Factory fabricated precompressed water and/or fire resistant expansion joint system transition

• US 9,637,915 B1
• Filed: 12/31/2012
• Issued: 05/02/2017
• Est. Priority Date: 11/20/2008
• Status: Active Grant

• Current Assignee: Emseal Joint Systems Limited
• Original Assignee: Emseal Joint Systems Limited
• Inventors: Hensley, Lester, Witherspoon, Bill
• Primary Examiner(s): Quast, Elizabeth A
• Application Number:
  US13/731,327
• Time in Patent Office: 1,583 Days
• Field of Search: 52393, 5239604, 5239607, 525861, 525862, 527414, 404 47, 404 68
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04B 1/6812 Compressable seals of solid form
• CPC Class Codes: E04B 1/948 Fire-proof sealings or joints for doors or windows E06B5/164

Abstract

A fire and/or water resistant expansion joint system for installation into a building joint in vertical and horizontal configurations is designed such that it can be used for either an inside or outside corner. The system comprises a core having a fire retardant infused therein. A layer of an elastomer is disposed on the core and is tooled to define a profile to facilitate the compression of the expansion joint system when installed between coplanar substrates. The system can be delivered to a job site in a pre-compressed state ready for installation into the building joint.

Claims

1. A fire and water resistant expansion joint system, comprising:

a core;

a fire retardant infused into the core; and

a water resistant layer disposed on the core;

wherein the layer is tooled to define a profile to facilitate compression of the expansion joint system when installed between substrates, wherein the core infused with the fire retardant compressed has as a density of about 160 kg/m³ to about 800 kg/m³; and

wherein the expansion joint system is angled around a corner, and the fire and water resistant expansion joint system and the core infused with the fire retardant are configured to pass testing mandated by UL 2079.

2. The expansion joint system of claim 1, wherein the core comprises a plurality of individual laminations assembled to construct a laminate, one or more of the laminations being infused with at least one of the fire retardant and a water-based acrylic chemistry.

3. The expansion joint system of claim 1, wherein vertically oriented surfaces of the core are retained between edges of the coplanar substrates.

4. The expansion joint system of claim 1, wherein the core comprises foam.

5. The expansion joint system of claim 4, wherein the water resistant layer disposed on the foam is selected from the group consisting of polysulfides, acrylics, polyurethanes, poly-epoxides, silyl-terminated polyethers, and combinations of one or more of the foregoing.

6. The expansion joint system of claim 4, wherein the core comprises a block of foam.

7. The expansion joint system of claim 1, wherein the water resistant layer disposed on the core comprises a silicone.

8. The expansion joint system of claim 1, wherein the water resistant layer is tooled to define at least one of a bellows profile and a bullet profile.

9. The expansion joint system of claim 1, wherein the expansion joint system is angled around the corner to extend from a horizontal plane to a vertical plane.

10. The expansion joint system of claim 9, wherein the angle around the corner is made continuous via the insertion of an insert piece located between a section of the core extending in the horizontal plane and a section of the core extending in the vertical plane.

11. The expansion joint system of claim 1, wherein the expansion joint system is angled around the corner and extends in a horizontal plane.

12. The expansion joint system of claim 11, wherein the angle around the corner comprises a miter joint between two sections of the core extending in the horizontal plane.

13. The expansion joint system of claim 12, wherein the two sections of core extending in the horizontal plane are adhesively joined.

14. The expansion joint system of claim 1, wherein the ratio of the fire retardant infused into the core is in a range of about 3.5:

1 to about 4;

1 by weight.

15. The expansion joint system of claim 1, wherein a layer comprising the fire retardant is sandwiched between the material of the core.

16. The expansion joint system of claim 1, wherein the fire retardant infused into the core is selected from the group consisting of water-based alumina tri-hydrate, metal oxides, metal hydroxides, aluminum oxides, antimony oxides and hydroxides, iron compounds, ferrocene, molybdenum trioxide, nitrogen-based compounds, phosphorus based compounds, halogen based compounds, halogens, and combinations of the foregoing materials.

17. The expansion joint system of claim 1, wherein the core uncompressed has a density of about 100 kg/m³ to about 180 kg/m³.

18. The expansion joint system of claim 1, further comprising a second layer disposed on the water resistant layer, wherein the second layer is selected from the group consisting of another water resistant layer, a fire barrier layer and combinations thereof.

19. The expansion joint system of claim 1, wherein a first coating is located on a surface of the core, and a second coating is located on a surface of the core opposing the first coating, wherein the first coating is the substantially the same as or different than the second coating.

