Method and apparatus for welding a fluoropolymer seam

Abstract

A method for sealing and smoothing a seam produced from applying flexible protective covering sheets of a fluoropolymer to a hull of a marine craft, thus forming a protective fluoropolymer film on the hull. The method comprises placing a thread of fluoropolymer caulk onto the seam produced from applying the flexible protective covering sheets and 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. The method includes smoothing the melted fluoropolymer caulk to produce a smooth seam with a sealed and smooth surface.

1 . A method for sealing and smoothing a seam produced from applying flexible protective covering sheets of a fluoropolymer to a hull of a marine craft, so as to form a protective film on an exterior of the hull, said method 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.    
   
   
       2 . The method according to  claim 1 , wherein the method comprises: 
 overlapping adjacent edges of adjacent flexible protective covering sheets to produce an overlap seam; and    placing a thread of fluoropolymer caulk onto the overlap seam.    
   
   
       3 . The method according to  claim 1 , wherein the method comprises: 
 butting together butt-cut edges of adjacent flexible protective covering sheets to produce a butt-cut seam; and    placing a thread of fluoropolymer caulk onto the butt-cut seam.    
   
   
       4 . The method according to  claim 1 , wherein the method comprises feeding the thread of fluoropolymer caulk onto the seam from a thread roll apparatus.  
   
   
       5 . The method according to  claim 4 , and further comprising feeding said thread of fluoropolymer caulk from a thread roll apparatus comprising a thread roll spool with spooled fluoropolymer caulk and a thread guide for guiding the thread of fluoropolymer caulk onto the seam.  
   
   
       6 . The method according to  claim 5 , and further comprising heating said fluoropolymer caulk with a heating device.  
   
   
       7 . The method according to  claim 6 , wherein said heating device comprises a soldering iron.  
   
   
       8 . The method according to  claim 1 , wherein said steps of applying sufficient heat and pressure, and smoothing the melted fluoropolymer caulk, comprise applying a soldering iron, an end of the soldering iron having a rollable wheel tip, the rollable wheel tip having a facial surface at the circumference suitably shaped for smoothing the melted fluoropolymer caulk as the wheel tip is rolled across the seam, applying sufficient heat and pressure through said rollable wheel tip to melt and weld the fluoropolymer caulk with the fluoropolymer of the flexible protective covering sheets.  
   
   
       9 . The method according to  claim 1 , wherein said steps of applying sufficient heat and pressure, and smoothing the melted fluoropolymer caulk, comprise applying a soldering iron, an end of the soldering iron having a chisel tip, the chisel tip suitably shaped for smoothing the melted fluoropolymer caulk as the chisel tip is moved across the seam, applying sufficient heat and pressure through said chisel tip to melt and weld the fluoropolymer caulk with the fluoropolymer of the flexible protective covering sheets.  
   
   
       10 . The method according to  claim 1 , wherein the fluoropolymer caulk comprises Fluorinated Ethylene Propylene (FEP) and the flexible protective covering sheets comprise Ethylene Tetrafluoroethylene (ETFE), and the sufficient heat has a temperature of at least approximately 500 degrees Fahrenheit (F.) and an upper bound of approximately 550 degrees Fahrenheit (F.).  
   
   
       11 . A method for sealing and smoothing a seam produced from applying flexible protective covering sheets of a fluoropolymer to a hull of a marine craft, thus forming a protective film on an exterior of the hull, said method 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.    
   
   
       12 . The method according to  claim 11 , wherein the method comprises applying sufficient heat and pressure to an overlap seam produced from overlapping edges of adjacent flexible protective covering sheets.  
   
   
       13 . The method according to  claim 11 , wherein the method comprises applying sufficient heat and pressure to a butt-cut seam produced from butting together butt-cut edges of adjacent flexible protective covering sheets.  
   
   
       14 . The method according to  claim 11 , wherein said steps of applying sufficient heat and pressure, and smoothing the melted seam, comprise applying a soldering iron, an end of the soldering iron having a rollable wheel tip, the rollable wheel tip having a facial surface at the circumference suitably shaped for smoothing the melted fluoropolymer of the seam as the wheel tip is rolled across the seam, applying sufficient heat and pressure through the rollable wheel tip to melt and weld together the fluoropolymer of the seam.  
   
   
       15 . The method according to  claim 11 , wherein said steps of applying sufficient heat and pressure, and smoothing the melted seam, comprise applying a soldering iron, an end of the soldering iron having a chisel tip, the chisel tip suitably shaped for smoothing the melted fluoropolymer of the seam as the chisel tip is moved across the seam, applying sufficient heat and pressure through the chisel tip to melt and weld together the fluoropolymer of the seam.  
   
   
       16 . The method according to  claim 11 , wherein the flexible protective covering sheets comprise Ethylene Tetrafluoroethylene (ETFE), and the sufficient heat has a temperature of at least approximately 500 degrees Fahrenheit (F.) and an upper bound of approximately 550 degrees Fahrenheit (F.).  
   
   
       17 . A protected marine craft hull, 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.    
   
   
       18 . The protected marine craft hull of  claim 17 , wherein the seam comprises overlapping edges of adjacent flexible fluoropolymer covering sheets.  
   
