CA2363159C - Method and composition for cosmetically repairing a blemish in a polyolefin object - Google Patents
Method and composition for cosmetically repairing a blemish in a polyolefin object Download PDFInfo
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- CA2363159C CA2363159C CA002363159A CA2363159A CA2363159C CA 2363159 C CA2363159 C CA 2363159C CA 002363159 A CA002363159 A CA 002363159A CA 2363159 A CA2363159 A CA 2363159A CA 2363159 C CA2363159 C CA 2363159C
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- repair composition
- polyolefin
- void
- repair
- composition
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
- B29C73/02—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using liquid or paste-like material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2791/00—Shaping characteristics in general
- B29C2791/001—Shaping in several steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
- B29K2105/0032—Pigments, colouring agents or opacifiyng agents
Abstract
There is disclosed a method and composition for cosmetically repairing a surface void in polyolefin objects. The method involves inserting a repair composition into the void and then applying heat thereto to fuse the repair composition with a surrounding portion of the polyolefin object. The repair composition is a physical mixture of a thermoplastic powder, a resin binder, and a solvent, having a paste-like consistency. The repair composition may be neutral in color, or may contain a colorant to closely match the underlying object. The heating step can be performed with an open flame or with a heat gun.
Description
Field of the invention.
6 The invention relates generally to repairing molded polyolefin 7 object s and, more particularly, to a method and composition for cosmetically 8 repairing a surface blemish in such an object.
Description of the related art.
11 Polyolefin plastics are a broad category of materials including, but 12 not limited to, polyethylene, polypropylene, and ethyl-vinyl acetate.
Numerous 13 everyday objects are made from polyolefin plastics (sometimes hereafter 14 "objects" or "polyolefin objects.") Such objects are commonly formed from various molding operations such as injection molding, blow molding, rotational 16 molding, and so on.
17 The manufactures of polyolefin objects generally strive to achieve 18 highly efficient, cost-effective manufacturing processes to effectively compete in 19 their given markets. The foregoing molding processes invariably damage a certain percentage of the objects, however, due to bad parting lines, trapped air 21 pockets, tight mold radii, difficult to mold resins, and the like. The damage is 22 often only cosmetic and not structural. The "damaged" object, therefore, could 23 easily perform its intended task. Because it is not marketable in its damaged 24 condition, however, the damaged object is usually discarded or ground up and 1 re-molded into subsequent objects, thereby increasing the overall 2 manufacturing cost and lowering the quality of the subsequent objects.
3 There remains a need, therefore, for a method and composition 4 for salvaging polyolefin objects which are nominally defective due only to cosmetic blemishes.
7 It is an objective of this invention to provide a method for 8 cosmetically repairing a blemish in a polyolefin object.
9 It is a further objective of the invention to provide a method for permanently repairing a blemish in a polyolefin object.
11 It is a further objective of the invention to provide a method for 12 cosmetically repairing a blemish in a polyolefin object wherein the repair 13 matches the color of the original object.
14 other and related objectives will be apparent from the following description of the invention.
18 In a first aspect, the invention may be regarded as a method of 19 repairing a surface blemish consisting of a void in a surface of a polyolefin object comprising the steps of: (a) inserting a repair composition into said void 21 wherein said repair composition consists essentially of: (i) 30 to 60 weight 22 percent of a thermoplastic component consisting of particulate polyolefin 23 powder selected from the group consisting of polyethylene, polypropylene, and 24 ethyl-vinyl acetate (EVA); (ii) 15 to 45 weight percent of a resin component PCT/US00/04b24 3 jgos 2 3 MAY 2001 1 selected from the group consisting of aliphatic and aromatic hydrocarbon, 2 polyterpene, rosin and rosin-ester, chlorinated polyolefin resins, petroleum, and 3 synthetic and oxidized waxes; and (iii) 5 to 35 weight percent of a solvent 4 component; and (b) heating the repair composition in said void and a surrounding portion of said polyolefin object by exposing the repair composition 6 and the surrounding portion of said polyolefin object to atmospheric heating at a 7 temperature sufficient to fuse said repair composition to said polyolefin object.
8 In a second aspect, the invention may be regarded as a repair 9 composition for repairing a surface blemish consisting of a void in a surface of a polyolefin object, said repair composition consisting essentially of: (a) 30 to 60 11 weight percent of a thermoplastic component consisting of particulate polyolefin 12 powder selected from the group consisting of polyethylene, polypropylene, and 13 ethyl-vinyl acetate (EVA); (b) 15 to 45 weight percent of a resin component 14 selected from the group consisting of aliphatic and aromatic hydrocarbon, polyterpene, rosin and rosin-ester, chlorinated polyolefin resins, petroleum, and 16 synthetic and oxidized waxes; and (c) 5 to 35 weight percent of a solvent 17 component The just summarized invention may best be understood with 21 reference to the Figures of which:
22 Figure 1 is a perspective view of a polyolefin object having a 23 cosmetic surface blemish;
24 Figure 2 is a close-up view of the surface blemish of Figure 1;
1 Figure 3 is a cross-sectional view of Figure 2, taken along section 2 lines 3-3, showing the wall of the polyolefin object and the void defining the 3 surface blemish;
4 Figures 4 to 7 show a method of repairing a surface blemish in a polyolefin object according to this invention, the method comprising the steps of 6 filling a first portion of said blemish with a repair composition made according to 7 this invention and then heating the repair composition to a temperature 8 sufficient to fuse said repair composition with said polyolefin object; and 9 Figures 8 to 12 show additional steps that may be needed in repairing a surface blemish in a polyolefin object according to this invention, the 11 additional steps being implemented if the initial repair steps of Figures 4 to 6 12 result in a recessed repair as shown in Figure 8, rather than a flush repair as 13 shown in Figure 7.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
16 Figure 1 shows a typical polyolefin object 21 consisting of a pot 17 made by rotationally molding polyethylene. Such an object 21 may be 18 manufactured to have a texture and color such that the resulting object 21 19 appears substantially like a terracotta pot made of heavy, more expensive clay.
