydrophobic material, a fire-retardant material, or a sintering material.

(28) Moreover, the material for the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 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 100-200% 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.

(29) 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).

(30) 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.

(31) 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 tis minimum compressed density. Additionally, close cell, partially closed cell and other foams can be used as in combination with the viscoelastic foams to reduce the overall cost.

(32) 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, an leakage, resilience in face of one or more cycling regimes, compressibility, relaxation rate, compression set, and elasticity.

(33) The material for one or more of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 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. One or more of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may also, or alternatively, be infused or impregnated or otherwise altered to retain a fire retardant, dependent on function. Where the any of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 is foam, any suitable open cell form 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.

(34) One or more of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may be selected from an inherently hydrophilic material or have a hydrophilic component such as a hydrophilic polymer that is uniformly distributed throughout. One or more of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 are constructed of foam may include strategically-placed surface impregnation or partially impregnate with a hydroactive polymer. Because the primary function of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 is waterproofing, the addition of a hydrophilic function does not negatively impact any desired fire-resistant properties, as an increased moisture content in any of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 are constructed of foam may increase fire resistive properties.

(35) One or more of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 could 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 prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 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.

(36) One or more of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may include an impregnate, such as a fire retardant such as aluminum trihydroxide, which may be throughout its entirety or for a desired depth from the 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.

(37) Beneficially, where fire retardancy is provided by first fire-retardant coating 130 and/or non-foam member 124, 232, 326, the present disclosure provides for an expansion joint sealant without the need to impregnate one or all of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 with a fire retardant.

(38) An adhesive may be applied to the rectangular prism body first side surface 108 and/or rectangular prism body second side surface 110.

(39) The one or all of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 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 as 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 one or all of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 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.

(40) The expansion joint seal 100 may further include an insulating layer 132, such as a silicate, atop the first fire-retardant coating 130 to add a refractory of insulating function. However, such a layer, unless otherwise selected, would not be a fire-retardant liquid glass formulation.

(41) The exposed top surface may be coated or partially coated with 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.

(42) Other variations may be employed. Referring to FIG. 3, the present disclosure may further incorporate a membrane 330, such as vapor impermeable layer, for further benefits. The membrane 330 may be positioned at the top or bottom surface of the rectangular prism body 102 are not susceptible to contaminants and therefore continue to function. As one or more prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may be composed of a vapor permeable foam, such a composition becomes particularly beneficial when a barrier or membrane 330 is present. The membrane 330 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 330 is preferably sized to be no smaller in any dimension than the adjacent core body. Alternatively, the membrane 330 may extend beyond the core bodies to provide a surface which may contact an adjacent substrate and even overlap its top. The membrane 330 may be intumescent or may otherwise provide fire retardancy in the expansion join seal 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.

(43) The expansion joint seal 100 may be constructed to withstand a hydrostatic pressure equal to or greater than 29.39 psi. Environmentally friendly foam, filler, binders, elastomer and other components may be selected to meet environmental, green and energy efficiency standards. One or more of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may exhibit auxetic properties to provide support or stability for the expansion joint seal 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. One or more of prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may have a rigid or semi-rigid central core equal to 5-65% of rectangular prism body width 122. One or more of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may have a central core rigid through normal joint cycling, typically +/25%, but collapsible under seismic (+/50%) joint cycling. One or more of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324 may have a central core both rigid and collapsible and coupled with a data feedback system where sensors collect data and supplies information to be stored internally or externally.

(44) Additionally, when desired, a sensor 332 may be included and may contact one of more of the component of the expansion joint seal 100. The sensor may be a radio frequency identification device (RFID), transponder, or other wirelessly transmitting sensor. A sensor may be beneficial to assess the health of an expansion joint seal 100 without accessing the interior of the expansion joint, otherwise accomplished by removal of the cover plate. It may identify when a failure occurs and thus provide an integral failure detection system. The failure detection system may be continuously or intermittently monitored and may provide feedback by powered, radio or inductive methods which may have an active or passive feedback system. It may alternatively provide environmental data, including air or water contamination. 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 in the expansion joint seal 100 may be particularly advantageous in circumstances where the expansion joint seal 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 at the rectangular prism body bottom surface 106, the user can scan the expansion joint seal 100 for any points of weakness due to water penetration. A heat sensitive sensor may also be positioned within the expansion joint seal 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.

(45) Inclusion of a sensor in rectangular prism body 102 may provide substantial benefit for information feedback and potentially activating alarms or other functions within the joint seal 101 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 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 may be positioned in other locations within the joint seal 101 to provide beneficial data. A sensor may be positioned within the rectangular prism body 102 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 so positioned might alternatively be selected to provide moisture penetration data, beneficial in cases of failure or conditions beyond design parameters. The sensor may provide data on moisture content, heat or temperature, moisture penetration, and manufacturing details. A sensor may provide notice of exposure from the surface of the expansion joint seal 100 most distant from the base of the joint. A sensor may further provide real time data. Using a moisture sensitive sensor in the expansion joint seal 100 and at critical junctions/connections would allow for active feedback on the waterproofing performance of the expansion joint seal 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 alters 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 in the expansion joint seal 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 within expansion joint seal 100 may provide a benefit over the prior art. Impregnated foam materials 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 within expansion joint seal 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 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.

(46) The selection of components providing resiliency, compressibility, water-resistance and fire resistance, the joint seal 101 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 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.

(47) 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.

(48) 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 but up to 8 hours may be required. 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 (P rating) and the Hose Stream teat. The temperature data is only relevant where building codes require the T to equal the P-rating.

(49) 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:

(50) TABLE-US-00001 Hourly Fire Rating Water Duration of Hose Time in Minutes Pressure (kPa) Stream Test (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
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.

(51) 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.

(52) 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.

(53) 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:

(54) TABLE-US-00002 Classification Flame Spread Smoke Developement A 0-25 0-450 B 26-75 0-450 C 76-200 0-450

(55) 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:

(56) TABLE-US-00003 Movement Minimum Mimimum cycling Classification number rate (cycles Joint Type (if used) of cycles per minute) (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

(57) 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.

(58) The expansion joint seal 100 may therefore perform wherein the bottom surface the rectangular prism body bottom surface 106 at a maximum joint width increases no more than 181 C. after sixty minutes when the body member 111 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.

(59) In expansion joint seal 100 may also perform wherein the rectangular prism body bottom surface 106, and may have a maximum joint width of more than six (6), increases no more than 139 C. after sixty minutes when the expansion joint seal 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.

(60) The expansion joint seal 100 may be adapted to be cycled one of 500 times at t cycle per minute, 500 times at 10 cycles per minute and cycles at 30 times per minute, without indication of stress, deformation or fatigue.

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

(62) As can be appreciated, the foregoing disclosure may incorporate or be incorporated into other expansion joint systems, such as those with fire-retardant members in a side of any of expansion joint seal 100 adjacent the substrate, the inclusion of a separate barrier within the expansion joint seal 100 and which may extend beyond the rectangular prism body first side surface 108 and the rectangular prism body second side surface 110 of the expansion joint seal 100 or remain encapsulated within, one or more longitudinal load transfer members atop or within any of the prism members 114, 116, 118, 214, 216, 218, 312, 314, 318, 320, 322, 324, without or without support members, a cover plate, a spline or ribs tied to the cover plate whether fixedly or detachably, use of auxetic materials, or constructed to obtain a fire endurance rating or approval according to any of the tests known in the United States and Europe for use with expansion joint systems, including fire endurance, movement classification(s), load bearing capacity, air penetration and water penetration.

(63) 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.