| Method and apparatus for welding a fluoropolymer seam -> Monitor Keywords |
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Method and apparatus for welding a fluoropolymer seamRelated Patent Categories: Ships, Boats, Boat Component, Or Attachment, Hull Construction, PlasticMethod and apparatus for welding a fluoropolymer seam description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060219151, Method and apparatus for welding a fluoropolymer seam. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] The present invention relates generally to applying flexible protective covering sheets of a fluoropolymer to a hull of a marine craft and more particularly, to smoothing and sealing the seams produced from applying the flexible protective covering sheets. BACKGROUND OF THE INVENTION [0002] The novel subject matter provided herein discloses an improvement to the subject matter of U.S. Pat. No. 5,769,019 (Inventor: Luis F. Dias da Silva, Date of Patent: Jun. 23, 1998) which is hereby incorporated by reference in its entirety. [0003] Hulls of marine craft may develop marine growth and inorganic deposits when left in water for long periods of time. Not only is the aesthetic beauty of the marine craft affected, but the deposits may add to the overall weight and increase the friction or resistance between the hull and the water as the craft travels through the water. An increased drag resistance and weight may decrease the speed of the marine craft and thus impact the performance of the marine craft. The da Silva patent describes flexible protective covering sheets composed of a fluoropolymer applied to the hull of the marine craft, the covering sheets having one side with an adhesive for adhering to the hull. [0004] The da Silva patent describes a solution wherein the fluoropolymer used for the flexible protective covering sheets is polytetrafluoroethylene (PTFE). Although PTFE has a drag resistance lower than other fluoropolymers, PTFE is relatively soft and easily damaged. A fluoropolymer which better withstands salt spray and abrasion, while still providing an extremely low coefficient of friction, is ethylene tetrafluoroethylene (ETFE). A second best performing fluoropolymer is fluorinated ethylene propylene (FEP), which offers a slightly improved coefficient of friction over ETFE, but is not as hard and does not withstand wear or abrasion as well as ETFE. Although the patent by da Silva suggests using PTFE as the fluoropolymer in the flexible protective covering sheets, ETFE provides a better choice. ETFE is harder and less easily damaged than PTFE. [0005] Although the patent of da Silva discloses applying flexible protective covering sheets of fluoropolymer to the hull of a marine craft, the seaming methodology described is different and results in an ineffective seam. The seams produced from the application of the flexible protective covering sheets still provide some drag resistance to the overall performance of the marine craft. The patent by da Silva suggests use of a caulk to fill the seams. However, the property of a fluoropolymer that prevents adhesion of contaminants, such as marine growth and inorganic deposits, to the hull also prevents a caulk from sticking to the hull very well. Seams created by butting two sheets of fluoropolymer film against each other must be absolutely flush to provide the expected anti-fouling qualities while maintaining the integrity of the seam and sheets of film. Any gap in the seam creates a point of entry for marine life to attack the underlying hull and attach themselves chemically to the boat. The method described in daSilva for applying a caulk to the hull will not fill the seam because the caulk will not adhere to the surfaces of the adjoining sheets of fluoropolymer film. The method of creating an overlapping seam using two adjoining pieces of fluoropolymer film is equally flawed. The adhesive on the underside of the overlapping piece of film is not sufficient to permanently adhere the two pieces of film together. While the adhesive will hold the overlap in place, the pressures created on the seam at normal operating speeds will cause the seam to break and the pieces of film to separate from the hull. The seams must be sealed close using heat and pressure alone or in conjunction with a thread of melted fluoropolymer in order to withstand normal operating stresses of direct and back pressure [0006] An improvement is still needed to effectively smooth and seal the seams produced from applying flexible protective fluoropolymer covering sheets to the hull of a marine craft. SUMMARY OF THE INVENTION [0007] In one embodiment, a method is provided for sealing and smoothing a seam produced from applying flexible protective covering sheets of a fluoropolymer to a hull of a marine craft. The seam may be produced by butting the edges of two fluoropolymer covering sheets to each other (a butt-cut seam) or may be produced by overlapping the edges of two fluoropolymer covering sheets (an overlapped