US20140209614A1 - Adhesive packaging system - Google Patents

Abstract

A two part adhesive packaging system is provided. The packaging system includes two containers for holding a two-part adhesive. The packaging system further includes a connector having two ports for communicating with the containers. A membrane is adhered overtop the ports to prevent the two-part adhesive from draining from the containers. The membrane is configured to break upon application of a sufficient force thereon, such as by pumping or pushing the two-part adhesive from the containers.

Description

CROSS-REFERENCE
• This application claims the benefit of U.S. Provisional Application No. 61/539,271, filed Sep. 26, 2011. The entire contents of the above application are incorporated herein by reference.
FIELD
• The present invention relates to an adhesive packaging system, and more particularly to an adhesive packaging system used in an applicator for dispensing an two-part adhesive on a roofing substrate.
BACKGROUND
• In many roofing applications, for example in large, flat commercial roof decks, a roofing membrane is used to seal and protect the roof deck from environmental weather conditions. The roofing membrane may be made of various materials, such as polymeric materials including EPDM (ethylene propylene diene M-rubber) or TPO (thermoplastic polyolefin). The roofing membrane is adhered overtop insulation boards or cover boards. The insulation boards are typically secured to the roofing substrate or roof deck via an adhesive composition. A conventional adhesive composition used to adhere the insulation boards to the roof deck, or used to adhere roofing membranes to rigid insulation boards, cover boards, or directly to the roof deck, includes polyurethane. The polyurethane adhesives are oftentimes applied directly onto the roof deck via an applicator system and the insulation boards are then laid onto the roof deck surface. Conventional polyurethane adhesives oftentimes include two separate parts that are mixed by an applicator just prior to being applied onto the surface of the roof deck. The two parts include an isocyanate blend and a simple polyol blend. Upon mixing, the isocyanate blend reacts or crosslinks with the simple polyol blend to form the polyurethane adhesive.
• These conventional two-part polyurethane adhesives must be packaged into separate containers to prevent mixing of the adhesive parts prior to application. In certain configurations, the adhesive parts are packaged into a single system having divided, separately sealed sides for storing the adhesive parts. Upon removal of a port cap, the adhesive sides communicate with an attached nozzle. However, if the nozzle is attached and then stored, it is possible for the adhesive parts to drain into the nozzle prior to application, crosslink, and plug the nozzle or the package with cured polyurethane. Therefore, there is a need in the art to provide an adhesive packaging system that prevents unwanted mixing of the adhesive parts prior to application on a substrate, but after the attachment of the mixing nozzle.
SUMMARY
• A two part adhesive packaging system is provided. The packaging system includes two containers for holding a two-part adhesive. The packaging system further includes a connector having two ports for communicating with the containers. A membrane is adhered overtop the ports to prevent the two-part adhesive from draining from the containers. The membrane is configured to break upon application of a sufficient force thereon, such as by pumping or pushing the two-part adhesive from the containers.
DRAWING DESCRIPTION
• FIG. 1 is a side view of a packaging system according to the principles of the present invention;
• FIG. 2 is a top view of the packaging system shown inFIG. 1 with a cap removed;
• FIG. 3 is a cross-section view of the packaging system viewed in the direction of arrow3-3 shown inFIG. 2;
• FIG. 4 is a perspective view of the packaging system with a mixing nozzle shown in an exemplary applicator device;
• FIG. 5 is a top view of an alternate packaging system according to the principles of the present invention; and
• FIG. 6 is a cross-section view of the packaging system viewed in the direction of arrow3-3 shown inFIG. 2.
DETAILED DESCRIPTION
• The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
• Referring toFIG. 1, a packaging system or cartridge for a two-part adhesive is generally indicated byreference number10. Thepackaging system10 is configured to store two separate components or parts of a two-part adhesive compound. For example, the two-part adhesive is a polyurethane adhesive for use on roofing substrates. Prior to mixing, the adhesive is comprised of two separate parts including an isocyanate blend and a polyol blend. Thepackaging system10 includes an “A”side container10A attached to a “B”side container10B. Each of thecontainers10A and10B define astorage space12A and12B, respectively. Eachspace12A and12B stores a different part of the two-part adhesive compound. Thespaces12A and12B are separated from one another by aninterior wall14 in order to prevent mixing of the parts prior to application of the adhesive on a substrate. In one example, thecontainers10A and10B are each generally cylindrical and are formed from a single molded body, though it should be appreciated that thecontainers10A and10B may have other shapes and be made from separately formed, attached components without departing from the scope of the present invention.
• Thepackaging system10 includes anoutlet16 located on an end of thecontainers10A and10B. Theoutlet16 includes an “A”side port18A and a “B”side port18B that communicate with thespaces12A and12B, respectively. Theports18A and18B are configured to allow the parts of the adhesive compound stored in thepackaging system10 to be pumped, pushed, or otherwise forced out of thecontainers10A and10B. For example, where the adhesive compound is pushed out of thepackaging system10, thepackaging system10 includes apiston25A disposed in an open end of thecontainer10A and apiston25B disposed in an end of thecontainer10B. Thepistons25A and25B are in contact with the contents of thecontainers10A and10B, respectively. Thepistons25A and25B may be separate pieces or connected. Pushing thepistons25A and25B forces the adhesive compound out of thepackaging system10 as described below.
