Process for producing an expansion joint cover

Claim 1

A process for producing a flexible, weather resistant, hinged expansion joint cover including a flexible strip and flexible hinged lateral portions having lock-in reinforcing members, and insulating material adjacent said planar strip, said flexible strip and portions being fabricated of extrudable material, said extrudable material being a resinous polymer extrudable when in a flowable state, and selected from the group consisting of polymers of polyethylenes, polypropylenes, polyurethanes, polyamides, polychloroprenes, polybutadienes, polyacrylonitriles, polyvinyl chlorides or polyacrylates, wherein said resinous polymer remains flexible and penetrable by a nail within the range of from about -50° about +200° F, and withstands prolonged direct exposure to outdoor weathering; said reinforcing member comprised of a strip of relatively thin planar spring material, said strip being perforated and having a rigidity substantially greater than that of said lateral portions and a thickness less than that of said lateral portions, said reinforcing member if coiled about a 5" diameter mandrel and released, being elastic so as to return to its original shape; said insulating material being planar and compressible, said insulating material being a polymeric foam selected from the group consisting of foamed polymers and copolymers of ethylene, propylene, choroprene, vinyl halides, urethanes, amides, butadienes, acrylonitriles, acrylates and natural and synthetic rubbers wherein said polymeric foam has a K factor of from about 0.012 to about 0.045 Btu-in/ft 2 -hr-= F; comprising the steps of: (a) simultaneously extruding said substantially flexible planar strip of said extrudable material, with said lateral portions extended one from each side of said planar strip in the same plane as said planar strip; (b) simultaneously placing and completely enclosing during said extrusion one of said reinforcing members in each of said lateral portions; (c) aligning a strip of said planar insulating material adjacent said planar strip subsequent to said extrusion step and confining said insulating material slightly within the edges of said planar strip, and (d) fastening said strip of said insulating material in said aligned position to said planar strip to form a flexible hinge between said planar strip and said lateral portions and produce said flexible hinged expansion joint cover.