Patent Application
20050198927
The present invention is related to self contained cartridges containing chemicals for use in conventional caulking guns, and more particular, the present invention relates to small, single-use, hand-held packaging for the containment and delivery of viscous, pasty reactive chemicals (primarily of the 2-component type, but also comprising 1-component reactive types) that are frequently used as adhesives, sealants, potting compounds, anchoring pastes, etc.
Both 1-component and multi-component (but preponderantly, 2-component) chemistries, which include adhesives, sealants, potting compounds, anchoring pastes, and the like (represented by such chemistries as epoxies, polyurethanes, polysulfides, acrylics, silicones, polyesters, etc.), are used throughout the world for bonding, sealing, encapsulating, anchoring and coating many different items in construction, manufacturing, aerospace, medical, transportation, consumer and other market areas. With 2-component chemistries, the two reactive materials are maintained separate from one another and unmixed until just prior to use. To use 2-component chemistries, the components are often mixed in a separate container and applied either using an automatic dispenser or manually. Alternatively, one frequently uses a specialized or custom dispenser having parallel cartridges to dispense the 2-component chemistries with the mixing being accomplished by a static mixer inside the dispensing nozzle.
Despite the inconvenience of having to mix 2-component chemistries or purchase specialty components prior to use, the industry considers 2-component chemistries superior in performance and prefers using 2-component chemistries in most applications. Generally, the industry prefers 2-component chemistries because they frequently have better physical and chemical properties than 1-component chemistries. However, while 2-component chemistries are currently and widely used in certain industries (both from bulk containers and from pre-loaded specialized packaging), such use has been restricted to using relatively expensive and relatively specialized application or dispensing equipment. Therefore, there is a need to provide a reactive-chemical dispensing cartridge packaging, which could be used for both 1-component or multi-component chemistries, that is capable of use in common, standard, inexpensive caulking guns of the type generally found in hardware stores, home centers, paint stores and the like.
It has been recognized previously by such inventors as, for example, Creighton (U.S. Pat. No. 3,323,682), Maziarz (U.S. Pat. No. 5,535,922) and Konuma (U.S. Pat. No. 5,593,066) that it would be advantageous to have a package that permitted the dispensing of 2-component chemistries from common, standard caulking guns, so that all users in all markets could take advantage of the high performance provided by such 2-component chemistries, while enjoying the low cost and ready availability of such standard dispensing equipment. Yet, none of the prior invention disclosures disclose a package design that is: uncomplicated to use by the applicator, technically feasible to manufacture (especially regarding the factory-filling of such containers with high viscosity, pasty materials), sufficiently rugged in its resistance to damage before use, economically viable overall, suitable for dispensing even high viscosity sealants or adhesives, easily recyclable, or comprehensively practical enough to be introduced into or gain acceptance by commercial markets.
Creighton, for instance, discloses no practical design, feasible method of manufacturing, or reasonable method of factory-filling his package with adhesives or sealants (and, consequently, this design has never been commercialized). The Maziarz design, while having found some commercial success, requires the use of a separate rigid adapter to permit the primary all-rigid package to be used in a standard caulking gun, and the maximum volume of material that can be placed into this primary package is only about ¼ to ½ the volume normally possible from packages typically used in such dispensing equipment (and the package cannot be readily recycled). The Konuma design also requires the use of a separate rigid adapter in order to be usable in a standard, common caulking gun. Also, the Konuma design involves a primary collapsible-film package that is much more prone to damage during transport, storage, adapter-insertion or use than typical rigid cartridges that are widely used in standard, common caulking guns.
One commercial package and product currently being sold in Europe (by Artur Fischer (UK) Ltd.—named “FIP 300 SF”) has a 2-part “sausage” or “chub”, sealed at each end with a strong metal clip, inserted into a rigid plastic caulking cartridge that can be installed in a common, standard caulking gun. Before use, the user pulls one end of the collapsible sausage, with a metal clip attached to it, through the treaded cartridge outlet port and cuts the metal clip is cut off with a knife—thus opening the sausage for dispensing. Then, the user screws a nozzle on the threaded outlet a, with the nozzle typically having a static mixer inside, and mixes/dispenses the 2-component, low viscosity, polyester anchoring mortar.
Several problems exist with this design. First, because the plastic film of the sausage is pulled into and left inside the narrow outlet of the cartridge, the wad of plastic film bunched up inside the outlet port can greatly restrict the flow of the chemical components during dispensing—which may only be a moderate problem if the viscosity of the fluids is very low (as in the case of this commercial “FIP 300 SF” product), but can be a great problem if the product viscosity is high and the product is pasty. Second, it is possible for the chemical components to contact and foul portions of the interior of the rigid cartridge either during dispensing or during spent-sausage removal from the rigid cartridge—making cartridge reuse or recycling very problematic or impossible, and messy in either case. Third, the rigid cartridge has several avenues of gaseous fluid communication between the outside atmosphere and the interior of the package that could partly endanger the shelf life of certain reactive sealants or adhesives during prolonged storage.
It is important to note that many previous inventors have described and, in some cases, commercialized 2-component specialized packaging that is suitable for use only in specialized, relatively expensive dispensing equipment, but not suitable for use in common, standard and inexpensive caulking guns. The commercial market place and the patent literature are replete with many instances of such inventions. Examples of such designs can be found in the works of Blette (U.S. Pat. No. 5,386,928), Sauer (U.S. Pat. No. 5,897,028), Koga (U.S. Pat. No. 6,019,251), Camm (U.S. Pat. No. 5,918,770), Vidal (U.S. Pat. No. 6,047,861), Anderson (U.S. Pat. No. 4,366,919), Penn (U.S. Pat. No. 4,846,373), Schiltz (U.S. Pat. No. 5,566,860), Giannuzzi (U.S. Pat. No. 5,184,757), etc. The present invention, however, permits the use of such reactive materials in simple, affordable and readily available caulking guns, so that virtually everyone, in all industries, can enjoy the benefits of said reactive materials at a low overall cost.
