Cover Plate Assembly and Centering Bar

This application claims the benefit of U.S. Provisional Application No. 63/574,545 filed Apr. 4, 2024 and entitled “EXPANSION JOINT CENTERING BAR AND COVER PLATE ASSEMBLY,” the entire contents of which are hereby incorporated by reference in their entirety.

The present disclosure relates to expansion joint cover assemblies, and more particularly, to a centering bar for an expansion joint cover assembly that allows for efficient alignment and installation of the expansion joint cover assembly.

Expansion joints are intentionally provided gaps in adjacent structures, such as concrete structures, that are design to accommodate movement caused by thermal expansion, seismic cycling, vibration, and other similar structural forces. These joints may prevent cracking and structural damage by allowing adjacent building members to expand and contract freely. However, for safety, aesthetics, and structural integrity, these expansion joints often utilize a protective cover assembly that spans the gap formed by the expansion joints while permitting controlled movement of the underlying structures.

Traditional cover assemblies used in connection with expansion joints may implement centering bars that align and support a cover plate of the cover assembly while still allowing for horizontal and/or vertical movement of the underlying structures. To secure the centering bar to the cover plate, traditional cover assemblies may utilize bolts that pass through pre-drilled apertures in each of the centering bar and the cover plate. However, the attachment method described herein presents challenges in manufacturing, assembly, and long term performance.

For example, traditional cover assemblies that utilize a centering bar and cover plate may be difficult to install, particularly in low-visibility environments and when working with heavy materials. Furthermore, the pre-drilled apertures may limit tolerance for movement of the underlying structure, which may result in misalignment, excessive wear, and/or failure of the cover assembly over time.

Accordingly, a need exists for a cover plate assembly that resolves the shortcomings of traditional assemblies by providing a cover plate and expansion joint centering bar that are cost-effective, easily installed, and highly durable.

In embodiments of the present disclosure, a cover plate assembly is disclosed. The cover plate assembly includes a first track of a first base plate that is affixed to a first structural member and a second track of a second base plate that is affixed to a second structural member. The cover plate assembly further includes a centering bar slidably engaged with the first track of the first base plate and the second track of the second base plate, and having a centering bar opening that receives a fastener. A guide is coupled to the centering bar and aligns the fastener with the centering bar opening, and a cover plate having a cover plate aperture aligns with the guide and the centering bar opening. A spring assembly is attached to the centering bar and receives the fastener after the fastener is inserted through the cover plate aperture and the centering bar opening.

In other embodiments, a cover plate assembly is disclosed. The cover plate assembly includes a centering bar including upper cavity defining an upper slit and a lower cavity defining a lower slit, a centering bar opening formed in a central portion of the upper cavity of the centering bar, a cover plate, a guide, and a spring having a flange positioned on an end of the spring, the spring being detachably coupled to the lower cavity of the centering bar via the flange. The guide is detachably secured within the centering bar opening to align the cover plate, the centering bar, and the spring.

In yet another embodiment, a cover plate assembly is disclosed. The cover plate assembly includes a cover plate including a cover plate aperture formed through the cover plate, a centering bar including a centering bar opening formed through the centering bar, a fastener, and a guide detachably attached to the centering bar between the cover plate aperture and the centering bar opening. The guide aligns the fastener with the cover plate aperture and the centering bar opening such that the fastener is insertable through the cover plate aperture and the centering bar opening to couple the cover plate to the centering bar.

Elements in the figures are shown for simplicity and clarity and are not necessarily drawn to exact scale. It can be understood that these accompanying drawings are not only intended to explain and illustrate the present disclosure and description, but also contribute to the scope of the present disclosure.

The implementation and application of embodiments of a cover assembly will be discussed in detail below. The cover assembly may include a first track of a first base plate that is affixed to a first structural member and a second track of a second base plate that is affixed to a second structural member. The cover plate assembly may further a centering bar slidably engaged with the first track of the first base plate and the second track of the second base plate, and having a centering bar opening that receives a fastener. A guide is coupled to the centering bar and aligns the fastener with the centering bar opening, and a cover plate having a cover plate aperture aligns with the guide and the centering bar opening. A spring assembly is attached to the centering bar and receives the fastener after the fastener is inserted through the cover plate aperture and the centering bar opening. In these embodiments, the guide may aid in reducing alignment issues during installation, thereby improving ease and efficiency of the overall installation process.

