Pre-formed Profile Element for Metal Deck Sealing
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Solution Overview
Problem
Existing sealant compounds used in building constructions to prevent environmental factors like noise, smoke, and fire from passing through gaps between structural components are costly and time-consuming to install, and often do not conform well to the contours of the components, leaving gaps unsealed.
Innovation Solution
A method and system for manufacturing a continuous profile element using a flowable reaction material that expands within a flat cover, which is then welded and cut to form pre-formed profile elements that conform to specific geometries, allowing for efficient and cost-effective sealing of gaps between structural components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If typical sealant compounds are used to seal gaps between structural components, then sealing effectiveness is improved, but installation cost and time increase
Solution Approach 1:
The profile element is pre-formed with the correct geometry and sealing properties before installation. The reaction material is pre-positioned within the flat cover, and the element is manufactured to exact specifications, eliminating the need for on-site application and adjustment of sealant compounds.
Solution Approach 2:
The profile element is manufactured as a precise replica or copy of the required seal geometry. By creating a pre-formed element that exactly matches the needed profile, the invention eliminates the time-consuming process of applying and shaping sealant compounds during installation.
2Reliability
If typical sealant compounds are used to seal gaps, then sealing is achieved, but installation cost increases
Solution Approach 1:
The profile element is pre-manufactured with all sealing properties integrated, eliminating the need for expensive on-site application processes. The reaction material is pre-positioned and the element is formed to exact specifications before delivery to the construction site.
Solution Approach 2:
The invention changes the physical state and properties of the sealing material by using a reaction material that expands within a mold. This allows the material to be applied in a compact, cost-effective form and then transformed into the final sealing geometry, reducing overall material and installation costs.
3Reliability
If sealant compounds are applied to seal gaps, then sealing is attempted, but the sealant does not conform to component contours, leaving gaps unsealed
Solution Approach 1:
The profile element is pre-formed with the exact contour geometry required for perfect fitting. The flat cover is shaped to match the specific contours of the structural components, ensuring that when the element is installed, it conforms precisely to the required geometry without leaving gaps.
Solution Approach 2:
The reaction material undergoes a phase change from liquid to expanded solid form within the confines of the shaped flat cover. This expansion process allows the material to perfectly replicate the contours of the mold, ensuring precise conformity to the required geometry while maintaining uniform density and sealing properties.
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 provides a cost-effective and efficient way to seal gaps between structural components, preventing environmental factors from passing through, while ensuring a precise fit and reducing manufacturing time through continuous production and cutting processes.
Implementation Method 1
applying a flowable reaction material continuously to the flat cover, where the reaction mixture is configured to expand within the flat cover
Implementation Method 2
welding the continuous flat cover around the reaction mixture to form an initial profile element
Data Source
AI summary
A method of manufacturing includes providing a continuous flat cover to an assembly line, where the assembly line includes a conveying means. The method also includes applying a flowable reaction material continuously to the flat cover, where the reaction mixture is configured to expand within the flat cover. The method also includes welding the continuous flat cover around the reaction mixture to form an initial profile element. The method also includes cutting the initial profile element, continuously along the assembly line, to form one or more profile elements. Each of the one or more profile elements is a portion of the initial profile element, and each of the one or more profile elements includes a geometry for conforming with a construction component.