U.S. patent application number 16/375515 was filed with the patent office on 2019-07-25 for two part molded part useful as a mixer for viscous curable materials.
The applicant listed for this patent is DDP Specialty Electronic Materials US Inc.. Invention is credited to Michael C. Cocca, Gary L. Jialanella, Andrew R. Kneisel, Larry R. Ruddy, Peter J. Schulz, Matthew J. Turpin, Lirong Zhou.
Application Number | 20190224634 16/375515 |
Document ID | / |
Family ID | 48050269 |
Filed Date | 2019-07-25 |
United States Patent
Application |
20190224634 |
Kind Code |
A1 |
Jialanella; Gary L. ; et
al. |
July 25, 2019 |
TWO PART MOLDED PART USEFUL AS A MIXER FOR VISCOUS CURABLE
MATERIALS
Abstract
The present invention relates to articles comprising a plurality
of molded hollow parts having different central axis through the
hollow elements further having passages in walls of the hollow
parts transverse to the central axis of the hollow parts. The
present invention also relates to methods of applying two part
curable materials to substrates using the molded parts of the
invention as mixing elements.
Inventors: |
Jialanella; Gary L.;
(Oxford, MI) ; Zhou; Lirong; (Rochester Hills,
MI) ; Kneisel; Andrew R.; (Clarkston, MI) ;
Ruddy; Larry R.; (Lake Orion, MI) ; Schulz; Peter
J.; (Midland, MI) ; Turpin; Matthew J.;
(Sanford, MI) ; Cocca; Michael C.; (Macomb,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DDP Specialty Electronic Materials US Inc. |
Midland |
MI |
US |
|
|
Family ID: |
48050269 |
Appl. No.: |
16/375515 |
Filed: |
April 4, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15498816 |
Apr 27, 2017 |
10265666 |
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16375515 |
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14765385 |
Aug 3, 2015 |
9675943 |
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PCT/US2013/031291 |
Mar 14, 2013 |
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15498816 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01F 5/0605 20130101;
B29B 7/04 20130101; B29C 65/485 20130101; B01F 2215/006 20130101;
B01F 5/061 20130101; B01F 5/0612 20130101; B01F 2215/0049 20130101;
Y10T 428/19 20150115; B01F 2005/0631 20130101; B01F 5/0615
20130101; B01F 3/10 20130101 |
International
Class: |
B01F 5/06 20060101
B01F005/06; B29B 7/04 20060101 B29B007/04; B29C 65/48 20060101
B29C065/48; B01F 3/10 20060101 B01F003/10 |
Claims
1. An article comprising: two parts wherein each part has two or
more sections connected together wherein each section is formed
from one or more a molded materials wherein the molded materials
form the periphery of a hollow structure having a proximal end, a
distal end, a cross section and open passages in the molded
material on the periphery of the hollow structure, and a central
axis through the hollow structure transverse to the cross section
of the molded material; wherein adjacent sections are connected
near the proximal end of each section and the angle formed by the
central axis of adjacent connected sections is from about 45 to
about 90 degrees.
2. The article of claim 1, wherein the molded material of each
section forms a consistent cross-section formed along planes
perpendicular to the central axis of the hollow structure.
3. The article of claim 1, wherein the cross-section formed by the
molded material is oval, circular or polygonal.
4. The article of claim 1, wherein the molded material comprises
metal, thermoplastic resins or thermoset resins.
5. The article of claim 1, wherein the molded material comprises
one or more thermoplastic resins or thermoset resins which further
comprises one or more fillers, reinforcing fibers or mixtures
thereof.
6. The article of claim 1, wherein the adjacent elements are
connected together near the proximal end at a location from the
proximal end that is equal to half the linear distance of the
central axis of two sequential elements of the same orientation
while in the assembled state.
7. The article of claim 1, wherein one or both parts have connected
to at least one end a molded structure of another shape.
8. The article of claim 1, wherein the passages in the molded
material have a central axis through the passages; and an angle
formed by the central axis of the hollow structure of each section
and the central axis of the passages in the molded material is from
about 45 to about 90 degrees.
9. The article of claim 8, wherein one part has connected to one
end a molded structure comprising one or more helical shaped
elements.
10. The article of claim 1, wherein the two parts are
assembled.
