NON-ADHESIVE THIN GEL SEALANTS AND METHODS OF MAKING AND USING THE SAME

Abstract

Applicant provides a number of embodiments of a sealant, the sealant comprising a polyurethane gel which, in some embodiments, has a thickness of 12 mil or less (uncompressed). Uses of the sealant are shown, including uses between aircraft parts under compression. Sometimes the sealant may have a very thin skeleton. Sometimes the sealant is in the form of a die cut gasket, a tape or a tacky gel sprayable. Methods for making the sealant are also disclosed. The sealants may be used pre-cured or may be sprayed on to the aircraft parts and form in place.

Description

This application claims the benefit of, priority to, and incorporates herein by reference and is a continuation in part of U.S. patent application Ser. No. 14/704,030 filed May 5, 2015 which claims the benefit of Provisional Patent Application No. 61/988,949, filed May 6, 2014; incorporated by reference US Publication No. 2003/0234498. This application incorporates by reference and claims the benefit of U.S. application Ser. No. 15/472,859, filed Mar. 29, 2017.

FIELD OF THE INVENTION

Gaskets, more specifically, a thin, pre-cured gel sealing member for in one use between two parts in an aircraft, the two parts under compression, such as a lap joint on a fuselage of an aircraft, and methods for making an assembly, such as a gasket and lap joint.

BACKGROUND OF THE INVENTION

A number of problems may be encountered with sealants. They must be dimensionally appropriate; they must provide an effective environmental seal; they must be adapted to receive rivets or other fasteners; they must maintain resiliency and avoid excessive creep under load; they must be able to withstand repeated thermal and pressure cycling; and they must be cost effective taking into account labor, manufacturing, installation, and in-service. Thus, typically, prior art sealant materials tend to be a compromise.

Applicant has heretofore used gaskets, gasket tape, and other sealants, as well as a method for making gaskets and other sealants as found and set forth in the following issued patents that are incorporated herein by reference: U.S. Pat. Nos. 6,530,577; 6,695,320; 7,229,526; and U.S. application Ser. No. 15/472,859. These patents also show uses for tacky polyurethane gel gaskets in aircraft which are also uses for the sealants disclosed herein.

Applicant has found certain problems inherent in the manufacture and use of very thin polyurethane only (no skeleton) gaskets. Applicant's disclosures herein solve some of these problems.

SUMMARY OF THE INVENTION

Resilient materials are provided for, in some embodiments, sealing complementary overlapping or closely abutting edges of aircraft on an aircraft fuselage, such as on lap joints or at other locations. Air and watertight seals are sometimes created by the use of cured in-place materials, where two parts are mixed together, then applied uncured very thinly to a sealing surface, and allowed to cure after assembly—that is to say, wet installed. In some assemblies the use of a thin, precured non-adhesive gel, such as polyurethane gel may be desirable. Applicants have found, however, that there are difficulties in handling very thin gel, in particular a gel with either no skeleton or a very thin skeleton—and less than about 12 mil thick. The gel tends to come apart very easily as it is tacky and, being thin and lacking structural integrity (no skeleton embodiments) may stick to the release paper upon which it is placed.

A thin, cured gel gasket is disclosed, including methods of making the thin gel gasket and the use of the thin gel gasket with aircraft parts, including in an aircraft lap joint. In some embodiments, the thin gel gasket has no skeleton or other structure and is comprised of only a stretchable, cured polyurethane gel and has a thickness of less than 12 mil. The gasket may be manufactured using a release film that is adapted in a number of ways to make removal from the gel prior to use easier. In certain methods of making and using this thin gel gasket, it is applied to a joint or assembly which is subject to compression, such as, for example, a lap joint of an aircraft fuselage.

A joint or assembly for use on an aircraft fuselage is also disclosed. The joint may include: a first aluminum panel (or one made of other suitable material) having an outer edge portion; a second aluminum panel having an outer edge portion; a multiplicity of rivets, each having a rivet head and rivet shaft, the rivets for joining the two panels along facing overlapping outer edge portions; a sealant between the overlapping edge portions, the sealant comprising a resilient cured polyurethane gel gasket having a tacky body. In some embodiments, the gasket has a thickness of less than 12 mil uncompressed. The gasket may have a thickness of between about 1-6 mil when compressed between the two panels or other aircraft parts.

In certain embodiments, at least some of the multiplicity of rivets may include a tacky polyurethane uncured gel mix on the shaft thereof. The gel mix may cure after a few minutes. This gel mix is uncured when first applied. The joint further may include a temporary tack decreasing agent on a surface of the gasket. The joint or assembly may, for example, be a lap joint, a double lap joint, a tapered lap joint or a snap joint.

An aircraft having a fuselage is disclosed, the fuselage comprising: multiple partially overlapping panels, the overlap comprising multiple lap joints; wherein the lap joints comprise facing surfaces with rivets, the facing surfaces with a thin, tacky, cured, deformable, resilient polyurethane preformed gasket therebetween; wherein the compressed gasket thickness is less than 6 mil.

