Materials, methods and devices for joining lines

A hand-held device for joining fishing line segments of monofilament, fluorocarbon, and/or braid lines of similar or differing sizes or combinations or securing hooks or other components to at least one line. The device includes an encasement for orienting the fishing line segments in a closed chamber in close, non-contacting orientation. A material is injected into the closed chamber to encase the lines. This material can be adhesive material or a flowable polymer material having a melting temperature lower than the line segments to be bonded. A pre-formed, flexible polymer sheath is used to retain the line segments in the chamber. A heater heats the polymer sheath within the encasement to allow the polymer to flow and encase the line segments without melting the line segments. Bonding of the line segments can be achieved without melting, abrading, compressing, or impairing the integrity the line segment(s) to be encased.

FIELD OF THE INVENTION

The present invention relates to devices and methods for joining monofilament and/or braided lines together using a flowable material such as an adhesive (e.g., a hot melt adhesive) or flowable polymer or blend or composite or low temperature metal, etc. that allows for bonding (mechanical and/or chemical) of the lines using a relatively lower melting temperature material and/or adhesive setting material.

BACKGROUND OF THE INVENTION

Recreational, commercial and sport fishing requires the use of fishing line which needs to be attached to a reel, to lines of different sizes and composition, to lures, hooks and weights, and the like. Current methods of knot-tying, metal crimping and/or fishing line welding require compressing, deforming, and/or abrading segments of line together, which have been shown to weaken the line strength. As a result, unintended or premature line breakage can occur.

Tying knots can be difficult due to line size, line stiffness, lighting (visibility) and cold temperatures (making it difficult to manipulate hands), etc.

Using metal crimping systems requires matching the correct crimp size to the line size in order to achieve optimal attachment. In addition, crimps require special tooling and the ability to apply the correct pressure to compress the line without excessively abrading the line, pinching the line, or leaving the crimp too loose so that the line ultimately slips.

Welding devices generally require the use of monofilament line, and also the use of special equipment to optimize the bond between the lines. However, with welding devices, the ability to bond different materials, or lines of different sizes, is not easy or straightforward, and has previously required compressing the line segments to weld, crimp, or tie them, which impacts the integrity of the raw line material and weakens the bond. Securing or joining lines together using any of the above methods generally, in most all instances, results in bond strength less than the line itself, which can result in line failure.

Failure can occur due to untying of knots, crimp slippage, weld bond failure, knots weakening the line, crimps weakening the line, weld heat or the friction stress of tying knots re-orienting the polymer materials in the line so as to weaken the line, etc.

U.S. Pat. No. 6,793,750 (Bittar) describes a hand-held fishing line welder that uses heat, RF energy or ultrasonic energy to heat and melt a monofilament line in order to bond it to another monofilament line, thereby creating a weld between the fishing lines. This approach can allow for joining lines of a single material and of a common size. However, the joining of lines of different materials, of different sizes, or a combination of different materials and different sizes, and maintaining a strong bond between the lines, is quite difficult using this approach. In addition, this welding approach requires compressing line segments together, which negatively impacts line strength at the bond. As such, developing a weld that is equal to, or stronger than, the original line strength is difficult using this welding technique.

It would, therefore, be advantageous to have a device that can join lines together (mechanically and/or chemically) in a quick, easy, and reproducible manner, for lines of the same or different materials, and for lines of the same or different sizes, using a hand-held device. The lines do not have to touch; in fact, having spacing between the lines will allow bonding material to surround or encase the lines, whereby to provide a much stronger bond. In addition, leaving space between individual line segments at the bond avoids compressing, abrading, deforming or otherwise impairing the physical integrity of the lines. The resulting bond can therefore be stronger than the original line strength.

SUMMARY OF THE INVENTION

Accordingly, the present invention relates to materials, methods and devices for providing a quick, easy and reproducible manner of joining fishing line segments, from one or more discrete lines and/or of a different or the same material and/or of the same or different size, together.

As used herein, the term “line” shall mean a polymer or metal line, particularly suitable for a fishing line, and may be a monofilament and/or braided line (including, but not limited to, polymer lines made of nylon, fluorocarbon, polyester, UHMWPE and/or biodegradable materials and, if metal, of steel, nitinol or titanium wire materials), of similar or differing materials and/or sizes and/or combinations of materials and/or sizes.

In one embodiment, a method and apparatus is used such that the fishing lines are held together in a parallel, non-contacting relation in a closed chamber and a flowable adhesive material (e.g., a hot melt adhesive material) is caused to enter the closed chamber to surround and encase the lines. After the hot melt adhesive material has set, the lines are removed from the closed chamber and are joined together in a strong bond.

