Patent Grant
6971787
This present invention relates to an apparatus and method for dispensing materials formed from components that should not be mixed until immediately prior to use. More specifically, the invention relates to a device and method for mixing a first component with a second component that causes a chemical reaction to take place.
A variety of materials are made of two or more initially separate components that are preferably not mixed until immediately prior to use. Examples of such materials include two reactive component polymers such as epoxies, polyurethanes, polyesters and silicones. In many instances, such two-component materials may unduly cure, harden or become otherwise unsatisfactory for use if mixed too far in advance of the actual time that the material is applied to the work site. As a result, the components are housed in separate, isolated containers.
The isolated containers for each component can be housed in standard sized, elongated disposable cartridges that are received in caulking guns or similar devices such as those disclosed in U.S. Pat. No. 3,323,682 to Creighton, Jr. et al. and U.S. Pat. No. 4,676,657 to Botrie. These cartridges can comprise a tubular cylindrical outer body with top and bottom ends. The top end contains an integral or detachable dispensing nozzle, while the bottom end permits access to a movable plunger that retains the materials within the body and provides a surface for the caulking gun to act against when applying dispensing pressure to the contents of the cartridge. The housing includes at least two internal reservoirs. Each of these reservoirs houses one of the components to be mixed and dispensed. In order to dispense the contained components, the disposable cartridge is securely positioned in the caulking gun or similar device as is known in the art. The action of the caulking gun on the plunger at the rear end of the cartridge causes the contained components to be mixed and the composition dispensed.
U.S. Pat. No. 4,676,657 to Botrie, which is hereby incorporated by reference, further discloses a mixing unit is located within the cartridge for mixing the two components as they are forced toward the dispensing nozzle by the plunger. The mixing unit has an inlet port through which the components enter the mixing unit and an outlet port by which the mixed components exit the mixing unit. The mixing unit also includes a mixing body formed of three identical discs. The discs include complementary opposite handed grooves formed on both sides and connected at their outer ends by a port. When the discs are secured together, they define a double spiral passage extending outwardly from the inlet port, through the ports between the discs and ending at the outlet port. Trapped within the spiral passage are passive mixing elements that combine the components. After being mixed along the circular mixing path of the double spiral passage, the composition exits the mixing unit through the outlet port and is delivered to the nozzle for dispensing. While the circular mixing path is acceptable for mixing some components, it may not evenly mix all components no matter their viscosity.
U.S. Pat. No. 5,386,928 to Blette discloses a system for dispensing compositions made from two components. The system includes a side-by-side pair of collapsible reservoirs that fit within a barrel of a pressurized air applicator. As air is admitted into the barrel, the tubes simultaneously collapse to direct components in the tubes through outlet ports and into a static mixer where the components are mixed to a homogeneous composition. The static mixer includes passive mixing elements positioned within the dispensing nozzle. Each tube includes a relatively rigid top and bottom end piece, and the end pieces are coupled together by pin elements for ease of handling and to facilitate dispensing of the contained components. The length of the mixing path in the dispensing nozzle and the number of passive mixing elements positioned within the mixing path are not sufficient to thoroughly mix the components for some applications, especially when the components have different viscosities. While additional static mixers could be placed in the dispensing nozzle to improve the mixing, the result is a very long and cumbersome nozzle that is awkward to place into position and to handle.
The present invention provides a disposable cartridge for a two component systems that can be manufactured economically, that can maintain accurate proportions of the components during use and that can provide efficient mixing of the components prior to dispensing. The present invention also includes a mixing unit that provides accurate and complete mixing of the components.
One embodiment of the invention includes a cartridge assembly for mixing components of a material. The cartridge assembly comprises a component carrying body with a longitudinal axis that extends between a front end and a rear end of the carrying body. The cartridge assembly also comprises a discharge nozzle that is proximate the front end of the carrying body and a mixing unit for mixing the components and delivering the mixed components to the discharge nozzle. The mixing unit includes a plurality of mixing cylinders that each have a longitudinal axis that extends substantially parallel to the longitudinal axis of the component carrying body.