A method of joining adjacent overlapping panels on an aircraft fuselage is disclosed, the method comprising: obtaining a thin, cured polyurethane gasket or gasket tape having a first, tacky side and release paper on a second side; applying the first, tacky side to an outer edge of one of either an inner panel or an outer panel of the overlapping panels; positioning an outer edge of the other panel of the overlapping panels adjacent the gasket or gasket tape such that an overlap width approximates a tape width; removing the release paper from the second side of the gasket or gasket tape before the following step; and joining the panels with rivets so the edges hold the gasket or gasket tape under compression.

A method of manufacturing a thin gel gasket assembly is also disclosed. The method may include: providing a release film that has been adapted to easily release from a thin gel gasket; applying an uncured mix of the gel to the adapted release film to a thickness of 12 mil or less; and allowing the gel to cure. The release film of the providing step, in certain embodiments, has multiple perforations therethrough. The release film of the providing step is, in some embodiments, at least partly coated with release agent. The release film of the providing step is, in particular embodiments, meltable.

In an effort to meet environmental sealing problems, Applicants provide, in certain embodiments, a thin, polyurethane-only (no skeleton) sealant, gasket or tape as more particularly set forth below. A method of making and using the same in a lap joint or other aircraft assembly is also provided.

In certain embodiments, there is provided a lap joint for use on an aircraft fuselage. The lap joint may include a first aluminum panel having an edge portion; a second aluminum panel having an outer edge portion; a multiplicity of rivets joining the two panels along complementary overlapping edge portions; a sealant, such as a tape, for placement between the overlapping edge portions, the sealant, in one embodiment, consisting essentially of a cured polyurethane tape gasket having a tacky upper and lower surface, the gasket having a pre-compression thickness of between 2-12 mil, more preferably, 6-8 mil, wherein the multiplicity of rivets includes an uncured polyurethane mix applied immediately upon mixing and before curing to the rivets and/or panel rivet holes, just before installation of the rivets, wherein optionally a temporary tack decreasing agent is applied to either or both of the edge portion(s) of the panels and/or the surfaces of the gasket, prior to contacting the gasket with the panel(s).

There is provided, in particular embodiments, a method of manufacturing a thin, tacky polyurethane gasket. The method may include: applying a thin film 2-12 mil thick, of an uncured polyol/isocynate mix to at least one release film that has a low bonding cohesion with respect to the polyurethane; allowing the polyurethane to cure; removing the release film; and applying the gasket to a lap joint of an aircraft.

The embodiments of the sealant disclosed is tacky, but not an adhesive. Adhesive based products and gel based sealants differ in several ways. One of them is not only what their intended use is, but also in their basic structures, bonding, and physical characteristics. Adhesives provide a more permanent, rigid and durable bond as opposed to sealants, such as gels, which are lower in strength and far more malleable. Sealants are typically not used to bond parts, such as parts under compression, permanently together. Adhesives have more power for holding and bonding, but sealants are good for air and water tight spaces and as gap fillers. Sealants have lower bonding strength and a higher elongation percentage than adhesives. Sealants are meant to provide a watertight seal, but are easily removable when necessary. Adhesives typically are not meant to be removed from the part to which they are bonded.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a gasket assembly comprising a tacky polyurethane gasket with release film on one or both sides for use in making a lap joint.

FIGS. 2A, 2B, and 2C illustrate a method of making a tacky polyurethane gasket for use in a lap joint or other assembly.

FIGS. 3A, 3B, and 3C illustrate a gasket having a bottom or top film that is perforated or mesh-like (FIG. 3A,); dissolvable (FIG. 3B); or, heat meltable (FIG. 3C).

FIG. 3D illustrates a gasket assembly comprising two release films, one on the top and one on the bottom of a thin, cured tacky polyurethane gasket.

FIGS. 4A, 4B, 4C, 4D, 4E, 4F, 4G, and 4H illustrate a method using applicant's thin skeleton-less gasket on an aircraft fuselage to create a lap joint.

FIG. 5A illustrates in isometric view another method for making a thin polyurethane gasket.

FIG. 5B illustrates a method of preparing a bottom film so that it releases cleanly from a polyurethane that has cured on it.

FIGS. 5C and 5D illustrate a device for and method of obtaining a controlled thickness on a thin polyurethane sealing member.

FIGS. 6A, 6B and 6C illustrate additional uses of applicants, then gasket, namely a double lap joint, a tapered joint and a snap joint, respectively.

FIGS. 7A, 7B, 7C, 7D, and 7E illustrate uses of Applicant's novel sealants disclosed herein.

FIGS. 7C1, 7C2, and 7C3 all illustrate a lap patch which uses embodiments of Applicant's sealants disclosed herein.

FIGS. 8A and 8B illustrate the use of Applicant's sealants disclosed herein with a titanium heat shield.

FIG. 9 illustrates the use of Applicant's sealants disclosed herein with joints comprised at least in part of laminated composites.

FIGS. 10A and 10B illustrate a two-part sealant that comes in a cartridge for use with a spray gun, the two-part sealant forming a mix that will cure to a tacky gel.