The particular object 21 shown is an exemplary object offered only to illustrate 21 the novel features of the present invention. The method and composition of this 22 invention, moreover, may be applied to virtually any object formed from a 23 polyolefin plastic object and the indication of polyethylene should also be 24 considered exemplary in nature.
~PEA~~~ 2 3 M AY 2001 1 Figure 1 furthers show that the polyolefin object 21 was 2 manufactured with a cosmetic imperfection or "blemish" 31 consisting of a small 3 void, pit, blow hole, or air pocket 32 (hereafter simply "void"). As noted above, 4 such a blemish 31 may render the polyolefin object 21 unmarketable and it may 5 be necessary to regrind the object 21 or even discard it altogether. The method 6 and composition of this invention, however, makes it possible to perform 7 cosmetic repairs on polyolefin objects and thereby salvage objects which may 8 otherwise be treated as scrap.
~;:., '~
6 The invention relates generally to repairing molded polyolefin 7 object s and, more particularly, to a method and composition for cosmetically 8 repairing a surface blemish in such an object.
Description of the related art.
11 Polyolefin plastics are a broad category of materials including, but 12 not limited to, polyethylene, polypropylene, and ethyl-vinyl acetate.
Numerous 13 everyday objects are made from polyolefin plastics (sometimes hereafter 14 "objects" or "polyolefin objects.") Such objects are commonly formed from various molding operations such as injection molding, blow molding, rotational 16 molding, and so on.
17 The manufactures of polyolefin objects generally strive to achieve 18 highly efficient, cost-effective manufacturing processes to effectively compete in 19 their given markets. The foregoing molding processes invariably damage a certain percentage of the objects, however, due to bad parting lines, trapped air 21 pockets, tight mold radii, difficult to mold resins, and the like. The damage is 22 often only cosmetic and not structural. The "damaged" object, therefore, could 23 easily perform its intended task. Because it is not marketable in its damaged 24 condition, however, the damaged object is usually discarded or ground up and 1 re-molded into subsequent objects, thereby increasing the overall 2 manufacturing cost and lowering the quality of the subsequent objects.
3 There remains a need, therefore, for a method and composition 4 for salvaging polyolefin objects which are nominally defective due only to cosmetic blemishes.
7 It is an objective of this invention to provide a method for 8 cosmetically repairing a blemish in a polyolefin object.
9 It is a further objective of the invention to provide a method for permanently repairing a blemish in a polyolefin object.
11 It is a further objective of the invention to provide a method for 12 cosmetically repairing a blemish in a polyolefin object wherein the repair 13 matches the color of the original object.
14 other and related objectives will be apparent from the following description of the invention.
18 In a first aspect, the invention may be regarded as a method of 19 repairing a surface blemish consisting of a void in a surface of a polyolefin object comprising the steps of: (a) inserting a repair composition into said void 21 wherein said repair composition consists essentially of: (i) 30 to 60 weight 22 percent of a thermoplastic component consisting of particulate polyolefin 23 powder selected from the group consisting of polyethylene, polypropylene, and 24 ethyl-vinyl acetate (EVA); (ii) 15 to 45 weight percent of a resin component PCT/US00/04b24 3 jgos 2 3 MAY 2001 1 selected from the group consisting of aliphatic and aromatic hydrocarbon, 2 polyterpene, rosin and rosin-ester, chlorinated polyolefin resins, petroleum, and 3 synthetic and oxidized waxes; and (iii) 5 to 35 weight percent of a solvent 4 component; and (b) heating the repair composition in said void and a surrounding portion of said polyolefin object by exposing the repair composition 6 and the surrounding portion of said polyolefin object to atmospheric heating at a 7 temperature sufficient to fuse said repair composition to said polyolefin object.
8 In a second aspect, the invention may be regarded as a repair 9 composition for repairing a surface blemish consisting of a void in a surface of a polyolefin object, said repair composition consisting essentially of: (a) 30 to 60 11 weight percent of a thermoplastic component consisting of particulate polyolefin 12 powder selected from the group consisting of polyethylene, polypropylene, and 13 ethyl-vinyl acetate (EVA); (b) 15 to 45 weight percent of a resin component 14 selected from the group consisting of aliphatic and aromatic hydrocarbon, polyterpene, rosin and rosin-ester, chlorinated polyolefin resins, petroleum, and 16 synthetic and oxidized waxes; and (c) 5 to 35 weight percent of a solvent 17 component The just summarized invention may best be understood with 21 reference to the Figures of which:
22 Figure 1 is a perspective view of a polyolefin object having a 23 cosmetic surface blemish;
24 Figure 2 is a close-up view of the surface blemish of Figure 1;
1 Figure 3 is a cross-sectional view of Figure 2, taken along section 2 lines 3-3, showing the wall of the polyolefin object and the void defining the 3 surface blemish;
4 Figures 4 to 7 show a method of repairing a surface blemish in a polyolefin object according to this invention, the method comprising the steps of 6 filling a first portion of said blemish with a repair composition made according to 7 this invention and then heating the repair composition to a temperature 8 sufficient to fuse said repair composition with said polyolefin object; and 9 Figures 8 to 12 show additional steps that may be needed in repairing a surface blemish in a polyolefin object according to this invention, the 11 additional steps being implemented if the initial repair steps of Figures 4 to 6 12 result in a recessed repair as shown in Figure 8, rather than a flush repair as 13 shown in Figure 7.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
16 Figure 1 shows a typical polyolefin object 21 consisting of a pot 17 made by rotationally molding polyethylene. Such an object 21 may be 18 manufactured to have a texture and color such that the resulting object 21 19 appears substantially like a terracotta pot made of heavy, more expensive clay.