11. The article of claim 1, comprising three or more elements
wherein the cross-section of the structure formed by the molded
material is a square for each element, the elements are connected
at opposing corners of the structure and one of the sections
further comprises a molded section comprising more than one helical
structures.
12. The article of claim 11, wherein each of the more than one
helical structures forms a helical path that rotates about 180
degrees and a starting point of the helical path of each helical
structure is rotated about 90 degrees relative to an ending point
of a preceding one of the more than one helical structures.
13. A method comprising a) introducing two parts of a curable
material having a high viscosity into an elongated mixing chamber
having a mixer comprising an article according to claim 1, an inlet
and an outlet; b) applying sufficient pressure on the material
entering the inlet of the chamber to move the material through the
chamber in contact with the mixer under conditions that the two
parts are mixed sufficiently to cure and perform the desired
function of the curable material; and c) applying the mixed two
parts of the curable material to one or more substrates.
14. The method of claim 13, which further comprises d) contacting a
first substrate with a second substrate with the mixed two part
curable material disposed between the two substrates; and e)
allowing the mixed two part curable material to cure and bond the
two substrates together.
15. The method of claim 13, wherein the mixer comprises a helical
portion including one or more helical elements and each of the two
parts includes two or more hollow elements wherein the helical
portion is disposed at the inlet end of the mixing chamber so that
the two parts of the curable material passes through the helical
elements before passing through the hollow elements.
16. The method of claim 15, wherein the mixer has from about 3 to
about 5 helical elements and from about 3 to about 6 hollow
elements.
17. The method of claim 13, wherein the viscosity of the two part
of the curable material is from about 30,000 to about 5,000,000
Pas.
18. The method of claim 13, wherein the pressure applied to the two
parts of the curable material is from about 150 to about 500
psi.
19. The method of claim 13, wherein the two part curable material
is contacted at a volumetric ratio of 1:1 to 100:1.
20. The method of claim 13, wherein the two parts of the curable
materials are introduced from a single tube having the lowest
volume part enclosed in a bag within the highest volume part.
Description
FIELD OF THE INVENTION
[0001] The invention relates to articles comprising a plurality of
molded hollow parts having different central axis through the
hollow elements further having passages in walls of the hollow
parts transverse to the central axis of the hollow parts. The
invention also relates to methods of applying two part curable
materials to substrates using the molded parts of as mixing
elements.
BACKGROUND OF THE INVENTION
[0002] Two part curable compositions are used in a variety of
applications such as adhesives, coatings, foams and the like, where
rapid cure is required for the application, especially where the
two parts are not shelf stable when in contact with one another.
Shelf stable means that the composition does not cure in storage.
Two part curable compositions which exhibit high viscosities may be
difficult to mix and apply. Examples of such systems are disclosed
in WO 2012/151086 and WO 2012/151085, incorporated herein by
reference in their entirety. This is especially a problem where the
two parts are mixed in a relatively high volumetric ratio of one
part to the other. When the two parts are mixed in high volumetric
ratio of one part to the other, the two dissimilar parts may be
stored in a bag in bag tube, wherein the smaller volumetric part is
stored in a bag disposed in the higher volumetric part, one of the
bags is generally disposed along the outer wall forming the tube.
The bag forms a barrier to contact of the two parts. This
configuration allows for utilizing any volumetric ratio without
concern for the size of the material tubes and their ability to
work with standard two part mixers. Common concerns include high
back pressure of the curable material and thorough mixing of the
materials. If the back pressure resulting from introducing highly
viscous materials into the mixer used is too high, the curable
materials will not pass through the mixing chamber and cannot be
applied. If the two parts are not adequately mixed the curable
material will not cure in a manner desired. A complicating factor
is that many two part composition are applied in remote locations
or by consumers, where there is limited or no access to applicators
capable of applying sufficiently high pressures to overcome the
back pressures and thoroughly mix the parts. Many common manually
driven or battery driven applicators do not have the capability to
overcome backpressures resulting from trying to pass a highly
viscous material through mixers capable of properly mixing such
compositions.
[0003] Complex mixing systems have been developed to address these
problems, see for example, EP 1,189,686; EP 1,830,070 and EP
2,011,562 incorporated herein by reference in their entirety. Such
systems can be complicated to use or costly to manufacture.
