Method of filling a seam of a panel assembly using a thixotropic polyurethane elastomeric filler adhesive

A method of filling a seam of a structural panel assembly having a plurality of panel members, said seam defined by edges of abutting panel members, said method comprising the steps of:

• forming a fast-curing, fluid, two-component, non-foaming thixotropic polyurethane elastomeric material by rapidly mixing and initiating the reaction of a first thixotropic component comprising an isocyanate-terminated compound having at least two reactive isocyanate groups and a second thixotropic component comprising a hydroxyl-terminated compound having at least two reactive hydroxyl groups, wherein said first thixotropic component includes from about 3% to 8% by weight fumed silica and said second thixotropic component includes from about 3% to 8% by weight fumed silica and from about 10% to 50% filler;
• applying said thixotropic polyurethane elastomeric material over said seam of said panel assembly;
• fluidizing said thixotropic polyurethane elastomeric material and driving said thixotropic polyurethane elastomeric material into said seam of said panel assembly;
• and
• allowing said thixotropic polyurethane elastomeric material to cure in said seam, thereby sealing and reinforcing said seam of said panel assembly.

A method of forming a structural panel assembly having a reinforced seam, said method comprising the steps of:

• forming a panel assembly comprising a plurality of panel members having adjacent side edges in abutting edge-to-edge co-planar relation, said edges defining a seam therebetween and a plurality of structural support members abutting and supporting said panel members;
• preparing a fast-curing, non-foaming, two-component, thixotropic polyurethane elastomeric material, by rapidly mixing and initiating the reaction of an isocyanate-initiated compound having at least two reactive isocyanate groups and a hydroxyl-terminated compound having at least two reactive hydroxyl groups, wherein said isocyanate-terminated compound includes, by weight, from about 3% to 8% hydrophobic fumed silica and said hydroxyl-terminated compound includes, by weight, from about 3% to 8% hydrophobic fumed silica and from about 10% to 50% filler;
• laying a relatively thin bead of said thixotropic polyurethane elastomeric material over said seam;
• and
• filling and sealing said seam with said thixotropic polyurethane elastomeric material by fluidizing said bead of said thixotropic polyurethane elastomeric material, driving said bead of thixotropic polyurethane elastomeric material into said seam, and allowing said thixotropic polyurethane elastomeric material to cure in said seam.