The particular object 21 shown is an exemplary object offered only to illustrate 21 the novel features of the present invention. The method and composition of this 22 invention, moreover, may be applied to virtually any object formed from a 23 polyolefin plastic object and the indication of polyethylene should also be 24 considered exemplary in nature.
~PEA~~~ 2 3 M AY 2001 1 Figure 1 furthers show that the polyolefin object 21 was 2 manufactured with a cosmetic imperfection or "blemish" 31 consisting of a small 3 void, pit, blow hole, or air pocket 32 (hereafter simply "void"). As noted above, 4 such a blemish 31 may render the polyolefin object 21 unmarketable and it may 5 be necessary to regrind the object 21 or even discard it altogether. The method 6 and composition of this invention, however, makes it possible to perform 7 cosmetic repairs on polyolefin objects and thereby salvage objects which may 8 otherwise be treated as scrap.
~;:., '~
9 Figures 2 and 3 show the hypothetical blemish 31 in more detail.
Figure 2, in particular, is a close-up view of the encircled portion of Figure 1, 11 showing the object 21 and its blemish 31. Figure 3, on the other hand, is a 12 cross-sectional view of Figure 2 taken along section lines 3-3, showing the 13 object's wall 21 and the blemish 31 from the side, with the latter's void 14 clearly visible. The challenge here was to develop an innovative method and composition suitable for filling the void 32 and thereby eliminating the blemish 16 31.
17 The invention, therefore, comprises filling the void 32 with a 18 suitable repair composition and then atmospherically heating the repair 19 composition such that the repair composition flows fully into the void and fuses with the underlying object 21.
21 The repair composition generally comprises a physical mixture of 22 a thermoplastic powder, a binder resin, and a solvent. The components and 23 relative proportions should be chosen such that the solvent forms less than 24 about 50 weight percent of the overall composition such that the resulting repair 1 composition has a paste-like consistency and can, therefore, remain in the void 2 32 prior to and during the application of heat and, perhaps, during an 3 Intermediate evaporation period.
4 The first component of the preferred repair composition is a thermoplastic component consisting of'particuiate polyolefin powder selected 6 from the group consisting of polyethylene (e.g. uitra-high molecular weight 7 polyethylene), polypropylene, and ethyl=vinyi acetate (EVA). The possible 8 polyethylene include ultra-high molecular weight polyethylene (UHD), 9 high-dbnsity polyethylene (HD), low-density polyethylene (LD), and linear iow density polyethyiene. UHD is not often used to rriake the underlying polyolefin 11 object because does not flow very well and is hard to process. UHD may be 12 suitable for this application, however, because it has exceptional abrasion 13 characteristics that prov'ide a tough repair patch. The particulate polyolefin 14 powder should have a particle size of about 50 mesh down to 5 microns in size and a relatively low melt index of 100 or below. The particulate polyolefin 16 powder should make up 30 to 60 weight percent of the overall repair 17 composition.
18 The second component of the preferred repair composition is a 19 binder resin selected from the group consisting of aliphatic and aromatic hydrocarbon, polyterpene, rosin and rosin-ester, chlorinated poiyoiefin resins, 21 petroleum, and_ synthetic and oxidized waxes. The preferred binder resin 22 component is a cycolaliphatic hydrocarbon resin having a water white coior 23 which, at least to some degree, transmits the color of the underlying polyolefin 24 object after completing the repair. The binder resin should make up 15 to PcT~usoo~04 624 {PE~~~ 22 MAY 1 7 1 weight percent of the overall repair composition.
2 The third component of the preferred repair composition is a 3 solvent including any solvent that will dissolve the selected binder resins.
The 4 possible solvents include water, Toluene, Hexane, and 1-chloro-4-trifluoromethylbenzene. Water may be used, but is tends to evaporate very 6 slowly. 1-chloro-4-trifluoromethylbenzene is desirable for many applications 7 because it evaporates relative quickly, but is not flammable.
8 Finally, in lieu of relying on the translucent nature of the neutral 9 "water white" color'of the particular binder resin as discussed above, the repair composition may optionally include an appropriate colorant that proactively 11 causes the resulting repair patch to closely match the color of the polyolefin 12 object 21. The use of a colorant may beneficially ensure a seamless match 13 between the patch and the product. The colorant may be any suitable pigment 14 or dye. Inorganic pigments that are useful include titanium dioxides (rutile , anatase), zinc oxide, iron oxides in hues such as yellow, buff, tan, brown, 16 salmon and black, iron chromates and molybdates for colors from light yellow to 17 red orange, lead chromates, lead sulfate, lead molybdate, chrome yellows and 18 oranges, cadmium pigments in a variety of yeilows, oranges, reds and maroons 19 as pure cadmium colors or with barium sulfide (lithopones), cadmium mercury mixtures, cadmium sulfide or cadmium sulfoselenides, nickel and titanium 21 dioxide mixtures, sodium, potassium or ammonium coordination compounds of 22 ferri-ferrocyanide, ultramarine blues, (a calcined mixture of china clay, sodium 23 carbonate, silica, sulfur and reducing agents), cobalts aluminate (cobalt blues), 24 chromium oxide, metal flake pigments such as aluminum, zinc, copper, bronze s=~~-~ .;~k~~~' 1 powders, metal silver pigments, peariescent and iridescent flakes of basic lead 2 carbonates, bismuth oxychlorides and titanium coated mica etc. Various 3 organic pigments which are useful include azo pigments, such as 4 benzimidazolone pigments, pyrazalone pigments, copper phthalocyanine, quinacridones, anthraquinones, condensation pigments, 6 tetra-chloro-isoindolinones, carbon blacks, etc.
