Multilayer Sealant Systems with Coreactive Extrusion
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Solution Overview
Problem
Existing sealant systems are typically homogeneous and lack the ability to tailor specific properties to individual layers, limiting their performance in terms of chemical resistance, flexibility, and adhesion.
Innovation Solution
A method for making multilayer systems with a sealant layer using a coreactive sealant composition, where a first reactive compound is mixed with a second reactive compound, extruded, and deposited to form the sealant layer, allowing for tailored properties in each layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If homogeneous sealant composition is used, then manufacturing process is simple, but performance attributes such as chemical resistance, flexibility, and adhesion are limited
Solution Approach 1:
The sealant system is divided into multiple discrete layers, each with distinct compositions and properties. The multilayer structure allows each layer to be optimized for specific functions such as adhesion, flexibility, or chemical resistance, while maintaining a relatively simple overall manufacturing process through sequential application
Solution Approach 2:
Different regions of the sealant system (individual layers) are assigned different material compositions and properties tailored to their specific functional requirements. For example, one layer may be optimized for adhesion to substrate while another layer provides chemical resistance, allowing each local region to have the quality needed for its purpose
2Reliability
If multilayer system with tailored properties is implemented, then performance attributes are improved, but device complexity increases
Solution Approach 1:
The complex performance requirements are broken down into separate functional layers, where each layer handles a specific aspect of performance. This segmentation allows the system to achieve high reliability through specialized layers while managing complexity by dividing the system into manageable, functionally-distinct components
3Reliability
If each layer is designed with specific properties, then adhesion and flexibility are enhanced, but manufacturing precision requirements increase
Solution Approach 1:
Each layer is formulated with specific local qualities (compositions) optimized for its function. The manufacturing process controls the placement and composition of each layer, allowing adhesion and flexibility to be enhanced through targeted material selection in each region while managing precision requirements through systematic layer-by-layer construction
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 multilayer system achieves enhanced performance attributes such as improved chemical resistance, flexibility, and adhesion by allowing each layer to be designed with specific properties, thereby overcoming the limitations of homogeneous sealant systems.
Implementation Method 1
the coreactive sealant composition comprises a first reactive compound and a second reactive compound; and the first reactive compound is reactive with the second reactive compound
Implementation Method 2
extruding the coreactive sealant composition to form an extrudate
Implementation Method 3
depositing the extrudate to form the sealant layer
Data Source
AI summary
Methods of making multilayer systems comprising a sealant layer by extruding a coreactive sealant composition are disclosed. The methods can be used to fabricate multilayer systems in which individual layers have different cured properties. Individual layers can also have an inhomogeneous concentration of one or more constituents within a layer. The multilayer systems can be made using three-dimensional printing that facilitate the use of a wide range of coreactive compositions.