Patent Application
20160327074
This application relates generally to tools for dispensing polymer fasteners as well as methods pertaining to the dispensing of polymer fasteners.
There are many applications in which two workpieces are permanently or semi-permanently connected together. Fasteners such as screws, bolts, rivets, etc., may be used in such applications. In some implementations, it is useful to join workpieces with blind joints with fasteners that are not visible and/or are not accessible to observers. Blind joints can provide an aesthetically pleasing appearance and can be more tamper proof than non-blind joints because the fasteners are hidden and the joint itself is less obvious.
Some embodiments are directed to a fastener dispensing device. The device includes a strand dispenser configured to dispense a strand, the strand comprising an oriented shape memory polymer configured to expand laterally and contract longitudinally when heated. The strand dispenser includes at least two grippers that operate cooperatively to dispense the strand. A strand metering mechanism is configured to be operable in conjunction with the strand dispenser to dispense a predetermined length of the strand. A cutting mechanism is configured to cut the strand to form a fastener of the predetermined length.
Some embodiments involve a method of operating a fastener dispensing device. The fastener dispensing device includes a strand dispenser, a metering mechanism, and a cutting mechanism that are operably connected. The method includes operating a strand dispenser to dispense a strand and operating a metering mechanism to meter the amount of strand dispensed to a predetermined length. The strand comprises an oriented shape memory polymer configured to expand laterally and contract longitudinally when heated. After the dispensing and metering, the strand is cut to form a fastener of the predetermined length.
Some embodiments involve a device that includes a strand dispenser configured to dispense a strand of an oriented shape memory polymer that is configured to expand laterally and contract longitudinally when heated. A strand metering mechanism is configured to be operable in conjunction with the strand dispenser to dispense a predetermined length of the strand. A cutting mechanism is configured to cut the strand to form fasteners of the predetermined length.
The above summary is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The figures and the detailed description below more particularly exemplify illustrative embodiments.
Throughout the specification reference is made to the appended drawings wherein:
The figures are not necessarily to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.
Embodiments described herein involve systems for dispensing polymer fasteners that can be transformed into rivets used to join workpieces. These rivets can be used, for example, to provide blind or double blind joints where the rivet is not visible or accessible from one or both sides of the joint. The fasteners are formed of a length of an oriented shape memory polymer strand configured to expand laterally and contract longitudinally when heated. The strand may be cut into individual fasteners of a predetermined length that may be adjustable depending on the application. When the fasteners are heated, they shorten in length and expand in diameter. The transformation of the fastener material forms rivet heads when used in the appropriate substrate geometries.
Shape memory polymers have the ability to be set in a pre-set shape, deformed to an altered shape, and then revert back to the pre-set shape when exposed to the appropriate stimuli (e. g., changes in temperature, application of solvent, etc.). The fasteners discussed herein comprise a shape memory polymer in at least a portion of the fastener. In some implementations, the entire fastener is made from a shape memory polymer. Additional information about shape memory polymer materials that are useful as polymer rivets and methods for using such polymer rivets are further described in U.S. Publication 2012/0017422.
Shape memory polymers have a defined melting point (Tm) or glass transition temperature (Tg). Collectively, the melting point (Tm) or glass transition temperature (Tg) can be referred to as the transition temperature (Ttrans). Above the transition temperature, the polymers are elastomeric in nature, and are capable of being deformed with high strain. The elastomeric behavior of the shape memory polymers results from either chemical crosslinks or physical crosslinks (often resulting from microphase separation). The shape memory polymers can be glassy or crystalline and can be either thermosets or thermoplastics.
Generally, the shape memory polymer is chosen such that the Ttrans is at a temperature suitable for fastening workpieces, and above any temperatures to which the fastened workpieces might be expected to be exposed. In some embodiments the Ttrans is at least 50° C., at least 100° C., or at least 125° C. Generally the shape memory polymer will have an elastic modulus of at least 0.5 MPa at 80° C.
Useful shape memory polymers may be physically or chemically crosslinked. Examples of suitable chemical crosslinked shape-memory polymers include, but are not limited to, high density polyethylene, low density polyethylene, and polyethylene/polyvinyl acetate copolymers. Examples of suitable physically crosslinked shape memory polymers include, but are not limited to, linear block copolymers, such as thermoplastic elastomer having a hard segment as permanent shape and having a soft segment as switching temporary shape.