As a further exemplary embodiment, a method and apparatus is used that also positions the fishing line segments in a closed chamber where the line segments are held so a flowable polymer sheath (or sleeve) can be molded around the line segments so that the line segments are locked together in a non-contacting parallel orientation. The line segments may, alternatively, be secured in a non-parallel non-contacting relationship. Segments from a single line may be secured together around a hook or other component, or segments from two or more lines may be secured together.

The polymer sheath (or sleeve) comprises a material that melts at a lower temperature than the lines themselves. The closed chamber is heated such that the material of the polymer sheath (or sleeve) melts so as to surround and encase the lines and, upon cooling, the line segments are joined together in a strong bond. The raw flowable polymer material may comprise a fluid, powder, solid component, or pellets that are introduced into the chamber such that, once heated, it is molded within the chamber, creating the polymer sheath (or sleeve) that encapsulates the line segments such that they are spaced apart, whereby to increase the contacting surface area between the line segments and polymer sheath (or sleeve). As an alternative embodiment of fabricating the bond, the raw material of the polymer sheath (or sleeve) may be in a flowable form that is actuated (i.e., set) using ultraviolet light or other mechanism, whereby to mold the flowable material so as to encapsulate the line segments in a bond, without relying on any melting of the raw material.

The resulting polymer sheath (or sleeve) may be formed in an elongate shape with one or more tapered ends so as to provide a smooth transition from the line to the polymer sheath (or sleeve); however, any other alternative shape that suits the application may also be utilized. The polymer sheath (or sleeve) may also be fabricated so as to partially encapsulate a component such as the eyelet of a hook or other component to be secured by the line segments, such that a smooth transition from the hook or other component to the line is produced.

The present invention also includes a device to carry out the methods heretofore described, and that device is a hand-held device that has a handle and jaws that can be moved between an open position and a closed position. When open, the lines can be inserted between the jaws and, when closed, the abutting jaws form a closed chamber where the joining of the lines takes place (e.g., by molding the flowable adhesive or flowable polymer around the lines).

In one embodiment of the hand-held device, an adhesive material (e.g., a hot melt adhesive) is injected into the closed chamber to surround and encase the lines, and when the material has set, the jaws can be opened and the joined lines removed,

In another embodiment, one or both of the jaws has a heater and there is a meltable polymer sheath (or sleeve) that is located within the jaws of the hand-held device and the polymer sheath (or sleeve) positions the line segments in a non-contacting, parallel (or non-parallel) orientation within the closed chamber when the jaws are in their closed position. The heater can be activated and the raw polymer material melts at a temperature below the melting temperature of the line(s), such that the polymer material flows in the closed chamber to surround and encase the line segments and, upon cooling, the line segments are strongly joined together by the polymer.

The molding instrument embodiments of the invention may comprise a cartridge system that houses the raw polymer material in the form of a fluid, powder, pellet or solid. This facilitates loading of the raw polymer material, changing polymer materials, and/or the addition of colors or other enhancement features such as scents, additives, or reinforcement materials, etc., whereby to enhance the ability of a single molding instrument to create polymer sheaths (or sleeves) with varying characteristics. Additionally, the mold cavity may be replaceable so as to accommodate different line segment sizes, different numbers of line segments (e.g., three of more line segments may be molded together with a single polymer sheath or sleeve), different orientations of line segments in parallel or non-parallel orientations, or the encapsulation of hook or other components within the polymer sheath (or sleeve).

The embodiments of the invention improve the bond strength between at least two line segments. The line segments may be spaced apart at the bond so as to avoid impairing the material of the lines. The segments may comprise discrete lengths of a single line; alternatively, the segments may comprise two or more lines that may be secured together. The embodiments of the invention may be used to secure segments of at least one line to secure a hook, lure, weight, additional fishing line(s) and/or other fishing components. In addition, the embodiments may attach at least one line for other applications outside of fishing. In particular, any application in which two segments of line, thread, yarn, suture, wire or other flexible elongated material are bonded together may benefit from the embodiments of the invention, which secure at least two segments together such that they are spaced apart so as to improve bond strength and the profile of the bond while preserving the physical integrity of the raw line material.

In one preferred form of the invention, the invention comprises the provision and use of a molded fastener, formed at least in part out of a flowable material, to secure two or more line segments in position relative to one another. In use, the line segments are positioned with a desired orientation (e.g., in a parallel or non-parallel, spaced relationship), the flowable material is flowed about the line segments so as to engulf the line segments, and then the flowable material is set so as to form an encasing structure about the line segments, whereby to lock the line segments in position relative to one another.