Notably, previous attempts at creating a practical 2-component package for this use have not addressed the need to be able to factory-fill, in a practical manner, such packaging with high viscosity, pasty adhesives and sealants. Either this issue has not been dealt with at all in previously disclosed designs, or, when addressed, the methods outlined or implied have not been feasible. For instance, Keller (U.S. Pat. No. 5,647,510) describes a device that has some similarities to the present invention, but Keller's design calls for the collapsible-film pouches within the device to be attached to one or more relatively small diameter dispensing nozzles that cannot be practically used for filling the pouches causing the pouches to be filled from the rear of said pouches (i.e., at the piston end)—as virtually all previous designers appear to have done, with such a filling approach not being readily or easily accomplished in a practical way. (Notice, in the context of this application, collapsible-film pouches and collapsible packages are generally used interchangeably). In particular, filling pouches from the rear and non-attached end can cause pinching, a crimping of the pouches, which inhibits the dispensing of the chemicals contained in the pouches. Furthermore, by filling the pouches from the rear, it is difficult, if not impossible, to completely fill the pouches with chemicals to fully use the possible volume.
Keller is a useful example of problems associated with conventional methods for filling chemicals in collapsible-film package (and possible explains why none have been successfully commercialized). For example, by filling the package from the rear (which is conventional and exemplified by Keller), the pouch must be held or gripped at the package edge. The gripping to effectuate a filling procedure can damage or weaken the film at the edge and make the edge prone to failure. Further, when filling the packages external to a cartridge body (again conventional and exemplified by Keller and the other cited prior art), they are susceptible to bulging along the length.
When the package bulges, it becomes difficult to insert the bulging package in the cartridge body without damaging the package. Even assuming the package was filled without damaging the edges, and inserted in the cartridge body without damaging the package, sealing the open end of the package (i.e., the end that was filled) is problematic at best. In particular, gathering the open end of the package to seal the package with a traditional clip would likely cause voids or unused space, which is not efficient. Alternatively, using a seal, such as a heat seal, runs the risk of fouling the sealing surface with the chemicals and causing a weaker seal. Finally, and specific to the Keller disclosure, the plunger is not removable from the rear end of the cartridge body (see sealing ring and lips in Keller
If the issue of efficiently filling such packages at the factory is not adequately addressed (and the factory-filling of such high viscosity, pasty materials as adhesives and sealants into hand-held, collapsible-film packaging is far more difficult than the factory-filling of low-viscosity, thin fluids), then it becomes difficult or impossible to economically produce such a package/product combination.
Moreover, the Keller device is not designed as a totally self-contained, integrated package, to be used in a common caulking gun; and, rather than recycling the main rigid cartridge body as taught below in the present invention, Keller's disclosed design calls for his rigid housing to be very stoutly built and aims at the repeated re-use of the stout, rigid housing by inserting fresh, collapsible-film pouches—which are relatively much more fragile and subject to damage, compared to integrated, mostly-rigid containers—into them in the field after the previously-used pouches have been emptied.
It is well known in the trade that 1-component, all-rigid, all-plastic polyethylene caulking cartridges typically used to contain many or most sealant and adhesive chemistries (and dispensed using common, standard caulking guns) are not currently used to contain 1-component, reactive, moisture-curable polyurethane sealants or adhesives. The reason is that such all-plastic containers do not provide sufficient moisture vapor permeability resistance to prevent premature and rapid curing of highly moisture sensitive polyurethanes during storage. Yet, because of the unsurpassed weather and damage resistance (as well as low cost) afforded by such rigid all-plastic containers (compared to the paperboard/aluminum foil cartridges most commonly used for such polyurethanes today), it would be advantageous to use such rigid, plastic containers for such products.
To attain the advantages of and in accordance with the purpose of the present invention, as embodied and broadly described herein, a method for filing cartridges for use with a conventional caulking gun include securing a collapsible package to the cartridge and applying pressure to an internal space of the collapsible package to expand the package. Drawing a vacuum on the cartridge to reduce pressure in the cartridge and removing the pressure applied to the internal space. The reduced pressure maintains the package in an expanded state. The package is filled and the vacuum released to increase the pressure in the cartridge.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate some preferred embodiments of the invention and, together with the description, explain the goals, advantages and principles of the invention. In the drawings,
FIGS. 7-A to 7-D show a conventional method of filling cartridge 1 and 4 (prior art);
FIGS. 8-A to 8-M show a show a method of filling a cartridge in accordance with the present invention;
FIGS. 9-A to 9-B show an embodiment of a cartridge in accordance with the present invention;
FIGS. 10-A to 10-B show another embodiment of a cartridge in accordance with the present invention;
FIGS. 11-A to 11-C show still another embodiment of a cartridge in accordance with the present invention;
FIGS. 12-A to 12-B show still another embodiment of a cartridge in accordance with the present invention;
FIGS. 13-A to 13-B show still another embodiment of a cartridge in accordance with the present invention;
FIGS. 16-A to 16-C show a method of using plunger 119 in accordance with the present invention;
FIGS. 18-A to 18-C show a method of using plunger 129 in accordance with the present invention;
FIGS. 19-C1 to 19-C2 show plunger 139 and cartridge 140;
FIGS. 19-D1 to 19-D2 show the 139 and cartridge 140;
FIGS. 20-A and 20-B show pouches 152 and 153, and inner tube wall grooves 148 in more detail;
FIGS. 22-A to 22-C shows a method of venting in accordance with the present invention.
While cartridges 1 and 4 are generally shown to have a cylindrical shape, other geometries are equally possible. Typically, however, conventional caulking guns, explained below, are designed to receive substantially cylindrical cartridges.