Examples of polymers that have been utilized in hard and soft phases of shape memory polymers include polyurethanes, polynorbornenes, polyethers, polyacrylates, polyamides, polysiloxanes, polyether amides, polyether esters, trans-polyisoprenes, polymethylmethacylates, cross-linked trans-polyoctylenes, cross-linked polyethylenes, cross-linked polyisoprenes, cross-linked polycyclooctenes, inorganic-organic hybrid polymers, copolymer blends with polyethylene and styrene-butadiene co-polymers, urethane-butadiene co-polymers, polymethylmethacrylate, polycaprolactone or oligo caprolactone copolymers, polylactic acids, polylactic acid/polyglycolic acid co-polymers, and photocrosslinkable polymers including azo-dyes, zwitterionic, and other photochromatic materials such as those described in the book Shape Memory Materials (Cambridge University Press 1998) by Otsuka and Wayman.
Suitable shape memory polymers include, but are not limited, to those described in Patent Application Publication WO 03/084489 Lendlein et al.); U.S. Pat. No. 5,506,300 (Ward et al.); U.S. Pat. No. 5,145,935 (Hayashi); U.S. Pat. No. 5,665,822 (Bitler et al.); Gorden, “Applications of Shape Memory Polyurethanes”, in Proceedings of the First International Conference on Shape Memory and Superelastic Technologies, SMST International Committee, pp. 115-19 (1994); U.S. Pat. No. 6,160,084 (Langer); U.S. Pat. No. 6,388,043 (Langer); Kim et al., in Polymer 37(26):578I-93 (1996); Li et al., in J Applied Polymer 62:631-38 (1996); Takahashi et al., in J. Applied Polymer Science 60:1061-69 (1996); Tobushi H., et al., in J Physique IV (Colloque C1) 6:377-84 (1996)); U.S. Pat. No. 5,155,199 (Hayashi); U.S. Pat. No. 7,173,096 (Mather et al.); U.S. Pat. No. 4,436,858 (Klosiewicz); U.S. Patent Application Publication 2005/244353 (Lendlein et al.); U.S. Patent Application Publication 2007/009465 (Lendlein et al.); U.S. Patent Application Publication 2006/041089 (Mather et al.); C. M. Yakachi et al., in Advanced Functional Materials, 18 (2008), 2428-2435; and D. L. Safranski et al., in Polymer, 49 (2008), 4446-4455.
Commercially available thermoplastic shape memory polymers include, but are not limited to, polymethylmethacrylate, poly(t-butyl acrylate) such as those available from PolymerExpert (France) under the trade designation “JTbu”, aliphatic polyether polyutherurethanes such as those available under the trade designation TECOFLEX (TFX) from Noveon Thermedics Polymer Products (Wilmington, Del.), polyether polyurethanes available under the trade designation DIARY (e.g., MM type, MP type, MS type and MB (microbead powder) type) from Diaplex Co., Ltd. (Japan), materials available under the trade designation CALO-MER from the Polymer Technical Group (Berkeley, Calif.), elastic memory composite available under the trade designation EMC from Composite Technology Development, Inc. (Lafayette, Colo.), and materials available under the trade designation VERIFLEX from Cornerstone Research Group (Beavercreek, Ohio).
Shape memory polymer can be produced in the form of an elongated strand of material having a substantially circular cross sectional shape, or having another cross sectional shape. In order for the strand to be useable as rivets, the polymer strand is cut into fasteners of appropriate length segments, where the length of the segments depends on its application. These fasteners can then be placed into their desired location to join two or more workpieces together. For example, in one implementation, a first end of the fastener can be inserted into a cavity in a first work piece and a second end of the fastener can be inserted into a cavity in a second workpiece. The fastener is heated producing longitudinal contraction and lateral expansion of the fastener within the cavities and causing the fastener to securely hold the first and second workpieces together.
In some implementations, longer fasteners can be used to create stronger bonds when compared to shorter fasteners because the additional fastener material of the longer fasteners forms deeper rivet heads when heated. However, the initial length of a fastener may be constrained by other factors, such as the depth of the cavity in a workpiece. In many applications, the fastener is cut to a predetermined length that produces a specified joining strength for a given application.
Embodiments described herein involve devices, systems, and methods for dispensing, metering, and cutting a shape memory polymer strand to a predetermined length. Some embodiments involve a device configured to dispense, meter, and cut a controlled, adjustable length of a continuous strand of polymer shape memory material with end deformation within a specified tolerance.
