Abstract:
An injector including a housing defining an inner passage extending from a first end to a second end; a seal positioned at a first end of the inner passage; internal threads positioned within the internal passage; a plunger threadably engagable with the internal threads of the inner passage; a resin container in communication with the inner passage; and an activation device for activating the resin container.

Description:
[0001]    This application is being filed on 6 Mar. 2014, as a PCT International patent application and claims priority to U.S. Provisional Application Ser. No. 61/788,305, filed Mar. 15, 2013, the subject matter of which is incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to apparatus and methods for repairing breaks in windshields. 
       BACKGROUND 
       [0003]    From time to time, a vehicle windshield will break, such as due to an object impacting against the windshield. A bull&#39;s-eye break may occur wherein the outer layer of safety glass incurs a break in the shape of an inverted cone. Other break shapes and cracks may be incurred in addition to or instead of the bull&#39;s-eye break. The inside layer of safety glass is typically unbroken. U.S. Pat. No. 4,291,866, issued Sep. 29, 1981, the disclosure of which is hereby incorporated by reference, illustrates an apparatus usable to repair a break in a vehicle windshield. The apparatus disclosed in the &#39;866 reference includes a support apparatus for supporting an injector held against the windshield so that repair material can be applied to the break site. A repaired windshield is desirable over replacement of the windshield which can be quite costly, and time consuming. 
         [0004]    Various concerns arise in connection with repair of windshields. One area of concern relates to the ease of use of the windshield repair apparatus. In particular, the ease in which the site is prepared, and the ease of application of the repair material are concerns. Accessibility to the site for the application of the repair material, and removal of impurities (e.g. air, moisture, dirt) from the break site and from the repair material are concerns. Visual access is also desired. In addition, the application of pressure above atmospheric pressure and the application of pressure below atmospheric pressure at the break site are desirable. Mechanical engagement of portions of the break site is also desirable. A goal of the repair process is to leave an optically invisible or virtually invisible repair site. Minimizing repair material waste is also a concern. 
         [0005]    There is a need in the prior art for apparatus and methods which address the above concerns and other concerns. 
       SUMMARY 
       [0006]    The present invention relates to a windshield repair apparatus including a support apparatus or bridge for holding an injector adjacent to a break area of a windshield. The windshield repair apparatus may include a suction cup for mounting the bridge to the windshield. In some embodiments, the injector is movable, such as for inspection of the repair site or for adjustment of proper positioning of the injector. The injector includes an opening adjacent to a break area on a windshield for the application of repair resin, such as ultraviolet light curable plastic resin. In some embodiments, the injector can be used to apply air pressure above and below atmospheric pressure to the break area. Further, in some embodiments, the injector facilitates use of a tool to mechanically engage the break area to facilitate repair during the application of pressure (plus or minus) and/or the repair material. In the various embodiments disclosed herein, the injector can be a single use injector. In some embodiments, once the repair is completed, the injector is discarded. The resin can be held in a self-contained, single use resin container which is opened at the desired time. The resin container can be held by the injector or mounted to and/or within the injector. The resin container can be discarded with the injector. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a perspective view of one embodiment of a windshield repair apparatus including an injector; 
           [0008]      FIG. 2  is a cross-sectional perspective view of a first embodiment of an injector including aspects of the present disclosure; 
           [0009]      FIG. 3  is another cross-sectional perspective view of the injector of  FIG. 2 ; 
           [0010]      FIG. 4  is a cross-sectional side view of the injector of  FIG. 2 ; 
           [0011]      FIG. 5  is a cross-sectional side view showing the plunger of the injector inserted into position within the outer body to apply resin to a repair site; 
           [0012]      FIG. 6  is a plan view of a resin holder before resin is inserted; 
           [0013]      FIGS. 7-10  show the resin holder of  FIG. 6 , with the resin fill port sealed; 
           [0014]      FIGS. 11-13  show the resin holder of  FIGS. 7-10 , with the sealed fill port open and ready for evacuation of the resin; 
           [0015]      FIGS. 14 and 15  show an injector with a pipette style resin holder with an externally threaded activation device; 
           [0016]      FIG. 15A  shows the pipette resin holder of the injector of  FIGS. 14 and 15 ; 
           [0017]      FIGS. 16 and 17  show an injector with a pipette style resin holder with an internally threaded actuation device; 
           [0018]      FIG. 18  shows an injector with an internal, sealed ampoule of resin, axially locate, with an externally threaded activation device; 
           [0019]      FIG. 19  shows an injector with an internal, sealed ampoule of resin axially located, with an internally threaded activation device; 
           [0020]      FIGS. 20-22  show an injector with a side resin port and a separate reservoir for resin; 
           [0021]      FIG. 23  shows an injector with an internal resin cartridge axially located within the injector outer body; 
           [0022]      FIG. 24  shows an injector with a side port and an ampoule of resin within the side port and with an externally threaded activation device; 
           [0023]      FIG. 25  shows an injector with a side port and an ampoule of resin within the side port and with an internally threaded activation device. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    Referring to  FIG. 1 , a first embodiment of a windshield repair apparatus  20  is shown. Apparatus  20  includes a support apparatus or bridge  22  which mounts to a top surface of a windshield with a resilient suction cup  24 . Suction cup  24  supports bridge  22  on the windshield. Bridge  22  holds an injector  26  in opening  28  adjacent to a break area on a windshield for the application of repair resin, such as ultraviolet light curable plastic resin. In addition, injector  26  can be used to apply air pressure above and below atmospheric pressure to the break area. Further, injector  26  facilitates use of a tool to mechanically engage the break area to facilitate repair during the application of pressure (plus or minus) and/or the repair material. Injector  26  can mount to bridge  22  by a threaded engagement, or a bayonet (e.g., quarter twist) arrangement. 
