Selectively Densified Membrane Sealant for Uneven Chemical-Exposed Interfaces
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Solution Overview
Problem
Existing sealants used in the aircraft industry face challenges in providing durable, temperature-resistant, and chemically resistant sealing solutions that can conform to various interface profiles without requiring lengthy curing times and complex installation procedures, while also being removable and effective against harsh chemicals like phosphate ester hydraulic fluid.
Innovation Solution
A selectively densified composite sealant comprising a porous layer with alternating densified and undensified portions and elastomeric layers that fill the valleys of the porous layer, providing a seal that is resistant to fluid ingress and capable of compressing to fit uneven surfaces, with elastomeric materials that are chemically inert to challenge fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If liquid sealant is used to conform to interface geometries, then adaptability to various interface profiles is improved, but installation complexity and curing time increase
Solution Approach 1:
The sealant combines a porous polymer base material with elastomeric particles to create a composite material that integrates the conformability of liquids with the structural integrity and ease of handling of solids, eliminating complex installation procedures while maintaining adaptability to various interface geometries
Solution Approach 2:
The sealant utilizes two-part chemistry that changes physical parameters during curing - initially liquid for easy application and conformability, then transitioning to a cured state with enhanced structural properties, allowing the material to adapt its characteristics based on the application stage
2Ease of operation
If polysulfide liquid sealant is used for sealing, then ease of application is improved, but resistance to harsh chemicals deteriorates
Solution Approach 1:
The sealant combines a porous polymer base material with elastomeric particles to create a composite material that integrates the conformability of liquids with the structural integrity and ease of handling of solids, eliminating complex installation procedures while maintaining adaptability to various interface geometries
Solution Approach 2:
The sealant utilizes two-part chemistry that changes physical parameters during curing - initially liquid for easy application and conformability, then transitioning to a cured state with enhanced structural properties, allowing the material to adapt its characteristics based on the application stage
3Reliability
If dry sealing materials like O-rings are used, then chemical resistance is improved, but adaptability to temperature ranges and conformability deteriorate
Solution Approach 1:
The sealant combines a porous polymer base material with elastomeric particles to create a composite material that integrates the conformability of liquids with the structural integrity and ease of handling of solids, eliminating complex installation procedures while maintaining adaptability to various interface geometries
Solution Approach 2:
The sealant utilizes two-part chemistry that changes physical parameters during curing - initially liquid for easy application and conformability, then transitioning to a cured state with enhanced structural properties, allowing the material to adapt its characteristics based on the application stage
4Adaptability or versatility
If liquid sealant is used for sealing, then conformability to interface geometries is improved, but removal difficulty increases
Solution Approach 1:
The sealant combines a porous polymer base material with elastomeric particles to create a composite material that integrates the conformability of liquids with the structural integrity and ease of handling of solids, eliminating complex installation procedures while maintaining adaptability to various interface geometries
Solution Approach 2:
The sealant utilizes two-part chemistry that changes physical parameters during curing - initially liquid for easy application and conformability, then transitioning to a cured state with enhanced structural properties, allowing the material to adapt its characteristics based on the application stage
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 composite sealant offers durable, temperature-resistant, and chemically resistant sealing capabilities, maintaining a liquid seal across a wide range of temperatures and pressures, while being non-wettable to challenge fluids and allowing for easy installation and removal.
Implementation Method 1
The selectively densified composite sealant includes a porous layer with alternating densified portions and undensified portions. The densified portions may be generated by increasing the density of the porous layer.
Implementation Method 2
The at least one elastomeric layer may comprise a first elastomeric layer... The first elastomeric material may be chemically inert with respect to at least one of the possible challenge fluids
Implementation Method 3
The undensified portions may be disconnected from each other and separated by the densified portions... capable of compressing to fit uneven surfaces
Data Source
AI summary
A selectively densified composite sealant includes a porous layer having a first major surface and an opposing second major surface. The porous layer is formed of a porous membrane and having alternating first densified portions and second undensified portions that form respective valleys and peaks in the porous layer. An elastomeric layer is disposed on the first major planar surface of the porous layer and is formed of an elastomeric material that fills the valleys between the undensified portions.