Premixed and frozen seal caps

• US 20030071421A1
• Filed: 09/26/2002
• Published: 04/17/2003
• Est. Priority Date: 09/28/2001
• Status: Active Grant

• Current Assignee: PRC-DeSoto International, Inc. (Nouryon BV)
• Original Assignee: PRC-DeSoto International, Inc. (Nouryon BV)
• Inventors: Obuhowich, George
• Granted Patent: US 7,438,974 B2
• Time in Patent Office: Days
• US Class Current: 277/316
• CPC Class Codes: C09K 3/1012 Sulfur-containing polymers, e.g. polysulfides
• CPC Class Codes: F16B 33/004 Sealing; Insulation by means of washers F16B43/001
• CPC Class Codes: F16B 37/14 Cap nuts; Nut caps or bolt caps
• CPC Class Codes: Y10T 428/2813 Heat or solvent activated or sealable

Abstract

A sealant, method for making the sealant, and method for applying the sealant includes a preformed at least partially hardened first quantity of sealant and a preformed at least partially unhardened second quantity of sealant. The first quantity of sealant is formed into a concave shell with an internal cavity. The second quantity of sealant is positioned within the internal cavity of the shell. The second quantity of sealant is maintained at a temperature sufficiently below the hardening temperature of the second sealant, such that said second sealant is at least partially retarded from hardening. The first and second quantities of sealant are packaged together for delivery to a substrate, such as a fastener.

Claims

1. A sealant comprising:

a preformed at least partially hardened first quantity of sealant; and

a preformed at least partially unhardened second quantity of sealant, wherein said first quantity of sealant and said second quantity of sealant comprise the same composition.

2. A sealant according to claim 1, wherein:

said first quantity of sealant comprises a concave shell comprising an internal cavity, said second quantity of sealant is positioned within said cavity.

3. A sealant according to claim 1, wherein:

said second quantity of sealant is at a temperature sufficiently below the hardening temperature of said second quantity of sealant, such that said second quantity of sealant is at least partially retarded from hardening.

4. A sealant according to claim 1, wherein:

said second quantity of sealant is inhibited from oxidizing, such that said second quantity of sealant is at least partially retarded from hardening.

5. A sealant according to claim 1, wherein:

said first quantity of sealant and said second quantity of sealant are packaged together for delivery to a substrate.

6. A sealant according to claim 5, wherein:

said substrate comprises a fastener.

27. A sealant according to claim 1, wherein:

said sealant comprises of at least one sealant chosen from PS-890®

, PR-1440®

, AC-236®

, and AC-250®

.

28. A sealant according to claim 1, wherein:

said sealant comprises PR-1776®

.

7. A method for making a sealant comprising:

obtaining a first quantity of sealant;

at least partially hardening said first quantity of sealant;

contacting a second quantity of sealant with said first quantity of sealant; and

maintaining said second quantity of sealant at least partially unhardened.

8. A method for making a sealant according to claim 7, wherein:

maintaining said second quantity of sealant at least partially unhardened further comprises thermally regulating said second quantity of sealant at a temperature sufficiently below its hardening temperature to at least partially retard hardening of said second quantity of sealant.

9. A method for making a sealant according to claim 7, wherein:

maintaining said second quantity of sealant at least partially unhardened further comprises inhibiting said second quantity of sealant from oxidizing to at least partially retard hardening of said second quantity of sealant.

10. A method for making a sealant according to claim 7, wherein:

at least partially hardening said first quantity of sealant further comprises compressing said first quantity of sealant to a predetermined thickness.

11. A method for making a sealant according to claim 10, wherein:

compressing said first quantity of sealant further comprises forming said first quantity of sealant into a concave shell having an internal cavity; and

contacting said second quantity of sealant further comprises positioning said second quantity of sealant into said cavity.

12. A method for making a sealant comprising:

obtaining a first quantity of partially unhardened sealant formed as a concave shell comprising an internal cavity;

at least partially hardening said first quantity of sealant;

positioning a second quantity of sealant within said cavity; and

thermally regulating said second quantity of sealant at a temperature sufficiently below its hardening temperature to at least partially retard hardening of the second quantity of sealant.

13. A method for making a sealant according to claim 12, further comprising:

thermally regulating said first quantity of sealant.

14. A method for making a sealant according to claim 12, wherein:

said first quantity of sealant is formed by molding, said molding comprising using an injection-filled mold.

15. A method for making a sealant according to claim 12, wherein:

forming said concave shell further comprises using male and female molds.

16. A method for making a sealant according to claim 15, wherein:

forming said concave shell further comprises shaping the shell at the interface between the male and female molds.

17. A method for making a sealant according to claim 16, wherein:

said means removes an excess amount of said first quantity of sealant forming a clean edge for said cavity.

18. A method for making a sealant according to claim 15, wherein:

forming said concave shell further comprises contacting with a film, said film comprising at least one component chosen from ethanoate, butanoate, pentanoate, hexanoate, and other flexible materials to which said sealant adheres.

19. A method for making a sealant according to claim 12, further comprising:

packaging said sealant to at least partially inhibit moisture from contacting said first quantity and said second quantity of sealant.

20. A method for making a sealant according to claim 12, wherein:

said temperature has a minimum of −

75°

C.

21. A method for making a sealant according to claim 12, wherein:

said temperature has a maximum of −

55°

C.

22. A method for making a sealant according to claim 12, wherein:

said temperature is approximately −

45°

C.

23. A method for making a sealant according to claim 12, wherein:

said temperature ranges from −

100°

C. to −

25°

C.

24. A method for making sealant comprising:

obtaining a first quantity of sealant formed as a concave shell using male and female molds;

separating said male and female molds with a film comprising at least one material chose from ethanoate, butanoate, pentanoate, hexanoate, and other flexible materials to which said sealant adheres;

at least partially hardening said first quantity of sealant;

removing said film and an excess amount of said first quantity of sealant that contacts said film;

at least partially filling said concave shell with a second quantity of sealant;

thermally regulating said second quantity of sealant at a temperature sufficiently below its hardening temperature to at least partially retard hardening of the second quantity of sealant; and

packaging said sealant to at least partially inhibit moisture from contacting said second quantity of sealant.

25. A method for applying a sealant to a substrate comprising:

obtaining a preformed sealant at a temperature sufficient to at least partially retard hardening of the sealant;

exposing said sealant to temperature sufficient to at least partially harden said sealant; and

contacting said sealant with said substrate.

26. A method for applying a sealant to a substrate according to claim 25, wherein:

exposing said sealant further comprises thermally regulating the sealant temperature to be maintained at a temperature sufficient to at least partially harden the sealant.