Sealant assemblies and methods

Abstract

Sealant assemblies and methods are provided for sealing an interface between a surface and a projection extending from the surface. The sealant assembly includes a body portion circumscribing an area to form a sealant pocket and a filling sealant at least partially filling the sealant pocket. The filling sealant and the body portion comprise substantially the same material.

1 . A sealant assembly for sealing an interface between a surface and a projection extending from the surface, the sealant assembly comprising: 
 a body portion circumscribing an area to form a sealant pocket; and    a filling sealant at least partially filling the sealant pocket, wherein the filling sealant and the body portion comprise substantially the same material.    
   
   
       2 . The sealant assembly of  claim 1 , wherein the body portion comprises a plurality of corner elements adapted to at least partially circumscribe the area to form the sealant pocket.  
   
   
       3 . The sealant assembly of  claim 2 , wherein each corner element includes a first extension arm with a first end portion including a tongue and a second extension arm with a second end portion including a groove.  
   
   
       4 . The sealant assembly of  claim 2 , wherein each corner element includes 
 a first extension arm extending along a first extension axis, the first extension arm including a first end portion with a first substantially flat surface that is substantially perpendicular to the first extension axis; and    a second extension arm extending along a second extension axis, the second extension arm including a second end portion with a second substantially flat surface that is substantially perpendicular to the second extension axis.    
   
   
       5 . The sealant assembly of  claim 2 , wherein the body portion further comprises at least a pair of intermediate segments, wherein the corner elements and the intermediate segments at least partially circumscribe the area to form the sealant pocket.  
   
   
       6 . The sealant assembly of  claim 1 , wherein the same material comprises a polymer material.  
   
   
       7 . The sealant assembly of  claim 6 , wherein the polymer material comprises a polyurethane material.  
   
   
       8 . The sealant assembly of  claim 6 , wherein the polymer material comprises a polyurea material.  
   
   
       9 . The sealant assembly of  claim 1 , wherein the filling sealant is integrally bonded to the body portion at an interface between the filling sealant and the body portion.  
   
   
       10 . A method of sealing an interface between a surface and a projection extending from the surface comprising the steps of: 
 positioning a body portion on the surface with the body portion circumscribing the projection and the projection extending through a sealant pocket defined by the body portion and the surface; and    adding a filling sealant into the sealant pocket, wherein the filling sealant subsequently solidifies such that the body portion and the solidified filling sealant form a solid sealant assembly with the body portion and the solidified filling sealant comprising substantially the same material.    
   
   
       11 . The method of  claim 10 , further comprising the step of providing the body portion with a plurality of corner elements and wherein the step of positioning the body portion comprises positioning the plurality of corner elements to at least partially circumscribe the projection.  
   
   
       12 . The method of  claim 10 , further comprising the step of providing the body portion with a plurality of corner elements that each include a first extension arm with a first end portion including a tongue and a second extension arm with a second end portion including a groove, wherein the step of positioning the body portion comprises positioning the tongue of each corner element within the groove of another corner element.  
   
   
       13 . The method of  claim 10 , further comprising the step of providing the body portion with a plurality of corner elements that each include a first extension arm extending along a first extension axis, the first extension arm including a first end portion with a first substantially flat surface that is substantially perpendicular to the first extension axis and a second extension arm extending along a second extension axis, the second extension arm including a second end portion with a second substantially flat surface that is substantially perpendicular to the second extension axis, wherein the step of positioning the body portion comprises attaching the first substantially flat surface of each corner element with the second substantially flat surface of another corner element.  
   
   
       14 . The method of  claim 10 , further comprising the step of providing the body portion with a plurality of corner elements and at least a pair of intermediate segments, wherein the step of positioning the body portion comprises positioning the corner elements and the intermediate segments to at least partially circumscribe the area to form the sealant pocket.  
   
   
       15 . The method of  claim 10 , wherein the same material comprises a polymer material.  
   
   
       16 . The method of  claim 10 , wherein the step of adding a filling sealant into the sealant pocket results in an integral bond of the filling sealant to the body portion at an interface between the filling sealant and the body portion.  
   
   
       17 . A sealant assembly comprising a body portion circumscribing an area to form a sealant pocket and a solidified filling sealant within the area and filling at least a portion of the sealant pocket, the sealant assembly formed by a process including the steps of: 
 positioning the body portion on a surface with the body portion circumscribing a projection extending from the surface;    adding a filling sealant into the sealant pocket, wherein the filling sealant is substantially contained within the sealant pocket; and    permitting the filling sealant to solidify such that the body portion and the solidified filling sealant form a solid sealant assembly with the body portion and the solidified filling sealant comprising substantially the same material.    
   
   
       18 . The method of  claim 17 , further comprising the step of providing the body portion with a plurality of corner elements and wherein the step of positioning the body portion comprises positioning the plurality of corner elements to at least partially circumscribe the projection.  
   
   
       19 . The method of  claim 17 , further comprising the step of providing the body portion with a plurality of corner elements that each include a first extension arm extending along a first extension axis, the first extension arm including a first end portion with a first substantially flat surface that is substantially perpendicular to the first extension axis and a second extension arm extending along a second extension axis, the second extension arm including a second end portion with a second substantially flat surface that is substantially perpendicular to the second extension axis, wherein the step of positioning the body portion comprises attaching the first substantially flat surface of each corner element with the second substantially flat surface of another corner element.  
   
   
       20 . The method of  claim 17 , further comprising the step of providing the body portion with a plurality of corner elements and at least a pair of intermediate segments, wherein the step of positioning the body portion comprises positioning the corner elements and the intermediate segments to at least partially circumscribe the area to form the sealant pocket.  
   
   
       21 . The method of  claim 17 , wherein the same material comprises a polymer material.  
   
   
       22 . The method of  claim 17 , wherein the step of adding a filling sealant into the sealant pocket results in an integral bond of the filling sealant to the body portion at an interface between the filling sealant and the body portion.