In some embodiments, dispensing 220 the fastener may include dispensing a first end of the cut polymer strand fastener into an opening in a first workpiece. The second end of the fastener may be inserted in an opening in a second workpiece. Next, the fastener may be heated to join the first and second workpieces through the transformation of the fastener including both the first and second ends under heat that causes the fastener to laterally expand and longitudinally contract.
In other embodiments, a first end of the polymer fastener is dispensed into an opening in a first workpiece and then heated to transform the fastener in the region of the first end. The heating does not substantially transform the fastener in the region of the second end. After the first end is heated and transformed, a second end of the fastener is placed in a second workpiece and then the second end is heated. The heating of the second end transforms the fastener in the region of the second end. In some embodiments, at least one of the openings in the first or second workpiece is a blind cavity. In some embodiments, at least one of the openings in the first or second workpiece is a through hole. Heating the first end may serve to affix the first end in the first workpiece to facilitate subsequent handling of the first workpiece, such as preventing the fastener from falling out of the through hole or cavity in the first workpiece during insertion of the second end of the fastener in the second workpiece.
In some embodiments, operating 210 the dispensing device comprises manually operating the dispensing device. The dispensing 220, metering 230, and cutting 240 may all occur as the result of user action, such as applying pressure to handles or other operating mechanisms of the dispensing device. In some embodiments, operating 210 the dispensing device comprises operating under automatic control. The dispensing 220, metering 230, and cutting 240 may all function automatically with minimal user input. In yet other embodiments, operating 210 the dispensing device involves operating the device by a combination of some manual and some automatic operations.
In the embodiment illustrated in
The second structure 382 includes a second handle 302, base plate 311, and a second gripper 322. The cutting mechanism 310 is attached to the base plate 311. The second structure 382 is rotatably attached to the first structure 381 by a pivot rod 375. A spring 376 is disposed between the first handle 301 and the second handle 302.
In the illustrated example shown in
In the “handles-open” position the second structure 382 is able to rotate in the counterclockwise direction (arrow 391) relative to the first structure 381 but additional rotational movement in the clockwise direction (arrow 392) is limited by the stop 331. In the “handles-closed” position the second structure 382 may be able to rotate in the clockwise direction (arrow 392) relative to the first structure 381 and may have limited or no additional rotational movement possible in the counterclockwise direction (arrow 391).
Moving from the “handles-closed” position to the “handles-open” position (also referred to herein as the first relative movement), the clockwise rotation of the second structure 382 relative to the first structure 381 causes the specified amount of strand 340a to be dispensed through an aperture 311a in the base plate. Moving from a “handles-open” position to the “handles-closed” position (also referred to herein as the second relative movement), the counterclockwise rotation (arrow 391) of the second structure 382 relative to the first structure 381 causes the strand that has been dispensed during the first relative movement to be cut, forming fasteners 345 of the predetermined length, L.
It will be appreciated that manual operation of a device configured to dispense polymer strand could be achieved in a number of other ways. The particular example disclosed herein is but one of a multitude of possible configurations for manual operation. Manual operation could be achieved by any manual mechanism that causes a length of polymer strand to be dispensed from a strand source, e.g., a roll, and cut to the predetermined length of the fastener.
To accomplish advancement of the strand with the device illustrated in
The metering mechanism 330 illustrated in
The metering mechanism 330 operates in conjunction with the strand dispenser 320 to dispense a predetermined amount of strand 340a. A larger exposed portion reduces the clockwise rotation (arrow 392) of the second structure 382 relative to the first structure 381 and reduces the length of the dispensed strand. A smaller exposed portion increases the clockwise rotation (arrow 392) of the second structure 382 relative to the first structure 381 and increases the length of the dispensed strand. The metering mechanism 330 shown in
In the device 300 illustrated in
When the handles 301, 302 move apart during the first movement, the spring 314 around the follower 312 pushes the follower 312 and the knife back away from the cut strand. As the knife moves away, the new piece of strand 340a is extended through the aperture 311a in the base plate 311 as described above.
