Adhesive delivery system

Abstract

An adhesive delivery system comprising a female component defining a cavity, a male component adapted to mate with the female component, a package containing a hardenable (e.g., curable) composition therein, the package selectively attachable to the female component and disposed within the cavity, wherein when the male component is mated with the female component, the male component contacts the package thereby dispensing the curable composition into the cavity.

Description

ADHESIVE DELIVERY SYSTEMCLAIM OF PRIORITY

[0001] This application claims the benefit of the priority dates of United States Provisional Application Serial Nos. 63 / 532,278 filed August 11 , 2023, and 63 / 532,505 filed August 14, 2023, the contents of these applications being incorporated by reference herein in their entirety and for all purposes.BACKGROUND

[0002] This application describes a fixation system in which a curable composition, an adhesive or chemical fixation product (which are referred to herein interchangeably) that goes from a flowable state, e.g., as a liquid (whether having a relatively high viscosity (e.g., > 1 x 106centipoise (cPs)) or a low viscosity at room temperature (e.g., < 1 x 104cPs) or an intermediate viscosity therebetween) to a generally hardened state as a solid or otherwise, is incorporated into a mechanical fixation system to produce a durably bonded assembly with both mechanical and chemical fixation. Ideally, the resulting fixation can be realized in one operation assembly step or otherwise in a reduced number of assembly steps.

[0003] To increase the durability of bonded assemblies, a combination of mechanical fixation and a composition, such as a curable composition, which goes from a flowable state to a hardened state (e.g., from liquid to solid) is often employed. Traditionally the hardenable (e.g., curable) composition would be an adhesive applied to individual surfaces (in one step), and then mated together and joined by mechanical fasteners such as nails, pins, rivets, or bolts in another subsequent step. Similarly, an adhesive could be applied within a cavity of a first structure (e.g., an assembly or other part) which is then matingly interconnected with a second structure (e.g., an assembly or other part) such as by using a male component such as dowels or biscuits inserted into a female component of a second part. This is common, for example, in furniture assembly.

[0004] With large scale assemblies, automated processes, or short cycle times, limiting the number of manual processes or assembly steps increases speed and efficiency. This leads to the desire to have the chemical fixation component incorporated into the mechanical fixation component so that durable bonding can occur in one step. Additionally, having the chemical component in packaging that extends its latency or keeps it in a non-reactive state until assembly occurs, offers freedom and flexibility to the assembly process.SUMMARY OF THE INVENTION

[0005] The present teachings provide an improved system, method and resulting assembly that achieves some or all of the above desired attributes. As will be demonstrated, the teachings herein pertain to an adhesive delivery system (and method of using it), in which the system includes a female component defining a cavity, a male component adapted to mate with the female component, a package containing a hardenable (e.g., curable) composition therein, the package selectively attachable to the female component and disposed within the cavity, wherein when the male component is mated with the female component, the male component contacts the package thereby dispensing the hardenable (e.g., curable) composition into the cavity.

[0006] There are various additional features that may be employed in combination with the above. For example, the adhesive delivery system may include a dispersion portion (e.g., a dispersion plate) disposed in the cavity. Such dispersion portion (e.g., a dispersion plate) may include a concave portion formed therein.

[0007] The adhesive delivery system may include a directional portion (e.g., a directional plate).

[0008] The adhesive delivery system may include a directional portion (e.g., a directional plate), disposed in the cavity and positioned adjacent to the dispersion portion (e.g., dispersion plate).

[0009] The adhesive delivery system may include a directional portion (e.g., directional plate) that is defined to include a hole formed there through wherein the dispensed curable composition flows through the hole upon mating of the male and female components.

[0010] The adhesive delivery system may have a directional portion (e.g., a directional plate) that includes contours formed on a surface (e.g., a top surface) directing the dispensed curable composition to a specified location.

[0011] The adhesive delivery system may include a package that is attached (e.g., by an interlock connection) to the directional portion (e.g., a directional plate).

[0012] The adhesive delivery system may be adapted for delivering a hardenable (e.g., curable) composition that transforms from a flowable state to a hardened state (e.g., a liquid state to a solid state) after dispensing into the cavity.