[0004] What is needed is mixer systems that can thoroughly mix
highly viscous two part compositions using manual and battery
operated applicators without creating unacceptable back pressures,
which are easy to use and can be manufactured in a cost effective
manner. What are needed are methods for applying viscous two part
curable systems utilizing such mixing systems.
SUMMARY OF THE INVENTION
[0005] The invention relates to articles comprising a plurality of
molded hollow parts having different central axis through the
hollow elements further having passages in walls of the hollow
parts transverse to the central axis of the hollow parts. The
invention also relates to methods of applying two part curable
materials to substrates using the molded parts as mixing
elements.
[0006] The invention relates to articles comprising: two parts each
part having two or more sections connected together wherein each
section is formed from one or more molded materials, which form the
periphery of a hollow structure having a proximal end, a distal
end, a cross section and open passages in the molded material on
the periphery of the hollow structure, a central axis through the
hollow structure transverse to the cross section of the molded
material and the passages in the molded material having a central
axis through the passages; wherein adjacent sections are connected
near the proximal end of each section and the angle formed by the
central axis of adjacent connected sections is from about 45 to
about 90 degrees and the angle formed by the central axis of the
hollow structure of each section and the central axis of the
passages in the molded material is from about 45 to about 90
degrees; wherein each part is a mirror image of the other and the
two parts can be assembled to form an article having a portion
which is symmetrical. Preferably, the molded material of each
section forms a consistent cross-section formed along planes
perpendicular to the central axis of the hollow structure.
Preferably, the adjacent elements are connected together near the
proximal end at a location from the proximal end that is equal to
about half or less of the linear distance of the central axis of
two sequential elements of the same orientation while in the
assembled state. In some embodiments one part has connected to one
end a molded structure comprising one or more asymmetrical
portions, such as helical shaped elements. Preferably, the two
parts are assembled.
[0007] In another embodiment, the invention is a method comprising:
a) introducing two parts of curable material having a high
viscosity into an elongated mixing chamber having a mixer
comprising an article of the invention, an inlet and an outlet,
wherein the helical portion is disposed at the inlet end of the
chamber so that the two parts of the curable material passes
through the helical section first; b) applying sufficient pressure
on the material entering the inlet of the chamber to move the
material through the chamber in contact with the mixer under
conditions that the two parts are mixed sufficiently to cure and
perform the desired function of the curable material; and c)
applying the mixed two parts of the curable material to one or more
substrates. Preferably the method further comprises: d) contacting
a first substrate with a second substrate with the mixed two part
curable material disposed between the two substrates; and e)
allowing the mixed two part curable material to cure and bond the
two substrates together.
[0008] The articles of the invention can be manufactured in two
part molds in a cost effective manner. The articles are effective
in mixing two part curable compositions using manual or battery
driven application systems.
DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 show two parts of an article of the invention useful
as a static mixer.
[0010] FIG. 2 shows the two parts of the article of FIG. 1 from
another angle.
[0011] FIG. 3 shows an article in two parts one having a helical
section.
[0012] FIG. 4 is an applicator of FIG. 3 from another angle.
[0013] FIG. 5 shows the article of FIGS. 3 and 4 assembled and from
its end.
DETAILED DESCRIPTION
[0014] The explanations and illustrations presented herein are
intended to acquaint others skilled in the art with the invention,
its principles, and its practical application. Accordingly, the
specific embodiments of the present invention as set forth are not
intended as being exhaustive or limiting of the invention. The
scope of the invention should 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. The following claims
are hereby incorporated by reference into this written
description.
[0015] The invention relates to an article that can be prepared in
two parts which two parts can be assembled to form an article which
is symmetrical or which has a symmetrical portion. The two parts
are molded parts and can be molded using two part molds. Where the
article is completely symmetrical a single two part mold may be
utilized to prepare the two parts. In other words if the two parts
are identical and can be mirror images of one another a single mold
can be utilized. The two parts are capable of being assembled to
form an article which is symmetrical or which has a symmetrical
portion. If one or both of the two parts contain a non-symmetrical
section two molds are required. Symmetrical as used herein means
the parts can fit together to form a part that is virtually
identical on each side of a plane running through the center from
the proximal to the distal end. In general the article comprises:
two parts wherein each part has two or more sections connected
together wherein each section is formed from one or more molded
materials wherein the molded materials form the periphery of a
hollow structure having a proximal end, a distal end, a cross
section and open passages in the molded material on the periphery
of the hollow structure, a central axis through the hollow
structure transverse to the cross section of the molded material
and the passages in the molded material having a central axis
through the passages; wherein adjacent sections are connected near
the proximal end of each section and the angle formed by the
central axis of adjacent connected sections is from about 45 to
about 90 degrees and the angle formed by the central axis of the
hollow structure of each section and the central axis of the
passages in the molded material is from about 45 to about 90
degrees; wherein each part or a portion thereof is a mirror image
of the other and the two parts mirrored parts can be assembled to
form a symmetrical structure.