During the second movement, when the handles 301, 302 are being squeezed together, the cam region 313 of the cam plate 309 pushes against the follower 312 to force the edge of the knife blade through the strand 340. As the handles 301, 302 are squeezed, the knife slides along the dispensing surface 311b and advances toward the strand 340 to cut the strand 340. The strand 340 is held stationary by the second gripper 322 and passes through the aperture 311a. During the second movement, a spring 314 disposed around the cam follower 312 is compressed between a first protrusion 311c of the base plate 311 and a collar 315 secured to the cam follower 312. In some embodiments, the cutting mechanism 310 is configured to cut the polymer strand 340 with less than 25%, less than 10% or even less than 2% distortion of a cross sectional shape of the polymer strand 340.
Gripper 400 shown in
Surface 881 may be angled such that surface 881 rises 0.75 inches (1.905 cm) above the top surface 884 of the base plate extension 811. Apertures 815 and 816 can have a diameter of 0.625 inches (1.588 cm). Aperture 816 extends through the base plate protrusion 311d, which has a thickness of 0.25 inches (0.635 cm). Aperture 815 extends through base plate protrusion 311c, which has a thickness of 0.25 inches (0.635 cm), and extends into the base plate extension 811 by an additional 0.5 inches (1.27 cm). Aperture 311a is located 0.375 inches (0.953 cm) from base plate side 885.
Returning now to the conceptual diagram of
The strand dispenser 101 pulls the polymer strand 105 from a source (not shown in
As discussed at least in connection with
In some embodiments, the strand dispenser 101 comprises one or more collet and tapered sleeve grippers. The collet and tapered sleeve grippers may be used to allow the polymer strand 105 to move in one direction, but not the opposite direction. Multiple collets can be used to move the polymer strand 105 by cooperatively moving the multiple collets relative to one another.
In another embodiment, the strand dispenser 101 comprises at least one dispensing roller. The dispensing roller assists in gripping and moving the polymer strand 105 through the device 100. In one embodiment, the polymer strand is disposed between a dispensing roller and a static element, such as a plate. The distance between the outermost edge of the roller and the plate is slightly smaller than the diameter of the polymer strand 105 to ensure pressure on the polymer strand 105. In another embodiment, the polymer strand is disposed between two dispensing rollers. The dispensing rollers may be capable of spinning in counterclockwise and/or clockwise directions, and as a result, moving the polymer strand 105 in a multiple directions. Where multiple rollers are used, the multiple rollers may be two rollers positioned directly across from one another, forming a straight line between the two centers of the rollers that is perpendicular to the lengthwise direction of the polymer strand 105. The distance between the outermost edges of the rollers is slightly smaller than the diameter of the polymer strand 105 to ensure pressure on the polymer strand 105. In some embodiments, the two or more dispensing rollers may be offset with one another along a length of the polymer strand.
In some embodiments, the strand dispenser 101 comprises at least one electromechanical motor, such as AC or DC rotary motor. The motor may be coupled to a dispensing roller so that the motor rotates the roller to control the movement of the polymer strand 105 toward the device output 100b. The motor may comprise a stepper motor that moves in discreet increments and is capable of controlling the dispensing of the polymer strand 105.
In some embodiments, the strand dispenser 101 comprises a ratchet wheel including a pawl and cogwheel arrangement. The pawl and cogwheel may be used to move the polymer strand 105 toward the output 100b of the device 100. The ratchet wheel may provide small increments of movement of the polymer strand 105 based on the size of teeth on a cogwheel. The ratchet wheel may be used in combination with an electromechanical motor or some other type of device to rotate the cogwheel.
In another embodiment, the strand dispenser 101 may comprise at least one spring loaded clamp. Two spring loaded claims may be used together as previously discussed to alternately grip the polymer strand and allow the polymer strand to pass through the clamps to move the polymer strand toward the output. A stepper motor, rotary motor, dispensing roller, and/or linear actuator may be used in combination with the spring loaded clamp to assist in moving the polymer strand 105.
In another embodiment, the strand dispenser 101 may comprise a mechanical or electromechanical linear actuator, such as a lead screw or solenoid. For example, the linear actuator may be coupled to the spring loaded clamps to open and close the clamps.