20. The expansion joint system of claim 1, wherein the fire and water resistant expansion joint system is capable of withstanding exposure to a temperature of about 930°

C. at about one hour.

21. The expansion joint system of claim 1, wherein the fire and water resistant expansion joint system is capable of withstanding exposure to a temperature of about 1010°

C. at about two hours.

22. The expansion joint system of claim 1, wherein the fire and water resistant expansion joint system is capable of withstanding exposure to a temperature of about 1260°

C. at about eight hours.

23. The expansion joint system of claim 22, wherein the ratio of the fire retardant material infused into the core is in a range of about 3.5:

1 to about 4;

1 by weight.

24. The expansion joint system of claim 1, wherein the expansion joint system is a tunnel expansion joint system.

25. The expansion joint system of claim 1, wherein the core infused with the fire retardant uncompressed has as a density of about 50 kg/m³ to about 250 kg/m³.

26. A fire and water resistant vertical expansion joint system, comprising:

a first section of core extending in a horizontal plane;

a second section of core extending in a vertical plane;

an insert piece of core located between the first section of core extending in the horizontal plane and the second section of core extending in the vertical plane, the insert piece being configured to transition the first section of the core from the horizontal plane to the vertical plane of the second section of the core; and

a water resistant layer disposed on the core, the water resistant layer imparting a substantially waterproof property to the core, wherein the water resistant layer is a continuous layer of the water resistant layer from the vertical plane to the horizontal plane and the water resistant layer is a continuous layer of the water resistant layer over the insert piece, and the insert piece is held in place by the continuous layer of the water resistant layer, and the expansion joint system is configured to accommodate at least one of thermal and seismic movement in the system;

wherein the core is infused with a fire retardant;

wherein the fire and water resistant vertical expansion joint system is installable between horizontal substrates and vertical substrates, wherein the core infused with the fire retardant compressed has as a density of about 160 kg/m³ to about 800 kg/m³; and

wherein the fire and water resistant vertical expansion joint system and the core infused with the fire retardant are configured to pass movement cycling and fire endurance testing mandated by UL 2079.

27. The vertical expansion joint system of claim 26, wherein the core comprises a plurality of individual laminations assembled to construct a laminate.

28. The vertical expansion joint system of claim 27, wherein the core comprises open celled polyurethane foam.

29. The vertical expansion joint system of claim 26, further comprising an acrylic infused in the core.

30. The vertical expansion joint system of claim 26, wherein the ratio of the fire retardant infused into the core is in a range of about 3.5:

1 to about 4;

1 by weight.

31. The vertical expansion joint system of claim 26, wherein a layer comprising the fire retardant is sandwiched between the material of the core.

32. The vertical expansion joint system of claim 26, wherein the fire and water resistant vertical expansion joint system is capable of withstanding exposure to a temperature of about 1010°

C. at about two hours.

33. The vertical expansion joint system of claim 26, wherein the fire and water resistant vertical expansion joint system is capable of withstanding exposure to a temperature of about 1260°

C. at about eight hours.

34. The vertical expansion joint system of claim 33, wherein the ratio of the fire retardant material infused into the core is in a range of about 3.5:

1 to about 4;

1 by weight.

35. The expansion joint system of claim 26, wherein the core infused with the fire retardant uncompressed has as a density of about 50 kg/m³ to about 250 kg/m³.

36. A fire and water resistant expansion joint system, comprising:

a core;

a fire retardant infused into the core;

wherein the core infused with the fire retardant is configured to define a profile to facilitate the compression of the expansion joint system when installed between substrates, wherein the core infused with the fire retardant compressed has as a density of about 160 kg/m³ to about 800 kg/m³; and

wherein the expansion joint system is angled around a corner, and the fire and water resistant expansion joint system and the core infused with the fire retardant are configured to pass testing mandated by UL 2079.

37. The expansion joint system of claim 36, wherein the core comprises a first outer surface and a second outer surface, and no coatings are located on either the first outer surface or the second outer surface.

38. The fire and water resistant expansion joint system of claim 36, wherein the fire and water resistant expansion joint system is capable of withstanding exposure to a temperature of about 1260°

C. at about eight hours, and the ratio of the fire retardant material infused into the core is in a range of about 3.5;

1 to about 4;

1 by weight.

39. The expansion joint system of claim 36, wherein the expansion joint system is a tunnel expansion system.

40. The expansion joint system of claim 36, wherein the core infused with the fire retardant uncompressed has as a density of about 50 kg/m³ to about 250 kg/m³.