Thermal Spray Plastic Coating for Edge Sealing and Fillet Sealing

Abstract

Tunable thermoplastic polymer sealants and tunable conductive thermoplastic polymer sealants, and edge seals and fillet seals produced from such sealants; and substrates, components and objects comprising the tunable edge seals and fillet seals, and methods for making and applying such edge seals and fillet seals are disclosed.

What is claimed is: 
     
         1 . An assembly comprising:
 a first substrate;   a second substrate, at least one of said first substrate and second substrate comprising at least one first substrate edge and at least one second substrate edge; and said second substrate located proximate to the first substrate to form a substrate interface between the first substrate and the second substrate; and   a high velocity spray-deposited thermoplastic polymer sealant configured to form a thermoplastic polymer seal at the substrate interface, said high velocity spray-deposited thermoplastic polymer sealant comprising a density ranging from about 1.0 to about 1.8 g/cc.   
     
     
         2 . The assembly of  claim 1 , wherein the high velocity spray-deposited thermoplastic polymer sealant comprises at least one thermoplastic polymer, said thermoplastic polymer comprising at least one of: nylon, polyetheretherketone, polyetherketoneketone, polyamide, polyphenylsulfide, polyphenylsulfone, polysulfone, and polyetheramide. 
     
     
         3 . The assembly of  claim 1 , wherein the high velocity spray-deposited thermoplastic polymer sealant further comprises:
 a conductive material comprising at least one of: titanium, nickel alloy, copper, carbon black, graphene powder, and carbon nanotubes.   
     
     
         4 . The assembly of  claim 1 , wherein the high velocity spray-deposited thermoplastic polymer sealant has a tunable Young's modulus ranging from about 1 Mpa to about 4 GPa. 
     
     
         5 . The assembly of  claim 3 , wherein the high velocity spray-deposited thermoplastic polymer sealant has a tunable resistivity value ranging from about 1×10 5  to about 1×10 8  ohm-m. 
     
     
         6 . The assembly of  claim 1 , wherein the high velocity spray-deposited thermoplastic polymer seal comprises at least one of: a fillet seal and an edge seal. 
     
     
         7 . An object comprising the assembly of  claim 1 . 
     
     
         8 . The object of  claim 7 , wherein the object is a vehicle selected from the group consisting of: a manned aircraft; an unmanned aircraft; a manned spacecraft; an unmanned spacecraft; a manned rotorcraft; an unmanned rotorcraft; a manned terrestrial vehicle; an unmanned terrestrial vehicle; a unmanned terrestrial vehicle; a manned surface water borne vehicle; an unmanned surface water borne vehicle; a manned sub-surface water borne vehicle and an unmanned sub-surface water borne vehicle. 
     
     
         9 . An object comprising the assembly of  claim 3 . 
     
     
         10 . The object of  claim 9 , wherein the object is a vehicle, said vehicle selected from the group consisting of: a manned aircraft; an unmanned aircraft; a manned spacecraft; an unmanned spacecraft; a manned rotorcraft; an unmanned rotorcraft; a manned terrestrial vehicle; a unmanned terrestrial vehicle; a unmanned terrestrial vehicle; a manned surface water borne vehicle; an unmanned surface water borne vehicle; a manned sub-surface water borne vehicle and an unmanned sub-surface water borne vehicle. 
     
     
         11 . A high velocity spray-deposited thermoplastic polymer sealant, the sealant comprising:
 a thermoplastic polymer comprising at least one of: nylon, polyetheretherketone, polyetherketoneketone, polyamide, polyphenylsulfide, polyphenylsulfone, polysulfone, and polyetheramide.   
     
     
         12 . The high velocity spray deposited thermoplastic polymer sealant of  claim 11 , further comprising:
 a conductive material comprising at least one of: titanium, nickel alloy, copper, carbon black, graphene powder, or carbon nanotubes.   
     
     
         13 . The high velocity spray deposited thermoplastic polymer sealant of  claim 11 , wherein the sealant has a tunable Young's modulus ranging from about MPa to about 4 GPa. 
     
     
         14 . The high velocity spray deposited thermoplastic polymer sealant of  claim 12 , wherein the thermoplastic polymer sealant has a tunable resistivity value ranging from about 10 5  to about 1×10 8  ohm-m. 
     
     
         15 . The high velocity spray deposited thermoplastic polymer sealant of  claim 11 , wherein the thermoplastic polymer sealant comprises a tunable density ranging from about 1.0 to about 1.8 g/cc. 
     
     
         16 . The high velocity spray deposited thermoplastic polymer sealant of  claim 12 , wherein the thermoplastic polymer sealant comprises a tunable density ranging from about 1.0 to about 1.8 g/cc. 
     
     
         17 . A seal comprising the high velocity spray deposited thermoplastic polymer sealant of  claim 15 . 
     
     
         18 . A seal comprising the high velocity spray deposited thermoplastic polymer sealant of  claim 16 . 
     
     
         19 . The seal of  claim 17 , wherein the seal comprises at least one of: a fillet seal and an edge seal. 
     
     
         20 . The seal of  claim 18 , wherein the seal comprises at least one of: a fillet seal and an edge seal.