Abstract:
A mask according to the invention includes a masking having a first side, a second side, and a perimeter opening. The second side is either tacky or has an adhesive applied and includes a backing, and the first side may include a cover. In use, the backing is removed to apply the mask to a hatch on a surface, with the perimeter of the hatch exposed through the perimeter opening. If used, the cover is then removed and liquid sealant is applied to the perimeter through the perimeter opening. Excess sealant collects on the masking rather than on the hatch or surface surrounding the perimeter. Once the sealant dries, the masking is removed.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates a mask and method for covering a hatch and surrounding surface when applying a sealant to the perimeter of the hatch. 
       BACKGROUND OF THE INVENTION 
       [0002]    Sealing hatches on machinery, particularly aircraft, requires that a liquid sealant be applied (preferably by spraying) onto the perimeter between an external hatch (such as the hatch on an airplane body) and the main surface in order to provide a tight seal and low drag at high altitudes and speeds. The hatches referenced herein are typically those that permit access to an area inside the outer surface, such as an area containing an electrical or hydraulic system, that requires periodic maintenance. Presently, these hatches are normally sealed by first applying tape to the surface of the hatch and the surrounding surface (such as the body of the plane surrounding the hatch perimeter) and then spraying the sealant onto the perimeter. Some of the sealant collects on the tape, which is ultimately removed from the surface. So, the tape prevents the sealant from collecting on the hatch or the surface surrounding the perimeter. Normally, standard duct tape or painter&#39;s tape is used for this purpose. Applying the tape and removing it is time consuming, which leads to more maintenance time than necessary. 
       SUMMARY OF THE INVENTION 
       [0003]    The invention provides a pre-formed mask that is simple to apply and remove from a surface, that greatly reduces the time required to mask a surface (such as the hatch and surface of a plane near the hatch), and that is custom sized and configured for a given hatch. Also disclosed is a kit of masks designed for a particular surface (such as for a particular type of airplane), wherein the kit contains at least one mask sized and configured to fit each hatch on the surface. 
         [0004]    Each mask includes multiple components. One is the masking that blocks the sealant from contacting the hatch or surface surrounding the perimeter. The masking is preferably a sheet of flexible plastic that is translucent (it should preferably have some cloudiness or colorization so it is easier to visually position the mask properly on the surface). The masking preferably has an adhesive backing or is a tacky material so it can stick to the surface once properly positioned. The masking has one or more open portions called perimeter openings that are positioned to expose the perimeter of the hatch. 
         [0005]    The mask also preferably includes a backing that is removed to expose adhesive (or the tacky masking material) on one side of the mask. When the backing is removed, the mask can be adhesively applied to the surface of the plane, with the perimeter opening exposing the perimeter, and the masking covering the hatch and the surface surrounding the perimeter. 
         [0006]    Another preferred component is a cover on the surface of the mask opposite the backing Preferably the cover is transparent or translucent, so a user can see the masking and the surface in order to properly position the mask on the hatch and align the perimeter opening with the perimeter. The purpose of the cover is to provide support for the masking so that it is relatively simple for a user to properly place. Without the cover, the mask component could be too flexible and bend or fold over when a user attempts to position it. Also, the masking is normally two or more separate, unconnected pieces, because the perimeter opening usually divides it into multiple pieces. So, the cover holds the pieces of the masking together in proper alignment for placement on the surface. Once the masking is attached to the surface, the cover is removed to expose the masking and perimeter opening. If the perimeter opening does not divide the masking into multiple pieces, the cover would not be required. 
         [0007]    Also disclosed is a kit for a surface (such as a plane) that includes at least one mask configured to align with each hatch on the plane. It is typical for a plane to have well in excess of 100 external hatches that must be resealed on a regular basis. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is an embodiment of a mask according to the invention. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0009]    Turning now to  FIG. 1 , wherein the purpose is to describe a preferred embodiment of the invention and not to limit same, an exemplary mask  10  is shown. 
         [0010]    Mask  10  is sized and configured to seal the perimeter of a hatch on a surface. In the embodiment shown, mask  10  includes a masking  12 , an opening  14 , and a perimeter opening  16 . Mask  10  also includes markings  18  that align with corresponding reference markings (such as rivets, screw heads, bolts, or any visible marking) on the surface to properly align mask  10  on the surface to which it is applied. 
         [0011]    Masking  12  is preferably formed of translucent vinyl, but can be made of any suitable material. If masking  12  is translucent, a user can visually align markings  18  with the corresponding reference markings on the surface, and also distinguish between the masking  12  and the perimeter opening  16 , which also can help with proper alignment. 
         [0012]    Masking  12  should be flexible enough to conform to contoured or curved surfaces, such as the surfaces on an airplane. The vinyl used for masking  12  is preferably made from flexible vinyl mask material. Masking  12  preferably has a light adhesive (not shown) applied on its back side and a backing (not shown) on the adhesive, that is removed in order to apply masking  12  to the surface once mask  10  is properly positioned. 