The device 100 also comprises a strand metering mechanism 102. The strand metering mechanism 102 controls the amount of polymer strand 105 that passes from the input 100a to the output 100b of device 100. By controlling the amount of polymer strand 105 that passes to the output 100b, the strand metering mechanism 102 can control the amount of polymer strand that is dispensed and the length, L, of the fastener that is cut from the polymer strand. The strand metering mechanism 102 may be adjusted to dispense a specific amount of polymer strand 105. The strand metering mechanism 102 may further comprise a calibration mechanism to ensure the strand metering mechanism 102 is dispensing the intended amount of polymer strand 105. The calibration mechanism allows the user to account for imperfections in the device or potential drift in accuracy of the strand metering mechanism 102 over the device's course of use. The strand metering mechanism 102 may comprise a stop feature, a metering wheel, and/or a software algorithm operating in conjunction with a stepper motor, an encoder, or any other component that facilitates the metering of a specified amount of the polymer strand 105 to be dispensed.
The metering mechanism is capable of stopping the strand dispenser 101 at a specific moment to dispense a specified amount of polymer strand 105. The metering mechanism may inhibit the strand dispenser 101 from dispensing additional polymer strand 105 until the polymer strand 105 has been cut by the cutting mechanism 103 to a form a fastener of predetermined length. The metering mechanism may include an adjusting component configured to adjust the metering mechanism to set the amount of polymer strand 105 that is dispensed at the output of the strand dispenser 101 and/or the length, L, of the fasteners cut from the strand. The adjustable component may be controlled by a dial, buttons, or any other input device that would allow the metering mechanism to be set to a particular state corresponding to a specified amount of strand dispensed and/or a predetermined fastener length, L. The adjusting component may be capable of locking into position to prevent the strand metering mechanism 102, once locked, from varying the amount of strand dispensed between cuts of the polymer strand 105.
The metering mechanism may have an element that displays an indicator of the amount of polymer strand 105 that will be dispensed and/or the length, L, of the polymer strand 105 that is to be cut by the cutting mechanism 103. The display may be a digital display, an analog display, a rule, or any other feature that provides an indication of the amount of polymer strand that will be dispensed by metering mechanism and/or the length, L of the fasteners to be cut from the strand.
In some embodiments, the strand metering mechanism 102 comprises a metering wheel. The metering wheel controls the amount of polymer strand 105 that moves through the device 100 and to the cutting mechanism 103. The metering wheel may have adjustable features described above. In some embodiments, the strand metering mechanism 102 comprises an encoder operating in conjunction with an electromechanical actuator such as a motor or linear actuator. An encoder can be arranged to provide an electrical signal or other indication related to the amount of strand dispensed and this signal can be used to control the dispensing of the strand.
The polymer strand is metered so that fasteners of predetermined length, L, are produced. There may be depth tolerances associated with cavities in the workpiece that polymer strand fasteners are placed into. Therefore, the metering mechanism may be arranged so that the fasteners are produced with a length that is within tolerance limits. If the fastener is too long, the fastener may not fit its designated cavity. Fasteners that are too short may result in fastener rivet heads having volumes that are below specified values. In some embodiments, the metering mechanism 102 is configured to meter the dispensed polymer strand so that the length of the fasteners is within 10%, 5%, or even 1% of the predetermined length, L.
The device 100 comprises a cutting mechanism 103. The cutting mechanism 103 can include at least one cutting feature arranged at a first location relative to the polymer strand 105. In some implementations, the cutting feature can include a blade having a sharp edge. The cutting feature may be configured to move across a dispensing surface of the device 100 towards the polymer strand 105. In some embodiments, the cutting mechanism 103 may further include a cutting stop to limit the motion of the cutting feature.
The cutting action occurs after a strand dispensing action during which the strand dispenser 101 dispenses a specified length of polymer strand 105. The cutting action cuts the strand into fasteners of a predetermined length, L. After the cutting feature cuts through the polymer strand 105, the cutting mechanism can be configured to return the cutting feature to its previous position in preparation for the next cut. For example, the cutting mechanism 103 may include a cutting feature retraction device, such as a spring, that retracts the cutting feature after the cutting action.
The polymer strand 105 may be held in place by a strand holder and/or gripper that is configured to limit movement of the polymer strand 105 while the strand 105 is being cut by the cutting mechanism 103. In some implementations, the strand holder comprises an aperture in the dispensing surface. The diameter of the aperture is larger than the strand diameter, allowing the strand 105 to move relatively freely along its longitudinal axis through the aperture, but limiting lateral movement of the strand 105 within the aperture. When a gripper is used in conjunction with an aperture, the aperture limits lateral movement and the gripper limits longitudinal movement of the strand during the cutting process. The lateral strand holder, the gripper, or both used together, facilitate an even cut to the polymer strand 105 and consistency between cut lengths.