[0016] The parts of the article of the invention are prepared from
any material that can be molded in a two part molding system or
which can be formed by casting. Exemplary materials include
thermoplastics, thermosets, metals and the like. Preferred
materials are thermoplastics and thermosets, with thermoplastics
preferred. Preferred thermoplastics comprise any plastic with a
glass transition temperature or heat deflection temperature above
room temperature and include polyolefins, polyamides, polystyrenes,
acrylonitrile butadiene styrene (ABS), blends of acrylonitrile
butadiene styrene with polycarbonate (PC/ABS) and the like.
Preferred thermosets comprise any thermosetting material with a
heat deflection temperature above room temperature and include
polyurethanes, polyureas, acrylics, polyesters, epoxies and the
like. The materials may further comprise fillers, reinforcing
agents, internal mold release agents, stabilizers, antioxidants,
fire retardants and the like known to those skilled in the art.
Exemplary fillers include talc, fumed silica and the like.
Preferred reinforcing fibers include polymer, glass, carbon fibers,
ceramics, clays and the like.
[0017] Two or more parts are assembled to form an article. Each
part comprises a plurality of hollow structures having a proximal
end and a distal end. The plurality of hollow structures are
affixed to one another near one end of the hollow structure,
designated as the proximal end. The distal end is the end furthest
from where the hollow structures are affixed to one another. The
point where the hollow structures are affixed together is
preferably formed during formation of the parts. The hollow
structures have a central axis passing through the center of the
molded hollow structure from the proximal end to the distal end.
The molded material forms walls about the central axis. The walls
form a cross-section transverse to the central axis passing through
the molded parts. The cross-section is preferably consistent along
the central axis of the hollow parts from the proximal end to the
distal end. The cross section can be any cross section suitable for
the desired end use, for example, irregular, circular, oval,
polygonal and the like. Preferably the cross section is, circular,
oval or polygonal. More preferably the cross section is polygonal,
even more preferably square or rectangular and most preferably
square. As is well known to the skilled artisan draft angles may be
engineered into the parts so as to facilitate formation of the
parts and removal of the parts from molds.
[0018] The walls of each hollow structure preferably contain
passages therethrough that have their own central axis that are
transverse to the central axis of the hollow structures. The
passages through the walls are of a size and shape to facilitate
the articles of the invention to perform the function the article
is designed to perform. The passages through the wall preferably
have a consistent shape. Exemplary shapes include irregular,
circular, oval, polygonal and the like. Preferably the shapes are
circular, oval, polygonal with polygonal being more preferred and
square or rectangular most preferred. The passages in the walls of
the hollow structure may pass through the opposite wall of the
hollow structure or there may be no passage opposite the passage in
the wall of the hollow structure. In some embodiments, it is
preferred that there is a wall opposite to passages in the wall of
the hollow structure.
[0019] The plurality of hollow structures of each part are
connected near the proximal end of the hollow structures such that
the central axis of adjacent parts form an angle. The angle is
chosen such that the parts can be manufactured using a two-part
mold and the articles formed from the parts can perform the desired
function. Preferably the angle of the central axis of the two
adjacent hollow structures is about 90 degrees or less. Preferably
the angle of the central axis of the two adjacent hollow structures
is about 45 degrees or greater, more preferably 60 degrees or
greater and most preferably about 85 degrees or greater. Most
preferably the angle is about 90 degrees.
[0020] Each hollow section is connected to an adjacent section.