As provided herein, it should be appreciated that the terms “disclosure”, “present disclosure” and variations thereof are not intended to mean every possible embodiment encompassed by this disclosure. Thus, the subject matter of each such reference should not be considered as necessary for, or part of, every embodiment hereof because of such reference.

The term “coupled” and the like, and variations thereof, is intended to mean either an indirect or direct connection or engagement. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections.

Certain terms are used herein to refer to particular components. However, it should be understood that different persons may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function.

Furthermore, the terms “including” and “comprising” are used herein in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.”

Further, reference herein to components and aspects in a singular tense does not necessarily limit the present disclosure to only one such component or aspect, but should be interpreted generally to mean one or more, as may be suitable and desirable in each particular instance.

Preferred embodiments of the present disclosure are well adapted to carry out one or more of the objects of this disclosure. However, the present disclosure does not require each of the components and acts described above and are in no way limited to the above-described embodiments. Any one or more of the above components, features and processes may be employed in any suitable configuration without inclusion of other such components, features and processes. Moreover, the present disclosure includes additional features, capabilities, functions, uses and applications that have not been specifically addressed herein but are, or will become, apparent from the description herein

As noted hereinabove, traditional expansion joint cover assemblies incorporate centering bars that are secured to a cover plate of the assembly by placing a bolt, or other similar fastener, through pre-fabricated openings formed in each of the centering bar and cover plate. However, aligning the bolt with the pre-fabricated openings in the cover plate and centering bar is often challenging, which may cause installation challenges to users.

Furthermore, the rigid fastening mechanisms (e.g., bolts, etc.) used to fasten the centering bar to the cover plate of traditional cover assemblies may not be capable of compensating for three-dimensional movement of the underlying structures. Accordingly, movement of the underlying structures may result in misalignment, wear, and/or failure of the cover plate assembly over time.

Moreover, expansion joints are manufactured in a variety of sizes, which necessitates the use of centering bars having different lengths. In traditional expansion joint cover assemblies, the variety of expansion joints may result in the need for multiple centering bars, which may increase production complexity, tooling costs, and material waste.

The cover plate assembly and centering bar described herein aim to address these shortcomings by providing a centering bar that includes a guide configured to direct a fastener (e.g., bolt, screw, etc.) into an aperture formed in the centering bar. As will be described in additional detail herein, the guide may aid in reducing alignment issues during installation, thereby improvement case and efficiency of the overall installation process.

Furthermore, the centering bar of the cover plate assembly described herein may include a plurality of cavities that may be configured to facilitate the attachment of extension components. Accordingly, a user may adjust a length of the centering bar via the extension components, which may clement the need for multiple tooling configurations. The manufacturing of the plurality of cavities and the centering bar may also allow for enhanced durability and versatility of the cover plate assembly, as will be described in additional detail herein.

The present disclosure will now be described more fully with reference to the accompanying drawings, in which some preferred embodiments of the disclosure are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like numbers refer to like elements throughout.

Referring now to, a cover plate assemblyis illustrated. The cover plate assemblymay be positioned between expansion gap, which may be formed between a first structural memberand a second structural member. In the embodiments described herein, it should be appreciated that the first and second structural members,may be concrete structural members, such as concrete floor structural members, or any other similar structural member in which an expansion gap may be formed.

Referring still to, the cover assemblymay further include a first base plateand a second base plate, which may be configured to be coupled to the first structural memberand the second structural member, respectively. In these embodiments, the first base platemay include a first track, such as a curved concave track, that extends into the expansion gapand couples the first base plateto the first structural member. Similarly, the second base platemay include a second track, such as a curved concave track, that extends into the expansion gapand couples the second base plateto the second structural member.

