Concrete expansion joint insert having multiple surface characteristics

Abstract

An illustrative example embodiment of a concrete expansion joint insert includes a body having two ends, two longitudinal edges between the ends and two side surfaces between the longitudinal edges. The body has a length, a width and a thickness. The length is greater than the width and the width is greater than the thickness. The width and thickness correspond to dimensions of the ends of the body. The length and the thickness correspond to dimensions of the longitudinal edges. The length and the width correspond to dimensions of the side surfaces. At least a portion of the body has a first surface characteristic and at least one of the longitudinal edges has a second surface characteristic that is different than the first surface characterization. The second surface characteristic comprises at least one of a color, a texture and a profile.

We claim: 
     
         1 . A concrete expansion joint insert, comprising
 a body having two ends, two longitudinal edges between the ends, and two side surfaces between the longitudinal edges, the body having a length, a width and a thickness,   wherein   the length is greater than the width,   the width is greater than the thickness,   the width and the thickness correspond to dimensions of the ends,   the length and the thickness correspond to dimensions of the longitudinal edges,   the length and the width correspond to dimensions of the side surfaces,   at least a portion of the body has a first surface characteristic,   at least one of the longitudinal edges has a second surface characteristic that is different than the first surface characteristic, and   the second surface characteristic comprises at least one of a color, a texture, and a profile.   
     
     
         2 . The concrete expansion joint insert of  claim 1 , wherein
 the second surface characteristic includes the color;   the portion of the body has a first color;   the at least one of the longitudinal edges has a second, different color; and   the second color is configured to correspond to a color of concrete with which the insert will be associated.   
     
     
         3 . The concrete expansion joint insert of  claim 2 , wherein
 the first color is black; and   the second color is grey.   
     
     
         4 . The concrete expansion joint insert of  claim 2 , wherein
 the body comprises a first material composition including recycled rubber; and   the at least one of the longitudinal edges comprises a second material composition including recycled rubber and at least one colorant.   
     
     
         5 . The concrete expansion joint insert of  claim 2 , wherein
 the second surface characteristic includes the texture;   the portion of the body includes at least some of the sides;   the portion of the body has a rough texture configured to facilitate avoiding relative movement between the insert and concrete with which the insert will be associated; and   the at least one of the longitudinal edges has a smooth texture.   
     
     
         6 . The concrete expansion joint insert of  claim 2 , wherein
 the second surface characteristic includes the profile;   the portion of the body has an angled profile; and   the at least one of the longitudinal edges has a rounded profile.   
     
     
         7 . The concrete expansion joint insert of  claim 2 , wherein the at least one of the longitudinal edges includes a coating of a rigid polymer along an outer portion of the at least one of the longitudinal edges. 
     
     
         8 . The concrete expansion joint insert of  claim 7 , wherein
 the coating extends across a first surface at the at least one of the longitudinal edges in a direction corresponding to the thickness;   the coating extends partially onto the side surfaces, respectively; and   the coating extends along the length.   
     
     
         9 . The concrete expansion joint of  claim 1 , wherein the surface characteristic of a first one of the longitudinal edges is different than the surface characteristic of a second one of the longitudinal edges. 
     
     
         10 . The concrete expansion joint of  claim 1 , wherein
 the second surface characteristic includes the texture;   the portion of the body has a rough texture configured to facilitate avoiding relative movement between the insert and concrete with which the insert will be associated; and   the at least one of the longitudinal edges has a smooth texture.   
     
     
         11 . The concrete expansion joint insert of  claim 1 , wherein
 the second surface characteristic includes the profile;   the portion of the body has a generally squared profile; and   the at least one of the longitudinal edges has a rounded profile.   
     
     
         12 . The concrete expansion joint insert of  claim 1 , wherein the width corresponds to a depth of concrete with which the insert will be associated. 
     
     
         13 . The concrete expansion joint insert of  claim 1 , wherein
 the body comprises recycled rubber; and   the at least one longitudinal edge comprises a polyethylene material.   
     
     
         14 . The concrete expansion joint insert of  claim 13 , wherein the polyethylene material comprises at least one of recycled low density polyethylene and high density polyethylene. 
     
     
         15 . An assembly for making a concrete expansion joint insert, the device comprising:
 an extruder; and   a device that receives material from the extruder, the device including
 a flow path through the device, and 
 at least one internal feature that directs the material away from a middle of the flow path and toward outside edges of the flow path to establish an approximately equal flow rate of the material through the middle and outside edges of the flow path. 
   
     
     
         16 . The assembly of  claim 15 , wherein the internal feature comprises at least one wedge that interrupts a portion of the flow path. 
     
     
         17 . The assembly of  claim 16 , wherein the internal feature comprises outside edge profiles that have a larger cross-sectional area than the middle of the flow path. 
     
     
         18 . The assembly of  claim 16 , wherein
 the internal feature comprises two wedges;   each of the wedges has a leading edge facing an entrance of the flow path;   each of the wedges has side surfaces that have a varying dimension along a flow direction of the flow path; and   the wedges have opposing surfaces that are spaced apart a distance corresponding to a thickness of the concrete expansion joint insert.   
     
     
         19 . The assembly of  claim 15 , wherein the extruder comprises
 a first extruder that delivers a first material to the flow path for establishing a body of the insert; and   a second extruder that delivers a second material into the flow path near at least one longitudinal edge of the insert.   
     
     
         20 . The assembly of  claim 19 , wherein
 the second material is co-extruded with the first material through the device; and   the second material establishes a surface characteristic on the at least one edge that is different than a surface characteristic of another portion of the insert.