Conventional caulking cartridge 1 is used with conventional caulking gun 10 by inserting cartridge 1 into an associated cavity (not specifically labeled) in caulking gun 10 such that nozzle 2 protrudes out of a slot (also not specifically labeled) in caulking gun 10 opposite the push-plate 10a. To use caulking gun 10 and cartridge 1 after the cartridge is inserted into caulking gun 10, a user “pulls” trigger 10c. Pulling trigger 10c causes push-rod 10b to apply pressure to push-plate 10a. Push-plate 10a, in-turn, applies pressure to the plunger (not shown) in rigid cartridge body 3 causing the plunger to move towards the nozzle 2. The movement of the plunger towards the nozzle causes the 1-component chemicals to be dispensed out of nozzle 2.
Using conventional caulking cartridge 4 is similar to using caulking cartridge 1 except that a user typically must perform two additional steps. First, nub 9 typically has a cap, cover or plug that prevents inadvertent discharge of the chemicals and to protect the chemicals from the environment. Thus, the user must remove the cap, cover or plug. After removing the cap, cover or plug, the user then connects nozzle 5 to nub 9 by screwing nozzle 5 on nub 9. Once nozzle 5 is attached to nub 9, the operation of conventional cartridge 4 is identical to conventional cartridge 1.
One disadvantage of conventional caulking cartridges 1 and 4 is that the chemicals contained in the cartridge are in direct contact with the inside surfaces of the caulking bodies 3 and 6 as well as the nozzles 2 and 5. By being in direct contact with the bodies and nozzles, the chemicals foul the bodies and nozzles making their reuse or recyclability difficult, if not impossible.
Another disadvantage of conventional cartridges 1 and 4 is that, typically, the bodies 3 and 6 do not provide sufficient isolation from the environment. Thus, conventional cartridges are normally used only for non-reactive chemistries, if the cartridges are made of only plastic.
Collapsible package 11 has been known in the trade for many years, and offers the benefits of providing good shelf stability for the contained chemicals, low package cost, and minimal packaging waste (both in weight and volume). However, such packages cannot be used in standard, common caulking guns without special adapters because the collapsible-film of the packages would burst without being well supported by a surrounding cylindrical rigid structure, such as, for example, barrel 16.
In operation, a user would remove end manifold 15 from industrial caulking gun 14 and insert collapsible package 11. The user would then remove clip 13 nearest the outlet of the gun, or otherwise puncture collapsible package 11, and insert package 11 in barrel 16. Normally clip 13 is removed with a knife. End manifold 15 would then be placed back in industrial caulking gun 14. With the manifold in place, and the clip 13 removed, pulling the trigger will cause the chemicals contained in collapsible package 11 to be extruded from the barrel 16 through the nozzle associated with end manifold 15. The actual operation of industrial gun 14 is similar to the operation of conventional caulking gun 10.
In normal operation, the collapsible film of the sausage folds up like an accordion as it is progressively squeezed by the action of the push-plate and push-rod (not shown) of the industrial caulking gun 14. Once the contents of the collapsible package 11 are dispensed, the substantially or completely empty collapsed package 11 and remaining clip 13 are removed and disposed. Industrial caulking gun 14 would then be ready to dispense another collapsible package 11. Notice, end manifold 15 and barrel 16 may become partially fouled during use and may require cleaning prior to the next use of industrial caulking gun 14.
Generally, collapsible packages for use in the industrial caulking guns 16 contain only 1-component chemistries. Although at least one inventor, Blette, for example, has described a 2-component package designed for use in such single-barreled industrial caulking guns 16, even though no such 2-component package as designed by Blette appears to have ever been commercialized.
FIGS. 7-A to 7-D show the conventional, normal and universally used method of filling standard, rigid caulking cartridges 1 (
The bottom-up approach to factory-filling has proven itself as the preferred method in the adhesives and sealants industry over many years.
In
After positioning outlet 18 of the filling nozzle 17 near the interior bottom 19 of the cartridge 1, the user can commence filling the cartridge 1 with chemicals. As mentioned above, outlet 18 is placed near the interior bottom 19 (toward the nozzle end) of cartridge 1 because the high viscosity of such pasty materials does not readily allow said materials to easily or quickly flow to the bottom of such containers on their own, and filling the cartridge is facilitated by placing the chemicals there during the filling. Moreover, when filling begins at this position, the adhesive or sealant has the opportunity to displace whatever vapor (usually air) may be in the container prior to the commencement of the filling process, and largely prevent the vapor from being trapped in the container with the sealant or adhesive during factory filling.
This process is called, in the trade, “bottom-up” filling, and is used for many sizes of hand-held packages, up to as large a container as a 29 fl. oz. cartridge. Notice, the arrows in the diagram show the relative movement of filling nozzle 17 with respect to the caulking cartridge 1.
Collapsible packages 11 are formed and filled substantially simultaneously. In particular, collapsible packages 11, or sausages and chubs, are formed and filled using highly specialized and expensive equipment. Generally, to make a chub, a filling nozzle (similar to nozzle 17 in FIGS. 7-A to 7-D) is placed in a heat-sealing unit. The heat-sealing unit uses a “bishop's collar” to form the chub by converting a flat sheet of high barrier collapsible film into an open ended cylindrical tube that has a heat-seal formed down a seam on the side of the tube. The chub has one end of the tube closed, typically with a metal clip, and the fill nozzle is inserted into the other end of the chub up to the closed end. The fill procedure is generally the same as described above, but must be carefully controlled because of the needed back-pressure balance of the collapsible package and the tight overall sequential timing required.