As further illustrated in, the first base plateand the second base platemay be attached to their respective structural members (e.g., first and second structural members,) using mechanical fasteners, such as anchors, bolts, nails, rivets, screws, tacks, or any other similar mechanical fastener. Althoughdepicts the first base plateand the second base plateas being coupled to the first structural memberand the second structural memberusing mechanical fasteners, it should be further appreciated that, in some embodiments, the first and second base plates,may be coupled to the first and second structural members with elastomeric concrete or any other similar attachment means without departing from the scope of the present disclosure.

In some embodiments, it should be further appreciated that each of the first base plateand/or the second base platemay include a plurality of alignment slots. The plurality of alignment slots may aid in ensuring that a centering bar of the cover plate assemblyis aligned with the first and second structural members,, as will be described in additional detail herein.

Referring still to, the cover assemblymay further include a centering bar, which may be secured to the first plateand the second base plate, respectively. In some embodiments, the centering barmay be directly secured (e.g., fastened or otherwise) to the first plateand the second base plate. However, in other embodiments, such as the embodiment depicted in, the cover assemblymay further include a plurality of extension member that are used to secure the centering barto each of the first base plateand the second base plate. It should be appreciated that the plurality of extension members may be implemented in embodiments in a centering bar length of the centering bar is less than an expansion gap length of the expansion gap, as will be described in additional detail herein.

Referring still to, the centering barmay be detachably and/or releasbly coupled to each of the plurality of extension members. For example, as depicted in, the plurality of extension members may include a first extension memberand a second extension membercoupled to the centering bar. In these embodiments, each of the first extension memberand the second extension membermay include a distal end that is a spherically shaped end, For example, the first extension membermay include a first spherically shaped endwhile the second extension membermay include a second spherically shaped end.

In the embodiments depicted in, the first and second spherically shaped ends,may be proportioned (e.g., sized and/or shaped) such that the first and second spherically shaped ends,are engageable with the curved concave tracksandformed in the first base plateand second base plate, respectively. For example, in these embodiments, the first and second spherically shaped ends,may be slidably engageable with the first base plateand the second base plate, such that the first and second spherically shaped ends,may slide relative the first trackof the first base plateand the second trackof the second base platein both a horizontal and a vertical direction (e.g., in the +/−x and/or +/−y-direction as depicted in the coordinate axis of).

Referring still to, the first extension memberand the second extension membermay each further include a proximal end (e.g., an end positioned opposite the first and second spherically shaped ends,, respectively) that may be attached to an end of the centering barsuch that, when the first extension memberand the second extension memberare secured to the centering bar, the first extension member, the second extension member, and the centering barhave a combined length that is fixed.

In operation, and as described hereinabove, the first and second structural components,may be subjected to forces (e.g., expansion and contraction forces, seismic events, mechanical vibrations, etc.) that may cause the first and second structural components,to shift, thereby adjusting the expansion gap length of the expansion gap. For example, during contraction of the expansion gap, a distance between the first and second spherically shaped ends,of the first extension memberand the second extension membermay decrease in a longitudinal direction (e.g., in the +/−x-direction as depicted in the coordinate axis of) as the first and second spherically shaped ends,slide or rotate along the curved concave surfaces of the first trackand the second trackof the first base plateand the second base plate, respectively.

It should be appreciated that, in these embodiments, equilibrium of the cover plate assemblymay be maintained by increasing the distance between the first and second spherically shaped ends,in either a transverse direction (e.g., the +/−z-direction as depicted in the coordinate axis of), a vertical direction (e.g., the +/−y-direction as depicted in the coordinate axis of), or both directions, such that the cover plate assemblyis capable of accommodating adjustments in the expansion gap length of the expansion gapwithout altering the centering bar length of the centering bar.

Similarly, during expansion of the expansion gap, the distance between the first and second spherically shaped ends,may increase in the longitudinal direction, and equilibrium of the cover plate assemblymay be maintained by decreasing the distance between the first and second spherically shaped ends,in either the transverse direction, the vertical direction, or both, such that the cover plate assemblyis capable of accommodating adjustments in the expansion gap length of the expansion gapwithout altering the centering bar length of the centering bar.

