Self-Adhesive Sealing Element for Fluted Metal Deck Corrugations
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Solution Overview
Problem
Current methods for sealing fluted metal decks and movement joints between metal decks and wall configurations are cumbersome, require protective clothing due to mineral wool use, and result in variable sealing quality, especially for fire-rated walls.
Innovation Solution
A moldable, self-adhesive sealing element with a predefined geometry that matches the shape of corrugations, ensuring a secure and tight seal, and a method involving a carrier strip for easier application and handling, allowing for quick installation of drywall configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mineral wool is stuffed into gaps and spray coating is applied, then sealing quality is improved, but working steps increase and productivity decreases
Solution Approach 1:
The sealing element is pre-formed with a specific geometry that matches the corrugation shape before installation. This preliminary preparation eliminates the need for on-site mineral wool stuffing and spray coating operations, reducing multiple working steps to a single insertion action while maintaining reliable sealing.
Solution Approach 2:
The sealing element combines multiple sealing functions (filling gaps, providing fire resistance, sound attenuation) into a single integrated component. This merges the separate processes of mineral wool stuffing and spray coating application into one operation, improving productivity without compromising sealing quality.
2Reliability
If mineral wool is used for sealing, then sealing performance is improved, but protective clothing is required and ease of operation decreases
Solution Approach 1:
The sealing element is made from a safe, non-harmful material that can be handled without protective clothing. This replaces mineral wool, which requires protective gear due to skin irritation, with a disposable sealing element that maintains sealing performance while eliminating safety concerns.
Solution Approach 2:
The sealing element is designed to be self-adhesive, automatically bonding to the corrugation surfaces without requiring additional coating or complex installation procedures. This self-service characteristic eliminates the need for spray coating operations and reduces the number of working steps while maintaining reliable sealing.
3Reliability
If spray coating is applied from both sides of the wall, then sealing completeness is improved, but installation time increases
Solution Approach 1:
The sealing element is pre-formed with the correct geometry and adhesive properties before installation. This preliminary preparation eliminates the need for time-consuming on-site spray coating operations from both sides of the wall, reducing installation time while maintaining complete sealing through the pre-designed element geometry.
Solution Approach 2:
The sealing function is extracted from the multi-step process of mineral wool stuffing and spray coating, and concentrated into a single self-adhesive sealing element. This extraction simplifies the installation process to one operation, significantly reducing installation time while maintaining sealing completeness.
4Reliability
If sealing element geometry is customized for each corrugation, then sealing tightness is improved, but manufacturing complexity increases
Solution Approach 1:
The sealing element uses a standardized geometry with specific dimensional parameters that are optimized to fit corrugations. By establishing standard parameter values (cross-sectional shape, dimensions, moldability), the design achieves tight sealing without requiring custom manufacturing for each corrugation, balancing sealing effectiveness with manufacturing simplicity.
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 sealing element provides a consistent, air-tight, sound-attenuating, fire-resistant, and thermally isolating seal without the need for additional steps or protective measures, ensuring quick and reliable sealing of corrugations during drywall installation.
Implementation Method 1
by being self-adhesive the sealing element is easy to install as it sticks to the fluted metal decks even upside down so it does not fall off under its own weight when adhered to a ceiling
Data Source
AI summary
A sealing element as well as a seal is for sealing a corrugation of a fluted metal deck. The sealing element is moldable and self-adhesive and has a predefined geometry adapted to seal the corrugation. Furthermore, a method is for installing a wall configuration, preferably a drywall configuration, to a fluted metal deck with corrugations.