Fabric (woven – knitted – or nonwoven textile or cloth – etc.) – Coated or impregnated woven – knit – or nonwoven fabric which... – Coating or impregnation intended to function as an adhesive...
Reexamination Certificate
1999-07-21
2001-10-23
Cole, Elizabeth M. (Department: 1771)
Fabric (woven, knitted, or nonwoven textile or cloth, etc.)
Coated or impregnated woven, knit, or nonwoven fabric which...
Coating or impregnation intended to function as an adhesive...
C029S402210, C029S402090, C156S094000, C427S099300, C427S099300, C427S099300, C427S140000, C428S036100, C428S144000, C428S145000, C428S149000, C428S293400, C442S069000, C442S092000, C442S129000, C442S157000, C442S180000, C442S088000, C442S104000, C442S155000, C442S168000, C442S170000, C442S173000, C442S174000
Reexamination Certificate
active
06306781
ABSTRACT:
BACKGROUND OF THE DISCLOSURE
The present invention is directed to an expansion joint patch apparatus and, more specifically, to an expansion joint patch apparatus for repairing or patching failed or torn fabric expansion joints. The present invention is also directed to a method for forming a fluoroelastomer patch for repairing fabric expansion joints, as a reinforcement material for existing fluoroelastomer expansion joints and/or as a reinforcement material for new-style fluoroelastomer expansion joints, which reduce material costs and may improve performance.
Fluoroelastomers (FKM), such as Viton® or Fluorel®, are high performance elastomers having outstanding resistance to chemical attack, abrasion, weathering, ozone, oil and heat aging as compared to any other elastomer. FKM are among the many elastomers and other objects commonly used in expansion joints.
Traditional expansion joint patch apparatuses, as shown in
FIGS. 1 and 2
, have been utilized for many years. These patches, of a material often used for air and gas ducting systems, usually comprise five (5) layers: 1) a cured external cover layer; 2) a fiberglass fabric reinforcing ply; 3) a cured skim stock; 4) a fiberglass fabric reinforcing ply; and 5) a cured inside cover layer. However, this five-piece construction can be too rigid and typically encounters difficulty in conforming to the existing shape of failed expansion joint belting. The present invention is substantially comparable in strength to the non-coated, pressed material and adequately repairs particular torn or failed expansion joint belting.
Expansion joint patch apparatuses have also been formed by dipping substrate materials, such as fiberglass, into various highly fluoronated elastoplastic and fluoroplastic solutions, such as PTFE/Teflon®. However, fluoroplastics do not bond to fluoroelastomers, such as Viton® or Fluorel®. Further, expansion joint patch apparatuses have been formed by utilizing raw, uncured Viton® to hot splice the patch member onto the expansion joint with high temperature and pressure to form a secure bond. However, adhesive caulks, such as Fluorodyn™ Viton® caulk, are not compatible with hot splicing.
It is therefore an object of the present invention to provide a more economical apparatus for repairing or patching failed expansion joint belting.
It is also an object of the present invention to provide an acid, tear and high temperature resistant expansion joint patch apparatus.
It is a further object of the present invention to provide a thinner, more flexible patch apparatus for adhering to the existing shape of failed expansion joint belting.
It is yet another object of the present invention to provide a woven, substrate material completely coated with a fluoroelastomer solution for adhering to the existing shape of failed expansion joint belting.
It is also an object of the present invention to provide a reinforcement material for existing fluoroelastomer expansion joints utilizing the same technology as the patch member.
It is yet another object of the present invention to provide a reinforcement material for new-style fluoroelastomer expansion joints utilizing the same technology as the patch member.
These and other objects of the invention will become apparent in light of the present specification, claims and drawings.
SUMMARY OF THE INVENTION
The invention comprises an expansion joint patch apparatus for repairing failed or torn existing expansion joint belting having a substantially flat, woven, substrate material, and a cured solution of suspended elastomer to coat the substrate material, with the substrate material being fully impregnated with the elastomer.
The substrate material is selected from the group consisting of aramid, fiberglass, corrosion resistant alloy wire, polyester, ceramic and kevlar fabrics. Preferably, the substrate material is a fiberglass fabric having a temperature capability of up to 1000° Fahrenheit.
The elastomer is selected from the group consisting of chloroprene, chlorosulfonated polyethylene, ethylene propylene, chloronated isobutylene isoprene, fluoroelastomers and silicon rubbers. Preferably, the elastomer is a fluoroelastomer, such as copolymers, dipolymers and terpolymers. These fluoroelastomers are resistant to chemical, oils and heats.
The patch apparatus further comprises an adhesive caulk for sealing the coated substrate material to an expansion joint region to maintain attachment of the substrate material and the expansion joint region. The caulk also ensures sealing between the substrate material and the expansion joint region, while preventing corrosion in the expansion joint. Preferably, the caulk is a single-component caulk, such as Fluorodyn™ Viton® caulk, that is flexible and provides leakproof sealing, for use in corrosive environments.
The invention further comprises a method for forming a fluoroelastomer patch for repairing fabric expansion joints. The method comprises the steps of (1) forming a patch substrate; (2) impregnating the patch substrate with a volatile solution of suspended elastomer; (3) curing the patch substrate to form a thin, dry patch member to repair a tear region having a particular shape; (4) preparing the tear region by first cleaning and then priming both surfaces of the tear region with a fluoroelastomer cleaner/primer; (5) applying an adhesive caulk to at least one, and preferably both, of the primed surfaces of an expansion joint; (6) positioning the patch member over the entirety of the tear region; and (7) curing the adhesive caulk to seal the patch member to the tear region.
The method for forming a fluoroelastomer patch may further include the step of fastening the patch member to the tear region.
Preferably, the patch substrate has a dimension at least two inches greater than the shape of the tear region.
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Cole Elizabeth M.
Dick and Harris
Senior Investments AG
Singh Arti R.
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