In one form of the invention, the molded fastener is formed in situ, e.g., the line segments are positioned in a mold with the desired orientation, the flowable material is flowed into the mold and about the line segments, and then the flowable material is set so as to form the encasing structure about the line segments, whereby to lock the line segments in position relative to one another.

In another form of the invention, the molded faster is at least partially pre-formed, and then the final configuration of the molded fastener is effected in situ, e.g., the line segments are positioned in the at least partially pre-formed molded fastener, the flowable material is flowed about the line segments, and then the flowable material is set so as to form the encasing structure about the line segments, whereby to lock the line segments in position relative to one another.

The flowable material may comprise any material capable of performing the desired function. In one form of the invention, the flowable material forms a mechanical bond with the line segments when set. In another form of the invention, the flowable material forms a chemical bond with the line segments when set. And in another form of the invention, the flowable material forms both mechanical and chemical bonds with the line segments when set. The flowable material may comprise an adhesive (including a hot melt adhesive) and/or a flowable polymer and/or any other appropriate material, and flowing/setting of the flowable material may be effected according to the nature of the flowable material, e.g., heating/cooling, the absence or presence of UV light, the absence or presence of a reactant, etc.

In one preferred form of the present invention, there is provided a system for securing at least two line segments in position relative to one another, the system comprising:

a molded faster formed at least in part out of a flowable material, wherein the flowable material is flowed about the at least two line segments after the at least two line segments have been positioned with a desired orientation and is thereafter set, whereby to form an encasing structure about the at least two line segments, whereby to lock the at least two line segments in position relative to one another.

In another preferred form of the present invention, there is provided a method for securing at least two line segments in position relative to one another, the method comprising:

positioning the at least two line segments in a hand-held tool with a desired orientation;

using the hand-held tool to flow flowable material about the at least two line segments so as to engulf the at least two line segments; and

setting the flowable material in the hand-held tool so as to form a molded fastener which acts as an encasing structure about the at least two line segments, whereby to lock the at least two line segments in position relative to one another.

In another preferred form of the present invention, there is provided a method for joining lines, the method comprising the steps of:

positioning the lines in a side by side relationship in a closed chamber;

introducing an adhesive material into the closed chamber to surround the lines; and

allowing the adhesive material to encase the lines and join the lines together.

In another preferred form of the present invention, there is provided a method for joining lines having a melting temperature, the method comprising the steps of:

providing a meltable fastener having a melting temperature below the melting temperature of the lines;

affixing the lines to the meltable fastener in a non-contacting, parallel orientation; and

heating the meltable fastener to the melting temperature of the meltable fastener to cause the meltable fastener to flow and surround and encase the lines to join the lines together.

In another preferred form of the present invention, there is provided a hand-held device to carry out the joining of lines, the device comprising a handle having a pair of jaws, at least one of the jaws being movable with respect to the other of the jaws to an open position wherein the jaws are spaced apart and a closed position wherein the jaws are abutting each other, the jaws forming a closed chamber when in the closed position, and a means of introducing an adhesive material into the closed chamber to surround and encase the lines to join the lines together.

In another preferred form of the present invention, there is provided a hand-held device to carry out the joining of lines having a melting temperature, the device comprising a handle having a pair of jaws, at least one of the jaws being movable with respect to the other of the jaws to an open position wherein the jaws are spaced apart and a closed position wherein the jaws are abutting each other, the jaws forming a closed chamber when in the closed position, at least one heater adapted to be activated to heat the closed chamber, a meltable fastener positioned within the closed chamber and adapted to retain the lines in a non-contacting parallel orientation, the at least one heater adapted to heat the meltable fastener to a temperature below the melting temperature of the lines to cause the meltable material to flow and surround and encase the lines to join the lines together.

In another preferred form of the present invention, there is provided a device to carry out the joining of lines having a melting temperature, the device comprising an upper housing and a lower housing, at least one of the housings being movable between a closed position where the upper and lower housings abut against each other forming a closed chamber therebetween and an open position where the upper and lower housings are separated from each other, at least one of the upper and lower housing having a heater to heat the closed chamber, a meltable fastener positioned within the closed chamber and adapted to retain the lines in a non-contacting parallel orientation, the at least one heater adapted to heat the meltable fastener to a temperature below the melting temperature of the lines to cause the meltable material to flow and surround and encase the lines to join the lines together.

