Foam Seal with Living Hinge for Angular Expansion Joints
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Solution Overview
Problem
Existing foam-based expansion joint seals face challenges in creating efficient corner transitions, particularly in accommodating angular changes, as they often require field assembly, result in stress concentrations, and are prone to failure due to unequal substrate movement and adhesive issues, leading to inefficiencies and waste in construction.
Innovation Solution
A unitary elongated body with a living hinge and hinge enclosure, made of compressible foam, which allows for non-uniform expansion and contraction, reducing stress concentrations and eliminating the need for additional elastomers, while providing a seamless corner transition without the need for multiple splices or special forms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If field-assembled transitions are created by abutting and adhering foam-based expansion joint seals, then corner transitions can be accommodated, but stress concentrations occur at the adhered seam causing failure
Solution Approach 1:
The foam-based expansion joint seal is divided into multiple segments (first leg, second leg, and intermediate section) that are adhered together to form the corner transition. This segmentation allows the seal to accommodate angular changes while distributing stress away from concentrated seam locations through the intermediate section design.
Solution Approach 2:
An intermediate section is introduced between the first and second legs of the corner transition. This intermediate section acts as a mediator that distributes and reduces stress concentrations at the adhered seams, preventing failure while maintaining the corner transition's adaptability to angular changes.
2Adaptability or versatility
If mitered joints are used for corner transitions, then angular changes are accommodated, but shear forces from unequal substrate movement cause adhesive failure
Solution Approach 1:
The intermediate section is designed with specific local properties (different from the leg sections) to provide stress distribution and reinforcement at the critical joint areas. This local quality enhancement protects the adhesive bonds from shear forces caused by unequal substrate movement while maintaining overall angular adaptability.
3Ease of operation
If foam-based expansion joint seals are compressed for installation, then they can be fitted into expansion joints, but stress concentrations occur at adhered faces leading to delamination
Solution Approach 1:
Dividing the seal into segments with an intermediate section allows compression forces to be distributed more evenly during installation. The segmentation prevents stress concentration at single adhesive seams, maintaining bond integrity while enabling feasible installation through compression.
Solution Approach 2:
The intermediate section serves as a stress-distributing intermediary that prevents delamination during compression installation. It mediates the transfer of compression forces across the joint, protecting the adhesive bonds from concentrated stresses that would cause failure.
4Manufacturing precision
If special forms and multiple splices are used for corner transitions, then precise angular transitions can be created, but manufacturing complexity and waste increase
Solution Approach 1:
The corner transition is created by segmenting the foam seal into standardizable sections (legs and intermediate sections) that can be manufactured using conventional processes. This segmentation achieves precise angular transitions without requiring complex special forms, reducing manufacturing complexity while maintaining precision.
Solution Approach 2:
The segmented design with standardized intermediate sections creates a universal component that can be used for various corner angles and configurations. This multi-functionality reduces the need for special forms for different applications, simplifying manufacturing while maintaining precise angular transitions.
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 solution enables efficient corner transitions with reduced stress concentrations, minimizing the risk of failure and waste, while ensuring a watertight seal and uniform expansion forces, thus improving the durability and ease of installation of expansion joint seals.
Implementation Method 1
a unitary elongated body which incorporates a living hinge, a hinge enclosure for containment of increased adhesive and to reduce stress concentrations
Implementation Method 2
these foam-based expansion joint seals are compressed on site, or may be provided in a compressed form, are worked into the expansion joint
Implementation Method 3
an adhesive where the elongated body has a body first section, a body living hinge section, and a body second section, the adhesive is adhered to the hinge base and to the hinge first surface adjacent the hinge base
Data Source
AI summary
A foam-based expansion joint seal for use in angular expansion joint segments includes a unitary elongated body having a living hinge, a hinge enclosure for containment of increased adhesive and to reduce stress concentrations, and adhesively-joined surfaces.