Note: Descriptions are shown in the official language in which they were submitted.
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SEALANT ASSEMBLIES AND METHODS
FIELD OF THE INVENTION
[0001] The present invention relates to sealant assemblies and
methods, and more particularly, to sealant assemblies and methods adapted to
seal
an interface between a surface and a projection extending from the surface.
BACKGROUND OF THE INVENTION
[0002] Buildings commonly incorporate roof surfaces designed to repel
water and prevent water from leaking into interior areas of the building.
Frequently,
roof surfaces are also designed to accommodate one or more roof projections
extending from the roof surface. For example, it is known to penetrate a roof
surface
with an exhaust pipe to allow venting of gases generated within the building.
When
roof projections are necessary, special care must be taken to avoid leak paths
at the
interface between the roof surface and the roof projection.
[0003] In an effort to prevent leaks, it is known to treat the interface
area between the exhaust pipe and the roof surface with a sealant assembly.
Conventional sealant assemblies are typically formed by circumscribing the
exhaust
pipe with a body portion to create a roof pocket about the exhaust pipe. Once
the
roof pocket is formed, a filling sealant is introduced into the roof pocket to
complete
the sealant assembly.
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[0004] While frequently useful in various applications, conventional
sealant assemblies may fail due to environmental exposure. For example,
conventional sealant assemblies include a body portion and a filling sealant
that
comprise different materials having substantially different coefficients of
expansion.
The differing coefficients of expansion can result in fracture of the
interface between
the body portion and the filling sealant as components of the assembly expand
and
contract at different rates during heating and cooling cycles. Moreover,
forming the
body portion and the filling sealant from different materials may discourage
or prevent
integral bonding that may further contribute to failure of any attachment
interface
between the body portion and the filling sealant.
[0005] For the reasons set forth above, conventional sealant
assemblies may eventually degrade such that the body portion and the filling
sealant
are disassociated from one another. Such disassociation can contribute to leak-
path
formation that can lead to unnecessary and potentially catastrophic water
damage
within the building. Disassociation of the body portion can also introduce a
loose
object on the roof surface that might introduce a tripping hazard. A
disassociated
body portion may also tumble from the roof and thereafter present a dangerous
falling
object.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is an aspect of the present invention to obviate
problems and shortcomings of conventional sealant assemblies and methods. More
particularly, it is an aspect of the present invention to provide sealant
assemblies and
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methods that discourage disassociation between the body portion and the
filling
sealant of the sealant assembly.
[0007] In accordance with one aspect, a sealant assembly is provided
for sealing an interface between a surface and a projection extending from the
surface. The sealant assembly includes a body portion circumscribing an area
to
form a sealant pocket. The sealant assembly further includes a filling sealant
at least
partially filling the sealant pocket. The filling sealant and the body portion
comprise
substantially the same material.
[0008] In accordance with another aspect, a method of sealing an
interface between a surface and a projection extending from the surface is
provided.
The method includes the step of positioning a body portion on the surface with
the
body portion circumscribing the projection and the projection extending
through a
sealant pocket defined by the body portion and the surface. The method further
includes the step of adding a filling sealant into the sealant pocket, wherein
the filling
sealant subsequently solidifies such that the body portion and the solidified
filling
sealant form a solid sealant assembly with the body portion and the solidified
filling
sealant comprising substantially the same material.
[0009] In accordance with still another aspect, a sealant assembly is
provided. The sealing assembly includes a body portion circumscribing an area
to
form a sealant pocket and a solidified filling sealant within the area and
filling at least
a portion of the sealant pocket. The sealant assembly is formed by a process
including the step of positioning the body portion on a surface with the body
portion
circumscribing a projection extending from the surface. The process further
includes
the step of adding a filling sealant into the sealant pocket, wherein the
filling sealant is
substantially contained within the sealant pocket. Still further, the process
includes
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the step of permitting the filling sealant to solidify such that the body
portion and the
solidified filling sealant form a solid sealant assembly with the body portion
and the
solidified filling sealant comprising substantially the same material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing and other features and advantages of the
present invention will become apparent to those skilled in the art to which
the present
invention relates upon reading the following description with reference to the
accompanying drawings, in which:
[0011] FIG. 1A is a perspective view demonstrating an exemplary step
of assembling a body portion to circumscribe a projection extending from the
surface;
[0012] FIG. 1B is a perspective view of an assembled body portion;
[0013] FIG. 1C is a perspective view demonstrating an exemplary
step of adding a filling sealant into a sealant pocket;
[0014] FIG. 1D is a perspective view of an exemplary sealant
assembly in accordance with aspects of the present invention;
[0015] FIG. 2 is a sectional view of the sealant assembly taken at
line 2-2 of FIG. 1D;
[0016] FIG. 3 is a top plan view of an exemplary corner element in
accordance with aspects of the present invention;
[0017] FIG. 4A is a sectional view of the corner element along
line 4A-4A of FIG. 3;
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[0018] FIG. 4B is a sectional view of the corner element along
line 4B-4B of FIG. 3
[0019] FIG. 5 is a left side elevational view of the corner element of
FIG. 3;
[0020] FIG. 6 is a front elevational view of the corner element of
FIG. 3;
[0021] FIG. 7 is an assembled body portion in accordance with
another exemplary embodiment of the present invention;
[0022] FIG. 8 is a sectional view of the body portion along line 8-8 of
FIG. 7; and
[0023] FIG. 9 is another embodiment of a corner element in
accordance with aspects of the present invention.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0024] Certain terminology is used herein for convenience only and is
not to be taken as a limitation on the present invention. Further, in the
drawings, the
same reference numerals are employed for designating the same elements, and in
order to clearly and concisely illustrate the present invention, certain
features may be
shown in somewhat schematic form.