DETAILED DESCRIPTION OF THE INVENTION

Referring now toFIGS. 1A-1C, there is shown schematic views of an exemplary embodiment of the present invention. Accordingly, takingFIG. 1A, there is a side schematic view illustrating two lines10,12that are to be joined together in accordance with the present invention. As can be seen inFIG. 1A, the lines10,12pass through a sleeve14that has sealing devices16(such as clamps) that provide lateral seals between the lines10,12and the sleeve14, creating a closed chamber18therein. It should be noted that the lines10,12may comprise segments from a single line, or segments from two or more lines, which will be secured together by a polymer sheath (or sleeve), with that polymer sheath (or sleeve) having a pre-defined geometry determined by the geometry of the closed chamber (or cavity)18.

As also can be seen inFIG. 1A, there is a syringe20that is in communication with the closed chamber18to allow a sealing, adhesive or bonding material to be injected into the closed chamber18, whereby to surround and encase the line segments10,12. It should be noted that this embodiment of the invention, as well as subsequent embodiments of the invention, may bond together at least two line segments, with those two line segments being from a single line, from two lines, or from more than two lines; alternatively, a hook, other fishing component, or miscellaneous part may be secured to one or more line segments by encapsulating a portion of the component to the line segment(s) via the molded adhesive bond construct, such that a bond is formed.

Examples of adhesive materials usable with the present invention include, but are not limited to, hot melt adhesives, epoxies, cyanoacrylates, acrylics, polyurethanes, silicones, phenolics, polyimides, plastisols, polyvinyl acetate and derivatives thereof.

The sealing, adhesive, or bonding material may also comprise flowable polymers, co-polymers, blends, composites, low temperature metals, etc., or any other flowable material appropriate for use with the present invention.

As to hot melt adhesives or flowable polymer materials, hot melt adhesives or flowable polymers are applied onto the lines to be bonded as adhesives, flowable melts, fluids that solidify, and/or flowable polymers. The hot melt adhesives or flowable polymer melts are molded in situ so as to encapsulate the line segments, set and then solidify upon cooling, whereby to secure together those line segments.

For example, hot melt adhesives or flowable polymers often possess a moderate-to-long “open time” (defined as the time span between adhesive application and assembly of the line segments being joined), but after immobilization of the line segments being joined, the hot melt adhesives or flowable polymers must set quickly enough to ensure a bond of appropriate quality. In addition to setting speed, viscosity is also an important property of a hot melt adhesive or flowable polymer. For uniform hot melt adhesive or flowable polymer application, the viscosity should be sufficiently low at a corresponding application temperature. Hot melt adhesives are highly thermally stressed over long periods of time upon application. One important requirement is, therefore, good thermal stability at application temperature. The thermal stability of hot melt adhesives or flowable polymers depends, among other factors, on the compatibility of the components on which the hot melt adhesive or flowable polymer is based. Incompatibility often exists, especially in the case of components that enhance adhesion. Hot melt adhesives or flowable polymers are usually based on one or more base materials, with various additives. The composition is usually formulated so as to have a glass transition temperature below the lowest service temperature and a suitably high melt temperature. The degree of crystallization should be as high as possible but within the limits of allowed shrinkage. The melt viscosity and the crystallization rate (corresponding “open time”) can be tailored. A faster crystallization rate usually implies a higher bond strength. The present embodiment allows the sealing, adhesive or bonding material to be tailored for optimum performance for the conditions of use and the line segments being bonded.

The nature of the adhesive or flowable polymer or other flowable material and the additives influences the nature of mutual molecular interaction and interaction with the line segments. Good wetting of the line segments is often desirable for forming a satisfying bond between the adhesive, etc. and the line segments. More polar compositions tend to have better adhesion due to their higher surface energy. Amorphous adhesives or polymers deform easily, and tend to dissipate most of the mechanical strain within their structure, passing only small loads onto the adhesive/line segment interface; even a relatively weak nonpolar-nonpolar surface interaction can then form a fairly strong bond prone primarily to a cohesive failure. The distribution of molecular weights and the degree of crystallinity influences the width of the melting temperature range. Polymers with a crystalline nature tend to be more rigid and have higher cohesive strength, than the corresponding amorphous ones, but they also transfer more strain to the adhesive/line segment interface. Higher molecular weights of the polymer chains provide higher tensile strengths and heat resistance. All of these conditions are to be considered in producing materials to optimize the resulting bonded sleeve (or sheath) structure.

An increase in bond strength and service temperature can be achieved by the formation of cross links in the polymer after solidification. This can be achieved by using polymers undergoing curing with residual moisture (e.g., reactive polyurethanes, silicones, etc.), exposition to UV radiation and the like.