7 In summary, the repair composition consists essentially of: (a) 30 8 to 60 weight percent of a thermoplastic component consisting of particulate 9 polyolefin powder selected from the group consisting of polyethylene (e.g.
ultra-high molecular weight polyethylene), polypropylene, and ethyl-vinyl 11 acetate (EVA); (b) 15 to 45 weight percent of a resin component selected from 12 the group consisting of aliphatic and aromatic hydrocarbon, polyterpene, rosin 13 and rosin-ester, chlorinated polyolefin resins, petroleum, and synthetic and 14 oxidized waxes; and (c) 5 to 35 weight percent of a solvent component (e.g.
water). A colorant is optional.
16 The preferred repair composition is specifically designed to repair 17 polyolefin objects formed from polyethylene. The preferred repair composition, 18 one that is particularly suitable for such purpose, consists essentially of about 19 44 weight percent of a polyethelene powder having a melt index of 100 or below; about 36 weight percent of a cycloalipathic hydrocarbon resin that is 21 compatible with the polyethelene powder when heat is applied (e.g. a softening 22 point and ultimate viscosity at the anticipated temperature) and has a desirable 23 color (e.g. water white as opposed to brown or yellow so that it that may be 24 suitable without colorant or is compatible with the use of a colorant); and about 9 1 20 weight percent of a non-flammable solvent called 1-chloro-4-2 trifluoromethylbenzene such that the composition is not flammable, paste-like, 3 and easily evaporated.
4 The ingredients should be intimately admixed and blended, a process which may be accomplished in any machine that can handle paste-like 6 products. Examples of such mixers include planetary mixers, horizontal 7 kneaders, extruders, and any other mixer that can handle high viscosity 8 materials.
9 Figures 4 to 7 illustrate the steps of a first preferred method of repairing a polyolefin object using a repair composition according to this 11 invention.
12 The first step generally comprises the step of filling a first portion 13 of the void 32 with the repair composition 41. The repair composition 41 may 14 be transported in any suitable container (e.g. bottle, can, squeeze tube, and so on) and then automatically or manually delivered to the void 32 in any suitable ..~. 16 manner (e.g. the end of a screw driver, a tooth pick, a putty knife).
Figure 4 17 shows a preferred delivery manner where a small amount of repair composition 18 41 is squeezed out of a tube 40 and directly into the void 32. Figure 5 shows 19 the void 32 filled with the repair composition 41 and, as may sometimes be desired, slightly over-filled to allow for subsequent shrinkage.
21 The second step generally comprises heating the repair 22 composition 41 filling the void 32 by exposing the repair composition 41 to 23 atmospheric pressure heating at a temperature sufficient to fuse the repair 24 composition 41 with the underlying object 21 containing the blemish 31. The 1 preferred way of implementing the heating steps us an open flame or hot air 2 from a heat gun so as to increase the temperature of the repair composition 3 and the surrounding portion of the object 21 to at least 270 degrees Fahrenheit.
4 Figure 6, in particular, shows a propane torch 50 being used to apply heat 5 through the direct application of an open flame. Other methods of applying 6 heat may be used, but care should be taken to heat only the area of the repair 7 and to make sure that warpage or discoloration does not occur due to 8 overheating the patch or surrounding plastic area. Figure 7 shows the final 9 repair wherein the repair composition 41 is suitable flush with the surface of the 10 underlying object 21.
Figure 2, in particular, is a close-up view of the encircled portion of Figure 1, 11 showing the object 21 and its blemish 31. Figure 3, on the other hand, is a 12 cross-sectional view of Figure 2 taken along section lines 3-3, showing the 13 object's wall 21 and the blemish 31 from the side, with the latter's void 14 clearly visible. The challenge here was to develop an innovative method and composition suitable for filling the void 32 and thereby eliminating the blemish 16 31.
17 The invention, therefore, comprises filling the void 32 with a 18 suitable repair composition and then atmospherically heating the repair 19 composition such that the repair composition flows fully into the void and fuses with the underlying object 21.
21 The repair composition generally comprises a physical mixture of 22 a thermoplastic powder, a binder resin, and a solvent. The components and 23 relative proportions should be chosen such that the solvent forms less than 24 about 50 weight percent of the overall composition such that the resulting repair 1 composition has a paste-like consistency and can, therefore, remain in the void 2 32 prior to and during the application of heat and, perhaps, during an 3 Intermediate evaporation period.
4 The first component of the preferred repair composition is a thermoplastic component consisting of'particuiate polyolefin powder selected 6 from the group consisting of polyethylene (e.g. uitra-high molecular weight 7 polyethylene), polypropylene, and ethyl=vinyi acetate (EVA). The possible 8 polyethylene include ultra-high molecular weight polyethylene (UHD), 9 high-dbnsity polyethylene (HD), low-density polyethylene (LD), and linear iow density polyethyiene. UHD is not often used to rriake the underlying polyolefin 11 object because does not flow very well and is hard to process. UHD may be 12 suitable for this application, however, because it has exceptional abrasion 13 characteristics that prov'ide a tough repair patch. The particulate polyolefin 14 powder should have a particle size of about 50 mesh down to 5 microns in size and a relatively low melt index of 100 or below. The particulate polyolefin 16 powder should make up 30 to 60 weight percent of the overall repair 17 composition.
18 The second component of the preferred repair composition is a 19 binder resin selected from the group consisting of aliphatic and aromatic hydrocarbon, polyterpene, rosin and rosin-ester, chlorinated poiyoiefin resins, 21 petroleum, and_ synthetic and oxidized waxes. The preferred binder resin 22 component is a cycolaliphatic hydrocarbon resin having a water white coior 23 which, at least to some degree, transmits the color of the underlying polyolefin 24 object after completing the repair. The binder resin should make up 15 to PcT~usoo~04 624 {PE~~~ 22 MAY 1 7 1 weight percent of the overall repair composition.