They can be connected in any manner known in the art, for example
by mechanical connection, adhesive, welding, by a molded or cast in
connection. A molded, or cast, in connection is formed during
molding, or casting, where a portion of the material utilized to
prepare the parts is formed between the adjacent sections which
holds the adjacent hollow sections together. Preferably the
connection utilized maintains the angle between the central axis of
adjacent hollow parts. The connection is located near the proximal
end of the hollow parts. The distance of the connection from the
proximal end is chosen so as to allow the article of the invention
to perform its desired function. Preferably, the adjacent elements
are connected together near the proximal end at a location from the
proximal end that is equal to half the linear distance of the
central axis of two sequential elements of the same orientation
while in the assembled state. Preferably the connection is disposed
with respect to the proximal end within 30 percent of the length of
the hollow section, and more preferably about 20 percent of the
length.
[0021] The two or more parts of the article are adapted to be
connected to form an article that is symmetrical or which has a
portion that is symmetrical. The parts comprise a plurality of
hollow elements. A sufficient number of the hollow elements are
utilized to allow the ultimate article to perform the function it
is designed to perform. Preferably each part comprises two or more
hollow sections and more preferably three or more sections. In some
preferred embodiments when the two parts are connected together
each hollow part has an adjacent hollow part having a central axis
parallel to its central axis. The pair of hollow parts form a
symmetrical element when the two or more parts are connected. The
number of pairs of adjacent hollow parts, hereinafter referred to
as elements, utilized in the article is chosen such that the
article can perform the function it is designed to perform. The two
or more parts are designed to be connected. They can be connected
by any method that facilitates the ultimate use of the articles of
the invention. They can be connected by mechanical devices, built
in snap fits, interference fit, adhesives, welding and the like.
Preferably the parts are connected by built in snap fits or
interference fit. In a preferred embodiment the two adjacent
sections are square or rectangular and have corners of the square
or rectangle adjacent to one another. Such elements from the
cross-sectional perspective have two squares or rectangles having
adjacent corners, such structure in the central part forms an X.
The next adjacent pair of elements have central axis disposed at
the angles described hereinbefore.
[0022] One or more of the parts may comprise a non-symmetrical
part. The non-symmetrical part may be formed by any means capable
of preparing the specific shape. The non-symmetrical part may be
attached to the symmetrical section using any known attachment
method, for instance formed with an integral connection, mechanical
methods, welding, an adhesive and the like. Preferably the
nonsymmetrical section is molded at the same time as one or more of
the parts and the connection is formed during the molding
operation.
[0023] In the embodiment wherein articles of the invention are
useful as mixers for flowable material. Each pair of hollow
elements with parallel central axis can be referred to as a mixing
element. In a preferred embodiment wherein the two adjacent
elements contact one another along a corner, the adjacent elements
form an X in the central section from a cross-sectional
perspective. In a preferred embodiment the passages in the walls of
the hollow section are opposite solid walls along the opposing wall
of the hollow section. This feature is utilized to force the
material passing through a passage in a first hollow wall of a
section to move in another direction when it meets the opposing
wall of the hollow section.
[0024] In a preferred embodiment mixers prepared according to the
invention comprise a nonsymmetrical section. Preferably the
nonsymmetrical portion is connected to one of the two or more parts
and preferably is formed integrally to the part it is attached to.
The non-symmetrical part can have any shape that enhances the
function of the article, for instance mixing along with the
symmetrical part. Preferably the non-symmetrical part forms a
helical path. As used herein element with respect to the
non-symmetrical part, helical element, means a single helical
section. A helical section comprises a sheet of material that has a
bend in it which bends about 180 degrees. Material flowing along
the helical section is turned about 180 degrees. Preferably the end
of a helical section comprises a straight edge. Preferably the
straight edge of one helical section is rotated 90 degrees from the
straight edge of the next section. This rotation forces material
flowing from one helical section to another to be divided by the
straight edge of the next helical section. If a series of helical
sections are used the flowing material is divided at the beginning
of each helical section.
[0025] The parts utilized to form the articles of the invention are
prepared by molding. Preferably injection molding. Preferably the
mold is a two part mold having actuated slides. The angle between
the direction of the actuated slides and the face of each mold is
dictated primarily by the angle of the central axis of one hollow
element to another within a molded part. In the event that one or
more parts comprise a non-symmetrical part a separate mold is
utilized for parts of different shapes. In essence, the moldable
material is converted into a flowable material. This may be done by
heating the material to a temperature at which it is molten. The
moldable material is injected into a closed mold as described. The
mold may be treated with a mold release prior to injection of the
moldable material or the moldable material may contain an internal
mold release. After injection the moldable material is cooled or
allowed to cool and the mold is opened to release the parts. The
particular conditions for molding are material dependent and one
skilled in the art would know the appropriate conditions for the
specific moldable material. After removal from the mold any
flashing is removed. The two or mare parts are assembled to form
the article.