FIG. 10C illustrates a fitted part on which a tacky polyurethane gel has been sprayed and a cover has been applied.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Applicant provides, as seen in FIGS. 1, 2D, 3D, 4G, and 4H, for example, a gasket assembly 10, including a gasket 12, the gasket comprised of tacky, cured polyurethane for use, in one embodiment, in a lap joint 11 (see FIGS. 4D and 4F). A lap joint 11 may include a first panel A and a second, adjacent panel B, the two panels of an aircraft fuselage overlapping and riveted together with a series of rivets R (or other attaching hardware) and with gasket 12 therebetween. Gasket 12 will create an effective environmental seal and help prevent corrosion of the panels at the joint. In a preferred embodiment, gasket 12 is, prior to placement on the workpiece, is part of the gasket assembly 10 which includes a release film 14 on at least one side thereof, the other side being tacky (see FIG. 1) or having a release film 14 on both sides. In one form, a thin, cured polyurethane gasket 12 is provided (see FIG. 3D). As further set forth below, release film 14 is not placed between the two overlapping riveted panels, but is simply useful in handling, prior to placement of gasket 12 on the workpiece, of gasket assembly 10 as the polyurethane of gasket 12 may be tacky and tacky or dimensionally somewhat unstable. The release film is removed after the tacky side is attached to the workpiece surface as set forth in more detail below. Thus, gasket assembly 10 is used to refer to gasket 12 having at least one release film 14 on the upper or lower surface thereof or on both surfaces.

Gasket 12, in one embodiment, has an uncompressed thickness of about 2 to 12 mil or, more preferably, about 6 to 8 mil, which thickness is the thickness as applied (see FIG. 4B) prior to any compression between members A and B of the lap joint or other aircraft assembly. Compression between the panels may cause some thinning and squeeze out as gasket 12 is both tacky, deformable and subject to flow or squeeze out 42 under compression, see FIG. 4E. Compressed thickness as, for example, in a lap joint, may be less than about 6 mil.

The composition of gasket 12 may be found in the patents incorporated herein by reference and is typically pre-cured, that is, cured prior to placement between panels A and B (see FIG. 4F) in a manner more specifically set forth below. Some of the patents incorporated herein by reference are: U.S. Pat. Nos. 6,530,577; 6,695,320; and 7,229,516. In preferred embodiments, there is no skeleton in gasket body 12. Handling and making the gasket with polyurethane gel that is both tacky and is thin as set forth in the ranges set forth above, creates some unique problems that are typically not present in dealing with polyurethane gaskets that are thicker, such as those having bodies between about 15 and 55 mil thickness, for example.

A. Methods of Making the Thin Gasket

One of the difficulties in working with a thin polyurethane gasket is in the manufacture of the gasket. FIGS. 2A, 2B, and 2C illustrate a method of manufacturing gasket assembly 10 that may overcome some of these difficulties. Gasket assembly 10 is seen to be, in one embodiment elongated, in the nature of a tape having a quite a small thickness range, a larger width, and an even substantially larger length. Width may be, for example, about 0.05 inches to 18 inches, and length may be about 80 inches to 218 inches.

In one embodiment, a flat, level mold 18 is provided having a bottom wall and side walls 20 and an open top. The mold may be about 2′ wide and about 12′ long. A bottom film 16 (a release film designated with 16 because of its placement beneath uncured mix) of release film or non-release film is laid either across the bottom or across the bottom and at least partially up the sides of the mold. In one embodiment, a two-part polyurethane comprising a polyol 24 and an isocyanate 26 is injected into mold 18 using a mixing cartridge 22 that has a nozzle 22a for mixing the two parts. The volume of the mix injected is known and set so that it provides the selected body thickness, for example, about 6 to 8 mil or in the range of 2-12 mil. The mix will chemically react and set (cure) at ambient temperature in mold 18 on top of bottom film 16. Typically, the cure (to about 90%) of final hardness occurs in about 30 to 90 minutes. Before it sets, it, being self-leveling, the mix will be spread out or may be leveled with a handheld straight edge. Bottom film 16 is provided for the releasing, post-curing of the tacky gasket polyurethane material from the mold.

FIG. 2B illustrates the cured polyurethane which cured upon bottom film 16 and upon which, after it is cured, a second release film 14 may be placed as a top film. Removal of polyurethane gasket body 12 with bottom film 16 attached thereto may be achieved as by manually lifting out. Following removal, a sharp knife may be used to produce a number of smaller width tape strips—for example, about twenty four one-inch strips.

It has heretofore been difficult to remove the release films from a thin polyurethane gel gasket 12. In an effort to help achieve clean removal of the release film, several solutions are set forth below.

B. Physical Configuration or Chemical Composition of the Film

In FIG. 3A, a first specific embodiment 16a of bottom film 16 is shown to be perforated with multiple small holes 17 and thus may be removed more easily than if it were a solid film. In the same form, this may be used as a release film on the top surface of the cured gel also.