[0013] The adhesive delivery system may include a catalyst or curing agent applied to a wall of the cavity promoting curing of the curable composition. In this manner, a hardenable resin of the adhesive may come into contact with the catalyst or curing agent during dispensing to initiate a chemical reaction involving the resin as a result.

[0014] The package may include a frangible seal that ruptures when the male component contacts the package.

[0015] The adhesive delivery system of claim 4 wherein the dispersion portion (e.g., dispersion plate) may include a pin formed thereon for piercing the package.

[0016] The teachings also contemplate a method for making a bonded assembly including the steps of providing an adhesive delivery system according to the above description and the description hereinafter and dispensing the hardenable composition using the adhesive delivery system (e.g., at or above room temperature) for bonding at least two parts together form a workpiece assembly using the hardenable (e.g., curable) composition of the of the adhesive delivery system.

[0017] The method may further include joining the at least two parts together with at least one mechanical fastener to form a work piece assembly that includes the at least two parts, the at least one mechanical fastener, and a hardened composition resulting from the hardenable composition.

[0018] Moreover, the teachings envision an assembly resulting from the use of the above and herein-described adhesive delivery system or from the method described above or hereinafter.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 is a partial sectional view of an adhesive delivery system.

[0020] Figure 2 is a partial sectional view of an adhesive delivery system showing a housing.

[0021] Figure 3 is a partial sectional view of an adhesive delivery system showing a housing and flow-path of a curable composition.DETAILED DESCRIPTION

[0022] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. Those skilled in the art may adapt and apply the teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes.Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0023] In general the adhesive delivery system herein contemplates a female component defining a cavity, a male component adapted to mate with the female component, a package containing a hardenable (e.g., curable) composition therein, the package selectively attachable to the female component and disposed within the cavity, wherein when the male component is mated with the female component, the male component contacts the package dispensing the hardenable (e.g., curable) composition into the cavity. The system further contemplates the employment of a flow control device, which may include one or both of a dispersing portion (e.g., dispersing plate) and a directional portion (e.g., directional plate). An actuator (e.g., a plunger) may be included for applying pressure to the package to cause the hardenable (e.g., curable) composition to exit the package. When included, the dispersing portion may be located upstream of either or both of the directional portion (e.g., directional plate) or the actuator.

[0024] To illustrate generally, referring to Figure 1-3, there is shown an adhesive delivery system 10. The adhesive delivery system 10 includes a female component 12 that defines a cavity 14 and receives a male component 15. The adhesive delivery system 10 includes a package 16 containing the curable composition 18 that may be kept in a temperature and / or humidity controlled environment before insertion into the cavity 14 of the female component 12 if desired. The system includes a frangible seal 20 for maintaining the composition within the package until use. A dispersing plate 22 and directional plate 24 are configured to facilitate, deflect, and / or redirect the flow of the adhesive after it exits passage from the collapsible package. An attachment method 26 attaches the dispersing plate 22 and directional plate 24. An actuator 28 can be activated to push the curable composition toward and out of the package.

[0025] In this application, a curable composition in a collapsible package is fixed within the cavity of the female component of a mechanical fixation. Any collapsible packaging from a molded polymeric container, a mono-layer polymeric sack or pouch to a multi-layer construction may be used. The collapsible package may have an attachment at one end to facilitate its insertion into the cavity such as a bayonet type fitting, a Luer lock type fitting, a compression type fitting, or a threaded type fitting.

[0026] The adhesive delivery system may include a directional portion (e.g., a directional plate) and / or a dispersing portion (e.g., a dispersing plate) as will be described in more detail below.

[0027] Though referred to as a “plate,” this is not intended to be limiting to a particular geometry for either of the dispersing or directional plates. However, it is preferable that either orboth plates have a width “WP” (e.g., a diameter if circular) greater than its height “HP”. Though illustrated with reference only to the dispersing plate the illustration of “WP” and “HP” applies also to the directional plate.