2 The third component of the preferred repair composition is a 3 solvent including any solvent that will dissolve the selected binder resins.
The 4 possible solvents include water, Toluene, Hexane, and 1-chloro-4-trifluoromethylbenzene. Water may be used, but is tends to evaporate very 6 slowly. 1-chloro-4-trifluoromethylbenzene is desirable for many applications 7 because it evaporates relative quickly, but is not flammable.
8 Finally, in lieu of relying on the translucent nature of the neutral 9 "water white" color'of the particular binder resin as discussed above, the repair composition may optionally include an appropriate colorant that proactively 11 causes the resulting repair patch to closely match the color of the polyolefin 12 object 21. The use of a colorant may beneficially ensure a seamless match 13 between the patch and the product. The colorant may be any suitable pigment 14 or dye. Inorganic pigments that are useful include titanium dioxides (rutile , anatase), zinc oxide, iron oxides in hues such as yellow, buff, tan, brown, 16 salmon and black, iron chromates and molybdates for colors from light yellow to 17 red orange, lead chromates, lead sulfate, lead molybdate, chrome yellows and 18 oranges, cadmium pigments in a variety of yeilows, oranges, reds and maroons 19 as pure cadmium colors or with barium sulfide (lithopones), cadmium mercury mixtures, cadmium sulfide or cadmium sulfoselenides, nickel and titanium 21 dioxide mixtures, sodium, potassium or ammonium coordination compounds of 22 ferri-ferrocyanide, ultramarine blues, (a calcined mixture of china clay, sodium 23 carbonate, silica, sulfur and reducing agents), cobalts aluminate (cobalt blues), 24 chromium oxide, metal flake pigments such as aluminum, zinc, copper, bronze s=~~-~ .;~k~~~' 1 powders, metal silver pigments, peariescent and iridescent flakes of basic lead 2 carbonates, bismuth oxychlorides and titanium coated mica etc. Various 3 organic pigments which are useful include azo pigments, such as 4 benzimidazolone pigments, pyrazalone pigments, copper phthalocyanine, quinacridones, anthraquinones, condensation pigments, 6 tetra-chloro-isoindolinones, carbon blacks, etc.
7 In summary, the repair composition consists essentially of: (a) 30 8 to 60 weight percent of a thermoplastic component consisting of particulate 9 polyolefin powder selected from the group consisting of polyethylene (e.g.
ultra-high molecular weight polyethylene), polypropylene, and ethyl-vinyl 11 acetate (EVA); (b) 15 to 45 weight percent of a resin component selected from 12 the group consisting of aliphatic and aromatic hydrocarbon, polyterpene, rosin 13 and rosin-ester, chlorinated polyolefin resins, petroleum, and synthetic and 14 oxidized waxes; and (c) 5 to 35 weight percent of a solvent component (e.g.
water). A colorant is optional.
16 The preferred repair composition is specifically designed to repair 17 polyolefin objects formed from polyethylene. The preferred repair composition, 18 one that is particularly suitable for such purpose, consists essentially of about 19 44 weight percent of a polyethelene powder having a melt index of 100 or below; about 36 weight percent of a cycloalipathic hydrocarbon resin that is 21 compatible with the polyethelene powder when heat is applied (e.g. a softening 22 point and ultimate viscosity at the anticipated temperature) and has a desirable 23 color (e.g. water white as opposed to brown or yellow so that it that may be 24 suitable without colorant or is compatible with the use of a colorant); and about 9 1 20 weight percent of a non-flammable solvent called 1-chloro-4-2 trifluoromethylbenzene such that the composition is not flammable, paste-like, 3 and easily evaporated.
4 The ingredients should be intimately admixed and blended, a process which may be accomplished in any machine that can handle paste-like 6 products. Examples of such mixers include planetary mixers, horizontal 7 kneaders, extruders, and any other mixer that can handle high viscosity 8 materials.
9 Figures 4 to 7 illustrate the steps of a first preferred method of repairing a polyolefin object using a repair composition according to this 11 invention.
12 The first step generally comprises the step of filling a first portion 13 of the void 32 with the repair composition 41. The repair composition 41 may 14 be transported in any suitable container (e.g. bottle, can, squeeze tube, and so on) and then automatically or manually delivered to the void 32 in any suitable ..~. 16 manner (e.g. the end of a screw driver, a tooth pick, a putty knife).
Figure 4 17 shows a preferred delivery manner where a small amount of repair composition 18 41 is squeezed out of a tube 40 and directly into the void 32. Figure 5 shows 19 the void 32 filled with the repair composition 41 and, as may sometimes be desired, slightly over-filled to allow for subsequent shrinkage.
21 The second step generally comprises heating the repair 22 composition 41 filling the void 32 by exposing the repair composition 41 to 23 atmospheric pressure heating at a temperature sufficient to fuse the repair 24 composition 41 with the underlying object 21 containing the blemish 31. The 1 preferred way of implementing the heating steps us an open flame or hot air 2 from a heat gun so as to increase the temperature of the repair composition 3 and the surrounding portion of the object 21 to at least 270 degrees Fahrenheit.
4 Figure 6, in particular, shows a propane torch 50 being used to apply heat 5 through the direct application of an open flame. Other methods of applying 6 heat may be used, but care should be taken to heat only the area of the repair 7 and to make sure that warpage or discoloration does not occur due to 8 overheating the patch or surrounding plastic area. Figure 7 shows the final 9 repair wherein the repair composition 41 is suitable flush with the surface of the 10 underlying object 21.
11 The solvent in the repair composition is preferably allowed to 12 evaporate before applying heat to the composition because the application of 13 high temperature heat may form bubbles within the patch. The evaporation 14 may occur at ambient temperatures or by way of "forced evaporation" through the application of heat at an elevated temperature that is sufficiently high to 16 speed up evaporation, but is below the melting point of the particulate polyolefin 17 powder. Forced evaporation may be conveniently implemented through the 18 use of a heat gun held at a distance from the patch.