In FIG. 3B (shown with gasket assembly inverted after removal from the mold to show bottom film 16 on top), a second specific embodiment 16b of film 16 is provided with water or chemical dissolvability. For example, water from a spray container 28 or damp cloth 30 may be applied to such dissolvable film and the film allowed to dissolve. This is in lieu of a mechanical separation as used in FIG. 3A above, with perforated film 16a. Adhesive Research provides a dissolvable film, including a water dissolvable film, that may be tailored in thickness, dissolution rate, texture, and tensile strength (see www.adhesiveresearch.com). Rice paper may also be used, as it is dissolvable in water and non-toxic.

In FIG. 3C, a heat meltable film 16c is provided as a bottom film for the manufacturing of a thin polyurethane gel gasket. Following removal of the gasket assembly from the mold 18, a heat lamp or other heat source 32 may be provided on or adjacent heat reactive meltable film 16c to remove it from gasket 12. In one embodiment, the heat meltable film melts at below about 275° F.

FIG. 3D illustrates that when gasket body 12 is removed from a mold and a bottom film removed from the surface thereof, a second release film 14 may be placed on the cured top surface so it is easy to handle by a user. This second release film is placed on cured gel so its removal may not be as problematic as film 16. In one embodiment, the top release film is in the same nature as bottom film 16 or it may be made from another material such as FET. While some embodiments use release film and agents disclosed herein are used with thin gaskets or skeleton-free gasket, they may be used with gaskets from 13 to 75 mil thick with or without skeleton.

In some embodiments (see FIG. 4H), the thin gel gasket has a very thin skeleton 13, encapsulated in the gel such as embodiment of a skeleton found in U.S. application Ser. No. 14/484,570, filed Sep. 12, 2014 (see FIG. 4H). A thin gel gasket may also have or thin skeleton, in some embodiments the skeleton in range of 2-12 mil in a body about 12 mil or less (uncompressed) (see FIG. 4H). The skeleton may be metal or non-metal. Metal skeletons may be made from aluminum, stainless steel, bronze, monel, and copper (including any alloys of these metals) and may be a mesh (woven from metal fibers or strands) or may be expanded metal sheet. Non-metal may be woven mesh, molded or extruded and may be any skeleton found in the U.S. application Ser. No. 14/484,570, filed Sep. 12, 2014, and US Publication No. 2003/0234498, which are incorporated by reference, but has numerous holes or openings for the gel to fill.

C. The Use of a Release Agent Applied to the Release Film

FIG. 5A illustrates a preferred alternate embodiment of making a very thin polyurethane-only tape, wherein no mold is used, just a flat bottom film 16, which may be a bottom film with any of the clean release qualities set forth herein. A two-part polyol isocyanate mix 24/26 is applied to the top surface of the bottom film 16. It may be applied in a known volume on a bottom film marked by a rectangle or other shape. The rectangle will show the area on which to spread the known volume of mix to give the desired “thinness.” An S-shaped motion of handheld mixing cartridge 22 will help application of the mix and a handheld straightedge may be used to help level—though in a preferred embodiment, the mix may be self-leveling. It will spread out somewhat and typically is applied (uncured) in an elongated stream (with a consistency similar to motor oil) and will start to set up and cure after it has spread out “width-wise.”

By controlling the speed at which one moves the mixing cartridge across the film and the rate of mix application, one can, with experience, obtain a thin, relatively wide strip. A top film may be placed on it, for example, after curing. Then it may be cut in multiple strips, lengthwise, to the desired width. In either method, leveling and a selected “thinness” may be further controlled by using a rigid roller 40 having end ridges 41, such as that shown in FIGS. 5C and 5D. This is done with a top release film in place and before the mix is fully cured. In an alternate method, the roller may be made from or coated with a polyurethane non-stick material.

FIG. 5B illustrates another manner in which release may be obtained from the polyurethane mix that cures in place on bottom film 16. In this application, a release agent 27 in liquid, dust or other suitable form may be applied to the bottom film before the uncured mix is applied thereto. Such an agent should be inert and non-volatile as regards to the polyurethane and may be applied with a brush 29, a spray application 28 or any other suitable method. One such material that may be applied is a hydrophobic material known as Rain-X®. Another is sold under the trademark PAM®. PAM® is made from a vegetable oil, typically canola oil, and Rain-X is a hydrophobic silicon polymer that also helps with release of cured polyurethane gel. The primary active ingredients in Rain-X are polysaloxines. In one embodiment, films 14/16, for example, when used with the method set forth in FIG. 5A above, may be glass, plastic or FET with Rain-X or other release agent 27 applied thereto, which Rain-X bonds well with the glass, but does not bond the polyurethane and thus allows easy release. Other release agents are wax, oil and other compositions as set forth in Publication No. US 2009/0020917, which publication is incorporated herein by reference.

Certain types of release film may work by being physically altered, chemically altered or receiving a release agent on the surface thereof as set forth in FIG. 5B. These include: Teflon, PET, PVC, PP, nylon, FEP (fluorinated ethylene propolene), and polyurethane. Any of the foregoing or any other film may be adapted as set forth herein.