As further illustrated in, the cover plate assemblymay further include a cover platethat extends across the expansion gapand a centering bar assembly(e.g., the centering barand the plurality of extension members). In these embodiments, the cover plateis coupled to the centering barusing a fastener, such as a bolt, screw, or any other similar fastening mechanism. As shown in, the fastenermay extend through an aperture formed in the cover plateand through a centering bar openingformed in centering bar, such that the fastener may be received within a spring assembly, as will be described in additional detail with reference to().

Referring still to, the cover plate assemblymay further include a guide, such as a hollow guide, that may be detachably and/or releasbly coupled to a top surface of the centering barand aligned with the centering bar opening. In these embodiments, the guidemay allow for easier alignment of the fastenerwith a central portion of the cover plateand the centering bar opening.It should be appreciated that, in the embodiments described herein, the guidemay have a conical shape, or any other shape configured to aid in aligning the various components of the cover plate assemblydescribed herein. For example, in embodiments in which the guideincludes a hollow, conical shape, a centering bar openinginterior section of the guidemay guide the fastenerinto the centering bar openingeven if the fasteneris initially inserted off center of the centering bar opening.

In the embodiments described herein, it should be appreciated that the various components of the cover plate assemblymay be strong enough to withstand forces from applied above and/or across the cover plate assembly(e.g., traffic passing over a concrete road in which the cover plate assemblyis used) and expansion and/or contraction forces (e.g. seismic forces) that impact the expansion gap length of the expansion gap, as has been described in detail herein. Accordingly, in these embodiments, suitable materials that may be used to manufacture the various components of the assembly may include metals, metal alloys and polymers, or any other similar materials without departing from the scope of the present disclosure.

More particularly, in some embodiments, the cover platemay be formed of aluminum, stainless steel, carbon steel, bronze plate or aluminum extrusion. Similarly, the centering barmay be formed of an aluminum extrusion, and the plurality of extension members may be fabricated from aluminum or carbon steel. Furthermore, the base members (e.g., first base plateand second base plate) may also be formed of aluminum extrusion. In these embodiments, the first and second spherically shaped ends of the extension members may be formed of a thermoplastic elastomer and may be attached to the extension members using roll pins, while the guide may be formed of a polyethylene plastic. As noted hereinabove, it should be appreciated that the various materials described herein are for exemplary purposes only, and the various components of the cover plate assemblymay each be formed of any material without departing from the scope of the present disclosure.

Turning now to(), the centering bar assemblyis depicted in additional detail. In these embodiments, as illustrated in, the centering barmay include an upper cavitythat is sized and shaped to allow the proximal ends of the first extension memberand the second extension member, respectively to be inserted into the upper cavity.

Referring still to(), the first extension memberand the second extension membermay each have an aperture that is aligned with at least one of centering bar apertures,formed in the centering bar. For example, the first extension membermay include a first extension member aperturewhich is aligned with a first centering bar apertureof the centering bar, while the second extension membermay include a second extension member aperturewhich is aligned with a second centering bar apertureformed in the centering bar. the centering bar aperture In these embodiments the first and second extension member apertures,and the first and second centering bar apertures,may be aligned during manufacturing using fasteners (e.g. screws or bolts)and washers.

Referring still to(), the upper cavityof the centering barmay further include an elongated slitthat extends across the centering bar length of the centering barfrom a first end of the centering barto a second end of centering bar. In these embodiments, a central portion of the elongated slitmay be enlarged to form an opening. As illustrated in, the openingmay allow the guideto be inserted into the top of centering barand fit (e.g., friction fit or otherwise) into place in alignment with the centering bar opening.

In the embodiments depicted in(), the centering barmay further include a lower cavitythat is sized and shaped to slidably accept a flangeof the spring assembly. For example, prior to the first extension memberand the second extension memberbeing attached to centering bar, the spring assemblymay be moved (e.g., slid or otherwise) into the lower cavityand moved into position under the centering bar openingsuch that the fastenercan be inserted into the spring assemblyand threaded into a socketformed at a bottom portion of the spring assembly.