19 Figures 8 to 12 illustrate additional repair steps which my be desired given a deep void 32 where it may be desired to apply several thin 21 layers of the repair composition 41 to ensure that each incremental amount of 22 composition 41 is heat cured during each intermediate heating step. Figure 8, 23 in particular, shows an intermediate repair that is recessed after completion of 24 steps 4 to 6 rather than flush as shown in Figure 7. In this case, as shown in 1 Figure 9, an additional filling step is implemented wherein more repair 2 composition 42 is inserted into the void 32 and on top of the repair composition 3 that was previously inserted therein and heated (steps 4 to 6). Figure 10 shows 4 the state of the repair after inserting the section portion of repair composition 42 and Figure 11 shows the application of heat thereto. Figure 12 shows the final 6 state of the repair.
7 The invention has been described with reference to a presently 8 preferred embodiment and particular polyolefin object. It is not intended that the 9 invention be unduly limited by this disclosure, but rather is intended that the invention be defined by the following claims.
19 Figures 8 to 12 illustrate additional repair steps which my be desired given a deep void 32 where it may be desired to apply several thin 21 layers of the repair composition 41 to ensure that each incremental amount of 22 composition 41 is heat cured during each intermediate heating step. Figure 8, 23 in particular, shows an intermediate repair that is recessed after completion of 24 steps 4 to 6 rather than flush as shown in Figure 7. In this case, as shown in 1 Figure 9, an additional filling step is implemented wherein more repair 2 composition 42 is inserted into the void 32 and on top of the repair composition 3 that was previously inserted therein and heated (steps 4 to 6). Figure 10 shows 4 the state of the repair after inserting the section portion of repair composition 42 and Figure 11 shows the application of heat thereto. Figure 12 shows the final 6 state of the repair.
7 The invention has been described with reference to a presently 8 preferred embodiment and particular polyolefin object. It is not intended that the 9 invention be unduly limited by this disclosure, but rather is intended that the invention be defined by the following claims.
Claims (24)
1. A method of repairing a surface blemish consisting of a void in, a surface of a polyolefin object comprising the steps of:
(a) inserting a repair composition into said void wherein said repair composition consists of:
(i) 30 to 60 weight percent of a thermoplastic component consisting of particulate polyolefin powder selected from the group consisting of polyethylene, polypropylene, and ethyl-vinyl acetate (EVA);
(ii) 15 to 45 weight percent of a resin component selected from the group consisting of aliphatic and aromatic hydrocarbon, polyterpene, rosin and rosin-ester, chlorinated polyolefin resins, petroleum, and synthetic and oxidized waxes; and (iii) 5 to 35 weight percent of an organic solvent component; and (b) heating the repair composition in said void and a surrounding portion of said polyolefin object by exposing the repair composition and the surrounding portion of said polyolefin object to atmospheric heating at a temperature sufficient to fuse said repair composition to said polyolefin object.
(a) inserting a repair composition into said void wherein said repair composition consists of:
(i) 30 to 60 weight percent of a thermoplastic component consisting of particulate polyolefin powder selected from the group consisting of polyethylene, polypropylene, and ethyl-vinyl acetate (EVA);
(ii) 15 to 45 weight percent of a resin component selected from the group consisting of aliphatic and aromatic hydrocarbon, polyterpene, rosin and rosin-ester, chlorinated polyolefin resins, petroleum, and synthetic and oxidized waxes; and (iii) 5 to 35 weight percent of an organic solvent component; and (b) heating the repair composition in said void and a surrounding portion of said polyolefin object by exposing the repair composition and the surrounding portion of said polyolefin object to atmospheric heating at a temperature sufficient to fuse said repair composition to said polyolefin object.
2. The method of Claim 1 wherein said step of inserting a repair composition into said void is accomplished by squeezing said repair
3. The method of Claim 1 wherein said repair composition further includes a colorant.
4. The method of Claim 3 wherein said colorant substantially matches a color of said polyolefin object.
5. The method of Claim 3 wherein said colorant is a pigment.
6. The method of Claim 3 wherein said colorant is a dye.
7. The method of Claim 1 wherein said repair composition is sufficiently translucent to transmit a color of said polyolefin object.
8. The method of Claim 7 wherein said binder resin is a cycloaliphathic hydrocarbon resin having a water white color.
9. The method of Claim 1 wherein said polyolefin object is a polyethylene object.
10. The method of Claim 1 wherein said heating step is accomplished by applying an open flame to the repair composition in the void.
11. The method of Claim 1 wherein said heating step is accomplished by applying hot air from a heat gun to the repair composition in the void.
12. The method of Claim 1 wherein the repair composition fills substantially all of said void after the heating step.
13. The method of Claim 1 wherein a first portion of the repair composition fills a lower portion of said void after the heating step.
14. The method of Claim 13 comprising the further steps of:
(a) inserting a second portion of repair composition into said void, above said first portion of repair composition; and (b) heating the second portion of repair composition in said void and a surrounding portion of said polyolefin object by exposing the second portion of repair composition and the surrounding portion of said polyolefin object to atmospheric heating at a temperature sufficient to fuse said second portion of repair composition to said polyolefin object.
(a) inserting a second portion of repair composition into said void, above said first portion of repair composition; and (b) heating the second portion of repair composition in said void and a surrounding portion of said polyolefin object by exposing the second portion of repair composition and the surrounding portion of said polyolefin object to atmospheric heating at a temperature sufficient to fuse said second portion of repair composition to said polyolefin object.
15. The method of Claim 14 including the further steps of repeating the inserting and heating steps until the repair composition fills the void and is substantially flush with a surface of the polyolefin object.
