Watertight structures and methods of making the same
This invention is directed to a structure and a method of sealing the structure as it is manufactured. The method uses a combination of thermoplastic sealants in the form of films and a substrate encapsulated tape.
1. A structure comprising an interior and an exterior, selected from the group consisting of recreational vehicle, utility vehicle, trailer, bus, walk-in van, box truck, rail car, ambulance, boat, and shed comprising:
a. a single-sided thermoplastic film tape,
b. a multi-sided thermoplastic tape, and
c. a substrate-encapsulated tape comprising a substrate core encapsulated with a thermoplastic sealant,
wherein a., b., and c., make up greater than 50% by weight of the sealant used to seal the exterior of the structure.
2. The structure of claim 1 wherein a., b., and c., make up at least 75% by weight of the sealant used to seal the exterior of the structure.
3. The structure of claim 1 wherein a., b., and c., make up 100% by weight of the sealant used to seal the exterior of the structure.
4. The structure of claim 1 wherein the exterior of the structure is free of sealants applied as a room temperature liquid.
5. The structure of claim 1 wherein the exterior of the structure is free of reactive sealants.
6. The structure of claim 1 wherein the exterior of the structure is free of silicone sealants applied as a room temperature liquid.
7. The structure of claim 1 wherein the exterior of the structure is free of: sealants applied as a room temperature liquid, and reactive sealants.
8. The structure of claim 1 , wherein the structure is airtight as tested by the Sealtech test.
9. The structure of claim 1 , wherein the single-sided thermoplastic film tape comprises:
a backing having a first and second side, and
a thermoplastic sealant applied in a film to one of the first and the second sides.
10. The structure of claim 1 wherein the single-sided thermoplastic film tape has a thickness of from 10 mil to 75 mil and a width of from 1 inch to 10 inches.
11. The structure of claim 1 wherein the single-sided thermoplastic film tape and the multi-sided thermoplastic tape pass the Penetration Seal Test.
12. The structure of claim 1 wherein the multi-sided thermoplastic tape is selected from the group consisting of double-sided thermoplastic film tape, butyl tape and combinations thereof.
13. The structure of claim 1 wherein the single sided thermoplastic tape and the multi sided thermoplastic tape comprise a thermoplastic sealant comprising a thermoplastic polymer selected from the group consisting of butyl rubber, styrene block copolymer, EPDM rubber and combinations thereof.
14. The structure of claim 1 wherein the single sided thermoplastic film tape and the multi sided thermoplastic tape comprise a thermoplastic sealant comprising:
a. thermoplastic polymer selected from the group consisting of butyl rubber, styrene block copolymer, EPDM rubber and combinations thereof, and
b. from 15% by weight to 60% weight of one or more fillers.
15. The structure of claim 1 , wherein the substrate encapsulated tape comprises a foam substrate and is encapsulated by a sealant comprising a polymer selected from the group consisting of butyl rubber, styrene block copolymer, EPDM rubber and combinations thereof.
16. The structure of claim 1 , wherein the substrate-encapsulated tape comprises a foam substrate encapsulated by a sealant comprising a butyl rubber and no greater than 60% by weight filler.
17. The structure of claim 1 , wherein the substrate-encapsulated tape passes the “U” channel penetration test method.
18. A structure comprising an interior and an exterior, selected from the group consisting of recreational vehicle, utility vehicle, trailer, bus, walk-in van, box truck, rail car, ambulance, boat, and shed comprising:
a. a single-sided thermoplastic film tape comprises a backing having a first and second side, and a thermoplastic sealant applied in a film to one of the first and the second sides,
b. a multi-sided thermoplastic tape comprising a double-sided thermoplastic film tape, and
c. a substrate encapsulated tape comprising a foam substrate encapsulated by a sealant comprising no greater than 60% by weight filler,
wherein a., b., and c., make up greater than 50% by weight of the sealant used to seal the exterior of the structure.
19. The structure of claim 1 , wherein the structure is a recreational vehicle.
20. A method of sealing a structure comprising an interior and an exterior, the method comprising:
a. positioning a single-sided thermoplastic film tape such that it overlaps a roof to wall joint,
b. positioning a multi-sided thermoplastic tape to seal and adhere one or more items selected from the group consisting of front cap, end cap, electrical outlet plate, vent, skylight, non-flanged items, and combinations thereof to the exterior of the structure, and
c. positioning a substrate encapsulated tape on the exterior structure facing side of a flange of a component inserted into a cut out, the component selected from the group consisting of a window and a door,
wherein the structure is selected from the group consisting of a recreational vehicle and a trailer, and wherein the single-sided thermoplastic film tape, the multi-sided thermoplastic tape and the substrate encapsulated tape make up greater than 50% by weight of the sealant used to seal the exterior of the structure.