[0026] The articles of the invention can be used for a variety of
purposes, for example as mixers, blenders applicators, rheology
modifiers, and the like. In a preferred embodiment the articles are
used as static mixers for mixing viscous materials. Preferably the
mixers are used for multipart systems that are reactive and mixed
just prior to use, for example adhesives, coatings, body fillers,
foamed plastics or polymers, dispersions and the like. More
preferably the articles are used for two part systems. Preferably
the articles are used for adhesive systems. Mixing systems that the
mixers can be utilized with typically comprise a mixing tube with a
nozzle at the end of the mixing tube. The mixing tubes generally
contain a passage for introduction of the material to be mixed into
the tubes. Disposed in the tubes can be static mixers adapted to
mix the parts of the material introduced into the tubes. Typical
mixers contain a system for applying pressure to the material
introduced into the tubes to drive the material through the mixer.
The system for applying pressure generally includes plungers that
push the material to be mixed into, through and out of the exit
nozzle of the mixing tube. Commonly the parts to be mixed are
disposed in two separate tubes of the material to be mixed and
separate plungers are used for each material to push the material
from each tube in the mixer. Typically the material in each tube is
reactive with the material in the other tube and the components
start to cure when mixed. Alternatively the two parts may be
located in the same tube with a membrane or film separating the two
parts so that they are not in contact in the tube. The smaller
volume part is typically located in the inner bag. Often the part
in the inner bag is located along the side of the tube. Thus the
mixer needs to disperse the smaller part throughout the mixed
materials to achieve even cure of the materials. This system is
often referred to as a bag-in-bag system and is often utilized when
the volumetric ratio of the two parts is high. This type of system
allows the use of materials having odd volumetric ratios. The
nozzle of the mixing tube may be shaped to extrude a bead of the
mixed material of a desired shape. In mixing the pressure applied
to the materials being mixed is sufficient to overcome the back
pressure of the materials being mixed as it passes through the
mixer. This sys-tem is especially useful for manual or battery
operated mixing systems as such systems are limited in the amount
of pressure that can be applied to the materials. Such systems are
typically utilized outside of workshops, for instance by wind
shield installers working remotely. Preferably the mixers utilized
apply pressure to the materials moved through the mixer of about
100 psi (6.89 kPa) or greater, more preferably about 150 psi or
greater and most preferably about 200 psi (1379 kPa) or greater.
Preferably the mixers utilized apply pressure to the materials
moved through the mixer of about 500 psi (3447 kPa) or less and
most preferably about 300 psi (2068 kPa) or less.
[0027] In preferred embodiments mixers of the invention comprise
symmetrical sections and non-symmetrical sections. In one
embodiment, the symmetrical sections are referred to as symmetrical
X grids. In a preferred embodiment the nonsymmetrical sections
comprise helical elements. The relative number of symmetrical and
non-symmetrical elements are chosen to passage of multiple part
systems through the mixer with adequate mixing and without undue
back pressure. Adequate mixing means that the parts mix
sufficiently to cure evenly throughout the applied mixture. Undue
back pressure means that the material cannot be moved through the
mixing tubes with the available system for applying pressure to the
mixed materials, for example a manual or battery operated mixing
system. Preferably the non-symmetrical part of the mixer is
disposed at the inlet end of the mixing tube. The inlet end is the
end to which the materials to be mixed are introduced. As a
corollary the symmetrical section is disposed nearest to the outlet
of the mixing tube that is the nozzle through which the mixed
material passes before application to a substrate. The mixers of
the invention preferably comprise more than one of each type of
element. Generally the mixers comprise sufficient number of helical
sections (non-symmetrical sections) to reduce the viscosity of the
materials to be mixed, for instance by shear thinning the
materials. The number of X grids, symmetrical sections, are chosen
to achieve adequate mixing. Preferably 3 or more non-symmetrical
sections (helical sections) are utilized. Preferably 4 or more
non-symmetrical sections (helical sections) are utilized.