[0028] The dispersing portion (e.g., dispersing plate) may include a hollowed out portion that is defined by a flat and / or contoured wall surface 30. The wall surface 30 is configured to deflect or redirect the flow of the adhesive after it exits passage from the collapsible package. The redirection may be at an angle relative to the directional arrow A that is at least 30°, 60°, 90°, 120° or more.

[0029] The dispersing portion (e.g., dispersing plate) may include walls or other surfaces that may be configured to co-act with the directional plate to cause the flow of the adhesive to be selectively re-directed from the direction of advancement of the actuator.

[0030] The dispersing portion and the directional portion may form an assembly that includes two or more parts connected together. They may be a single part formed to include the functionalities of both plates, such as by an additive manufacturing technique.

[0031] Either or both of the dispersing portion (e.g., dispersing plate) or the directional portion (e.g, directional plate) may include one or a plurality of grooves, bores or other channel structures for directing flow of adhesive. Such channel structures may be dimensioned to have an average width in a direction transverse to the direction of travel of the adhesive during dispensing that is at least 1 mm, 3 mm, 5 mm or 10 mm. Such channel structures may be dimensioned to have an average width in a direction transverse to the direction of travel of the adhesive during dispensing that is less than 30 mm, 25 mm, or 20 mm.

[0032] The actuator (which may be a plunger) may be driven manually, by a motor, or otherwise. It may be part of or attached to a robot arm. It may be part of an applicator device (e.g., an applicator gun).

[0033] As can be appreciated, a volume of adhesive exiting the package first encounters the dispersing portion (e.g., dispersing plate) so its flow is redirected. The redirected flow then passes through the directional portion (e.g., directional plate). It is thus possible for the ultimate flow direction of the adhesive is determined by the directional portion. The directional portion (e.g., directional plate) may be configured as a manifold. It may include one or a plurality of channels that branches into a plurality of sub-channels before terminating at respective discharge orifices.

[0034] Upon assembly of the male and female components of the mechanical fixation, the package is compressed by the male component or actuator, and ruptured either at a frangible seal, a micro-perforated location, by contact with a lance or other suitable pin, or along a seam, forcing the curable composition out of the package and into the surrounds of the cavity. Theactuator may have a concave portion formed thereon at its end to maintain alignment of the collapsible package. Alternatively, no concave portion may be included.

[0035] In one aspect, the extruded or injected curable composition may be guided through a hole or a series of holes to an area between a directional plate and a dispersing plate as illustrated in Figure 1 . It is also possible that the directional or dispersing plate contains a pin or a lance to puncture the package. The dispersing plate may include a shaped portion formed therein that directs a flow of a curable composition that flows from the package to the top surface of the directional plate. The directional plate may include various contours formed thereon to direct the curable composition to a desired location. In one aspect, the directional plate top surface is shaped to direct flow downwardly as shown by the directional arrows B in the figures. The directional plate may include slots or openings formed therein to allow passage of the curable composition to the cavity.

[0036] In one aspect, when a directional plate is utilized, the curable composition may flow through an opening formed in the directional plate. For such applications, the collapsible package may rupture at the interface with the directional plate. For applications that do not include a directional plate, the collapsible package may rupture at any location, distributing the curable composition throughout the cavity.

[0037] The directional plate and the dispersing plate may guide the curable composition to specific locations within the cavity such as, but not limited to, the wall of the cavity as shown in Figure 2. Or, in the case of a double walled cavity, between the inner and out walls as shown in Figure 3.

[0038] Upon release from the package, the curable composition will begin to increase in molecular weight, going from a liquid to a solid. In one aspect, the rheology of the curable composition at a given temperature will allow it to flow where it is directed when released from the collapsible packaging but remain within the cavity until it solidifies. In one aspect, the cavity may be treated with an accelerator, catalyst, or curative which could cause an increase in the cure rate of the curable composition upon contact.

[0039] Various hardenable (e.g., curable) compositions may be utilized. Curable compositions may include polyurethanes, epoxies, acrylics, silicones, silane modified polymers (SMP), and hybrids of described chemistries. The collapsible package should maintain the latency of these chemistries. For example, in the case of acrylics, the collapsible packaging should protect the curable composition from free radical generation. In the case of an SMP composition, the collapsible packaging should protect from moisture.