• Theports18A and18B communicate from thespaces12A and12B, respectively, through aconnector20. Theconnector20 is a cylindrical extension located the end of thecontainers10A and10B opposite thepistons25A and25B. Theconnector20 includes a flat or planartop surface22 and a threadedside surface24. It should be appreciated that theside surface24 may include other kinds of connection features in addition to or in place of threads, such as lips or grooves, without departing from the scope of the present invention. The planartop surface22 is preferably completely flat. Amembrane26 is disposed overtop theflat top surface22. Themembrane26 is preferably a light gauge foil, a plastic coated foil, or laminates of paper, foil, and/or plastics. Themembrane26 is adhered to theflat top surface22 by an adhesive disposed circumferentially around each of theports18A and18B. Acap28 is removably attached to theconnector20 via mating threads (not shown) complementary to the threadedside surface24. Alternatively a membrane constructed of foil or coated paper or foil may simply be held in place by crimping the membrane onto the threaded sides ofconnector20 by the attachment of thecap28. Alternatively a heat-shrink plastic or UV activated shrinkable plastic may be used to secure the membrane over theconnector20. Thecap28 securely fits overtop theconnector20 and themembrane26 to protect themembrane26 during shipment or storage of thepackaging system10. The inside of thecap28 is preferably a flat surface that seats firmly against themembrane26 to prevent premature rupture of themembrane26 during shipping and handling.
• Turning toFIG. 4, prior to application of the adhesive, thecap28 is removed from theadhesive system10 thereby exposing theconnector20 and themembrane26. Anapplicator nozzle30 is then attached to theconnector20 via mating threads (not shown) complementary to the threadedside surface24. Theapplicator nozzle30 is an extended member that mixes the “A” side fluid with the “B” side fluid. Thenozzle30 is disposable and is preferably an element, static mixing nozzle, though it should be appreciated that other types and grades of nozzles may be employed without departing from the scope of the present invention.
• Thepackaging system10 and attachedconnector20 are then loaded into anapplicator device32. An exemplary applicator device is disclosed in commonly owned U.S. Pat. No. 7,056,556, hereby incorporated by reference. It should be appreciated that any other number of applicator devices such as pneumatic single-bead applicators, battery powered single-bead applicators, manual applicators, among other devices may be employed without departing from the scope of the present invention. Contractors often are required to pre-attach the mixingnozzle30 to thepackaging system10 to efficiently stage a job. Once pre-staged, job interruptions such as rainstorms can occur. Isocyanates, commonly used in 2-part polyurethane adhesives are moisture sensitive and rainwater dripping into a mixing nozzle can cause a chemical reaction to occur. Likewise, pre-staged jobs left overnight can suffer from dew forming in the mixing nozzle and causing reaction of the isocyanate. In addition, contractors often load the cartridges into equipment and then must pause while they wait for obstructions to be removed from the path of intended adhesive application. This is especially an issue for newer low-viscosity adhesive formulas for applications such as membrane attachment that can be problematic due to how fast the low-viscosity adhesives run into thenozzle30 when loaded into theapplicator32. However, themembrane26 prevents the adhesive parts from draining through theports18A and18B when stored without thecap28 thereby preventing the adhesive parts from mixing prematurely in theapplicator20 ornozzle30. Some adhesives are formulated with substantially different viscosities in the polyol and isocyanate portions. In this case the lower viscosity portion tends to gravity feed into the mixing nozzle prior to the mechanical operation of the equipment causing an off-ratio adhesive mix during the initial dispense. The off-ratio adhesive may not perform as expected. Thepackaging system10 may then be installed and stored in thedevice32 without theapplicator20 becoming blocked due to the adhesive components crosslinking in theapplicator20 or without off-ratio initial dispenses or without messy adhesive draining through the mixing tip.
• To apply the adhesive, thedevice32 pumps, pushes, or otherwise forces the components out of thepackaging system10. The components create a pressure on themembrane26 which ruptures or breaks themembrane26, thereby allowing the components to enter theapplicator20. Themembrane26 has a pressure breaking point that allows themembrane26 to burst before the pressure in thecontainers10A and10B builds such that the components leak out of the back sides of thecontainers10A and10B. Theapplicator20 mixes the A and B side components and the combined fluid exits theapplicator20 and is dispensed in the form of elongated beads on asubstrate34. The mixed compound then cures and forms an adhesive.
• Turning toFIGS. 5 and 6, and alternate embodiment of a packaging system is generally indicated byreference number10′. Thepackaging system10′ is similar to thepackaging system10 and like components are indicated by like reference numbers. However, thepackaging system10′ includes aradial flange40 disposed along the circumference of theconnector20. Theradial flange40 surrounds theports18A and18B. Alinear flange42 is disposed between theports18A and18B thereby bifurcating theradial flange40. Themembrane26 is disposed overtop theradial flange40 and thelinear flange42. Themembrane26 is adhered to theradial flange40 and thelinear flange42 by an adhesive disposed on theradial flange40 and thelinear flange42. Thepackaging system10′ operates in a manner similar to thepackaging system10.
• The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Claims (20)