[0025] FIGS. 1A-1D illustrate an exemplary method of providing a
sealant assembly 20 adapted to seal an interface 204 between a surface 200 and
one
or more projections 202 extending from the surface 200. Sealant assemblies and
methods herein may be applied in a wide range of applications. For instance,
sealant
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assemblies may be used in applications where it is necessary to provide a
fluid seal
at an interface between a projection and a surface. In one example, the
sealant
assembly can be used to seal an interface between a roof surface and a vent
pipe
extending from the roof surface.
[0026] Sealant assemblies herein include a body portion that may
circumscribe a single projection or any plurality of projections in accordance
with
aspects of the present invention. Body portions may be provided in a wide
variety of
shapes and/or sizes depending on the particular application. Moreover, the
body
portion may be provided as a single piece or might be provided as a plurality
of
pieces that can be assembled together to circumscribe the one or more
projections.
For instance, the body portion might comprise a continuous ring in a variety
of shapes
such as a continuous circular, oval, square, triangular, rectangular, or other
continuous shape that can circumscribe a projection. The continuous ring can
be
placed over the top of the projection to circumscribe the projection adjacent
the
interface. In further embodiments, the ring may be split so that it is not
necessary to
place the ring over the top of the projection. For example, the ring may be
split at a
single location wherein the projection may be laterally inserted through the
slit to
enter the interior area of the ring. In another example, the ring may be split
at two
locations, wherein the ring halves may be closed around the projection to
circumscribe the projection.
[0027] In still further examples, the body portion might comprise a
plurality of corner elements adapted to at least partially circumscribe the
projection.
For example, as shown in FIGS. 1A-1D, a body portion 30 includes a plurality
of
corner elements 40 that are arranged to at least partially circumscribe the
one or
more projections 202. One exemplary corner element 40 is illustrated in FIGS.
3-6.
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As shown in FIG. 3, the corner element 40 can include a first extension arm 42
extending along a first extension axis 42a and a second extension arm 44
extending
along a second extension axis 44a. As shown, the first extension axis 42a and
second extension axis 44a are substantially perpendicular with respect to one
another. It is also contemplated that the first and second extension axis may
be
located at different angular orientations depending on the shape of the body
portion.
For example, the first and second extension axis might be located at an angle
of 60
degrees from one another to form a triangular body portion having three corner
elements.
[0028] The illustrated corner element is shown to include relatively
sharp corners. In further embodiments, the corner elements may comprise
rounded
corners to reduce stress points. For example, the corner element can comprise
a first
and second extension arm together with a rounded corner portion positioned
between
the first and second extension arm. In further embodiments, the entire corner
element may comprise a rounded corner portion.
[0029] As shown in the illustrated embodiment, the extension
arms 42, 44 comprise the same length. It is contemplated that the extension
arms, if
provided, may be longer or shorter than the relative length illustrated in the
figures.
Moreover, it is contemplated that the extension arms might comprise different
lengths
in further embodiments.
[0030] In accordance with exemplary embodiments of the present
invention, the first extension arm 42 can include a first end portion 46a with
a first
substantially flat surface 48a that is substantially perpendicular to the
first extension
axis 42a. Similarly, the second extension arm 44 can include a second end
portion 46b with a second substantially flat surface 48b that is substantially
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perpendicular to the second extension axis 44a. Providing the end portions
with a
substantially flat surface that is substantially perpendicular to the
respective extension
axis can facilitate connection of body portion elements. For example, end
portions
with perpendicular surfaces can allow compression of the end portions without
significant development of shear stress and without deforming the end portions
away
from the extension axis. In contrast, compression of diagonal surfaces can
develop
significant shear stresses and might wedge against each other to deform the
end
portions away from the extension axis and therefore interfere with the
fastening
process.