D. Joint or Other Aircraft Assemblies Using Applicant's Thin Polyurethane Gel Sealant

FIGS. 4A-4G illustrate a lap joint 11 wherein a single-sided tacky (release film on one side only) tape embodiment may be applied along a complementary edge of panel A, such as aluminum panel of the fuselage of an aircraft. The edge of gasket 12 is aligned with the edge of the panel. The bottom side is tacky polyurethane and will immediately adhere to the location at which it is placed with only a minimal ability to move it after it touches. This requires careful alignment and placement of the tape, tacky side down. However, the placement of the gasket may be less critical, if the edge of panel A and panel B, or the surfaces of gasket 12, are first treated with a temporary tack reduction material 37, FIG. 4B. This renders them temporarily non-tacky to the polyurethane. Temporarily is in the nature of minutes, typically, up to about 5-20 minutes, during which there may be some relative movement between gasket body 12 and either the lower and/or the upper panels. This ability to move allows careful alignment of the gasket along one panel and careful alignment of the second panel with respect to the first panel and the gasket. Alignment is especially important if the panels are pre-drilled for the placement of rivets (or other attaching hardware) therein and, thus, require careful alignment of the rivet holes.

FIG. 4B shows a container of such temporary tack reduction material 37, which may be applied to both the underside of panel B or the upper surface of gasket 12 or (not shown) the upper surface panel A or the bottom surface of the gasket before it is applied. Application may be by any means, such as brush, spray, cloth (wipe on) or a thin film or a solid liquid or the like.

The compositions that may be used in this step illustrated in FIG. 4B include the aforementioned compositions used for treating the surface of the bottom film. They are typically non-reactive to aluminum or other metals and, thus, usually contain no acids and are inert and non-volatile. While the ability to do some “post contact” adjustment of the workpieces (panels A and B) with respect to the tacky, thin gasket is important, the nature of the compositions applied to the various surfaces to allow one to make alignment adjustments. Applicants' gasket is deformable and flows somewhat under compression and therefore spreads. Any temporary tack reduction material 37 or release agent 27 should not contain any material that would cause corrosion or inhibit the environmental seal that tacky, cured polyurethane produces between the adjacent compressed panels. Isopropyl alcohol is one temporary tack reduction material 37 that may be applied by spraying, in one embodiment that will help temporarily inhibit the stickiness between the workpiece and gasket 12.

FIGS. 4C and 4D illustrate that, after alignment of the holes for the receipt of rivets 36 (or other attaching hardware), a wet seal 34 may be applied from an applicator 33. In one embodiment, wet seal 34 may be an uncured two-part polyurethane mix 24/26, which mixes in the nozzle of the applicator, which will cure in place at ambient temperature when applied around the rivet hole before or during the insertion of the rivets (or other attaching hardware) through the holes with the gasket 12 lying therebetween. Such a wet seal, such as Self Leveling Green or Self Leveling Red, is available from AVDEC located at 1810 Mony Street, Fort Worth, Tex. 76102. It is applied to and around the rivet holes and/or on the rivet prior to affixing the rivet between the two panels A/B and will help, after curing, create a good environmental seal and help prevent liquids or moisture from accessing to the space around the rivet holes between the panels, where they overlap through the rivet holes. Indeed, the wet seal may be used for creating the lap joint. Even when no gasket is used.

FIG. 4D illustrates lap joint 11 where panels A and B may be under compression between their edge portions. Compression typically occurs during the process of fastening the rivets to the panels. Because Applicant's thin polyurethane gel gasket 12 is relatively soft, squeeze out 42 may occur at the lap joint edges is seen in FIG. 4E. A cloth 30 that may be soaked with isopropyl alcohol or other appropriate medium may be used to wipe down the squeeze out to give a tapered edge (see FIG. 4G) or flat, which conforms to the panel edges (see FIG. 4D).

Additional embodiments appropriate for receiving applicants thin skeleton less gasket conclude include double lap joints FIG. 6A, tapered lap joints, FIG. 6B, and snap joints, FIG. 6C. The aluminum of the joints may be aluminum alloy or any other material, lap joint referring to the physical position of the overlapping panels. While the term “gasket” is used, with a tape being a gasket with a particular geometry, a gasket may be a pre-cured sealant for placement between two pieces. Lap joints are used in many manufacturing processes and in a number of vehicles, including trains and motor homes. The overlapping sections, such as aluminum panels, may be treated or untreated. If treated, it may have a conversion coating (for corrosion control) or a paint coating (may include a corrosion inhibiting primer).

Other non-lap joint aircraft parts or assemblies that may use the sealants disclosed herein include aircraft antennas, between floorboards and floorboard support structures, between window seat tracks and window seat floors where wing lugs join fuselage lugs, in electronic equipment bays where electronic equipment rests in racks, on a floor or shelves (where moisture can collect and cause corrosion), where dissimilar metals meet to help prevent galvanic corrosion, conductive and non-conductive thin gel washers or tapes for EME (electromagnetic environment) grounding or isolating metal or electronic elements, including conductors and/or grounds, on electrical and structural aircraft systems. Any of the sealants disclosed herein may also be used in EME areas, electronic sources and fixtures. Applicant's sealants can be used on or around radio transmitters, receivers, oscillators, motors, lamps, energy ignition relays, heaters, computers, and peripherals and the like.