In addition, other materials that are biodegradable may also be utilized so as to provide a means for the polymer to erode over time in the environment under certain conditions. Such materials may comprise biodegradable polymers that have been treated so as to be easily broken down by microorganisms and return to nature. Many technologies exist today that allow for such treatment. Currently there are some synthetic polymers that can be broken down by microorganisms (e.g., polycaprolactone), others are polyesters and aromatic-aliphatic esters which, due to their ester bonds, are susceptible to attack by water. Some examples of these are the PHA family of natural polymers that include poly-3-hydroxybutyrate, and in addition, the renewably-derived polylactic acid, and the synthetic polycaprolactone. Others are the cellulose-based cellulose acetate and celluloid (cellulose nitrate).

The hot melt adhesives or flowable polymers or other flowable materials can also contain, in addition to the aforesaid base materials, other additives. These include, for example, plasticizers, tackifiers, stabilizers, waxes, adhesion promoters, fillers, elastic thermoplastics and antioxidants. Specific applications-engineering properties (e.g., cohesive strength, viscosity, elastics properties and softening point) can thereby be influenced.

The adhesives or flowable polymers are selected by one skilled in the art in such a way that good compatibility exists with the other additives of the hot melt adhesive or flowable polymer.

If applicable, the hot melt adhesive or flowable polymer can have waxes added to it, e.g., in quantities from 0 to 45 wt %. The quantity is preferably such that the viscosity is lowered into the desired range, but adhesion is not negatively influenced. The wax can be of natural origin, chemically-modified form, or synthetic. Plant waxes and animal waxes can be used as natural waxes, also mineral waxes or petrochemical waxes. As chemically modified waxes, hard waxes such as montan ester waxes, sasol waxes, etc. can be used. Polyalkylene waxes and polyethylene glycol waxes are utilized as synthetic waxes. Petrochemical waxes such as petrolatum, paraffin waxes, microcrystalline waxes and synthetic waxes can be used.

Plasticizers are used in order to adjust the viscosity or flexibility of the final construct, and are contained in the hot melt adhesive or flowable polymer generally at a concentration of from 0 to 20 wt %. Suitable plasticizers are mineral oils, naphthenic mineral oils, polypropylene, polybutene, polyisobutylene, polyisoprene oligomers, hydrogenated polyisoprene and/or polybutadiene oligomers, benzoate esters, phthalates, adipates, vegetable or animal oils, and derivatives thereof. Hydrogenated plasticizers are selected, for example, from the group of the paraffinic hydrocarbon oils. Polypropylene glycol and polybutylene glycol, as well as polymethylene glycol, are also suitable. Esters are also used, as applicable, as plasticizers, for example liquid polyesters and glycerol esters, or plasticizers based on aromatic dicarboxylic acid esters.

The purpose of the stabilizers is to protect the adhesive or polymer composition from breakdown during processing. Antioxidants and light-protection agents are among those which are preferred. They are added to the hot melt adhesive or flowable polymer, typically in quantities of up to 3 wt %.

Further additives can also be incorporated into the hot melt adhesive or flowable polymer in order to vary specific properties. These can be, for example, dyes, or fillers such as titanium dioxide, talc, clay and the like.

The hot melt adhesive or flowable polymer can also contain adhesion promoters. Adhesion promoters are substances that improve the adhesion of the hot melt adhesive or flowable polymer with respect to the line segments that are to be adhesively bonded. Among other things, the adhesion promoters are intended to improve the aging behavior of adhesive bonds under the influence of a moist atmosphere. Typical adhesion promoters are, for example, ethylene/acrylamide comonomers, polymeric isocyanates, reactive organosilicon compounds or phosphorus derivatives. The wetting properties of the adhesive or flowable polymer on the substrates can likewise be influenced.

The additives, such as plasticizers, stabilizers, or adhesion promoters, are known to one skilled in the art. They are commercial products, and one skilled in the art can select them in accordance with the desired properties. Care must, of course, be taken for compatibility with the adhesive or flowable polymer and the line segments being joined.

The hot melt adhesive or flowable polymer or other flowable material is generally manufactured by mixing. In this context, all of the components can be made ready simultaneously, heated, and then homogenized; or firstly, the more-easily melted components are made ready and mixed, and then the further adhesive or polymer constituents are added, and finally further additives that are temperature-sensitive are added. It is also possible to manufacture the hot melt adhesive or flowable polymer continuously in an extruder. After decanting or portioning of the completely homogenized mixture, it is allowed to cool, whereupon it solidifies.