   
       19 . The protected marine craft hull of  claim 17 , wherein the seam comprises butt-cut edges of adjacent flexible fluoropolymer covering sheets butted together.  
   
   
       20 . The protected marine craft hull of  claim 17 , wherein the flexible fluoropolymer covering sheets comprise Ethylene Tetrafluoroethylene (ETFE), and the sufficient heat has a temperature of at least approximately 500 degrees Fahrenheit (F.) and an upper bound of approximately 550 degrees Fahrenheit (F.).  
   
   
       21 . The protected marine craft hull of  claim 17 , wherein the seam has a smooth and sealed surface produced by first placing a thread of fluoropolymer caulk onto the seam and then applying sufficient heat and pressure at the seam to melt and weld the fluoropolymer caulk with the fluoropolymer of the flexible fluoropolymer covering sheets.  
   
   
       22 . The protected marine craft hull of  claim 21 , wherein the flexible fluoropolymer covering sheets comprise Ethylene Tetrafluoroethylene (ETFE), the thread of fluoropolymer caulk comprises Fluorinated Ethylene Propylene (FEP), and the sufficient heat has a temperature of at least approximately 500 degrees Fahrenheit (F.) and an upper bound of approximately 550 degrees Fahrenheit (F.).  
   
   
       23 . An apparatus 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.    
   
   
       24 . The apparatus of  claim 23 , wherein the heating device is a soldering iron, an end of the soldering iron having a rollable wheel tip for applying the heat and pressure to the fluoropolymer seam.  
   
   
       25 . The apparatus of  claim 23 , wherein the heating device is a soldering iron, an end of the soldering iron having a chisel tip for applying the heat and pressure to the fluoropolymer seam.  
   
   
       26 . The apparatus of  claim 23  and further 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.    
   
   
       27 . An apparatus 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.    
   
   
       28 . The apparatus of  claim 27 , wherein the flexible heat strap is coupled to a piston, the piston being movable to alter the configuration of the flexible heat strap to a flat surface, a concave surface, or a convex surface, as desired.  
   
   
       29 . An apparatus for sealing the seam between two abutting sheets of fluoropolymer film, said 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.    
   
   
       30 . An apparatus 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.    
   
   
       31 . The apparatus of  claim 30 , further comprising a trowel member for spreading the fluoropolymer caulk on the seam after dispensing.  
   
   
       32 . The apparatus of  claim 30 , wherein the glue gun apparatus pre-heats the fluoropolymer caulk to a temperature of at least approximately 500 degrees Fahrenheit (F.).  
   
   
       33 . The apparatus of  claim 30 , further comprising a guide adapter for use with a flexile guide rail apparatus for guiding the heating device and the glue gun apparatus along the seam.  
   
   
       34 . A flexible guide rail apparatus, 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.    
   
   
       35 . The flexible guide rail apparatus of  claim 34  and further comprising a sliding carriage coupled to the flexible guide rail strip and configured to slide along the flexible guide rail strip.  
   
   
       36 . The flexible guide rail apparatus of  claim 35 , wherein the sliding carriage is configured to hold a heating device for applying heat and pressure to a fluoropolymer seam.  
   
   
       37 . The flexible guide rail apparatus of  claim 36 , wherein the heating device is a soldering iron.  
   
   
       38 . The flexible guide rail apparatus of  claim 36 , wherein the heating device is a glue gun apparatus.  
   
   
       39 . The flexible guide rail apparatus of  claim 35 , wherein the sliding carriage is configured to hold a knife an adjustable distance for cutting a fluoropolymer film.  
   
   
       40 . The flexible guide rail apparatus of  claim 34 , wherein the flexible guide rail strip may be coupled to another flexible guide rail strip to extend a length of the flexible guide rail strip.  
   
   
       41 . The flexible guide rail apparatus of  claim 34 , wherein the at least one of a plurality of suction cups is configured to be removable from the flexible guide rail strip.  
   
   
       42 . The flexible guide rail apparatus of  claim 34 , wherein the at least one of a plurality of suction cups is configured to allow diminishing of suction pressure in order to move the at least one of a plurality of suction cups to realign the flexible guide rail strip.  
   
   
       43 . The flexible guide rail apparatus of  claim 34 , wherein the flexible guide rail strip is configured with a laser to produce a visible laser beam to assist a user in guiding the heating device along a fluoropolymer seam.  
   
   
       44 . A glue gun apparatus for applying a pre-heated fluoropolymer caulk to a fluoropolymer seam to form a seam having a smoothly sealed surface, comprising: 
 a glue gun having a guide adapter, the guide adapter configured to be coupled to a sliding carriage of a flexible guide rail apparatus; and    the glue gun having a trowel member for spreading the pre-heated fluoropolymer caulk as the fluoropolymer caulk is dispensed from the glue gun.    
   
   
       45 . The glue gun apparatus of  claim 44 , wherein the glue gun has a laser configured to produce a laser light onto the seam to assist a user of the glue gun in guiding the glue gun along the seam.  
   
   
       46 . The apparatus of  claim 23  and further comprising a laser configured to produce a laser light onto the seam to assist a user of the apparatus in guiding the apparatus along the seam.