         [0013]    The masking material should be resistant to solvents (if the sealant used will be solvent-based), so when the sealant is applied, the masking  12  does not dissolve or otherwise lose the characteristics that makes it suitable for use. 
         [0014]    Materials that may be used for mask  10  typically come in rolls of various lengths and widths. A preferred material comes in a roll 40″ wide by 150′ long, although any suitable size may be used. One such material is ORACAL paint mask vinyl, and another is made by AVERY. 
         [0015]    Mask  10  includes one or more perimeter openings  16 . The perimeter opening(s) are to allow sealant to pass through and seal the perimeter of a hatch. In this embodiment, perimeter opening  16  has straight sides  16 A and curved ends  16 B, but perimeter opening  16  is of any suitable shape to expose the perimeter of the hatch that will be sealed. Perimeter opening divides masking  12  into an outside section  12 A and an inside section  12 B. The cover (not shown) keeps masking  12  in position temporally until the backing (not shown) is removed from the back of mask  10  and the masking is adhered to the surface. 
         [0016]    Alternatively, perimeter opening may not be a continuous opening, but may contain binding pieces of material that connect section  12 A and section  12 B. These sections can later be removed after the masking  12  is applied to the surface in order to create a continuous opening  16 . In that case, the cover may not be required since inside section  12 B and outside section  12 A are connected until masking  12  is applied to the surface. 
         [0017]    In this example, mask  10  has a masking  12  with an inner portion  12 B, an outer portion  12 A, an opening  14  centered in inner portion  12 B. Opening  14  is optional and is utilized by a user to remove the inside section  12 B, because the outer edges of section  12 B will be covered with sealant and are difficult to lift from the surface. Opening  14  can be of any suitable size and located at any suitable position. 
         [0018]    Markings  18  can be of any shape, size or location to align with corresponding markings on the surface or hatch in order to position mask  10  so that the perimeter opening or openings  16  are over the perimeter that will be sealed. 
         [0019]    Mask  10  can be held in place initially by a section of tape. Masking (or painter&#39;s) tape may be used for this purpose. This could be any suitable tape, such as standard masking or painter&#39;s tape (which has a relatively light adhesive backing). This may be used on an edge of each mask  10  to initially place each of the masks  10  on the surface, to be certain that each aligns properly, prior to attaching each mask  10  onto the surface using the adhesive backing 
         [0020]    If tape is used to temporarily adhere a mask  10  to the surface, the mask  10  does not have to be removed from the surface in its entirety to remove the backing and adhesively apply mask  10  directly to the surface. Mask  10  could just be pulled away from the surface while still being connected by the tape on one edge in order to expose and remove its backing and then adhere the mask  10  to the surface. 
         [0021]    Preferably, multiple masks  10  are organized as a kit, so there is at least one mask  10  for each hatch on a particular surface. This is useful for machines such as airplanes that have numerous hatches of varying sizes that should be sealed after the hatches are opened to access the interior. A single plane may have over 100 hatches, and as many as 150 hatches or more. So, a kit of masks for an airplane would have at least one mask for each hatch on the airplane. Therefore, such a kit could include masks of varying shapes and/or sizes, with different size and shape perimeter opening(s)  16  that correspond to each hatch. Markings  18  could also vary according to the corresponding markings on the airplane surface and/or hatch where the particular mask  10  will be positioned. 
         [0022]    To assist a user in positioning a mask  10  onto a surface, such as the surface of an airplane, an image of the surface (such as an airplane) could be printed onto each mask  10 , showing the position of the hatch on which each mask  10  should be placed. Alternatively or additionally, a map or image, or a plurality of maps and images, may be provided as part of the kit and separate from the masks themselves, wherein the map or images show where each mask  10  is to be applied to the surface. 
         [0023]    The mask  10  can either be created manually or by computer modeling of the hatches to which each mask  10  is to be applied. 
         [0024]    Once the computer program has created the mask pattern using information inputted by a user, the program directly or indirectly controls a machine to punch the perimeter opening(s)  16  and opening  14  in the mask material, and to add markings  18 . In one embodiment, the respective markings  18  are printed onto each hatch  10 , although any suitable technique can be used to form the markings  18 . 
         [0025]    Once punched and printed, the vinyl mask roll can then be cut into individual mask pieces. This could be done by a machine or by hand, and may be done as the vinyl mask is being marked and the openings are being punched. 
       Applying the Masks 
       [0026]    Each mask  10  is applied to the surface by identifying its location on the surface using indicia as explained above, such as an image of the surface showing the hatch for which each mask  10  is configured. Each mask  10  is preferably first applied to the surface by applying masking tape or any other suitable tape to one or more edges of the mask, and, when the mask  10  is properly positioned on the surface relative the appropriate hatch, the mask  10  is attached to the surface as previously described. 
         [0027]    Having thus described some embodiments of the invention, other variations and embodiments that do not depart from the spirit of the invention will become apparent to those skilled in the art. The scope of the present invention is thus not limited to any particular embodiment, but is instead set forth in the appended claims and the legal equivalents thereof. Unless expressly stated in the written description or claims, the steps of any method recited in the claims may be performed in any order capable of yielding the desired result.