Expansion Joint Seal with Integrated Load Transfer

Solution Overview

Problem

Existing expansion joint systems face challenges in providing durable, flexible, and fire-resistant seals that can withstand temperature variations and mechanical loads, often requiring rigid materials that lack resiliency and are prone to adhesive or cohesive failure, and may pose tripping hazards due to elevated cover plates.

Innovation Solution

An expansion joint design featuring an elongated core of resilient compressible foam with integrated incompressible longitudinal load-transfer members, which allows for flexible movement and load transfer without a cover plate, incorporating viscoelastic foams and intumescent materials for enhanced fire resistance and water resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If rigid extruded rubber or polymer glands are used to support transfer loads, then load transfer capability is improved, but resiliency and seismic movement capability deteriorate

Engineering Contradiction:

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The expansion joint seal is divided into multiple functional layers: a compressible foam core that provides resiliency and movement capability, and discrete load transfer members (such as steel bars or rigid strips) embedded within or attached to the foam. This segmentation allows each component to perform its specialized function - the foam handles compression and movement while the load transfer members handle structural loads.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining a compressible foam material (such as polyethylene foam) with rigid load transfer members. The foam provides elasticity and movement capability while the rigid members provide load transfer strength. This composite approach allows the system to simultaneously achieve both resiliency and load transfer capability that neither material could provide alone.

Inventive Principle:

Principle #40Composite materials

2Strength

If cover plates are used to support transfer loads, then load transfer capability is improved, but tripping hazards and installation complexity worsen

Engineering Contradiction:

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention removes the cover plate component entirely from the expansion joint system. Instead of using a separate cover plate to transfer loads, the load transfer members are integrated directly into the foam seal body, allowing load transfer without requiring any protruding elements that could create tripping hazards.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The load transfer function is merged with the seal body itself. Load transfer members are embedded within or structurally integrated to the foam seal, combining the sealing function and load transfer function into a single integrated component, eliminating the need for separate cover plates.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If mechanically attached cover plates are used, then load transfer capability is improved, but installation complexity and substrate damage worsen

Engineering Contradiction:

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The load transfer members are integrated into the foam seal during manufacturing, combining the seal and load transfer components into a single pre-assembled unit. This eliminates the need for separate mechanical attachment operations and substrate drilling, simplifying installation while maintaining load transfer capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The load transfer members are pre-positioned and secured within the foam seal during manufacturing before installation. This preliminary action ensures proper alignment and secure attachment without requiring complex field installation procedures or substrate modifications.

Inventive Principle:

Principle #10Preliminary action

4Strength

If continuous compression and tension on the bond line are applied, then load transfer capability is improved, but joint system lifespan deteriorates

Engineering Contradiction:

Core Design Contradiction:

StrengthVSDuration of action of stationary object

Solution Approach 1:

The system segments the load transfer function from the seal bond line by using discrete load transfer members that are either embedded in or attached to the foam. This allows load transfer forces to be carried by the rigid members rather than being transmitted through the adhesive bond line, reducing stress on the seal-to-substrate connections and extending system lifespan.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system provides improved resistance to upward deflection during installation, increased flexibility, and extended lifespan by distributing load effectively, while maintaining fire resistance and water resistance, and reducing the risk of tripping hazards.

Implementation Method 1

an elongated core of a resiliency compressible material

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

resiliently compressible foam

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 3

at least one incompressible longitudinal load transfer member

Methodology Applied

Scientific EffectCompression resistance: Compression

Implementation Method 4

incorporating viscoelastic foams and intumescent materials for enhanced fire resistance

Methodology Applied

Scientific EffectIntumescent expansion: Intumescent Materials

Implementation Method 5

incorporating viscoelastic foams and intumescent materials for enhanced fire resistance

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Data Source

PatentUS10480136B2Expansion joint seal with load transfer and sensor

Publication Date: 2019.11.19

AI summary

An expansion joint design for supporting transfer loads. The system, includes an elongated core and at least one longitudinal load-transfer member which are bonded together.