FIGS. 7A, 7B, 7C, 7D, and 7E illustrate additional uses of a thin gel only or thin gel with thin skeleton on, with or as part of an aircraft assembly. FIG. 7A illustrates any embodiments of Applicant's sealant disclosed herein between the underside of an aircraft wing and an aircraft pod, which pod may carry fuel or electronics or anything else. FIG. 7B illustrates an aircraft interior showing an aircraft floor where any embodiment of Applicant's sealant as disclosed herein is used between an avionics box or other structure mounted to the floor and/or a seat track mounted to the aircraft floor. FIGS. 7C and 7D illustrate a lap joint or battle damage repair, such as may be required when a bullet or shrapnel hole is torn into the aircraft outer skin and/or structural members. FIG. 7C illustrates a structural member with any of the embodiments of Applicant's sealant between the aircraft skin and the structural member to which the aircraft skin mounts. In FIG. 7D, any of the sealants that Applicant's disclosed herein is applied to the recess or border area before a patch panel is installed with fasteners, such as rivets or the like. FIG. 7E is a cross-sectional view of the patch of FIG. 7D.

FIGS. 7C1, 7C2, and 7C3 are additional drawings of an ABDR (aircraft battle damage repair) or a lap joint repair. FIG. 7C1 shows a first or outer patch and a second or inner patch (dashed lines) with the sealant between the holes shown in dashed lines. In other words, the aircraft skin in the border area adjacent the hole receives an outer patch and an inner patch (or at least one) with fasteners therethrough to reinforce the hole. Applicant's sealant may be between the outer patch and the skin border area or between the inner patch and the skin border area, but typically is between both the outer patch and the skin border area and the inner patch and the skin border area, and fasteners, such as rivets, can be used between the outer and inner patch. FIG. 7C2 shows an inside view of a patch, which in this embodiment, may be a single patch reinforcing an area around battle damage. FIG. 7C3 shows another view, close up, of FIG. 7C2, showing the gel of the deformable gel sealant oozing out between the aircraft skin and the inner patch.

FIG. 7E shows an inside the aircraft patch, also known as a doubler, with a filler patch (typically flush) on the outside where the hole in the aircraft skin is located. Any of the sealants disclosed herein may be used as illustrated between the inside patch or the doubler and the skin border area around the hole. In some cases, a sealant may be used between the filler patch also and structural fastener elements may be provided as indicated.

FIGS. 8A and 8B illustrate the application of any of the thin sealants combined herein to an auxiliary powered unit heat shield, such as an APU heat shield used on the co-pilot side of a British Aerospace 146 cockpit. FIG. 8A shows the shield with a hole for the exhaust, which shield has a thin gel sealant on the either or both surfaces thereof. FIG. 8B illustrates how the shield can be placed over areas of corrosion or areas where corrosion is likely to occur on an aircraft skin or an aircraft member with the gel between the skin/member and the heat shield.

FIG. 9 illustrates the use of Applicant's thin gel sealants with composites as in aircrafts that are made from composites, including, for example, the Boeing Dreamliner. Applicant's thin gel may be used in a composite to composite joint, a composite to an aluminum joint, a composite to titanium joint or a composite to a steel or other material joint. Typically, the joints are held together with fasteners rather than adhesive bonded. The thin gel sealant disclosed herein may be applied prior to assembly of the joint or during repair and/or replacement of one or more parts of the joint. The joint may be held together with fasteners known in the art, rivets, bolts, and nuts or the like. Applicant's thin gel sealant may be used in place of adhesively bonded joints or may be used in joints that do not necessarily need to be strong in shear. Moreover, Applicant's thin gel sealants may be especially used for non-bonded joints which require removability. Bolted or riveted joints (mechanically fastened) in fibrous composite structures may be appropriate for Applicant's thin gel sealants.

Areas where Applicant's thin gel sealant may be applied, either as a cured, tacky gel gasket or spray-on cure-in-place (see below), include between the faying surfaces of the following types of joints: bonded doubler; unsupported single lap joint; single strap joint; tapered single lap joint; double lap joint; double strap joint; tapered strap joint; stepped lap joint; and scarf joint (see NIAR.wichita.edu/nairworkshops/portals/0/jun17_0345_stevew_dh.pdf, incorporated herein by reference), NSE Composites, page 4, article entitled “Composite Bonded Joints Analysis, Data and Substantiation,” Jun. 16-18, 2004, D. M. Hoyt and Steve Ward, NSE Composites, Seattle, Wash. While these show bonded joints, the use of Applicant's thin gel sealants provide for non-bonded joints that are fastener held (mechanically bonded rather than adhesively bonded), where the joints are under compression but, with Applicant's novel sealant compositions, removability is retained, though some shear strength is sacrificed. In some embodiments, Applicant's thin gel sealants are used with bolted composite structures, that is, non-adhesive joints (adhesive bond joints), Applicant's sealants provide removability and good environmental seal. Some mechanically fastened permanent or removable joints may be found in U.S. Pat. No. 7,678,437, incorporated herein by reference.