         [0025]    Bridge  22  includes a base  40  which mounts to suction cup  24  with a latch  50 . Latch  50  lifts a central portion of suction cup  24  upwardly to cause latching of suction cub  24  on the windshield. Latch  50  is an over center latch which includes corners  52  and sides  56 ,  58  which engage a top  42  of base  40 . Top  42  can be an additional wear plate or washer as shown, positioned on a top of the base body. Latch  50  is shown in the latched position in the figures. Latch  50  pivots upward to unlatch the suction cup  24 . 
         [0026]    Bridge  22  includes an arm  70  which is pivotally mounted about a hinge  72  defining a pivot axis  74  which is generally perpendicular to the windshield. Arm  70  includes a forward portion  80  defining the injection holder, and a rearward portion  82 . Rearward portion  82  includes a registration system  90  which allows for securement of arm  70  to a remainder of base  40  at base area  46 . Registration system  90  includes a lower pin (not visible) and a slot (not visible) in base area  46 . Ramps  96  can lead to the slot so that the pin will automatically fall into the slot once arm  70  is rotated back to the repair position. To rotate arm  70  away from the repair position, to an inspection position, the pin is pulled upwardly out of the slot. Pin  92  is spring loaded. Pin  92  includes a handle  98 . Further details of similar registration systems are shown for example in U.S. Pat. No. 6,302,670, the disclosure of which is hereby incorporated by reference. Arm  70  moves in the direction of arrows A in the figures. In the repair position, arm  70  is generally aligned with the side walls  48  of base area  46  to further facilitate ease of use. Further details of the aligned side walls are shown for example in U.S. Pat. No. 6,139,300, the disclosure of which is hereby incorporated by reference. 
         [0027]    Forward portion  80  of arm  70  preferably includes a threaded adjustment mechanism  100  which allows for injector  26  to be moved toward and away from the windshield, such as for use on curved portions on the windshield in the direction of arrows B. Injector  26  is also threadably adjustable, as described above for vertical adjustment in the direction of arrows C. Threaded adjustment mechanism  100  includes a front end portion  102  which is hinged at a hinge  104  about a pivot axis  106  which is generally parallel to the windshield. A threaded adjustment screw  108  moves in the direction of arrow D to move front end portion  102  in the direction of arrows B. Front end portion  102  is spring loaded away from the windshield. Further details of the threaded adjustment mechanism  100  and various mounts for injector  26  are shown for example in U.S. Pat. No. 6,139,300, the disclosure of which is incorporated by reference. 
         [0028]    Windshield repair apparatus  20  includes an arm attachment location  120  which permits attachment of an articulating arm (not shown) for holding a light, a light blocker (sun shade), and/or a tool holder. 
         [0029]    During use of injector  26 , resin  200  is applied to the break area through injector  26 . Injector  26  includes an outer housing or outer body  202  defining an inner passage  204  and a seal  206 . Seal  206  seals against the windshield. Seal  206  includes internal seals  220 ,  222 . Internal threads  208  allow threaded attachment to an axial moveable plunger  210  which includes external threads  212 . By moving plunger  210  toward seal  206 , the resin  200  is applied to the break area. External threads  214  on outer housing  202  allow for attachment of injector  26  to bridge  26 . 
         [0030]    Apparatus  20  is an example for holding an injector  26  over a repair site. Other apparatus  20  can be used as desired. 