[0031] In further examples, end portions of body components may
have alternative configurations to facilitate connection of the components to
one
another. For example, FIG. 9 depicts a corner element 140 including a first
end
portion 146a with a tongue 142 and a second end portion 146b with a groove
144.
When fastening a plurality of corner elements together, the tongue 142 of one
corner
element may be inserted within a groove 144 of another corner element to link
the
corner elements to one another. Providing a tongue and groove arrangement can
facilitate fastening the end portions together and can increase the overall
strength of
the subsequently formed joint.
[0032] As shown in FIGS. 4A, 4B, 5 and 6 each corner element can
include a substantially flat base 42b, 44b adapted to rest on a substantially
flat
surface 200. The corner elements further include boundary surfaces 42c, 44c
adapted to at least partially define a perimeter boundary of the interior area
32 of the
body portion 30. The corner elements further include an outer surface 42d, 44d
extending between the corresponding flat bases 42b, 44b and boundary surfaces
42c, 44c. As shown in FIGS. 4A and 4B, the outer surface, boundary surface,
and
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flat base can form a triangular configuration although other configurations
may be
employed in accordance with aspects of the present invention.
[0033] FIG. 7 is an assembled body portion 130 in accordance with
another embodiment of the present invention. The body portion 130 includes at
least
a pair of intermediate segments 50a, 50b. The intermediate segments, if
provided,
can extend at least one dimension of the body portion to create an enlarged
sealant
pocket 134. In the illustrated embodiment, a second pair of intermediate
segments
52a, 52b is also provided to extend a second dimension of the body portion to
further
enlarge the sealant pocket 134.
[0034] The intermediate segments, if provided, can include a wide
variety of sizes to customize the size of the sealant pocket. For example, the
first pair
of intermediate segments 50a, 50b may have a first length and the second pair
of
intermediate segments 52a, 52b may have a second length. The first and second
lengths may be equal or different from one another depending on the desired
size of
the body portion. For example, the intermediate segments 50a, 50b, 52a, 52b
can
have substantially identical lengths to form a substantially square shaped
body
portion. In further examples, the first pair of intermediate segments 50a, 50b
may
have a different length than the second pair of segments 52a, 52b to form a
substantially rectangular shaped pitch pocket. In still further examples, only
one pair
of segments is used to extend the length of the pitch pocket in a single
desired
direction. In further examples, the body portion may be provided as a kit with
four
relatively long intermediate segments. The relatively long intermediate
segments
may be cut on site to provide a customized body portion having an appropriate
size.
Customizing the body portion can reduce the overall size of the body portion
wherein
less filling sealant is necessary to fill the sealant pocket.
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[0035] The intermediate segments may also have various shapes in
accordance with aspects of the present invention. As shown in FIG. 8, for
example,
the intermediate segment may have a triangular configuration that matches the
configuration of the corner elements. In further examples, the intermediate
segments
can include a substantially flat surface 56 that is substantially
perpendicular to the
extension axis of the intermediate segment. Providing a perpendicular flat
surface 56
can facilitate fastening of the intermediate segments between opposed corner
elements. The intermediate segments can also extend along a substantially
straight
axis but might extend along a substantially curved axis in further
applications.
[0036] An exemplary method of sealing an interface between a surface
and a projection extending from the surface is described with respect to FIGS.
1A-1D
but can apply equally to exemplary embodiments described throughout this
application. First, the body portion 30 is positioned on the surface 200 with
the body
portion 30 circumscribing the projections 202. In the illustrated embodiment,
the
corner elements 40 are sufficient to circumscribe each of the projections 202.
Double-sided tape 49 or other adhesive may be used to fasten together the flat
end
surfaces to maintain the desired shape of the assembled sealant pocket. Once
fastened together, the complete body portion 30 is formed as shown in FIG. 1B.
The
boundary surfaces 42c, 44c of each extension arm of the completed body portion
cooperate to form a peripheral boundary defining the interior area 32. Once
the
assembled body portion 30 is placed against the surface 200, the boundary
surfaces
42c, 44c of each extension arm cooperate with the surface 200 adjacent the
interior
area 32 to form a sealant pocket 34. As shown, the sealant pocket 34 is formed
with
the projections 202 extending through the sealant pocket 34.