As can be determined from the above descriptions, conventional plastic cartridges have an advantage over chubs in that it is easier to fill such conventional cartridges with chemicals and much less expensive equipment can be used. Chubs, however, have an advantage over conventional plastic cartridges in that they provide better isolation between the chemicals within the chub and the environment (due to films being used that include aluminum foil and other high-barrier materials). Therefore, it would be desirous to develop a cartridge that contained the filling advantage of conventional cartridges with the isolation advantage of the chub (with the a collapsible package also ultimately being permanently protected by the surrounding substantially rigid cartridge).
FIGS. 8-A to 8-G show one embodiment of a new and novel overall package design that permits the factory-filling of cartridges comprised of rigid plastic elements and collapsible packages with high-viscosity, pasty chemicals, that combines the filling and durability advantage of conventional cartridges and the isolation advantages of the chub. For example, the collapsible packages are positioned within the surrounding substantially rigid shell of the cartridge and filled using a conventional fill method. Further, the cartridge design of the present invention allows the collapsible package to be filled (using large diameter fill nozzles) in a bottom-up manner analogous to, but opposite from the method proven for many years in the trade. Such a reversal in filling methods is totally new, unique and novel—and requires the package design of the present invention to allow such a filling method to be used.
Preferably, the retaining collar 28 is internal to the collapsible package 22A. Moreover, it is preferable to heat-seal collapsible package 22A to retaining collar 28 such that collapsible package 22A covers collar edge 30. As shown in
As will be explained in more detail below, when a nozzle, or some type of manifold, is threaded on the substantially rigid cartridge body 24, the pressure from threading the nozzle will cause edges 30 and 29 to form a tighter mechanical seal. The mechanical seal, in conjunction with the heat seal, inhibits the collapsible package 22A from moving further down the bore of the cartridge body 24 toward the plunger end 25 of the substantially rigid cartridge body 24. Of course, it is possible to use the mechanical seal or the heat seal alone; however, it is preferred to use both seals. Furthermore, while it is preferable to have tapered edges to form a mechanical seal, the mechanical seal could be formed by a “tight” friction fit between the retaining collar 28 and the inside surface of the substantially rigid cartridge body 24. While not preferred, in the event a mechanical seal is not used, retaining collar 28 could be external to the collapsible package 22A and the leading edge of collapsible package 22A could be heat sealed to the inner surface (not labeled) of the retaining collar 28.
FIGS. 8-D and 8-E show cartridge 22 with collapsible package 22A inserted into substantially rigid cartridge body 24. Further, the plunger end 25, without the plunger, of the substantially rigid cartridge body 24 is coupled to a vacuum fixture 26. The vacuum fixture 26 would be coupled to, for example, a vacuum pump, not shown, such that when the vacuum pump is activated, it pulls a vacuum on the internal space at the plunger-end 25 of the substantially rigid cartridge body 24.
Pulling a vacuum on the plunger-end 25 causes the collapsible package 22A to “reverse inflate,” which expands the pouch and pulls it forcefully toward the plunger end 25 of the cartridge (as shown in
FIGS. 8-J and 8-K show the completion of the filling cycle. After filling, collapsible package 22A of cartridge 22 is completely, or substantially completely, filled with chemical 20. To protect the chemical 20 from the environment, a film seal 32 can be placed over inlet 23 (or 37) of the substantially rigid cartridge body 24. Seal 32 can be a foil-laminated patch that is heat-sealed to patch receiving lip 33 of inlet 23, but seal 32 could be any equivalent device including, without limitation, a plug, a cap, plastic seal, etc. Alternatively, seal 32 could be attached to collar 28 instead of a patch receiving lip 33 of inlet 23. Seal 32 could be placed prior to removing the vacuum on the plunger end 25 of the cartridge 22. This helps to prevent spillage or leakage out of inlet 23 when the vacuum on the back end of the cartridge 22 is removed.
When the collapsible package is filled in this way, it substantially conforms to the interior surfaces of the substantially rigid cartridge body 24. By substantially conforming to the interior surfaces of the substantially rigid cartridge body 24, the collapsible package 22A receives the support required to resist the pressure developed within the cartridge 22 during the dispensing operation to avoid failure or rupture of the collapsible package 22A. In particular, when installed in the conventional caulking gun 10 (
FIGS. 8-L and 8-M show additional components to cartridge 22. As shown in
It is the unique, novel and functional cartridge design that makes this unique and novel factory filling process possible, necessary and useful.
In more detail, collapsible packages 42a and 42b are shown in the “reverse inflated” or full position. In this position, the ends of collapsible packages 42a and 42b towards the plunger 40 are closed by seals 45a. Conventionally, seals 45a are metal or plastic clips or clamps. Alternatively, seals 45a could be replaced by other sealing means, such as film-to-film heat sealing. The other end of collapsible packages 42a and 42b are attached to package retaining collars 44a and 44b. Package retaining collars 44a and 44b can have barbed teeth 51 along an outer surface, which will be explained further below. Referring specifically to collapsible package 42a, a leading edge 43a of collapsible package 42a is heat-sealed to an outer tapered edge (not labeled) of package retaining collar 44a. While this example uses a heat-seal to seal the collapsible package to the retaining collar, other means of sealing are acceptable, such as induction welding, hot air fusing, thermal impulse, ultrasonics, adhesives, etc. Collapsible package 42b is formed in an identical manner to that of collapsible package 42a and will not be further described. Collapsible packages 42a and 42b have package openings that are relatively as large as possible to facilitate fill operations by permitting large diameter fill nozzles to be inserted.
Substantially rigid cartridge body 39 has openings defined by a perimeter edge 46 of substantially rigid cartridge body 39, and internal edges 47 of a dividing septum 53. Generally, the openings defined by perimeter edge 46 and internal edges 47 will match the shapes formed by the package retaining collars 44a and 44b. In this case, the shapes are back-to-back “D” shapes of equal sizes. Other shapes are equally possible depending on the chemistries contained in the collapsible packages. Preferably, the substantially rigid cartridge package has threaded portion 50, which will be explained further below.