Another aspect of the invention includes a cartridge assembly for mixing components of a material. The cartridge assembly comprises a component carrying body having a front end and a rear end. A discharge nozzle is positioned proximate the front end for dispensing the mixed components. The cartridge assembly also includes a mixing unit for mixing the components and delivering the mixed components to the discharge nozzle. The mixing unit comprises a plurality of spaced cylindrical mixing chambers and at least one mixing element positioned in at least one of the mixing chambers.
Another aspect of the invention includes a cartridge assembly for use with a caulking gun to mix and dispense components of a material. The cartridge assembly comprises a component carrying body having a front end, a rear end and a mixing unit for mixing the components and delivering the mixed components to a discharge nozzle. The mixing unit comprises a mixing body including a mixing path that extends between a front end and a rear end of the mixing body. The mixing path has a first mixing region that is offset from a terminal mixing region in a direction that is opposite the direction of the mixing path. This change in direction provides improved mixing with fewer static mixers than would be required if the mixers were arranged in a straight, linear pattern. This new design can also hold more length of static mixers than the conventional mixer design described, for example, in U.S. Pat. No. 4,676,657 to Botrie.
A further aspect of the present invention includes a cartridge assembly for use with a caulking gun to mix and dispense components of a material. The cartridge assembly comprises a component carrying body having a front end, a rear end and a mixing unit for mixing the components and delivering the mixed components to a discharge nozzle. The mixing unit comprises a mixing body including a mixing path that extends between a rear end and a front end of the mixing body for moving the components from the rear end of the mixing body to the front end of the mixing body and then back to the rear end of the mixing body.
A still further aspect of the present invention includes a cartridge assembly for mixing and dispensing components of a material. The cartridge assembly comprises a component carrying body having a front end, a rear end and a mixing unit for mixing the components and delivering the mixed components to a discharge nozzle. The mixing unit comprises a mixing body including a substantially sinusoidal shaped mixing path.
Further features of the invention will become apparent from the following description of preferred embodiments thereof with reference to the accompanying drawings.
As illustrated in
As illustrated in
The cylindrical body 2, end plate 4 and discharge nozzle 8 can be formed by any manner of conventional construction. For example, the cylindrical body 2 can be formed of metal, cardboard or plastic, while the end plate 4 and discharge nozzle 8 can be metal or plastic. If the end plate 4 is formed of a plastic, it can be integrally molded with the body 2 as a single, continuous unit. Additionally, the end plate 4 and discharge nozzle 8 can be integrally molded together as a single unit, no matter if the end plate 4 is molded together with the cylindrical body 2. In an additional embodiment, the end plate 4 can be removably secured to the body 2 in a known manner, such as by cooperating threaded surfaces.
As shown in
The body 2 also includes a collapsible container 12 for holding a first of the two components A. An outer surface of the collapsible container 12 and an inner surface of the body 2 define a reservoir 13 for holding a second of the two components B. As can be understood, the walls of the container 12 and the plunger 10 keep the two components separated and isolated from each other.
The container 12 is formed by a cylindrical tube 15 made of a thin flexible film, such as a synthetic plastic film that is resistant to both components A, B of the mixture contained within the body 2. The tube 15 is closed at both ends for securely holding the contained component A. As shown in
As shown in
When the plunger 10 is forced toward the front of the cartridge 1, the component A in tube 15 is forced into the well 42 through collar 18 and opening 41, while the component B in reservoir 13 is forced through channels 45 into well 42. A front opening 44 in the flow directing member 40 is open to the well 42 to deliver and direct the components A, B from the well 42 to a mixing unit 60 in response to the movement of the piston 10.
As illustrated in
A light gauge compression coil spring 110 (
The mixing unit 60, shown in FIGS. 2 and 8–13, is also provided within the body 2 for mixing the components A, B delivered from the flow directing member 40 through opening 44. The mixing unit 60 includes a rear plate 61, a front plate 71 and a mixing body 80 positioned between the plates 61, 71 (
As shown in 11A–11D, the rear plate 61, front plate 71 and mixing body 80 define a substantially sinusoidal shaped mixing path that extends around the mixing unit 60 as discussed below. The rear plate 61 includes a central, inlet opening 62 that is aligned with and in communication with the front opening 44 of the flow directing member 40 so that the unmixed components A, B are delivered from the well 42 to the mixing body 80 after being united in the flow directing member 40. The rear plate 61 also includes a rear surface 63 that forms the rear outer surface of the mixing unit 60, and an inner surface 64 that faces the mixing body 80.