In the embodiments described herein, it should be understood that the spring assemblymay enhance the engagement of the fastenerand the centering bar, while also offering vibration resistance and accommodating movement within the expansion gap. For example, the spring assemblymay provide a preloaded force on the fastenerwhen the fastener is inserted into the socket, which may aid in ensuring that the fastenerremains secured within the socket. Furthermore, the spring assemblymay act to absorb dynamic forces acting on the cover plate assemblyand/or the first and second structural elements,. For example, the spring assemblymay absorb shocks and/or other vibrations that may otherwise gradually loosen the fastenerfrom the socketover time.

It should be appreciated that the upper and lower cavities,may allow for the easy attachment of the first and second extension members,, the guide, and the spring assembly. Furthermore, in some embodiments, the upper and lower cavities,may further include housings, notches, passages, recesses, slots, tracks, rails, grooves, or any other similar features which may enable the first and second extension members,, the guide, and the spring assemblyto be inserted into and secured within the centering bar.

Referring now to(), the guideis depicted in additional detail. For example, in the embodiments described herein, the guidemay further include an enlarged guide openingthat tapers (e.g., funnels down to) into a conduit, such that the conduithas a narrower profile relative the enlarged guide opening. In these embodiments, the guidemay also include a plurality of extensionsthat allow the guideto be inserted into an enlarged centering bar opening, such that the conduitof the guide is received within the centering bar opening. Once the guideis positioned within the centering baras described herein, the guidemay be rotated (e.g., 90 degrees or any other similar degree of rotation) such that the guidemay be secured within the upper cavityof the centering barvia a friction and/or interference fit. As depicted most clearly in, the guidemay have a generally hexagonal profile that allows for use of wrenches or adaptive tools as assistive devices in order to rotate guideinto place, thereby reducing risk of repetitive stress injury by assemblers.

Referring now to(), assembly of the cover plate assemblywill be described. For example, in operation, when the centering bar assemblyis placed in the expansion gap, the guidemay allow for easier insertion of the fastenerthrough the cover plateand into the centering barand the spring assembly. In the embodiments described herein, the guidemay also have a color and/or finish that cases the ability of a user to see through the cover plate aperture. For example, in some embodiments, the guide may be formed of a translucent and/or transparent material.

As provided herein, it should be appreciated that the disclosed centering bar assemblymay lower material costs and assembly costs of the cover plate assembly. For example, extruding long sections of the centering barallows for the centering bar to easily be cut to desired lengths, rather than requiring different tooling and manufacturing for various centering barshaving different center bar lengths. Accordingly, once a desired centering bar length is determined, After determining a desired length of the centering bar, the centering bar assemblymay be formed simply by forming the centering bar openingand the centering bar apertures,in the centering barand then attaching the centering barto the first and second extension members,, the guide, and the spring assembly. It should be further appreciated that the centering bardescribed herein may also allow for savings in material costs as the extruded shapes with hollow cavities that form the centering barmay provide structural strength but require but require less material than traditional centering bars.

Turning now to(), another embodiment of the cover plate assemblyis illustrated. The cover plate assemblyis structurally similar to that depicted in(), such that like references will be used to refer to like structure where possible.

As illustrated in(), in some embodiments, the cover plate assemblymay be formed without the spring assembly. In these embodiments, removal of the spring assembly may aid in minimizing costs, simplifying installation, and increasing durability of the cover plate assembly. For example, elimination of the spring assemblymay allow the cover plate assemblyto be formed with fewer components, thereby reducing material and production costs.

As illustrated most clearly in, in these embodiments, the cover plate assemblymay utilize a locking nutto secure the fastenerand couple the cover plateto the centering bar. As illustrated in, as the fastenerextends through the locking nut, the fastenermay also form a friction and/or interference fit with the centering barto further aid in securing the fastenerin a desired position.