Abstract: A fabric and elastomeric material (referred to as a fabric trilayer) combined with a sealant may be applied in such a fashion so as to eliminate or minimize air entrapment in an elastomeric composite structure that forms a seal-sealing volume. The performance of the self-sealing volume is dramatically improved with this minimizing of air entrapment. Surprisingly and unexpectedly, this construction approach may be accomplished without significantly adding to the weight or thickness of the volume and without affecting the outer dimension of the self-sealing volume. Thus, a method and system for forming a self-sealing volume are described. The system includes an elastomeric composite structure comprising at least one layer of an elastomeric material derived from a neat (no solvent) elastomeric material that does not substantially react at room temperature.

Abstract: A method and system for forming a self-sealing volume includes an elastomeric composite structure. The structure includes layers of a cast polyurethane derived from a neat polyurethane monomer reaction mixture that does not substantially react at room temperature. The polyurethane monomer reaction layer includes a reaction product of an organic polyisocyanate and a reactive hydrogen-containing material reacted with a mixture of a monomeric polyol and polymeric polyols. The structure may further include one or more layers of a fabric that have been precoated with an aliphatic polyurethane, and one or more sealing layers. A fuel impermeable inner liner may be positioned in an inner region. The sealing layers may comprise at least one of partially vulcanized natural rubber (NR), polyisoprene (IR), styrene butadiene (SBR), or a blend of SBR with NR or IR. A dimensionally correct, self-sealing volume may be created by inflating the volume during its cure.