Manifold 48 includes a nub 54 with threads 56, a manifold outlet septum 41, a manifold retaining collar 49, and mating lip 52. Nub 54 and manifold outlet septum 41 form passageways 55. Passageways 55 form the same shape as package retaining collars 44a and 44b, and perimeter edge 46 and internal edges 47; however, the passageways 55 do not need to be the same shape. Not labeled, manifold 48 can have a shoulder around the perimeter on which a corresponding shoulder of manifold retaining collar can rest. Manifold retaining collar 49 has threads that correspond to threads 50 of substantially rigid cartridge body 39.
Once the collapsible packages 42a and 42b are fabricated, with the fabrication preferably occurring outside of the substantially rigid cartridge body 39, they are inserted into the substantially rigid cartridge body 39 through the opening defined by perimeter edge 46 and internal edges 47, which are at the end of the substantially rigid cartridge body 39 opposite the plunger 40, and typically filled, using a fill operation generally similar to the fill operation described above in
When the collapsible packages 42a and 42b are inserted into the substantially rigid cartridge body, the D-shaped package retaining collars 44a and 44b form a mechanical seal by abutting and mating with the correspondingly tapered perimeter edge 46 of the substantially rigid cartridge body 39 and the tapered inner leading edges 47 of the dividing septum 53. Because the leading edges 43a and 43b of the collapsible packages 42a and 42b were coupled to the outer tapered edges of the package retaining collars 44a and 44b, the mating of the various tapered edges sandwiches the collapsible packages 42a and 42b between the rigid mating parts forming the mechanical seal.
The sandwiching of the film between these two tapered and mated surfaces in this manner gives the collapsible packages more support and sealing strength than that provided from just the heat-seal to the package retaining collars 44a and 44b. The seals, for example the heat-seal and the mechanical seal, help inhibit the collapsible package from moving down the bore of the substantially rigid cartridge body during fill operations. Moreover, as shown best in
As described above, the pouch-retaining collars 44a and 44b are, but do not need to be, equipped with barbed teeth 51 that engage mating lip 52 molded into the corresponding regions of the manifold 48, with the teeth 51 and the lip 52 snapping into one another as the manifold 48 is pressed onto the package retaining collars 44a and 44b to lock the collapsible packages 42a and 42b to the manifold 48 so that, when the package-user disassembles the cartridge to recycle most of the dispensing cartridge 38, the fouled elements of the package that contain small amounts of chemical residue will be kept together for disposal and to prevent a mess. Notice, manifold 48 is not typically attached until after the filling operation. Other variations of such an interlocking method are also possible, with such interlocking variations also being within the scope of the present invention. In addition, gaskets (not shown) may also be installed to further seal the junction between the manifold and the retaining collars. Furthermore, instead of screwing the manifold retaining collar to the cartridge body, the manifold may be coupled to the substantially rigid cartridge body using a bayonet mount or other suitable means.
As shown in
The dividing septum 53, with inner leading edges 47 on either side, can be a molded integral part of the substantially rigid cartridge body 39, although it could also be manufactured separately and mated to the substantially rigid cartridge body 39. The manifold outlet septum 41 engages and aligns with the dividing septum 53 so that each passageway 55 is in fluid communication with the corresponding chemical in one of the collapsible packages 42a and 42b. Thus, the chemicals remain separate until they exit the passageway 55 into a nozzle (not shown), which can contain a static mixing unit.
The plunger 40 can be a conventional plunger or an embodiment of a plunger that is described below.
The nub 54 that protrudes from the center of the outer face of the manifold 48 contains male threads 56 that engage a correspondingly female-threaded disposable nozzle (not shown) that has contained within it a static mixer for properly blending the two components from the cartridge just prior to application. Located within the nub 54 are the two passageways 55 that are in fluid communication with the pouch assemblies 42a and 42b, directing the contents of the cartridge to the nozzle and the static mixer (not shown). Prior to use and during storage, the outlet openings of the nub 54 are closed with a plastic/metal-foil-laminated patch (not shown) that can be heat sealed to the perimeter of said outlet openings (with other closing methods also being possible), with the heat-sealed patch being removable before the cartridge is used. Notice that while it is preferable to have nub 54 be coupled to the nozzle by a threaded connection, other connections are possible, such as for example, a bayonet mount or other suitable means.
The components of this embodiment that are easily recyclable are: the substantially rigid cartridge body 39, the cartridge plunger 40, and the threaded manifold retaining collar 49, which components constitute the majority of the weight of the empty cartridge. The rest of the components of the cartridge 38, including the collapsible packages 42a and 42b and the manifold 48, will not be recyclable (at least not without some form of cleaning), and can be disposed of after the contents of the cartridge are dispensed.
Then, once the two respective chemical components are deposited within the collapsible packages 58a and 58b, the manifold 63 is lowered into place so that the tapered bottom edges 64 of the manifold 63 are abutted and mated to the corresponding interior tapered leading edges 60 of the substantially rigid cartridge body 62. Then, once the threaded manifold retaining collar 65 is screwed onto the threaded end 61 of the substantially rigid cartridge body 62, with the leading edges 59 of the collapsible packages 58a and 58b clamped between the mechanical seal formed by the mating tapered surfaces, the leading edges become mechanically supported around their entire perimeter, thus reducing the risk of failure of the film at this critical point. Moreover, once the clamping operation has been completed, it is then possible to cause the film to be sealed to both rigid surfaces 60 and 64, by heat sealing ultrasonic sealing, induction heating, thermal impulse or other means, to more positively effect a total seal at this junction. The septum 66 shown can be an integral part of the substantially rigid cartridge body 62 and both parts can be monolithically injection molded together when initially created. Alternatively, the septum 66 and the substantially rigid cartridge body 62 could be made separately. If made separate, septum 66 needs to be attached to the substantially rigid cartridge body 62. The attachment could be via glue, adhesives, heat sealing, snapping in place, latches, etc. The septum 66 is generally identical to the septum 53 shown in
In this embodiment, only the manifold retaining collar is readily recyclable.
