Corner Rail Extrusion Sealing RV Panel Joints

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for sealing joints at the corners of structures like recreational vehicles and metal buildings, such as using butyl tape, fail to effectively conform to irregular surfaces, leading to water infiltration and durability issues due to tape degradation and expansion.

Innovation Solution

A corner rail extrusion made of weather-resistant, pliable rubber-like material with a bulbous interior and adjustable legs that fits into the gap between panels, providing a positive seal and accommodating surface irregularities, secured using a pressure-sensitive adhesive and metal fasteners.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If butyl tape is used to seal corner joints, then the joint can be temporarily secured during assembly, but the tape does not conform to surface irregularities and creates gaps that lead to water infiltration

Engineering Contradiction:

Improveease of assemblyVSAvoidsealing effectiveness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces rigid butyl tape with a flexible extruded corner rail made of pliable rubber-like material that can conform to surface irregularities and corrugations while maintaining a reliable seal

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The invention changes the physical state and properties of the sealing material from tacky tape to extruded flexible profiles with specific cross-sectional geometries that enable conforming to surfaces through controlled deformation

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If butyl tape is used to seal corner joints, then assembly is simplified, but the tape expands when subjected to heat and creeps away from fasteners creating gaps

Engineering Contradiction:

Improveease of assemblyVSAvoiddimensional stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent selects rubber-like materials with specific viscoelastic properties that exhibit minimal thermal expansion and creep behavior, changing the material parameters to achieve dimensional stability under thermal loading

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The extruded corner rail may incorporate composite material structures combining rubber-like polymers with reinforcing elements to enhance dimensional stability while maintaining flexibility for sealing

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If butyl tape is used to seal corner joints, then temporary securing is achieved, but the tape dries out and chemically breaks down after a period of use

Engineering Contradiction:

Improveease of assemblyVSAvoidservice life

Core Design Contradiction:

Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The patent replaces the short-lived butyl tape with durable extruded rubber-like profiles designed to last the lifetime of the structure, eliminating the need for periodic replacement

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The use of weather-resistant rubber-like composite materials provides long-term durability and resistance to environmental degradation, significantly extending the service life of the sealing system

Inventive Principle:

Principle #40Composite materials

4Ease of manufacture

If standard corner rails are used with butyl tape, then assembly is straightforward, but the rigid structure cannot accommodate fabrication tolerances and surface variations

Engineering Contradiction:

Improveease of assemblyVSAvoidadaptability to surface variations

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The extruded corner rail profiles are made of pliable rubber-like material that can deform and conform to fabrication tolerances and surface irregularities, providing adaptability while maintaining structural integrity

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing system transitions from a rigid static configuration to a dynamic flexible structure that can adapt its shape to accommodate variations in panel surfaces and assembly tolerances

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution creates a durable, leak-resistant seal that lasts the lifetime of the structure, maintains integrity under heat, and does not require trimming or frequent maintenance, effectively compensating for fabrication tolerances and surface variations.

Implementation Method 1

secured using a pressure-sensitive adhesive and metal fasteners

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS7735891B2Corner rail extrusion

Publication Date: 2010.06.15 TITAN DISTRIBUTION LLC

AI summary

A corner rail extrusion (124) is disclosed for facilitating the sealing of joints at the corners of structures such as recreational vehicles. The corner rail extrusion (124) includes a pair of outwardly and generally perpendicularly extending legs comprising a first leg (126) and a second leg (128). The rail extrusion (124) also includes a central bulbous interior (130). The central bulbous interior (130) is positioned so as to span a corner formed by a side wall (104) and rear wall (106), with the bulbous interior (130) essentially “fitting into” a gap (122).