Thermoplastic Tape Sealing for Durable Watertight Structures

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Solution Overview

Problem

Existing sealants for recreational vehicles and similar structures are difficult to handle, messy, and require frequent reapplication due to exposure to weather conditions, leading to incomplete sealing and potential damage from water ingress.

Innovation Solution

The use of single-sided and multi-sided thermoplastic film tapes, and substrate-encapsulated tapes made from thermoplastic sealants like butyl rubber and styrene block copolymer, which form the majority of the sealant used to seal the exterior of the structure, eliminating the need for room temperature liquid sealants and providing a durable, long-lasting seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If room temperature liquid sealants are used to seal the exterior of the structure, then sealing coverage is achieved, but the sealant is exposed to weather conditions causing it to age and crack over time

Engineering Contradiction:

Improvesealant durabilityVSAvoidsealant service life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent extracts the sealant from its vulnerable outdoor location by applying it internally to the interior surface of the roof and walls. This removes the sealant from direct exposure to weather conditions (sun, rain, temperature extremes) that cause aging and cracking, while still maintaining the watertight seal function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an intermediary layer (the internal sealant application) between the external water exposure and the structural components. This internal sealant acts as a mediator that prevents water infiltration without needing to withstand external environmental degradation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If liquid sealant is applied on the outside of the structure, then sealing is achieved, but it requires frequent patching and reapplication

Engineering Contradiction:

Improveseal integrityVSAvoidmaintenance time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The sealant is extracted from the external environment where it degrades quickly, and placed internally where it is protected from weathering. This single internal application eliminates the need for frequent external patching and reapplication.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If room temperature liquid sealants are used, then sealing coverage is achieved, but they are difficult to handle and result in squeeze-out that must be cleaned by hand

Engineering Contradiction:

Improveseal coverageVSAvoidsealant application ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent changes the physical parameters of the sealant application by using a sealant with specific viscosity and application method suitable for interior surfaces. This allows for controlled application without excessive squeeze-out, making the process easier to handle while maintaining effective seal coverage.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If liquid sealants are used to seal around the outside of items such as vents and windows, then sealing is attempted, but they are messy and do not always seal the structure completely

Engineering Contradiction:

Improveseal completenessVSAvoidapplication cleanliness

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Instead of applying sealant externally around items like vents and windows, the patent inverts the approach by applying sealant internally along the interior surfaces where these items penetrate the structure. This internal application is cleaner and ensures complete sealing without the messiness of external application.

Inventive Principle:

Principle #13The other way round (Inversion)

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

These tapes ensure a watertight seal, are easier to apply, maintain a neat appearance, and do not require frequent reapplication, effectively preventing water ingress and maintaining structural integrity over time.

Implementation Method 1

The method includes heating the thermoplastic sealant to melt the thermoplastic sealant and then cooling the thermoplastic sealant to solidify the thermoplastic sealant around the exterior of the structure

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

cooling the thermoplastic sealant to solidify the thermoplastic sealant around the exterior of the structure

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS11820209B1Watertight structures and methods of making the same

Publication Date: 2023.11.21 HB FULLER CO

AI summary

This invention is directed to a structure and a method of sealing the structure as it is manufactured. The method uses a combination of thermoplastic sealants in the form of films and a substrate encapsulated tape.