The hot melt adhesive in this example is of solid consistency and (aside from contaminants) free of solvents. Methods for manufacturing, decanting, and packaging hot melt adhesives are known to one skilled in the art. It is homogeneous in the solid and liquid phase, i.e., a melt is clear and not opaque or cloudy. No separation of the hot melt adhesive constituents is to be observed even if the melted state continues for a long time.

In terms of utilization, it is best to use a hot melt adhesive or flowable polymer having the lowest possible viscosity at application temperature. This ensures better applicability and easier delivery of the hot melt adhesive or flowable polymer. Wetting of the line segments is also thereby promoted. Good application properties are achieved with the hot melt adhesive or flowable polymer according to the present invention. No separation of individual constituents, or phase separation, is to be observed even when held for a longer period in the molten phase. Adhesion to the line segments is good. Bonding of the adhesive or flowable polymer exists even at different temperatures.

InFIG. 1B, there can be seen the actual injection of the adhesive material or flowable polymer or other flowable material22into the closed chamber18so as to surround both of the line segments10,12for joining them together.

As seen inFIGS. 1A-1C, there is an appearance that the two lines10,12are in contact with each other, however, in the exemplary embodiment, the lines10,12are parallel but separated from one another by a finite distance so that the adhesive material or flowable polymer22can enter into the space between the lines10,12, whereby to enhance the ultimate joinder of the lines10,12.

Lastly, in this embodiment, inFIG. 1C, the syringe20has been withdrawn and is no longer in communication with the closed chamber18, such that the adhesive material or flowable polymer or other flowable material is allowed to set. The sleeve14can then be removed since the joining of the lines10,12has been completed.

Turning next toFIGS. 2A and 2B, there is shown a sleeve24that can be used with the present invention and which is basically a cylindrical configuration with a hollow core26therethrough. Sleeve24can be made out of flexible plastic material. InFIG. 2A, the lines10,12can be seen passing though the sleeve24such that the adhesive material or flowable polymer or other flowable material can be injected into the space between the sleeve and the line segments10,12so as to join the line segments10,12together as described with respect to theFIG. 1A-1Cembodiment. Again, upon setting of the adhesive material or flowable polymer or other flowable material, the sleeve24can simply be removed, leaving the line segments10,12joined together by the set adhesive or flowable polymer or other flowable material. Alternatively, if desired, sleeve24can remain part of the bonding construct.

It will be appreciated that the line segments10,12can be of differing diameters and still be efficiently and strongly joined together with the use of the present invention and, as will be appreciated, the use of differing diameter lines, or lines having different materials, can be joined by means of any of the embodiments disclosed and explained in the present specification.

In addition, as is true of the line segments10,12, and as well as all further embodiments shown herein, the bonding process may be enhanced by some treatment of the relevant portions of the line segments, either chemical or mechanical, so as to make the ultimate joint stronger. The chemical enhancement may be by etching the ends of the lines, the mechanical enhancement may be by roughing the lines. The enhancement may also be effect by appropriate thermal processing.

Turning next toFIGS. 3A-3C, there is shown perspective views of an exemplary embodiment of the present invention, wherein a single line28is used to form a loop30in which segments of the line28are secured together by an adhesive or flowable polymer or other flowable material construct. As will be appreciated, while a loop30is formed in this embodiment, the same invention can also be used to join two separate lines together.

As can also be seen inFIG. 3A, the upper section34has a pair of separate, semicircular channels40,42formed therein, with a ridge44located therebetween; and, in likewise manner, the lower section36also has a pair of semicircular channels46,48formed therein, with a ridge50located therebetween. InFIG. 3A, the clamshell encasement32is shown in its open position, such that the two separate segments52,54of the single line28can be oriented within the aligned channels40,42of upper section34and the aligned channels46,48of lower section36, whereby to retain the segments52,54securely within the clamshell encasement32.

A set of tabs56on the upper section34latches with a pair of recesses58formed on the lower section36so that the upper and lower sections34,36can latch together, whereby to secure the clamshell encasement32in its closed position as shown inFIG. 3B, however, various alternative devices and latches can also be used to secure the clamshell encasement32in the closed position.

As such, with the clamshell encasement32in the closed position shown inFIG. 3B, the respective channels40,42and46,48surround the separate segments52,54of the line28and form a seal between the line28and the separate segments52,54against the clamshell encasement32, thereby forming a closed chamber60within the clamshell encasement32. As also seen inFIG. 3B, there is an inlet62in the upper section34of the clamshell encasement32and its purpose will be later explained.