[0040] In use, when the female component is mated with the male component, the male component is moved relative to the female component along the directional arrow A. The male component contacts the package. The package releases the curable composition as described above and the curable composition is directed through the opening formed in the directional plate. The curable composition then is retained between the directional plate and the dispersing plate. The contours on the top surface may then direct the curable composition as shown by the directional arrows B to a specified location in the cavity.General Comments Applicable to All Embodiments

[0041] It will be appreciated that, even though multiple embodiments may be described separately, features of one may be combined with features of another and remain within the present teachings. The depictions therein thus should be regarded as generalized and applicable to the teachings as a whole herein.

[0042] As discussed above, it can be seen that the teachings are applicable to compositions that can be hardened by a curing reaction that results in crosslinking to form a thermoset hardened (e.g., cured) adhesive composition. The teachings herein also may be employed with compositions that realize a hardened thermoplastic adhesive. Further, the system herein could be adapted for use with a hot melt adhesive (e.g., by introducing a heater therein (such as in and / or upstream of the directional and / or dispersion plate) to soften the adhesive to make it flowable during use of the system).

[0043] The present system may be employed with a one component adhesive or a multicomponent adhesive (e.g., a two-component adhesive). The adhesive may be a room temperature cure adhesive. It may be an activatable adhesive, which requires application of elevated heat (e.g., to above 50°C, 75°C, 100°C or more, radiation (e.g., ultraviolet radiation) and / or moisture to cause the adhesive to cure.

[0044] Thus it is possible that the present system may be used with an adhesive that includes a cross-linkable monomer and a curing agent that are kept separate until time of application. An example of such an adhesive includes an A side and a B side, wherein the A side includes an epoxy and the B side includes a phosphate ester and / or phosphoric acid. Such a system is described in WO 2020 / 101732 A1 , incorporated by reference in its entirety. Also, among the adhesives that may be employed are those described in U.S. Patent No. 9,586,363, incorporated by reference in its entirety. The adhesive may thus include bisphenol A diglycidyl ether (BADGE) and monoethanolamine and may exhibit a Tg of 80° C. For some applications that may require a higher glass transition temperature (Tg), it is contemplated that BADGE may be replaced by an epoxy monomer with less mobility. Such epoxy monomers may includediglycidylether of fluorene diphenol or 1 ,6 naphthalene diepoxy. Also, it is contemplated that where fire resistance is desired, BADGE can be replaced by a brominated bisphenol A epoxy resin.

[0045] Still further among the adhesives useful herein are one component epoxy adhesive compositions that include a curing agent (e.g., dicyandiamide), one or more optional thermoplastic ingredients (e.g., a phenoxy), one of more core-shell particle impact modifier, and optionally a blowing agent.

[0046] Any of the adhesives may include a blowing agent, a thixotrope, a filler (e.g., a calcium compound (e.g., calcium carbonate and / or calcium oxide)), a flame retardant, graphite (e.g., intercalated graphite and / or expandable graphite), or any combination thereof.

[0047] Any of the adhesives may include an ingredient that is derived from a plant. For example, it may include cashew nutshell oil or a derivative thereof (e.g., a derivative that includes a glycidyl or epoxide functionality).

[0048] Viscosity as discussed herein is measurable using ASTM D1084-16(2021).

[0049] The term “harden” is not intended as being limited to only thermosetting materials. Hardening may be a result of crosslinking and curing of resin. In both scenarios one particular consideration for “hardening” is that the material exhibits rigidity like a solid and is significantly more resistant to flow as compared with the material in a liquid state.

[0050] The disclosures of all articles and references, including patent applications and publications, are incorporated by reference in their entirety for all purposes. The term “consisting essentially of’ to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist of, or consist essentially of the elements, ingredients, components or steps.

[0051] Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of “a” or “one” to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

[0052] It is understood that the above description is intended to be illustrative and not restrictive. Many embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of theinvention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventors did not consider such subject matter to be part of the disclosed inventive subject matter.