Adhesive based products and gel based sealants differ on several scales. One of them is not only what their intended use is, but also in their basic structures, bonding, and physical characteristics. Adhesives provide a more permanent, rigid and durable bonding as opposed to sealants, such as gels, which are lower in strength (including shear) and far more malleable. Sealants are typically not used to bond things permanently together. Adhesives have more power for holding and bonding, but sealants are good for air and water tight spaces and as gap fillers. Sealants have lower bonding strength and a higher elongation percentage than adhesives. Sealants are meant to provide a watertight seal, but are easily removable when necessary. Adhesives typically are not meant to be removed.

E. A Tacky Sprayable Polyurethane Cure in Place Sealant

While the embodiments set forth above illustrate a thin gel (gel only or gel with a thin skeleton), sealant or gasket, in some embodiments, with a gasket body having a release film engaged therewith, Applicant may also provide for a sprayable tacky sealant that comes in a two-part cartridge 102 for use with a pneumatic gun 104 (see WO 2017/172906 entitled “A Clear Sprayable Sealant for Aircraft Parts and Assemblies”; see also PCT/US2017/024735, incorporated herein by reference).

FIG. 10A (FIG. 11 in the '906 International Publication) shows pneumatic gun 104 that has engaged therewith a two-body cartridge. The cartridge is fitted into the pneumatic gun and air pressure forces the two separate parts of the gel components (typically a polyol and diisocynate) to mix in the mixing nozzle 104a and to be emitted from the tip of the nozzle in an atomized, uncured polyurethane spray. Such a polyurethane spray can be used to spray a workpiece, which may have a flat section or may include a gap. The workpiece may be masked off, which workpiece can then be used as one part of the two-part joint, which two parts of a joint “sandwich” the thin tacky gel spray-on layer therebetween, and which two pieces may be held under compression as with the use of fasteners. If a gap is present, the pneumatic spray gun may be moved closer to fil the gaps with thicker gel. Any overspray beyond the two parts under compression may be removed with a clean, alcohol soaked cloth. The sealant is a cure-in-place tacky gel, which may or may not be clear, created from a two-part polymer mix applied with a pneumatic mix and spray gun. It may be applied as thin gel (12 mil or less thick) or thicker—up to 50 mil in some applications. The two parts are kept separate until application where they mix in the mixing nozzle 104a, may be used to form a gasket or sealant that is gel only and in the thickness ranges disclosed herein. In addition, the workpiece, prior to spraying, may be overlaid with a skeleton (metallic or non-metallic, any skeleton disclosed herein), which may be taped or otherwise fixed in place, and upon which the spray can be applied (see FIG. 10B). When the mix sets up to form a tacky gel, it will hold the skeleton and a second piece may be fastened to it. Applicant's spray mix may be used between faying surfaces and as a gap filler on laminated composites or metal structures, including mixed composite/metal joints. FIG. 10C illustrates the use of the tacky spray on a pitted surface, such as pits caused by corrosion on a part, on which the sprayable gel has been applied as a pit filler. A flat cover or second part may be applied and the inherent tack may hold the part in place. Or, fasteners may be used, with little or no compression generated. One two-part cartridge that may be used to apply the two-part sprayable is Part Number CS-5410-1 available from KBS Chemical, Dodd City, Tex.

Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. On the contrary, various modifications of the disclosed embodiments will become apparent to those skilled in the art upon reference to the description of the invention. It is therefore contemplated that the appended claims will cover such modifications, alternatives, and equivalents that fall within the true spirit and scope of the invention.

Claims

1. A device for use on an aircraft assembly, the aircraft assembly having a first part having an inner face portion; a second part having an inner face portion; and a multiplicity of fasteners for joining the two parts, the device comprising:

a sealant for placement between the two inner face portions, the sealant comprising a tacky, deformable body of polyurethane gel, the body with tacky outer faces wherein the body has a thickness of 12 mil or less uncompressed;

further comprising a skeleton configured with many openings, the skeleton encapsulated in the body and the skeleton having an uncompressed thickness of 12 mil or less.

2. The device of claim 1, wherein the body has a thickness of between about 1-6 mil when compressed between the two parts.

3. The device of claim 1, wherein the polyurethane gel is cured.

4. The device of claim 1, wherein the assembly is a lap joint, a double, a patch, a heat shield or include electronic equipment.

5. The device of claim 1, wherein the tacky body is deposited on one or both of the first or second part by a pneumatic spray gel.