Turning then toFIG. 3C, taken along withFIGS. 3A and 3B, there is a perspective view of the present invention and illustrating the use of a syringe64that is used to inject the adhesive material or flowable polymer or other flowable material into the closed chamber60so as to allow the adhesive material or flowable polymer or other flowable material to surround the line28and, when set, join the separate segments52,54together via the adhesive or flowable polymer or other flowable material construct.

Turning next toFIGS. 4A-4D, there is shown perspective views of a portable hand-held device66that can be used to join two line segments together. Accordingly, inFIG. 4A, the hand-held device66is shown as having a handle68and a forward section70that extends laterally outwardly from the handle68. The forward section70includes an upper jaw72and a lower jaw74.

In the embodiment ofFIG. 4A, the upper jaw72is pivotable between an open position (as shown inFIG. 4A) and a closed position where the upper jaw and lower jaw72,74abut against each other (FIG. 4C). In this respect it should be appreciated that while only the upper jaw72is shown inFIGS. 4A-4Das movable or pivotable, in alternative embodiments the lower jaw74may be movable or, alternatively, both the upper and lower jaws72,74can be movable. The opening and closing of the jaws72,74may be accomplished manually or by means of some mechanism within the hand-held device66.

In the embodiment ofFIG. 4A, a heater76, such as a resistance heater, is located in the lower jaw74for a purpose that will be later explained and, again, the heater76may be in the lower jaw74, the upper jaw72or both the upper and lower jaws72,74. Control for the heater76may be by means of a trigger switch78located for the convenience of the user, with the power being supplied by one or more batteries80located in the handle68. The batteries80may be disposable or conventional rechargeable batteries that can be recharged by a separate power source. Alternatively, the hand-held device66may be powered by a line cord (not shown) plugged into a receptacle on, for example, a boat.

As can be seen inFIGS. 4A and 4B, there is a cavity82formed in the lower jaw74and, when the upper and lower jaws72,74are closed together, there is formed a closed chamber84(FIG. 4C) therebetween that includes the cavity82. A source of adhesive material or flowable polymer or other flowable material can be provided in a reservoir86located in the hand-held device66, such as within the handle68, that can be forced through a supply line88to inject the adhesive material or flowable polymer or other flowable material into the closed chamber84. Alternatively, the adhesive material or flowable polymer or other flowable material can be supplied from an external source.

Turning then toFIG. 4B, there is shown an enlarged perspective view of the lower jaw74and illustrating the cavity82formed therein. As can be seen inFIG. 4B, there are two sets of grooves, that is, there is a first set90,92and a second set94,96, that are parallel, spaced-apart, and provide a means of accurately orienting lines along the lower jaw74such that the lines span the cavity82in parallel, spaced-apart relation.

Turning then toFIG. 4C, taken along withFIGS. 4A and 4B, there is shown the upper and lower jaws72,74in their closed position, thereby forming the closed chamber84. In this embodiment, there is a single line98that forms a loop100such the two separate line segments102,104of the line98pass though the closed chamber84and the separate line segments102,104are aligned within the grooves90,92and94,96such that the line segments102,104are held in a parallel orientation while separated from each other.

The adhesive material or flowable polymer or other flowable material is then injected into the cavity82of the closed chamber84so as to surround and encase the line segments102,104of the line98. Once the adhesive material or flowable polymer or other flowable material properly sets, the upper and lower jaws72,74can be opened and the line98removed, with the set adhesive material or flowable polymer forming a solid structure (e.g., a sheath or sleeve)101(FIG. 4D) that fully joins the line segments102,104together and sealing the loop100.

It can be seen that the adhesive material or flowable polymer or other flowable material can comprise a wide variety of adhesives and flowable polymers or other flowable material that can join the line segments. Thus, in an alternative embodiment, the adhesives or polymers or other flowable material may be molded around the line segments as a flowable fluid or mass that then can be activated by a number of setting mechanisms. By way of example but not limitation, the present invention may utilize UV-activated adhesives with a UV light provided within the jaws72,74to carry out the curing, or the adhesive material may be a multi-component adhesive such as an epoxy material.

Furthermore, while a loop100is illustrated in the embodiment ofFIGS. 4A-4D, it can be seen that the same hand-held device66can be used to simply join two or more line segments (of the same or discrete lines) together, and the line segments may be of differing diameters or materials. Also, the hand-held device66can be used to secure at least one hook and/or other component to a single line segment or to multiple line segments. Due to the encapsulation capabilities of the present invention, the resulting molded sheath (or sleeve)101may also be configured by the geometry of the molding chamber to cover the eyelet of the hook or other component.