16. A repair composition for repairing a surface blemish consisting of a void in a surface of a polyolefin object, said repair composition consisting of:
(a) 30 to 60 weight percent of a thermoplastic component consisting of particulate polyolefin powder selected from the group consisting of polyethylene, polypropylene, and ethyl-vinyl acetate (EVA);
(b) 15 to 45 weight percent of a resin component selected from the group consisting of aliphatic and aromatic hydrocarbon, polyterpene, rosin and rosin-ester, chlorinated polyolefin resins, petroleum, and synthetic and oxidized waxes; and (c) 5 to 35 weight percent of an organic solvent component.
(a) 30 to 60 weight percent of a thermoplastic component consisting of particulate polyolefin powder selected from the group consisting of polyethylene, polypropylene, and ethyl-vinyl acetate (EVA);
(b) 15 to 45 weight percent of a resin component selected from the group consisting of aliphatic and aromatic hydrocarbon, polyterpene, rosin and rosin-ester, chlorinated polyolefin resins, petroleum, and synthetic and oxidized waxes; and (c) 5 to 35 weight percent of an organic solvent component.
17. The repair composition of Claim 16 wherein said thermoplastic component is an high-density polyethylene.
18. The repair composition of Claim 16 wherein said repair composition further includes a colorant.
19. The repair composition of Claim 18 wherein said colorant substantially matches a color of said polyolefin object.
20. The repair composition of Claim 19 wherein said colorant is a pigment.
21. The repair composition of Claim 19 wherein said colorant is a dye.
22. The repair composition of Claim 16 wherein said repair composition is sufficiently translucent to transmit a color of said polyolefin object.
23. The repair composition of Claim 22 said binder resin is a cycloaliphathic hydrocarbon resin having a water white color.
24. The repair composition of Claim 16 wherein the solvent component is selected from the group consisting of water, toluene, Hexane, and 1-chloro-4-trifluoromethylbenzene.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US09/256,646 | 1999-02-23 | ||
| US09/256,646 US6287405B1 (en) | 1999-02-23 | 1999-02-23 | Method and composition for cosmetically repairing a blemish in a polyolefin object |
| PCT/US2000/004624 WO2000050243A1 (en) | 1999-02-23 | 2000-02-22 | Method and composition for cosmetically repairing a blemish in a polyolefin object |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2363159A1 CA2363159A1 (en) | 2000-08-31 |
| CA2363159C true CA2363159C (en) | 2008-03-11 |
Family
ID=22973015
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002363159A Expired - Fee Related CA2363159C (en) | 1999-02-23 | 2000-02-22 | Method and composition for cosmetically repairing a blemish in a polyolefin object |
Country Status (14)
| Country | Link |
|---|---|
| US (1) | US6287405B1 (en) |
| EP (1) | EP1171302B1 (en) |
| JP (1) | JP2002542062A (en) |
| AT (1) | ATE270186T1 (en) |
| AU (1) | AU759807B2 (en) |
| BR (1) | BR0008488A (en) |
| CA (1) | CA2363159C (en) |
| DE (1) | DE60011884T2 (en) |
| ES (1) | ES2226795T3 (en) |
| IL (1) | IL145086A (en) |
| MX (1) | MXPA01008552A (en) |
| NO (1) | NO326750B1 (en) |
| NZ (1) | NZ513892A (en) |
| WO (1) | WO2000050243A1 (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5746961A (en) * | 1995-12-04 | 1998-05-05 | Michael J. Stevenson | Method for enhancement of the surfaces of molded plastic products |
| US7446146B2 (en) * | 2001-12-05 | 2008-11-04 | Michael J. Stevenson | Polyethylene low temperature caulking composition |
| US6852788B2 (en) * | 2001-12-05 | 2005-02-08 | Michael J. Stevenson | Reinforcement composition for rotational molding |
| US7647682B2 (en) * | 2004-06-17 | 2010-01-19 | Adams Marve D | Motor mount repair system and methods therefor |
| US8709325B2 (en) * | 2005-07-21 | 2014-04-29 | Michael J. Stevenson | Liquid low temperature injection molding process |
| US20090278271A1 (en) * | 2008-05-08 | 2009-11-12 | Wolfe Jason L | Thermal Revitalization of Polymer-Containing Materials |
| ES1158187Y (en) * | 2016-05-13 | 2016-08-29 | Plastic Repair System 2011 S L | REPAIRED PLASTIC PRODUCT |
| EP3495124A1 (en) * | 2017-12-06 | 2019-06-12 | 3M Innovative Properties Company | Repair solution and process for wind turbine leading edge protection tape |
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| CA659037A (en) * | 1959-01-26 | 1963-03-05 | E.I. Du Pont De Nemours And Company | Blends of petroleum wax and copolymers of ethylene and vinyl acetate |
| US3067156A (en) * | 1959-02-05 | 1962-12-04 | Simoniz Co | Paraffin wax, oxidized wax, and polyethylene polishing composition |
| LU40795A1 (en) | 1960-11-25 | 1962-05-08 | ||
| US3227669A (en) * | 1961-09-06 | 1966-01-04 | Atlantic Refining Co | Hydrocarbon wax-ethylene polymer compositions |
| US3607808A (en) * | 1966-12-19 | 1971-09-21 | Phillips Petroleum Co | Thermoplastic ink |