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[0037] The body portion 30 may also be sealed or fastened with
respect to the surface 200. Providing a seal between the body portion 30 and
the
surface 200 may help contain filling material within the sealant pocket as the
filling
material solidifies. Fastening the body portion 30 to the surface 200 can also
help
maintain the sealant pocket 34 in the desired location with respect to the one
or more
projections 202. In the illustrated example, tape 36, such as a Butyl tape,
can be
used to form a seal the body portion 30 to the surface 200 and/or can help
fasten the
body portion 30 with respect to the surface 200. In further examples, an
adhesive
layer or other sealant layer may be used to aid in sealing and/or fastening of
the body
portion.
[0038] As shown in FIG. 1C, filling sealant 60 may then be added into
the sealant pocket 34. In the illustrated embodiment, filling sealant 60 is
added by
pouring the filling sealant 60 into the sealant pocket with a bucket 70. In
further
examples, the filling sealant 60 may be introduced with a hose or other
container.
Still further, the filling sealant may be added without pouring. For example,
filling
sealant may be scooped into the cavity, shoveled into the cavity, packed into
the
cavity, or otherwise introduced into the cavity. The filling sealant 60 may
comprise a
premixed sealant material or may comprise material of segregated components
that
are mixed just prior to adding the sealant to the pocket. Mixing just prior to
adding the
sealant can be conducted in a variety of ways. For example, two or more
sealant
components may be mixed in a container using a mixing paddle, stirring blade,
or
manually using a spatula or the like. In further examples, two or more sealant
components may be segregated in a cartridge and mixed just prior to adding the
filling
sealant to the sealant pocket. In one example, a cartridge may be provided
with
segregated sealant reservoirs that are in communication with a static mixing
tip.
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When dispensing the components from the cartridge, the static mixing tip
causes the
components to mix as the filling sealant is added to the cavity. Sufficient
filling
sealant can be added until the level of filling sealant extends to a fill line
61 relative to
the projections 202. The fill line 61 may be predetermined or may simply
comprise
the final level that the filling sealant 60 reaches with respect to the
projections 202.
The fill line 61 may be less than, equal to, or greater than the height of the
body
portion 30. Providing a fill line 61 that is less than the height of the body
portion 30
can reduce the overall amount of filling sealant 60 necessary to complete the
sealant
assembly. Providing a fill line 61 that is equal to the height of the body
portion 30 (as
shown in FIG. 1D), or greater than the height of the body portion can avoid
trapping
water within unfilled portions of the sealant pocket.
[0039] As shown in FIG. 2, providing the body portion and the
solidified filling sealant as the same material can cause the filling sealant
60 to be
integrally bonded to the body portion 30 at an interface 47 between the
filling sealant
and the body portion. Integral bonding can occur as outer layers of the
boundary
surfaces of the body portion 30 soften and blend with the filling sealant that
is added
into the sealant pocket. After a sufficient period of time, the filling
sealant and
softened and blended portions solidify wherein the filling sealant 60 is
integrally
bonded with the body portion 30 at the interface 47.
[0040] Accordingly, the corner elements, intermediate segments (if
provided), and the filling material comprise substantially the same material
to form a
solid, sealed block around the roof protrusions 202. Being formed from the
same
material, the assembled body portion and the filling material have the same
coefficient of expansion and therefore resist cracks or other failures that
may
otherwise occur due to temperature fluctuations. Still further, forming the
assembled
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=
body portion and the filling material from substantially the same material can
facilitate
integral bonding at the interface between the body portion and the tilling
sealant to
further resist cracks or other failures of the connection between the body
portion and
the filling sealant
[00411A wide range of materials may be used as the common material
to form the corner elements, intermediate elements (if provided), and the
filling
material. For example, the common material can comprise a wide variety of
polymers, such as polymers and copolymers EPDM, Butyl rubber, Neoprene, SSBS,
SEBS, HypeIon, Acrylic elastomers, CPE, PVC, CPVC, epichlorohydrin, ethylene
= acrylic elastomers, EPR, FIB, polybutadiene rubbers, polynorbomenes,
polysulfide,
one and two part urethane elastomers, and the like. Other materials may be
used as
the common material to provide a sealant assembly with components having the
same coefficient of expansion or components that form an integral bond with
the
filling material.
[0042] From the above description of the embodiments, those skilled in the art
will perceive improvements, changes and modifications. The embodiments are
presented as examples only and the scope of the claims should not be limited
by the
embodiments set forth in the examples, but should be given the broadest
interpretation
consistent with the description as a whole.
=
=
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