Outer collapsible package 69 has a leading edge 71 defining a central opening 78, and an outer package retaining collar 73. Further, outer collapsible package has an end opposite central opening 78 that is closed with seal 80. Seal 80 is shown to be a conventional metal or plastic clamp or clip, but seal 80 could be any type of seal, such as a heat seal. Outer package retaining collar 73 has an outer perimeter edge 72, an inner perimeter edge 79, and optionally has collar support ribs 75b. Preferably, leading edge 71 is heat sealed to the outer perimeter edge 72 of the outer package retaining collar 73. Outer perimeter edge 72 and inner perimeter edge 79 can have tapered edges. Further, outer package retaining collar 73 can have barbed lips or grooves 88, which use will be explained further below.
Inner collapsible package 70 has a leading edge 74, which also defines an opening (not labeled), and an inner package retaining collar 77. Further, inner collapsible package 70 has an end opposite the opening (not labeled) that is closed with seal 80. Seal 80, conventionally is a metal or plastic clamp or clip, but seal 80 could be any type of seal, such as a heat seal. Inner package retaining collar 77 has an outer perimeter edge 76, preferably tapered. Inner package retaining collar 77 can have barbed lips or grooves 88 also, which use will be explained further below. Preferably, leading edge 74 is heat sealed to the outer perimeter edge 76 of the inner package retaining collar 77. Notice, while inner collapsible package 70 and outer collapsible package 69 are shown closed with a single seal 80, outer collapsible package 69 and inner collapsible package 70 could have a separate seal as a matter of design choice.
Inner collapsible package 70, with the leading edge 74 heat sealed to the outer perimeter edge 76, is inserted into the central opening 78 of the outer collapsible package 69. When inserted, the tapered outer perimeter edge 76 of the inner package retaining collar 77 mates with the corresponding tapered inner perimeter edge 79 of the outer package retaining collar 73. Thus, forming the concentric inner and outer collapsible packages 70 and 69.
The mating of perimeter edge 76 and inner perimeter edge 79 sandwiches the leading edge 74 of the inner collapsible package 70. Leading edge 74 can be sealed to inner perimeter edge 79 via heat sealing, ultrasonic sealing, induction heating, glues, adhesives, or other equivalent methods of sealing generally known in the art. The sandwiching of the leading edge 74 forms a mechanical seal to provide a clamping effect that gives mechanical support to the leading edge 74 of the inner collapsible package 70. If leading edge 74 is heat sealed to either perimeter edge 76 or inner perimeter edge 79, the heat seal provides support for the inner collapsible package 70.
Substantially rigid cartridge body 68 includes leading edge 81 and threads 91. When the inner and outer collapsible packages 70 and 69 are inserted in the substantially rigid cartridge body 68, a tapered portion of leading edge 81 forms a mechanical seal by abutting the corresponding tapered portion of outer perimeter edge 72 or outer package retaining collar 73. The leading edge 71 of outer collapsible package 69 is sandwiched between outer perimeter edge 72 of the outer collapsible package and inner leading edge 81 of the substantially rigid cartridge body 68. The sandwiching provides a clamping effect that provides additional mechanical support to the outer collapsible package 69.
Once the concentric inner and outer collapsible packages 70 and 69 are filled with chemicals, then a patch (not shown) can be sealed to a patch-receiving lip 85 of the inner package retaining collar 77 to provide enhanced isolation for the chemical contained within the inner collapsible package 70. The patch could be a plastic or foil laminate, or adhesives, a cap, a plug, etc. The patch provides separation between the chemical contained in the inner collapsible package 70 and the environment as well as the chemical contained in the outer collapsible package 69. The patch would be ruptured, punctured, or removed by the user prior to attempting to dispense the cartridge contents. If one of the chemistries contained in the concentric inner and outer collapsible packages 70 and 69 is more reactive to the environment then the more sensitive of the chemicals could be placed within the inner collapsible package 70 such that the outer collapsible package 69 (along with the patch sealed to the patch receiving lip 85), and the chemical in the outer collapsible package 69, would provide additional isolation from the environment. While not specifically shown, a separate patch could be provided over the outer package retaining collar 73, also. Alternatively, one patch could be provided over both the outer package retaining collar 73 and the inner package retaining collar 77.
Concentric septum 82 has septum alignment ribs 75a and a barbed groove or lip 87. Barbed groove or lip 87 corresponds to the barbed lip or groove 86 of the inner package retaining collar 77. Concentric septum 82 has an opening that defines an inner passageway (not labeled). Concentric septum 82 is connected to the inner package retaining collar 77 by snapping barbed groove 87 into barbed lip 86. Alternative connection means, such as snaps, glues and adhesives, are possible instead of the barbed groove and lip. Moreover, gaskets, such as “O-rings,” may be placed at the interlocking interface. While not necessary, aligning alignment ribs 75a with outer package retaining collar ribs 75b decreases resistance to the flowing of the chemicals during dispensing.
Manifold 83 fits over concentric septum 82. Of course, it is possible to design manifold 83 and concentric septum 82 as a single unit; however, for clarity, they have been shown as separate components. Manifold 83 has a barbed lip or groove 89 and a nub 90. Nub 90 has threads and a nub opening. The nub opening is of a larger diameter than the concentric septum opening and the space between the nub opening and the septum opening defines an outer passageway (not labeled). Barbed lip 89 can couple with the corresponding lip or groove 88 in the outer package retaining collar 73. The coupling between lips 89 and 88 can be eliminated, or accomplished in a number of different ways, such as pegs and holes, glues, tapes, etc.