The cutting mechanism 103 may comprise a knife blade, a scissors, a pincer, a saw blade, a rotary blade, a wire, a blunt edge, a pair of shear plates or any other feature that would assist in cutting the polymer strand 105.
The cutting mechanism 103 may comprise a knife blade having a sharp edge configured to provide a relatively smooth and clean cut of the polymer strand 105. The cutting mechanism may include a sharpening device that maintains the knife blade edge to a specified sharpness. The cutting edge of the knife blade may be straight, curved, or angled. For example, the cutting edge of the knife blade may have a semi-circle indentation in the blade material that is similar to the outer shape of the polymer strand 105. This indented half circle knife blade shape may distribute the forces applied on the polymer strand 105 resulting in a cleaner cut.
The cutting mechanism may have multiple blades that converge on the polymer strand 105. In some embodiments, the cutting mechanism may include two blades disposed on opposite sides of the polymer strand. For example, two indented semicircular circle knife blade may be disposed on opposite sides of the polymer strand 105, proving a large amount of cutting blade contact with the polymer strand 105. The cutting mechanism 103 may comprise a scissor, a pincer mechanism, or multiple shear plates.
When cutting the polymer strand 105, it is possible to distort the cross sectional shape of the polymer strand 105. For circular cross section strands, the distortion can increase the cross sectional diameter of the strand at some points. The tolerances associated with the holes that polymer strand fasteners are placed can be relatively small. Therefore, the cutting mechanism may be arranged so that the polymer strand 105 substantially maintains its original cross sectional shape and does not substantially distort when cut. If the polymer strand 105 is substantially distorted, the resultant polymer rivet fastener may not fit into its designated hole. In some embodiments, the cutting mechanism 103 is configured to cut the polymer strand 105 with less than 25%, less than 10% or even less than 2% distortion of a cross sectional shape of the polymer strand 105. In some embodiments, the knife blade or the multiple shear plates may cut the polymer strand 105 with less deformation and distortion of a cross sectional shape of the polymer strand 105 than other cutting features.
In some embodiments, the device 100 may also include a heater 107. The heater may be located near the spot where the polymer strand 105 and cutting mechanism 103 interact at the output 100b. The heater 107 can be arranged to heat a fastener after it is cut off from the polymer strand 105. The heater 107 may be configured to heat the fastener at both ends. In some embodiments, the heater may be configured to heat the fastener at a first end, but to not substantially heat the fastener at its opposite end. The heater 107 raises the temperature of the polymer material of the fastener above its transition temperature such that it expands laterally and contracts longitudinally to secure the fastener in the location it is placed. The heater 107 may comprise a heat shielding that protects the polymer strand 105 from the heater 107. Using the heat shield, the polymer strand 105 can be protected from stray heat so that the polymer strand that has not yet been dispensed from the device retains its original shape. In some embodiments, the heater is located on the side of the fastener farthest from the point of the polymer strand 105 that is cut. Some embodiments allow for the fastener to be heated on both ends, other embodiments allow for heating only at one end of the fastener.
In some embodiments, the strand dispenser 101 is configured to dispense multiple polymer strands from multiple sources, to dispense multiple strands of multiple diameters, and/or to dispense multiple strands of different types or lengths. Dispensing multiple polymer strands may increase the efficiency of the device 100 by increasing the production and/or placement of fasteners. In some configurations, the device is configured so that the multiple strands can be dispensed using one strand dispenser 101, one strand metering mechanism 102 and/or one cutting mechanism 103. In other embodiments, the device is configured so that each polymer strand of the multiple strands may have its own strand dispenser 101, its own strand metering mechanism 102, and/or its own cutting mechanism 103.
In some embodiments, the strand dispenser 101 is configured to allow selection of the source of the polymer strand from multiple possible strand sources. For example, the strand dispenser may be configured to allow selection of a polymer strand from multiple sources, wherein each source provides a strand of a different diameter. In this configuration, the diameter of the strand dispensed is selectable, either automatically or manually. The device 100 of this embodiment would be capable of being used for dispensing strands of multiple diameters without having to reconfigure the device to change the strand source. The strand dispenser 101 could comprise an input capable of accepting polymer strands from multiple sources, and an output capable of dispensing one strand, sequentially dispensing multiple strands and/or dispensing multiple strands substantially simultaneously.
