Pre-attached Sealant Concrete Expansion Joint Insert

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Solution Overview

Problem

Conventional expansion joint sealants in concrete installations are messy, time-consuming, and labor-intensive due to the need for separate application and potential misapplication, and require removal of joint insert material to create a cavity for sealant, increasing costs and labor.

Innovation Solution

A concrete joint insert with a sealant pre-secured along one of its longitudinal edges, allowing simultaneous installation and heating to melt and seal the sealant within the joint, eliminating the need for additional adhesive and reducing installation time and mess.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional separate sealant application is used, then the expansion joint can be sealed, but the installation process becomes messy and time-consuming

Engineering Contradiction:

Improvesealing effectivenessVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The sealant is integrated directly onto the expansion joint insert, combining two separate components (insert and sealant) into a single unified product. This eliminates the need for separate application steps, reducing installation time while maintaining sealing effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sealant is pre-applied to the expansion joint insert during manufacturing, before installation. This preliminary action ensures proper sealant placement and eliminates on-site application mess and time consumption.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If conventional separate sealant application is used, then the expansion joint can be sealed, but the jobsite appearance becomes messy

Engineering Contradiction:

Improvesealing effectivenessVSAvoidjobsite mess

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

By combining the sealant and insert into a single pre-assembled unit, the harmful effect of messy sealant application is eliminated. The sealant remains contained on the insert until installation, preventing it from getting on surrounding concrete.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sealant is pre-applied in a controlled manufacturing environment rather than on the jobsite, eliminating the mess and unprofessional appearance associated with on-site sealant application.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If conventional sealant application is used, then the expansion joint can be sealed, but additional labor and expense are incurred

Engineering Contradiction:

Improvesealing effectivenessVSAvoidinstallation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The integration of sealant and insert into a single component simplifies the installation process to one step, eliminating the need for workers to handle and apply separate sealant materials, thereby reducing labor complexity and expense.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pre-applied sealant on the insert provides a self-contained sealing solution that requires no additional sealant application steps, allowing the installation to be completed with a single component placement action.

Inventive Principle:

Principle #25Self-service

4Reliability

If a cavity is created for sealant reception, then the sealant can be installed, but the joint insert material must be removed increasing time and labor

Engineering Contradiction:

Improvesealant installationVSAvoidinstallation speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The sealant is pre-applied to the insert in the manufacturing process, eliminating the need to create a cavity during installation. This preliminary preparation removes the time-consuming step of material removal and speeds up installation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The need to create a cavity by removing joint insert material is extracted from the installation process. The pre-applied sealant eliminates this unnecessary step, improving productivity without compromising sealant installation.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Facilitates faster, more consistent, and aesthetically pleasing sealing of expansion joints by ensuring controlled adhesive application and reducing labor and time required for installation, while maintaining a professional appearance.

Implementation Method 1

heating the sealant to at least partially melt the sealant

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

heat the sealant to at least partially melt the sealant to cause the sealant to establish a seal

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11371237B2Methods of making and installing a concrete expansion joint insert including a sealant on one edge

Publication Date: 2022.06.28 JD RUSSELL CO

AI summary

An illustrative example method of making a concrete expansion joint insert includes establishing an insert body having two ends, two longitudinal edges between the ends, and two side surfaces between the longitudinal edges and the ends. A sealant is secured to one of the longitudinal edges so that the insert and the sealant can be simultaneously inserted into an expansion joints.