         [0031]    Various resin holders or containers are provided within the present disclosure for managing the resin prior to and during application to the repair site. In some embodiments, the resin holders or containers are single use containers. The resin containers hold a predetermined amount of resin suitable for repair of a typical break site. The injectors are also single use injectors in some preferred embodiments. 
         [0032]    A first example resin holder is shown in  FIGS. 2-13  in the form of a bellows  230 . Bellows  230  includes a compressible body  232 , a first end  234  and an opposite end  236 . During manufacture, a fill port  240  connects to an interior  242 . 
         [0033]    Once resin  200  is placed in interior  242 , fill port  240  is sealed as shown in  FIGS. 7-10  in the form a flat tab  244 . Tab  244  can be broken off at the time the technician desires to inject the resin  200  into the break area. 
         [0034]    As shown in  FIGS. 11-13 , bellows  230  is ready for use with an open port  248 . At opposite end  236 , a weakened area  250  is provided in the form of pie shaped portions with weakened break lines. Bellows  230  is positioned in pocket  216  of outer housing  202  of injector  26  for compression by plunger  210 . A tip  218  of plunger  210  pushes bellows  230  to compress bellows  230  and force resin  200  out through open port  248 . Eventually, tip  216  of plunger  210  extends through weakened area  250  which opens up, through bellows  230  in the compressed state and through open port  248 , pushing the resin  200  towards seal  206  and the break area. See  FIG. 5 . By manipulating the plunger  210  with the manual application of force, and the additional use of the threads, the bellows empties the contained resin and the plunger  210  pushes the resin toward the break site. Plunger  210  can include a solid construction, or a hollow construction, allowing for the application of pressure and/or manual manipulation of the break site area with a mechanical probe inserted axially. Once the resin has been applied and the repair completed, injector  26  can be discarded, along with bellows  230 . 
         [0035]    Bellows  230  is one example of a collapsible container for holding resin. Other shapes are possible. 
         [0036]    Referring now to  FIGS. 14 ,  15 , and  15 A injector  326  includes a pipette  328  which holds resin a self-contained area within plunger  410 . End cap  420  engages external threads  422  on plunger  410  and empties the contents of pipette  328  into an interior of injector  326  for application to a break site. Plunger  410  can be moved toward the repair site through the threads as noted above. End  330  opens when enough pressure is applied to pipette  328 . As shown, plunger  410  is hollow. 
         [0037]      FIGS. 16 and 17  show a similar injector  526  to injector  326  including the use a pipette  328 . However, activation is through an end cap  620  which engages internal threads  622  in plunger  610 . 
         [0038]    Referring now to  FIG. 18 , resin is stored in an ampoule  628  in plunger  710  of injector  626 . Upon the application of pressure by an end cap  720  engaging external threads  722  on plunger  710 , ampoule  628  will open and allow the resin to flow down through plunger  710 . A sharp edge  724  on injector  626  may be provided to break open the ampoule  628 . As shown, plunger  710  is hollow. 
         [0039]    Referring now to  FIG. 19 , an injector  826  includes an ampoule  628  activated by an end cap  920  which engages internal threads  1022  on plunger  1010 . 
         [0040]    Referring now to  FIGS. 20-22 , an injector  1026  includes a side port  1030  which is filled with a reservoir  1040 . Reservoir  1040  includes a break off tab  1042 . Plunger  1110  pushes the resin from reservoir  1040  toward the break site through the use of threads as noted above. 
         [0041]    Referring now to  FIG. 23 , injector  1226  is provided with a central cartridge  1230  of resin positioned below plunger  1310  within housing  1240 . Cartridge  1230  may include a weakened area which is broken open by the application of force on plunger  1310  relative to housing  1240 , and through the application of force through threaded engagement of plunger  1310  and housing  1240 . 
         [0042]    Referring now to  FIG. 24 , an injector  1426  includes a side port  1430  including an ampoule  1440  of resin which is broken open by the application of force from an end cap  1450  which engages external threads  1460  on the side port  1430 , and a sharp edge  1470  disposed within side port  1430 . 
         [0043]    Referring now to  FIG. 25 , an injector  1526  includes a side port  1530  and an ampoule  1540  which is broken open by the application of force by end cap  1550  which engages internal threads  1560  on the side port  1530 , and a sharp edge  1570  disposed within side port  1530 . 
         [0044]    Use of the single use injectors and resin containers facilitates ease of use for the technician. The technician does not need to fill the injector from a larger container of resin a desired or appropriate amount for the break site. The prefilled resin containers can be prefilled with the correct amount, so the technician need only select an injector or a resin container for an injector and then proceed to make the repair. Waste is reduced and the chance of insufficient resin being provided is also reduced. 
         [0045]    The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.