Claims

Claims1. An adhesive delivery system comprising: a female component defining a cavity, a male component adapted to mate with the female component, a package containing a hardenable (e.g., curable) composition therein, the package selectively attachable to the female component and disposed within the cavity, wherein when the male component is mated with the female component, the male component contacts the package thereby dispensing the curable composition into the cavity.

2. The adhesive delivery system of claim 1 including a dispersion portion (e.g., a dispersion plate) disposed in the cavity.

3. The adhesive delivery system of claim 2 wherein the dispersion portion (e.g., a dispersion plate) includes a concave portion formed therein.

4. The adhesive delivery system of claim 2 including a directional portion (e.g., a directional plate)disposed in the cavity and positioned adjacent to the dispersion portion (e.g., dispersion plate).

5. The adhesive delivery system of claim 4 wherein the directional plate includes a hole formed there through wherein the dispensed curable composition flows through the hole upon mating of the male and female components.

6. The adhesive delivery system of claim 4 wherein the directional portion (e.g., a directional plate) includes contours formed on a top surface directing the dispensed hardenable (e.g., curable) composition to a specified location.

7. The adhesive delivery system of claim 4 wherein the package is attached to the directional portion (e.g., a directional plate).

8. The adhesive delivery system of claim 1 wherein the curable composition transforms from a flowable state to a hardened state (e.g., a liquid state to a solid state) after dispensing into the cavity.

9. The adhesive delivery system of claim 1 including a catalyst or curing agent applied to the cavity promoting hardening (e.g., curing) of the curable composition, preferably by having a hardenable resin contact the catalyst or curing agent during dispensing to cause a chemical reaction involving the hardenable resin to occur.

10. The adhesive delivery system of claim 1 wherein the package includes a frangible seal that ruptures when the male component contacts the package.

11. The adhesive delivery system of claim 4 wherein the dispersion portion (e.g., dispersion plate) includes a pin formed thereon for piercing the package.

12. The adhesive delivery system of any of the previous claims wherein the dispersion portion (e.g., a dispersion plate) includes a concave portion formed therein.

13. The adhesive delivery system of any of the previous claims including a directional portion (e.g., directional plate) disposed in the cavity and positioned adjacent (e.g., possibly in at least partial contact) to the dispersion portion (e.g., directional plate) .

14. The adhesive delivery system of any of claims 2 through 13 wherein the directional portion (e.g., directional plate) includes a hole formed there through wherein the dispensed curable composition flows through the hole upon mating of the male and female components.

15. The adhesive delivery system of any of claims 2 through 14 wherein the directional portion (e.g., directional plate) includes contours formed on a top surface directing the dispensed curable composition to a specified location.

16. The adhesive delivery system of any of claims 2 through 15 wherein the package is attached to the directional portion (e.g., directional plate).

17. The adhesive delivery system of any of claims 2 through 16 wherein the curable composition transforms from a flowable (e.g., liquid) state to a hardened (e.g., solid) state after dispensing into the cavity.

18. The adhesive delivery system of any of claims 1 through 17 including a catalyst or curing agent applied to the cavity promoting hardening (e.g., curing) of the hardenable (e.g., curable) composition, preferably by having a hardenable resin contact the catalyst or curing agent during dispensing to cause a chemical reaction involving the hardenable resin to occur.

19. The adhesive delivery system of any of claims 1 through 18 wherein the package includes a frangible seal that ruptures when the male component contacts the package.

20. The adhesive delivery system of any of claims 2 through 19 wherein the dispersion portion (e.g., dispersion plate) plate includes a pin formed thereon for piercing the package.

21. A method for making a bonded assembly including the steps of providing an adhesive delivery system according to any of claims 1 through 20, and dispensing the hardenable composition using the adhesive delivery system (e.g., at or above room temperature) for bonding at least two parts together form a workpiece assembly using the hardenable (e.g., curable) composition of the of the adhesive delivery system.

22. The method of claim 21 , wherein the method further includes joining the at least two parts together with at least one mechanical fastener to form a work piece assembly that includes the at least two parts, the at least one mechanical fastener, and a hardened composition resulting from the hardenable composition.

23. An assembly resulting from the use of the adhesive delivery system of any of claims 1 through 20 or from the method of claims 21 or 22.

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