| JPS4842211A (en) | 1971-10-04 | 1973-06-20 | ||
| BE791166A (en) | 1972-04-12 | 1973-03-01 | Evg Entwicklung Verwert Ges | WIRE OR METAL TAPE CRUSHER |
| FR2352649A1 (en) | 1976-05-25 | 1977-12-23 | Delacoste & Cie | PLASTIC BALL AND ROTATION MOLDING MANUFACTURING PROCESS |
| US4156672A (en) * | 1978-03-27 | 1979-05-29 | The Continental Group, Inc. | Method for preparing dispersions of propylene polymers |
| JPS54132631A (en) * | 1978-04-07 | 1979-10-15 | Mitsui Petrochem Ind Ltd | Powdered coating composition |
| US4252762A (en) | 1978-12-21 | 1981-02-24 | Stevenson Michael J | Method for printing and decorating products in a rotomolding process |
| US4260439A (en) * | 1979-02-05 | 1981-04-07 | Repair-It Industries, Inc. | Apparatus and method for repairing plastic materials |
| US4239796A (en) | 1979-06-21 | 1980-12-16 | The General Tire & Rubber Company | In-mold coating of structural foams and resultant product |
| US4282285A (en) | 1979-10-24 | 1981-08-04 | International Telephone & Telegraph Corporation | Process for preparing polyurethane molded part |
| DE3014161A1 (en) | 1980-04-12 | 1981-10-22 | Basf Ag, 6700 Ludwigshafen | METHOD FOR PRODUCING POLYURETHANE MOLDED BODIES |
| US4356230A (en) | 1980-07-10 | 1982-10-26 | International Telephone And Telegraph Corporation | Molded plastic product having a plastic substrate containing a filler and an in-mold plastic coating firmly bonded thereon and a process for its manufacture |
| NL8203904A (en) | 1982-10-08 | 1984-05-01 | Synres Internationaal Nv | COATING POWDER. |
| US4548779A (en) | 1982-11-15 | 1985-10-22 | Allied Corporation | Rotational molding multilayered articles |
| US4519972A (en) | 1983-05-18 | 1985-05-28 | Stevenson Michael J | Method for use of pattern transfers in rotomolding |
| US4544578A (en) * | 1983-11-23 | 1985-10-01 | Chem-Pak, Inc. | Method of touching up surface-blemished matt-finished surface grained colored molded plastic parts |
| JPS61111335A (en) | 1984-11-05 | 1986-05-29 | Dainippon Toryo Co Ltd | Molding of plastic |
| US4659525A (en) * | 1985-11-12 | 1987-04-21 | Speer Lawrence L | Dashboard repair method |
| US4980113A (en) | 1987-09-24 | 1990-12-25 | Morton International, Inc. | In-mold coating powders with two initiators or 1,1-di(t-butylperoxy)-3,3,5-trimethylcyclohexane as a single initiator |
| US4980107A (en) | 1988-09-12 | 1990-12-25 | Moline Paint Manufacturing Co. | Lacquer coating process for polyurethane-molded articles |
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| US5470609A (en) * | 1992-12-07 | 1995-11-28 | Gencorp Inc. | Repair of plastic substrates utilizing powder coating compositions |
| DE4405148C1 (en) * | 1994-02-18 | 1995-05-11 | Herberts Gmbh | Aqueous one-component coating composition and its use |
| US5746961A (en) | 1995-12-04 | 1998-05-05 | Michael J. Stevenson | Method for enhancement of the surfaces of molded plastic products |
| US5840142A (en) | 1996-11-22 | 1998-11-24 | Stevenson; Michael J. | Decoration and printing on polyolefin surfaces |
-
1999
- 1999-02-23 US US09/256,646 patent/US6287405B1/en not_active Expired - Lifetime
-
2000
- 2000-02-22 ES ES00911930T patent/ES2226795T3/en not_active Expired - Lifetime
- 2000-02-22 BR BR0008488-3A patent/BR0008488A/en active Search and Examination
- 2000-02-22 MX MXPA01008552A patent/MXPA01008552A/en active IP Right Grant
- 2000-02-22 WO PCT/US2000/004624 patent/WO2000050243A1/en active IP Right Grant
- 2000-02-22 NZ NZ513892A patent/NZ513892A/en not_active IP Right Cessation
- 2000-02-22 IL IL14508600A patent/IL145086A/en not_active IP Right Cessation
- 2000-02-22 AU AU33744/00A patent/AU759807B2/en not_active Ceased
- 2000-02-22 DE DE60011884T patent/DE60011884T2/en not_active Expired - Fee Related
- 2000-02-22 JP JP2000600842A patent/JP2002542062A/en active Pending
- 2000-02-22 CA CA002363159A patent/CA2363159C/en not_active Expired - Fee Related
- 2000-02-22 AT AT00911930T patent/ATE270186T1/en not_active IP Right Cessation
- 2000-02-22 EP EP00911930A patent/EP1171302B1/en not_active Expired - Lifetime
-
2001
- 2001-08-22 NO NO20014086A patent/NO326750B1/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| NZ513892A (en) | 2003-02-28 |
| EP1171302A4 (en) | 2003-02-05 |
| DE60011884D1 (en) | 2004-08-05 |
| MXPA01008552A (en) | 2002-07-09 |
| NO20014086L (en) | 2001-10-22 |
| NO326750B1 (en) | 2009-02-09 |
| BR0008488A (en) | 2002-05-28 |
| AU3374400A (en) | 2000-09-14 |
| AU759807B2 (en) | 2003-05-01 |
| IL145086A (en) | 2004-09-27 |
| WO2000050243A1 (en) | 2000-08-31 |
| NO20014086D0 (en) | 2001-08-22 |
| ES2226795T3 (en) | 2005-04-01 |
| CA2363159A1 (en) | 2000-08-31 |
| EP1171302A1 (en) | 2002-01-16 |
| EP1171302B1 (en) | 2004-06-30 |
| JP2002542062A (en) | 2002-12-10 |
| IL145086A0 (en) | 2002-06-30 |
| ATE270186T1 (en) | 2004-07-15 |
| US6287405B1 (en) | 2001-09-11 |
| DE60011884T2 (en) | 2005-08-25 |
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| EEER | Examination request | ||
| MKLA | Lapsed |