The manifold retaining collar 84 fits over manifold 83 and couples to the threads 91 on the substantially rigid cartridge body 68. Other means of attachment are possible, such as a friction fitting, glues, heat seals. Also, while not labeled, it is possible to provide matching shoulders on manifold 83 and manifold retaining collar 84.
While sealing the chemicals was explained above, it is possible to replace the seals on, for example patch receiving lip 85 with a seal over the opening defined by the nub 90, or use patches at both locations for enhanced sealing.
During dispensing, the chemical in the inner collapsible package 70 moves to the outlet through the inner passageway defined by the concentric septum 83. The chemical in the outer collapsible package 69 moves to the outlet by moving around ribs 75a and 75b and through the passageway defined by the space between the nub 90 of manifold 83 and the concentric septum 82. The concentric septum unit 82 provides a barrier between the chemical from the inner collapsible package 70 and the chemical from the outer collapsible package 69 until they emerge at the outlet and enter the dispensing nozzle (not shown) and the static mixer (not shown, but which is normally contained within the dispensing nozzle).
Several joints, abutments, and mating surfaces have been identified above. Each of these “mechanical seals” can include a gasket, such as an “O-ring” or adhesive. Also, the above identified locking mechanisms using barbed lips or grooves, which can be removed or accomplished by alternative means, can be useful for disassembling the cartridge 67 for recycling the major parts of the cartridge after use.
Couplings defined above by threaded connections or friction fittings could also be accomplished by other devices, such as, metal bands or spin-welded plastic rings.
The plunger 92 is slidably inserted into the rear of the main rigid cartridge body 68. Other embodiments of plunger 92 are possible, some of which are explained further below.
The outlet end of the nub 90 can be sealed (via ultrasonics, induction weld sealing or other means) with a peelably removable plastic/aluminum-foil patch (not shown), or the outlet opening of the nub 90 can be sealed in other common alternative ways to isolate the contents of the cartridge from the outside atmosphere until the user opens the package to dispense the contents of the container.
Retaining collar 96 is placed internal to leading edge 93 of collapsible package 94. Leading edge 93 is sealed to the perimeter edge 95 using ultrasonic bonding, thermal bonding, thermal impulse bonding, induction-welding, glues, tapes, bands, or other methods, to form a collapsible package assembly 98.
Just like the embodiment described in FIGS. 8-A to 8-M, this embodiment is specifically designed for 1-component chemistries that are reactive to the environment, such as moisture-cured polyurethanes (in particular), polysulfides and some silicones that currently cannot be packaged in conventional all-plastic rigid caulking cartridges successfully because the moisture-vapor transmission rate (MVTR) through the plastic side-walls of such packages is too high to prevent the reactive chemistries from curing in the package after factory-filling and during storage. In particular, the plastic used for such conventional cartridges is polyethylene or polypropylene, because of their low cost and ease of injection molding or extrusion, among other reasons. The present invention provides an external, substantially rigid package, using such plastics as polyethylene or polypropylene, but provides an improved MVTR to conventional packages because of the use of the internal collapsible package that can be composed of, for example, aluminum foil, aluminum foil laminated within a plastic film sandwich, plastics with high resistance to moisture vapor transport. These packages make it possible to contain environmentally reactive chemistries with its major external substantially rigid components made of plastic.
To reiterate, the package assembly 98 is inserted into the substantially rigid cartridge body 97 from the nozzle end such that the tapered outer perimeter 95 of the package retaining collar 96 abuts and mates with the corresponding tapered leading edge 99 of the substantially rigid cartridge body 97, with the leading edge 93 of the collapsible package 94 being clamped between the two said rigid plastic components. This mechanical clamping action further supports and strengthens the ability of the collapsible film at this juncture to resist failure when pressure builds within the cartridge during dispensing or filling.
After the collapsible package 94 is filled with chemical, manifold retaining collar 101 is threaded to manifold 100 using threads 102 assist the clamping in a manner similar to that described in the previous embodiments. Similar to the embodiment described in
The components that are easily recyclable in this embodiment are the main rigid cartridge body 97, the plunger (not shown), and the threaded manifold retaining collar 101.
If the leading edge 105 of the collapsible package 106 is bonded to the leading edge 107 of substantially rigid cartridge body 108, then the manifold retaining collar 111 is easily recyclable. If the leading edge 105 is not bonded to leading edge 107, then the substantially rigid cartridge body is also easily recyclable.
Alignment grooves 120a and 120b in outer surface 121 are designed to help maintain plunger 119 in proper alignment with the collapsible packages to facilitate complete dispensing of the chemicals contained in each of, in this embodiment, two collapsible packages. Alignment grooves 120a and 120b are shown as generally “V-shaped” grooves; however, the grooves could be rounded, such as a “U-shaped”, or square or some other shape. Moreover, while two alignment grooves are shown, more or less could be used as a matter of design choice. Further, the grooves do not need to have 180 degrees separation, but could be placed closer together. Further, instead of alignment grooves, plunger 119 could have alignment rails or lips.