The strand dispenser 101 may be capable of selecting a polymer strand from a first source, moving the selected strand to the output 100b using the strand dispenser 101, metering a specific amount of the selected strand using the strand metering mechanism 102, and cutting the selected strand using the cutting mechanism 103. After the selected polymer strand 105 is cut, the strand dispenser 101 may be configured to keep the polymer strand from the first source in the strand dispenser 101 if the next desired fastener is to be cut from the first strand source or to move the polymer strand back out of the strand dispenser 101 and to select a new polymer strand from a second source.
In some embodiments, the device is configured to dispense and cut the predetermined length of polymer strand 105 by manual operation. The strand dispenser 101, strand metering mechanism 102 and cutting mechanism 103 may all function as the result of user action. In other embodiments, the device is configured to dispense and cut the predetermined length of polymer strand 105 by automatic operation. The strand dispenser 101, strand metering mechanism 102 and cutting mechanism 103 may all function automatically with minimal user input. In other embodiments, the device is configured to dispense and cut the predetermined length of polymer strand 105 by a combination of both manual and automatic operations.
The system 1000 of
The processor 1051 may be programmed to implement software instructions that control the strand dispenser 1001, the metering mechanism 1002, the cutting mechanism 1003, to automatically produce fasteners 1004 having a predetermined length L. For example, the strand dispenser, metering mechanism, and cutting mechanism may include components as previously discussed in connection with
The system 1000 may also contain a positioning mechanism 1052 that moves the strand dispenser and device 1010. The positioning mechanism 1052 may be controllable by the processor 1051. The positioning mechanism 1052 moves the strand dispenser over holes 1120 positioned in a workpiece 1100 as illustrated in
A user may program the different diameters into the system or the processor 1051 may determine the diameter of the polymer strand based on measured or sensed parameters. One possible parameter could include the diameter of the hole or cavity where the polymer fastener is to be placed. For example, the processor 1051 may calculate the polymer fastener diameter based on the diameter of the cavity. In some embodiments, the processor 1051 may contain a predetermined sequence of various polymer fastener diameters and lengths that are to be dispensed into the holes 1120 of the workpiece 1100.
Particular materials and dimensions thereof recited in the disclosed examples, as well as other conditions and details, should not be construed to unduly limit this disclosure. Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as representative forms of implementing the claims.
Various devices and methods are provided.
Embodiment 1 is a device comprising: a strand dispenser configured to dispense a strand of an oriented shape memory polymer configured to expand laterally and contract longitudinally when heated, the strand dispenser including at least two grippers that operate cooperatively to dispense the strand; a strand metering mechanism configured to be operable in conjunction with the strand dispenser to dispense a predetermined length of the strand; and a cutting mechanism configured to cut the strand to form a fastener of the predetermined length.
Embodiment 2 is the device of embodiment 1, wherein the strand dispenser comprises a first structure and a second structure, the first and second structures configured to rotate relative to one another, wherein a first relative movement of the second structure relative to the first structure causes the strand dispenser to dispense the predetermined length and a second relative movement of the second structure relative to the first structure causes the cutting mechanism to cut the strand at the predetermined length.
Embodiment 3 is the device of embodiment 2, wherein the strand metering mechanism includes a stop configured to limit movement of the second structure relative to the first structure during the first relative movement to an amount of relative movement associated with the predetermined length.
Embodiment 4 is the device of embodiment 3, wherein the stop feature is adjustable to adjust the predetermined length.
Embodiment 5 is the device of any of embodiments 2 through 3, wherein the strand dispenser includes first and second grippers; and during the second movement, the second gripper grips the strand; the first gripper allows movement of the strand within the first gripper; and the first and second grippers move apart from one another.
Embodiment 6 is the device of embodiment 5, wherein the strand dispenser is configured so that during the first movement, the first gripper grips the strand; the second gripper allows movement of the strand within the second gripper; and the first and second grippers move toward one another.
Embodiment 7 is the device of any of embodiments 1 through 6, wherein the strand dispenser includes first and second grippers, each gripper configured to grip the strand, and wherein the strand dispenser is configured to move the grippers relative to each other to dispense the predetermined length of the strand.
Embodiment 8 is the device of embodiment 7, wherein the metering mechanism includes a stop configured to limit the relative movement between the first and second grippers.
Embodiment 9 is the device of any of embodiments 7 through 8, wherein the each of the first and second grippers comprises a collet and a sleeve.