Preferably 5 or less non-symmetrical sections (helical sections)
are utilized. Most preferably 5 non-symmetrical sections (helical
sections) are utilized. Preferably 3 or more symmetrical sections
(X grid sections) are utilized and more prefer-ably 4 or more
symmetrical sections (X grid sections) are utilized. Preferably 6
or less symmetrical sections (X grid sections) are utilized and
more preferably 5 or less symmetrical sections (X grid sections)
are utilized. Most preferably 5 symmetrical sections (X grid
sections) are utilized. The length of each symmetrical (X grid)
section and each non-symmetrical section is chosen to achieve the
objectives of the formed parts. A skilled artisan would adapt the
specific lengths for the particular application.
[0028] The mixers of the invention are adapted to fit in the mixing
chambers in which they are used. Preferably the mixer fills the
mixing chamber to prevent materials to be mixed from passing around
the mixer and thus not mixing. Preferably the mixer has the same
cross-sectional shape as the mixing chamber for this reason.
Preferably the cross section is circular or oval. The articles are
preferably designed and manufactured such that when the parts are
assembled they have the proper cross-sectional shape. The
symmetrical section parts are adapted to have outside shapes for
this purpose. The portion of the symmetrical section that will be
on the outside of the part is contains design features to form the
appropriate cross-sectional shape.
[0029] In some embodiments the symmetrical, nonsymmetrical or both
sections contain reinforcing structures. Such reinforcing
structures can be any shape or in any location such that the mixer
has sufficient structural strength to withstand the pressures
utilized during mixing. The reinforcing structures can be rails or
ribs. Preferably the ribs or rails are disposed in the direction of
mixing. Preferably a plurality of such structures are utilized. The
helical section preferably contains ribs or rails to support this
section. Preferably 2 to 4 rails are disposed substantially equally
about the helical sections.
[0030] The mixers of the invention are useful in mixing any
multipart compositions, preferably two part compositions. Such
mixers are useful in mixing highly viscous multipart systems. In
preferred embodiments the mixers of the invention are useful in
mixing systems having a viscosity of about 30,000 centipoises or
greater and more preferably about 100,000 centipoises or greater.
Preferably the mixers of the invention are useful in mixing systems
having a viscosity of about 5,000,000 centipoises or less. The
mixers can be used to mix any curable systems, for example adhesive
systems. The mixers can be utilized to mix two part hybrid systems
containing isocyanate functional prepolymers and acrylate
containing monomers, oligomers or polymers, such systems are
disclosed in WO 2012/151086 and WO 2012/151085, incorporated herein
by reference.
[0031] The separate parts are placed into the mixing system and
passed into and through the mixing tube to mix the parts. As the
mixed parts are passed through the nozzle at the outlet such mixed
parts are applied to a substrate. Where the mixed parts are useful
as an adhesive two substrates are contacted with the mixed parts
disposed between them and the mixed parts are allowed to cure and
bond the substrates together.
[0032] FIG. 1 shows two parts of an article of the invention 10
useful as a mixer known in the art as an SMX mixer. Illustrated are
two symmetrical parts 11 and 11'each having sections 12 and 12'
with different central axis 14 and 15 through the molded material
forming each section, the angle between the central axis of
adjacent sections being theta. The arrows show how the two parts
are placed together. FIG. 2 shows the two parts from a different
angle. Shown are parts 11 and 11', sections 12 and 12' and central
axis 14 and 15. Also shown are a plurality of passages 16 in the
molded material wherein the passages each have central axis 13,
disposed through the center of the passages 16. Each section has a
proximal end 17 and a distal end 18. Dotted line 19 illustrates the
direction of the plane of the cross section of the sections. Many
mixers are adapted to the shape of the mixing chamber into which
they are placed. Common mixers have round or oval cross-sectional
shapes and elongated chambers. The mixing elements are often
adapted in cross-section to the shape of the mixing chamber. The
taper of the corners of the SMX elements is illustrated, 20. The
arrows show how the two parts are placed together. FIG. 2 also
shows the angle between the central axis 15 of a section and the
central axis of a window 13, {acute over (.alpha.)}.
[0033] FIG. 3 shows a part 11 which is forms a symmetrical article
and a part 21 which forms a symmetrical article further having a
non-symmetrical section. Part 21 contains a symmetrical forming
portion 22 and a non-symmetrical section 23. FIG. 3 also shows a
support rib or rail 24 on the non-symmetrical portion. The two
parts are shown in an exploded format. FIG. 4 shows the article of
FIG. 3 from a different angle. FIG. 5 shows an article shown in
FIGS. 3 and 4 from an end section wherein the two parts are
connected and to show the circular cross-sectional shape of the
article adapted for use in a mixing chamber having a circular
shape.