The following is claimed:

1. A package system comprising:

a first container that defines a first space;

a second container that defines a second space, the second container connected to the first container;

a connector connected to an outer surface of the first container and an outer surface of the second container, wherein the connector has an outer surface, a side surface, and a connection feature disposed on the side surface;

a first port disposed in the outer surface of the connector and in communication with the first space;

a second port disposed in the outer surface of the connector and in communication with the second space; and

a membrane adhered to the outer surface of the connector, wherein the membrane covers the first port and the second port.

2. The package system ofclaim 1 further comprising a cap removably attached to the connector by the connection feature, wherein the cap contacts the membrane.

3. The package system ofclaim 1 further comprising a mixing nozzle removably attached to the connector by the connection feature, wherein the mixing nozzle is disposed overtop the membrane.

4. The package system ofclaim 3 wherein the connection feature includes threads.

5. The package system ofclaim 4 wherein the connector is fixedly connected to the first and second containers.

6. The package system ofclaim 5 further comprising a polyol disposed within the first space and an isocyanate disposed within the second space, and wherein the polyol and the isocyanate are mixed by the mixing nozzle to form a urethane adhesive.

7. The package system ofclaim 6 further comprising a first piston disposed in the first space and a second piston disposed in the second space, and wherein the pistons move to push the polyol and the isocyanate out through the ports to break the membrane and enter the mixing nozzle.

8. The package system ofclaim 7 wherein the first piston is in contact with the polyol and the second piston is in contact with the isocyanate.

9. The package system ofclaim 1 wherein the outer surface of the connector is planar.

10. The package system ofclaim 1 wherein the connector includes a peripheral flange disposed along an outer circumference of the connector and a linear flange disposed on the outer surface between the first port and the second port, and wherein the membrane is adhered to the peripheral flange and the linear flange.

11. A package system comprising:

a first container that defines a first space;

a second container that defines a second space, the second container connected to the first container;

a connector connected to a outer surface of the first container and an outer surface of the second container, wherein the connector has a planar outer surface, a side surface, and a connection feature disposed on the side surface;

a first port disposed in the planar outer surface of the connector and in communication with the first space;

a second port disposed in the planar outer surface of the connector and in communication with the second space; and

a membrane adhered to the outer surface of the connector, wherein the membrane covers the first port and the second port.

12. The package system ofclaim 11 further comprising a cap removably attached to the connector by the connection feature, wherein the cap contacts the membrane.

13. The package system ofclaim 11 further comprising a mixing nozzle removably attached to the connector by the connection feature, wherein the mixing nozzle is disposed overtop the membrane.

14. The package system ofclaim 13 wherein the connection feature includes threads.

15. The package system ofclaim 14 wherein the connector is fixedly connected to the first and second containers.

16. The package system ofclaim 15 further comprising a polyol disposed within the first space and an isocyanate disposed within the second space, and wherein the polyol and the isocyanate are mixed by the mixing nozzle to form a urethane adhesive.

17. The package system ofclaim 16 further comprising a first piston disposed in the first space and a second piston disposed in the second space, and wherein the pistons move to push the polyol and the isocyanate out through the ports to break the membrane and enter the mixing nozzle.

18. The package system ofclaim 17 wherein the first piston is in contact with the polyol and the second piston is in contact with the isocyanate.

19. A package system comprising:

a first container that defines a first space;

a second container that defines a second space, the second container connected to the first container;

a connector connected to an outer surface of the first container and an outer surface of the second container, wherein the connector has an outer surface, a peripheral flange disposed along an outer circumference of the outer surface of the connector and a linear flange disposed radially on the outer surface of the connector;

a first port disposed in the outer surface of the connector and in communication with the first space;

a second port disposed in the outer surface of the connector and in communication with the second space, wherein the second port is located on an opposite side of the linear flange than the first port; and

a membrane adhered to the peripheral flange and the linear flange of the connector, wherein the membrane covers the first port and the second port.

20. The package system ofclaim 19 further comprising a mixing nozzle removably attached to the connector by the connection feature, wherein the mixing nozzle is disposed overtop the membrane.

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