The alignment grooves 120a and 120b engage correspondingly shaped rails 127a and 127b (shown in
The leading face 122 of the plunger 119 (as used herein, leading face means the surface of the plunger in contact with the collapsible packages instead of the surface in contact with, for example, the push-plate 10a,
In this embodiment, the alignment grooves 120a and 120b of the plunger 119 assist in proper positioning of the plunger 119 when it is first slidably coupled to a substantially rigid cartridge body. Further, the alignment grooves of the plunger 119 help prevent the plunger 119 from rotating while it is slidably forced down the longitudinal bore of the substantially rigid cartridge body by, for example, the push-plate 10a of a conventional caulking gun 10 (
FIGS. 16-A, 16-B and 16-C illustrate the plunger 119 of
As shown in
To further facilitate ejection of the chemicals, the plunger 119 can have a tight interference fit within the substantially rigid cartridge body 126 from the plunger opening 125 to the nozzle end 128. However, a tight interference fit may inhibit the venting of any gas (usually air) trapped within the void regions between the inside surfaces of the main rigid cartridge body 126 and outer surfaces of the collapsible packages (not shown). While such a tight fit can aid in extending the shelf stability of the chemicals within the cartridge during storage or non-use, it can also lead to problems associated with vapor locking the plunger or pressurizing the trapped gas that may exist within the cartridge during dispensing. Pressure generated within the cartridge during dispensing, not only makes it difficult to dispense any chemicals, but could also cause chemicals to flow from the nozzle during pauses in or after completion of the dispensing operation.
Also shown in
As shown in phantom, substantially rigid cartridge body 131 can have alignment rails 138a and 138b. Alignment rails 138a and 138b are used with alignment grooves 137a and 137b in a manner similar to the one described above. Further, plunger 129 could have the shape and lobes as the plunger 119 described above.
As will be shown more fully in describing FIGS. 18-A to 18-C, plunger 129 provides the added benefit of venting whatever trapped air might be inside the cartridge during the dispensing operation. Moreover, plunger 129 reduces the amount of force required by the user to overcome frictional resistance of the interference fit of the plunger within the main rigid cartridge body as the said plunger is driven down the bore of the said cartridge. Plunger 129 is adaptable to be used with any cartridge described herein.
Plunger 129 is shown in various stages of travel down the bore of substantially rigid cartridge body 131 in FIGS. 18-A to 18-C.
In this example, the leading face 142 of the plunger 139 is uniformly concave in shape, which is one of many suitable shapes for the 1-component version of the present invention. The concavity of the plunger leading face 142 helps to fold the collapsible film of the pouch away from the wall of the cartridge and direct it toward the center of the plunger face and away from the edge of the plunger face, thus minimizing the possibility of pinching the pouch film between the edge of the plunger and the wall of the cartridge. Perimeter ribs 143, which are for convenience shown equally shaped and placed around the circumference of the plunger, are, in a longitudinal direction, flush with rear edge 144 of the plunger, but have protrusions 145 that extend slightly beyond the plunger leading face 142. Also shown in this view of the plunger 139 are the optional V-shaped alignment grooves 146a and 146b (shown larger for convenience), which operate in a manner described above in other embodiments of the present invention.
Upper inner surface 141a and lower inner surface 141b are described with transverse sectional views taken along the substantially rigid cartridge body 140 at A-A′ and B-B′ in
As shown in FIGS. 19-C1 and 19-C2, the shape of both the interior surface of the cartridge in the upper inner surface 141a of said cartridge body and the shape of the plunger 139 can be seen in their frictional-fit orientation to one another. The gray shaded area is a transverse cross-sectional view of the plunger 139, while the unshaded area is a transverse cross-sectional view of the 141a region of the cartridge body 140. The ribs 143 of the plunger fit tightly into the corresponding grooves 147 of the upper inner surface 141a of the said cartridge body. From this view, it can be appreciated that the plunger 139 slidably fits into the upper inner surface 141a the substantially rigid cartridge body 140 tightly in order to provide a barrier to gaseous fluid communication between the outside atmosphere and the interior of the cartridge body.
Then, if a transverse view is taken of substantially rigid cartridge body 140 at B-B′ in
Moreover, some additional advantages can be appreciated from the interaction of plunger 139 and cartridge body 140. First, as the said plunger travels from upper inner surface 141a to lower inner surface 141b the total surface contact area between the plunger and the cartridge interior is reduced, thus reducing the force required by the user to cause the plunger to slidably move down the bore of the cartridge. Second, because the peaks 150 of the ribs 143 and the protrusions 145 of the plunger 139 contact the bottoms 148a of the rectangular grooves 148 of the lower inner surface 141b of the substantially rigid cartridge body, it can be seen that the protrusions 145 can slide underneath the collapsible packages, which lie against the tops 148b of the rectangular grooves of the inside wall of the cartridge, during travel down the bore of the cartridge to gather it up, collapse it like an accordion, and avoid it being pinched between the said plunger and said cartridge body. Also, the protrusions 145 can act as a mechanical stop for the plunger 139 when it reaches the bottom or nozzle end of substantially rigid cartridge body 140.
In
FIGS. 22-A, 22-B and 22-C show, in sequence, another embodiment of the present invention capable of venting the inside of substantially rigid cartridge body 156 to the environment. In particular, a sidewall 155 of the substantially rigid cartridge body 156 has one or more vent passageways, or holes, 157 that can provide a means of gaseous fluid communication between the outside atmosphere and the interior regions of the cartridge. In
While the invention has been particularly shown and described with reference to some embodiments thereof, it will be understood by those skilled in the art that various other changes in the form and details may be made without departing from the spirit and scope of the invention.
This patent application is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/183,107, filed Jun. 26, 2002, titled METHOD OF FILLING DISPENSING CARTRIDGES, which is a divisional of U.S. patent application Ser. No. 09/908,420, titled DISPENSING CARTRIDGES HAVING COLLAPSIBLE PACKAGES FOR USE IN CAULKING GUNS, now U.S. Pat. No. 6,464,112, which is a continuation-in-part of U.S. patent application Ser. No. 09/391,798, filed Sep. 9, 1999, titled PACKAGING FOR MULTI-COMPONENT MATERIALS AND METHODS OF MAKING THE SAME, abandoned.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 09908420 | Jul 2001 | US |
| Child | 10183107 | Jun 2002 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10183107 | Jun 2002 | US |
| Child | 10996397 | Nov 2004 | US |
| Parent | 09391798 | Sep 1999 | US |
| Child | 09908420 | Jul 2001 | US |