As shown in
As shown in
Channels 79A, 79B and 79C are shaped substantially like a kidney bean and have a continuous sidewall 76 as discussed above with respect to channels 69A–C. The channels 79A–79C cooperate with the mixing body 80 to deliver the components A, B to a fourth channel 77, which then directs the mixed components A, B to the discharge nozzle 8. The channel 77 extends radially across the front plate 71 and has a discontinuous sidewall 76 with an end that is open to the outlet opening 72 for delivering the mixed components A, B to the outlet opening 72 and the discharge nozzle 8.
As shown in
At the front end 83 of the mixing body 80, the mixing cylinders 89 of adjacent mixing housings 84–87 are connected and in communication with each other by a flow channel 88 so that the components A, B can flow from a mixing cylinder 89 of one mixing housing 84–87 to a mixing cylinder of an adjacent mixing housing 84–87. Unlike at the rear end 82, the mixing cylinders 89 of the same mixing housing 84–87 are isolated from each other at the front end 83 of the mixing body 80 by the wall(s) of the channels 88.
As illustrated in
The opening 92 has a diameter that is only slightly larger (1 to 5 mm) than that of the stem 121 of the piercing rod 120 (
While only four mixing housings 84–87 and two mixing cylinders 89 per mixing housing are illustrated, the mixing body 80 could include any number of mixing housings, for example between two and ten housings, and any number of mixing cylinders, such as between one and ten. As illustrated, three of the housings 84–86 have a substantially kidney bean shaped cross section and the radially extending housing 87 has a substantially keyhole shaped cross section. However, as with the channels 65, 75, the housings 84–87 could have any shape. Additionally, each mixing cylinder 89 is an open ended tube with a round cross section. However, any shaped cross section could be used.
As shown in
In use, the cartridge 1 is loaded into a conventional caulking gun, and the piercing rod 120 is advanced toward the rear end 5 of the body 2. As the piercing rod 120 is advanced, the head 124 of the piercing rod 120 moves from its rest position, where the head 124 is retracted into the mixing cylinder 90, through the seals 26, 27 and into the interior of the cylinder 15. The piercing rod 120 is pushed into the tube so that the flat section 123, is parallel to the top of the nozzle 6, this will ensure that barriers 26 and 27 are punctured and no longer prevent components A and B from contacting each other. After the head 124 has been located within the cylinder 15, the nozzle 8 is screwed into the discharge opening 6.
When pressure is applied to the plunger 10 by the gun, the first component A from the inner, collapsible container 12 is advanced into the well 42 past the ruptured seal 26, whilst the second component B in the reservoir 13 is forced through the channels 45 and into the well 42 where it meets with the first component A. The components A, B then pass through the openings 44, 62 and into the centrally located mixing cylinder 90.
The below discussed steps are best illustrated in
At the front end 83 of the mixing body 80, the mixing cylinder 93 opens to a channel 88 and the cover channel 75. As discussed above, each channel 88 extends around one of the mixing cylinders 89 of two adjacent mixing housings 84–87. As a result, when the mixed components A, B are forced out of the mixing cylinder 93, they travel into and across the channel 88 extending along the front end 83 and into a mixing cylinder 94 of the adjacent mixing housing 84. The mixed components A, B are then forced through the mixing cylinder 94 where they pass the mixing elements 140 as the mixed components continue along the mixing path and return to the rear end 82 of the mixing body 80. After reaching the rear end 82 of the mixing cylinder 94, the mixed components A, B are forced along the channel 88 at the rear end 82 and into mixing cylinder 95 of the same mixing housing 84. As illustrated in
After entering the mixing cylinder 95, the mixed components A, B are again forced toward the front end 83 of the mixing body 80. If mixing elements 140 are positioned within the mixing cylinder 95, the components are further mixed as they pass through the mixing cylinder 95. Upon reaching the front end 83, the mixed components A, B travel within another channel 88 and into the mixing channel 96 of the next mixing housing 85. The mixed components A, B are then forced through the mixing channel 96 toward the rear end 82 and past any contained mixing elements 140. Similar to that previously described, the mixed components A, B then travel across a portion of the rear end 82 within another channel 88 of the mixing housing 80 in the direction of the next circumferentially positioned mixing channel 97 of mixing housing 85. Upon reaching the mixing channel 97, the mixed components A, B enter the mixing channel 97 and are forced past any contained mixing elements 140 in the direction of the front 83 of the mixing housing 80.