seam). A heating device, e.g. a modified soldering iron, or other suitable heating device, is provided either for melting the fluoropolymer of the seam or for applying a melted fluoropolymer caulk to the seam, thus sealing and smoothing the seam. [0008] In another embodiment, a method is provided comprising: placing a thread of fluoropolymer caulk onto the seam produced from applying the flexible protective covering sheets; applying sufficient heat and pressure to the thread of fluoropolymer caulk to melt and weld the fluoropolymer caulk with the fluoropolymer of the flexible protective covering sheets; and smoothing the melted fluoropolymer caulk to produce a smooth seam having a smoothly sealed surface. [0009] In yet another embodiment, a method is provided comprising: applying sufficient heat and pressure to the seam to melt and weld the seam of fluoropolymer of adjacent flexible protective covering sheets; and smoothing the melted seam to produce a smooth seam having a smoothly sealed surface. [0010] In still yet another embodiment, a protected marine craft hull is provided, comprising: a hull having an external portion covered with flexible fluoropolymer covering sheets adhered to the hull; the flexible fluoropolymer covering sheets being arranged with at least two adjacent flexible fluoropolymer covering sheets meeting and forming a seam; and the seam having a smooth and sealed surface produced through an application of sufficient heat and pressure at the seam. [0011] In another embodiment, an apparatus is provided for applying heat and pressure to a fluoropolymer seam to melt and weld the fluoropolymer of the seam into a seam having a smoothly sealed surface, comprising: a heating device having a heating surface suitable for applying the heat and pressure to the fluoropolymer seam; and a thread roll apparatus having a thread roll spool configured to have a spool of fluoropolymer caulk and a thread roll guide for guiding the fluoropolymer caulk onto the fluoropolymer seam. [0012] In another embodiment, an apparatus is provided for applying heat and pressure to a fluoropolymer seam to melt and weld the fluoropolymer of the seam into a seam having a smoothly sealed surface, comprising: a heating surface for heating a portion of a flexible heat strap; and the flexible heat strap configurable to have a shape of at least one of a flat surface, a concave surface, and a convex surface for applying the heat and pressure correspondingly, to at least one of a flat fluoropolymer surface, a convex fluoropolymer surface, and a concave fluoropolymer surface. [0013] In another embodiment, an apparatus for sealing the seam between two abutting sheets of fluoropolymer film is provided, the apparatus comprising: a thread roll apparatus having a thread roll spool configured to have a spool of fluoropolymer caulk; a thread roll guide for guiding the fluoropolymer caulk onto the fluoropolymer seam; a heating apparatus for heating at least a portion of the spool of fluoropolymer caulk; and a trowel member for spreading the fluoropolymer caulk on the seam after dispensing. [0014] In yet another embodiment, an apparatus is provided for applying heat and pressure to a fluoropolymer seam to melt and weld the fluoropolymer of the seam into a seam having a smoothly sealed surface, comprising: a heating device having a heating surface suitable for applying the heat and pressure to the fluoropolymer seam; and a glue gun apparatus for pre-heating a fluoropolymer caulk before application of the fluoropolymer caulk to the seam. [0015] In another embodiment, a flexible guide rail apparatus is provided, comprising: a flexible guide rail strip adapted for guiding a heating device along a fluoropolymer seam; and at least one of a plurality of suction cups fitted to the flexible guide rail strip to allow coupling of the flexible guide rail strip to a surface. DETAILED DESCRIPTION OF THE DRAWINGS [0016] The invention will be more readily understood in view of the following description when accompanied by the below figures and wherein like reference numerals represent like elements. [0017] FIGS. 1A-1C illustrate an example of a method for sealing and smoothing a butt-cut seam produced from applying flexible protective covering sheets of a fluoropolymer to a marine craft hull in accordance with an embodiment of the invention; [0018] FIGS. 2A-2B illustrate an example of a method wherein a thread of fluoropolymer caulk is not used to seal and smooth an overlap seam in accordance with an embodiment of the invention; [0019] FIGS. 3A-3C illustrate an example for sealing and smoothing an overlap seam in accordance with an embodiment of the invention; [0020] FIGS. 4A-4C illustrate an example of a heating device suitable to apply sufficient heat and pressure for a melting and welding process in accordance with an embodiment of the invention; Continue reading about Method and apparatus for welding a fluoropolymer seam... 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