Preformed Uncured Sealant Assembly for Squeeze-Out Control
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Solution Overview
Problem
Conventional sealant application methods result in limited control over the amount and distribution of uncured sealant between faying surfaces, leading to excess material waste and increased effort for removal, especially on complex and hard-to-reach surfaces.
Innovation Solution
The use of uncured sealant assemblies comprising two protective layers and a specifically sized and shaped uncured sealant layer, stored at a cure-inhibiting temperature to minimize curing rate, allowing precise control over sealant distribution and elimination of excess material by selecting the size and shape of the uncured sealant layer to match the faying surfaces and prevent squeeze-out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If excess uncured sealant is applied to ensure complete coverage and filling of gaps, then sealing reliability is improved, but material waste increases and additional removal effort is required
Solution Approach 1:
The uncured sealant layer is pre-formed with a specific shape and size that matches the faying surfaces before application. This preliminary shaping ensures that the sealant is distributed exactly where needed, eliminating the need to apply excess material and subsequently remove it, while still ensuring complete coverage and gap filling for reliable sealing
Solution Approach 2:
The uncured sealant layer is designed with non-uniform thickness and shape characteristics tailored to the specific geometry of the faying surfaces. Thicker regions are provided where gap filling is needed, while thinner regions prevent squeeze-out, achieving reliable sealing with precise material distribution and no waste
2Reliability
If excess uncured sealant is applied to ensure complete coverage, then sealing reliability is improved, but process complexity increases due to additional removal steps
Solution Approach 1:
The sealant is pre-shaped to the exact configuration needed before application to the faying surfaces. This preliminary action of shaping eliminates the need for post-application removal steps, simplifying the overall process while ensuring complete coverage and reliable sealing through proper distribution
3Reliability
If uncured sealant is applied to complex and hard-to-reach faying surfaces, then sealing reliability is improved, but application difficulty increases
Solution Approach 1:
The uncured sealant is pre-formed into the exact shape and size needed for the specific faying surface configuration before application. This preliminary shaping allows the sealant to be applied as a single unit that conforms to complex geometries, eliminating the need for difficult manual application and distribution on hard-to-reach surfaces while ensuring complete coverage and reliable sealing
4Ease of operation
If the uncured sealant layer is stored at room temperature, then ease of handling is improved, but premature curing occurs reducing shelf life
Solution Approach 1:
The storage temperature of the uncured sealant layer is controlled to be below a specific threshold temperature. This parameter change (lower temperature) slows down the curing reaction rate, extending the shelf life and usable duration of the sealant while maintaining its uncured state for proper application. The temperature parameter is adjusted to balance shelf life extension with handling properties
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
This method ensures complete coverage and filling of gaps without excess sealant, reducing material waste and simplifying the sealing process by allowing precise control over the uncured sealant's distribution and curing, thereby improving the efficiency and accuracy of the sealing process.
Implementation Method 1
The uncured sealant assembly is stored and provided at a cure-inhibiting temperature, selected to minimize the curing rate of the uncured sealant layer
Data Source
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AI summary
Described herein are methods of forming uncured sealant assemblies and also methods of forming seals between various parts using such assemblies. In some examples, an uncured sealant assembly comprises two protective layers and an uncured sealant layer, disposed in between. The uncured sealant assembly is stored and provided at a cure-inhibiting temperature, selected to minimize the curing rate of the uncured sealant layer. The size and the shape of the uncured sealant layer are specifically selected to ensure the complete coverage of the faying surfaces, filling of all gaps and voids between the faying surfaces, and controlling the shape and size of uncured sealant squeeze out between the faying surfaces. In some examples, the size and shape of the uncured sealant layer maybe be specifically selected to have no uncured sealant squeeze out between parts. The method (200) described herein is forming a seal (170) between a first part (180) and a second part (190) using an uncured sealant assembly (100), the method (200) comprising: removing the uncured sealant assembly (100) from a cure-inhibiting temperature, wherein the uncured sealant assembly (100) comprises a first protective layer (120), a second protective layer (130), and an uncured sealant layer (110) disposed between the first protective layer (120) and the second protective layer (130), wherein the cure-inhibiting temperature is below room temperature and selected to reduce a curing rate of the uncured sealant layer (110); removing the first protective layer (120) from the uncured sealant layer (110) thereby exposing a first sealant surface (111) of the uncured sealant layer (110); contacting the first part (180) with the first sealant surface (111); removing the second protective layer (130) from the uncured sealant layer (110) thereby exposing a second sealant surface (112) of the uncured sealant layer (110), the second sealant surface (112) being opposite to the first sealant surface (111); and contacting the second part (190) with the second sealant surface (112) such that the uncured sealant layer (110) is disposed between the first part (180) and the second part (190), wherein the uncured sealant layer (110) is cured into the seal (170).