[0034] One or more as used herein means that at least one, or more
than one, of the recited components may be used as disclosed.
Preferably the cure rate is determined by determining the dynamic
yield stress, measured by G' on a rheometer. Preferably the G' is
6.times.10.sup.6 Pa the strength of the curing adhesive at a
designated time.
Illustrative Embodiments of the Invention
[0035] The following examples are provided to illustrate the
invention, but are not intended to limit the scope thereof. All
parts and percentages are by weight unless otherwise indicated.
[0036] Mixing Examples A two part adhesive prepared as described in
WO 2012/151086 and WO 2012/151085 with the viscosity adjusted by
adding additional plasticizer to the recited press flow viscosity
of 25 or 30 seconds are placed in a bag in bag tube and applied
using a battery operated mixer which applies about 220 psi (1517
kPa) pressure to the mixture in the tube. A mixer having a length
of 7 inches is used. The impact energy of the adhesive and Shore D
hardness are measured 20 minutes after cure. The flow rate in grams
per minute of the mixed adhesive is measured. The press flow
viscosity of the adhesive varies from 25 to 30 seconds. Cure rate
is measured by impact energy and Shore A hardness. The results are
compiled in Table 1.
TABLE-US-00001 TABLE 1 Press Mixer flow Impact Flow Diameter
viscosity Energy Rate Shore D Mixer configuration mm (s) (mJ)
(g/min) Hardness 5 element helical 5 element X- 20 25 6693 1000 23
Grid 10 Element Helical 20 25 2366 840 12 Element Helical 16 25 AF
420 Hand Mixed 25 8578 28 X Grid Only 20 25 <1000 NM 5 element
helical 5 element X- 20 30 6645 1000 23 Grid 10 Element Helical 20
30 2000 800 X Grid Only 20 30 <1000 >1000 4 element helical 5
element X- 20 30 13 Grid 3 element helical 5 element X- 20 30 11
Grid 3 element helical 6 element X- 20 30 12 Grid 4 element helical
6 element X- 20 30 18 Grid 4 element helical 4 element X- 20 30 11
Grid 4 element helical 3 element X- 20 30 CD Grid
[0037] AF means applicator failure. NM means not measured. CD means
cannot dispense. These results illustrate that the best mixer
design is 5 helical and 5 X grid elements, as indicated by the high
values for impact energy and Shore A hardness, which are closest to
the values for the hand mixed example.
[0038] Impact Energy is measured using the Izod impact test. Press
Flow Viscosity: The press flow viscosity is determined as the time
(seconds) required to extrude 20 grams of adhesive through a
capillary. The width of the capillary is fixed at 0.104 in (2.6 mm)
and the applied pressure is 60 psi (4.1.times.10.sup.5 Pa). Unless
otherwise noted, all press flow viscosity values were determined at
23+/-1.degree. C.
[0039] Parts by weight as used herein refers to 100 parts by weight
of the composition specifically referred to. Any numerical values
recited in the above application include all values from the lower
value to the upper value in increments of one unit provided that
there is a separation of at least 2 units between any lower value
and any higher value. As an example, if it is stated that the
amount of a component or a value of a process variable such as, for
example, temperature, pressure, time and the like is, for example,
from 1 to 90, preferably from 20 to 80, more preferably from 30 to
70, it is intended that values such as 15 to 85, 22 to 68, 43 to
51, 30 to 32 etc. are expressly enumerated in this specification.
For values which are less than one, one unit is considered to be
0.0001, 0.001, 0.01 or 0.1 as appropriate. These are only examples
of what is specifically intended and all possible combinations of
numerical values between the lowest value, and the highest value
enumerated are to be considered to be expressly stated in this
application in a similar manner. Unless otherwise stated, all
ranges include both endpoints and all numbers between the
endpoints. The use of "about" or "approximately" in connection with
a range applies to both ends of the range. Thus, "about 20 to 30"
is intended to cover "about 20 to about 30", inclusive of at least
the specified endpoints. 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 essentially of the elements, ingredients,
components or steps. 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.
* * * * *