The method of forcing the mixed components A, B along the mixing path through the mixing cylinders 90 and 93–99 and along the channels 88 continues until the mixed components A, B are forced through the mixing cylinder 99 and past any mixing elements 140 contained there within. After exiting the mixing cylinder 99 at the front end 83 of the mixing body 80, the mixed components enter the channel 88A bounded by the mixing body and the end plate 71. The forced components A, B travel through the channel 88A to an opening 105 that opens into the front of the central mixing channel 90 and out the discharge opening 6 and into the discharge nozzle 8 for application.
As can be understood from the above descriptions, the front end 83 of the mixing cylinder 99 is at the terminal end of the mixing path, whereas the rear end 82 of mixing element 93 is at the beginning end of the mixing path. Also can be seen from the figures, the front end 83 of the mixing element 93 is counter clockwise to the rear end 82 of the mixing element 93 when the mixing path extends in a clockwise pattern. The converse is also true if the mixing path extends in a counter-clockwise pattern. The mixing cylinders 89 are spaced from each other around the circumference of the mixing body by a predetermined distance, such as 360° or the length of the circumference divided by N, where N is the number of circumferentially spaced mixing cylinders 93–99, not including the centrally spaced mixing cylinder 90. Other known ways of spacing the cylinders can also be used.
According to the above described embodiments, it may be necessary to use the entire contents of the cartridge at one time, or to discard the remainder, at least in the case of components that harden after mixing, since the mixed components in the mixing unit 60 will set if allowed to remain therein, thus ruining the mixing and blocking access to the remainder of the discharge nozzle 8.
The concentric passageways 281, 282 for the two components provide for the saving of any unused portions of the contents of the cartridge by removing the well 242 and the mixing unit 260 and replacing the cap over the punctured seal 26. In this embodiment, a cleaned or new well 242 and mixing unit 260 are attached to the coupling 250 before the cartridge 1 is used again.
Alternative embodiments of connecting the body 2 and the well 42 to the mixing unit 60 can also be used. For example, these alternative embodiments could include those embodiments disclosed in U.S. Pat. No. 4,676,657, which has been incorporated by reference.
In some applications, particularly using large, fully enclosed caulking guns, it is preferred to use cartridges, or “sausages” in which the conventional rigid body is replaced by a flexible tubular bag containing the material to be dispensed, the remaining functions of the body being provided by the gun itself. The present invention can be adapted for such a use as described in U.S. Pat. No. 4,676,657. In this embodiment, a flexible cylindrical tube, of similar construction to cylinder 15, previously described, replaces the body 2. In order to maintain proper proportioning of the components, it will usually be desirable to support the outer bag by a light spring in the same manner as the cylinder 15 is supported. The remainder of the cartridge is substantially the same as described above with respect to the cartridge in
While the above described embodiments each contemplate the dispensing of a product made up of two components stored concentrically, it will be appreciated that the principles of the invention may be utilized with products made up of more than two components, and these need not necessarily be stored coaxially, provided that provision can be made for breaking any necessary seals before use of the cartridge. It will also be understood that the words used are descriptive rather than limiting, and that various changes may be made without departing from the spirit or scope of the invention as claimed below.
This application is a continuation of application Ser. No. 10/094,963, filed Mar. 12, 2002, Pat. No. 6,705,756 now allowed. The application is hereby incorporated herein by reference in its entirety.
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| Number | Date | Country | |
|---|---|---|---|
| 20040159678 A1 | Aug 2004 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10094963 | Mar 2002 | US |
| Child | 10778349 | US |