6. The device of claim 1, wherein the body is pre-cured before placement on one of the two inner face portions.

7. The device of claim 1, wherein the body cures after placement on one of the two inner face portions.

8. The device of claim 1, further comprising a release film.

9. The device of claim 1, wherein the skeleton is a woven mesh.

10. The device of claim 1, wherein the skeleton is metallic.

11. The device of claim 1, wherein the skeleton is non-metallic.

12. The device of claim 1, wherein the skeleton is molded or extruded polyamide or polypropylene.

13. An aircraft having a fuselage, the fuselage comprising:

multiple panels which overlap partially, the overlaps comprising multiple lap joints; wherein the lap joints comprise facing surfaces, the facing surfaces having a thin, tacky, cured, deformable, resilient polyurethane gasket for compression therebetween.

14. The fuselage of claim 13, wherein the compressed gasket thickness is less than about 6 mil.

15. The fuselage of claim 13, wherein the gasket includes a skeleton.

16. A method of joining two adjacent parts on an aircraft, the method comprising the steps of:

obtaining a thin gasket assembly comprising a cured polyurethane gel body gasket or tape having a first, tacky side and a second tacky side, the gasket assembly comprising a release film on one of the sides;

applying the first side to an inner face of one of the two parts;

positioning an inner face of the other of the two parts adjacent the gasket or tape;

removing the release film from the second side of the gasket before the following step; and, joining the parts with fasteners.

17. A method of manufacturing a thin gasket having a tacky polyurethane gel body, the method comprising the steps of:

providing a release film that has been to easily release from a cured tacky polyurethane gel body;

applying an uncured mix of the gel to the adapted release film to a thickness of about 12 mil or less; and

allowing the uncured mix to cure.

18. The method of claim 17, wherein the release film of the providing step has multiple perforations therethrough.

19. The method of claim 17, wherein the release film of the providing step is at least partly coated with release agent.

20. The method of claim 17, wherein the release film of the providing step is meltable.

21. A sealant for use with an aircraft having a first part and a second part connected with fasteners, the sealant consisting essentially of:

a sealant for receipt between the parts of the aircraft, the sealant comprising a resilient, cured, deformable, polyurethane body having a tacky polyurethane upper surface and a tacky polyurethane lower surface; and

at least one release film for placement against at least one of the upper or lower surfaces of the body, the release film for removal from the body before placement of the sealant on an aircraft part.

22. The sealant of claim 21, wherein the body has an uncompressed thickness of less than 12 mil.

23. The sealant of claim 21, wherein the body has an uncompressed thickness of between 2 and 12 mil.

24. The sealant of claim 21, wherein the body has a compressed thickness of between about 1-6 mil.

25. The sealant of claim 21, further including a temporary tack decreasing agent on at least one of the upper or lower surface of the body.

26. The device of claim 21, wherein the at least one release film is one release film on one of the upper or lower surface of the sealant and a second release film on the other of the upper or lower surface of the sealant.

27. The device of claim 21, wherein the release film has multiple small perforations.

28. The device of claim 21, wherein the release film is dissolvable in a liquid.

29. The device of claim 21, wherein the release film is heat meltable.

30. The device of claim 21, wherein the release film is an FEP (fluorinated ethylene propylene) sheet.

31. The device of claim 21, wherein the release film is plastic.

32. The device of claim 21, wherein an inert agent is applied to a surface of the release film which engages the sealant.

33. A method of joining with multiple fasteners, adjacent, inner and outer overlapping panels of an aircraft fuselage, the panels having fastener holes, the method comprising the steps of:

obtaining a sealant tape comprising a thin, cured, tacky polyurethane gel body having a first, tacky polyurethane surface and a release film on a second cured tacky polyurethane surface;

applying the first, tacky polyurethane surface of the body to an outer edge of one of either the inner panel or the outer panel of the overlapping panels;

positioning the outer edge of the other panel of the overlapping panels adjacent the sealant tape such that an overlap width approximates a sealant tape width;

removing the release film from the second surface of the sealant tape; and

joining the panels with the fasteners so the edges hold the polyurethane gel body under sufficient compression to cause some deformation of the polyurethane gel.

34. The method of claim 33, further comprising the step of:

applying an uncured mix of polyurethane gel proximate the fasteners.

35. The method of claim 33, wherein the release film of the providing step has multiple perforations therethrough.

36. The method of claim 33, wherein the release film of the providing step is at least partly coated with release agent.

37. The method of claim 33, wherein the release film of the providing step is meltable.

38. The method of claim 33, wherein the release film is plastic.

39. The method of claim 33, wherein the release film is dissolvable.

40. The method of claim 33, further including the step of, prior to the joining step, covering at least partly the first surface with a temporary tack release agent.

41. The method of claim 33, wherein the uncompressed thickness of the sealant tape is about 12 mil or less and the compressed thickness is between about 1-6 mil.

42. A device for use with an aircraft assembly having a first part and a second part, and fasteners, for applying compression to the two parts, the device comprising:

a sealant for receipt between the parts of the aircraft, the sealant comprising a resilient, cured, deformable, skeleton-free, polyurethane body having a tacky polyurethane upper surface and a tacky polyurethane lower surface; and

a skeleton between 1-12 mm thick, the skeleton covered and encapsulated in the polyurethane body.