Embodiment 10 is the device of embodiment 9, wherein the sleeve is tapered and the collet is split and comprises multiple wedges.
Embodiment 11 is the device of embodiment 10, wherein the collet wedges are serrated and each gripper includes a spring that pushes the collet into the taper of the sleeve.
Embodiment 12 is the device of any of embodiments 10 through 11, wherein each gripper is configured so that when the strand moves in the sleeve in a direction towards a wider portion of the taper, the collet wedges separate allowing the strand to move in the collet.
Embodiment 13 is the device of any of embodiments 1 through 12, wherein the strand dispenser comprises a plate having an aperture and wherein the strand dispenser is configured so that at least the predetermined length of strand extends through the aperture after cooperative operation of the first and second grippers to dispense the strand.
Embodiment 14 is the device of embodiment 13, wherein the strand dispenser is configured so that the second gripper grips the strand while the cutting mechanism cuts the strand at the predetermined length.
Embodiment 15 is the device of any of embodiments 13 through 14, wherein the cutting mechanism comprises a blade that slides over a surface of the plate and across the aperture.
Embodiment 16 is the device of any of embodiments 1 through 15, wherein the strand dispenser comprises a plate having a dispensing surface; and an aperture in the plate; and the cutting mechanism comprises a knife blade disposed proximate to the dispensing surface of the plate, the knife blade including the sharp edge; and a cam follower configured to move the knife blade toward the strand that extends through the aperture.
Embodiment 17 is the device of embodiment 16, wherein the cutting mechanism includes a spring coupled to the knife blade and configured to retract the knife blade away from the aperture.
Embodiment 18 is the device of any of embodiments 1 through 17, wherein the cutting tool is configured to cut the strand with less than 25%, less than 10%, or less than 2% distortion of a cross sectional shape of the strand.
Embodiment 19 is the device of any of embodiments 1 through 18, further comprising: a heater configured to heat the strand after the cutting mechanism cuts the strand at the predetermined length, the heating sufficient to cause the fastener to expand laterally and contract longitudinally at one end of the strand.
Embodiment 20 is a method comprising: operating a strand dispensing device comprising a strand dispenser, a metering mechanism, and a cutting mechanism that are operably connected, the operating comprising: dispensing a strand from the strand dispenser, the strand comprising an oriented shape memory polymer configured to expand laterally and contract longitudinally when heated; metering a predetermined length of the strand during the dispensing; and cutting the strand to form a fastener of the predetermined length.
Embodiment 21 is the method of embodiment 20, wherein dispensing the fastener comprises dispensing a first end of the fastener into an opening in a first workpiece; and after dispensing, metering and cutting; inserting a second end of the fastener into an opening in a second workpiece; and heating the fastener to join the first and second workpieces.
Embodiment 22 is the method of embodiment 21, wherein the opening in at least one of the first and second workpieces is an opening to a blind cavity.
Embodiment 23 is the method of embodiment 21, wherein the opening in at least one of the first and second workpieces is a through hole.
Embodiment 24 is the method of any of embodiments 20 through 23, wherein dispensing the fastener comprises dispensing a first end of the fastener into an opening in a first workpiece; heating the first end of the fastener; and after heating the first end of the fastener, inserting the second end of the fastener into a second workpiece; and heating the second end of the fastener.
Embodiment 25 is the method of any of embodiments 20 through 24, wherein operating the dispensing device comprises manually operating the dispensing device.
Embodiment 26 is the method of any of embodiments 20 through 25, wherein at least one of the dispensing, metering, and cutting is performed by the dispensing device under automatic control.
Embodiment 27 is a device comprising: a strand dispenser configured to dispense a strand; a strand metering mechanism configured to be operable in conjunction with the strand dispenser to dispense a predetermined length of the strand; and a cutting mechanism configured to cut the strand to form fasteners of the predetermined length, wherein the strand comprises an oriented shape memory polymer configured to expand laterally and contract longitudinally when heated.
Embodiment 28 is the device of embodiment 27, wherein the strand dispenser is configured to allow selection of strand diameter.
Embodiment 29 is the device of any of embodiments 27 through 28, wherein the cutting mechanism is configured to cut the strand with less than 25%, less than 10% or less than 2% distortion of a cross sectional shape of the strand.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2014/070439 | 12/16/2014 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 61916421 | Dec 2013 | US |