Thus it will be seen that with the embodiments ofFIGS. 1A-1C, 2A and 2B, 3A-3C and 4A-4D, the line segments which are to be secured together are positioned within a mold or cavity, then an adhesive or flowable polymer or other flowable material is introduced into the mold so that the adhesive or flowable polymer or other flowable material flows around the line segments within the mold, and then the adhesive or flowable polymer or other flowable material is set so as to form a solid construct (e.g., a sheath or sleeve) which secures the line segments to one another.

Turning next toFIGS. 5A-5D, there is shown schematic views illustrating an exemplary embodiment of the present invention that uses a meltable material, e.g., a flowable polymer, to carry out the joining of two or more line segments. InFIG. 5A, there can be seen two line segments106,108in position to be fitted, by movement in the direction of the arrows A, into a pre-formed polymer sheath (or sleeve)110. The pre-formed polymer sheath (or sleeve)110comprises a material that has a melting temperature that is lower than the melting temperature of the line segments106,108, and is configured so as to have two circular indentations112,114dimensioned to receive and retain the line segments106,108, with the line segments106,108being separated by a center portion116.

The material for the pre-formed polymer sheath (or sleeve)110can be any material that has a lower melting (or glass transition) temperature than the line segments106,108and, upon melting, the melted polymer sheath (or sleeve)110surrounds and fully encases the line segments106,108so as to join them together chemically and/or mechanically. The polymer sheath (or sleeve) material may be formed out of a fully biodegradable material.

In this form of the invention, the pre-formed polymer sheath (or sleeve)110comprises an upper portion118that provides an excess of material, the purpose of which will be later explained. Turning next toFIG. 5B, there is shown a schematic view of the line segments106,108and the pre-formed polymer sheath (or sleeve)110positioned within an upper housing120and a lower housing122. While the upper and lower housings120,122are illustrated to be two separate housings, it will be appreciated that the upper and lower housings120,122can be hinged together, e.g., in the manner of the upper and lower jaws72,74ofFIG. 4A. As such, while this embodiment will be described as using housings, the steps ofFIGS. 5A-5Dare also intended to be carried out using a hand-held device similar to the hand-held device66ofFIG. 4A.

The upper and lower housings120,122include, like the upper and lower jaws,72,74ofFIG. 4A, respectively, an upper heater124and a lower heater126that can be activated by a user so as to provide the heat needed to melt the pre-formed polymer sheath (or sleeve)110, i.e., so that it may be molded about line segments106,108. InFIG. 5B, the upper and lower housings120,122are in their open position and there may be male keys128and corresponding female recesses130to align the housings120,122as they are moved toward the closed position ofFIG. 5C. Again, as described with respect to the embodiment ofFIG. 4A, while an upper and lower heater124,126is disclosed in this embodiment, there may be a heater in only one of the upper or lower housing120,122in carrying out the present invention.

Thus, inFIG. 5C, the upper and lower heaters124,126have been activated to melt the polymer material of the pre-formed polymer sheath (or sleeve)110, such that the material of the polymer sheath (or sleeve)110flows over and between the line segments106,108, whereby to join those line segments together. As noted, the excess material of the pre-formed polymer sheath (or sleeve)110at the upper portion118of the pre-formed polymer sheath (or sleeve)110provides material sufficient to cover the upper surfaces of the line segments106,108so that the line segments106,108are fully encased in the material of the polymer sheath (or sleeve)110.

The final result is illustrated inFIG. 5D, where the line segments106,108are fully encased in the material of the polymer sheath (or sleeve)110such that they are securely joined together. The material of the polymer sheath (or sleeve) can also be provided in strips, pre-fabricated molds, microspheres, powder, fluid, pellets, sheets, polymer coated stents and the like in this embodiment and in other embodiments herein disclosed.

Turning next toFIGS. 6A-6C, there is shown a further exemplary embodiment of the present invention using a pre-formed polymer sheath (or sleeve)132. Again, the pre-formed polymer sheath (or sleeve)132has a pair of channels134,136formed therein for receipt and securement of line segments142,144, with the channels134,136being cylindrical in shape with V-shaped entries138,140so that line segments142,144can be simply snapped into the channels134,136, separate from each other and retained therein.

Thus, inFIG. 6B, the line segments142and144have been snapped into position within the channels134,136where they are retained therein. Again, there is an application of heat (not shown) that may be supplied by a clamshell encasement of the type shown inFIG. 3A-3C, 4A-4D, or5A-5D, or by other heating means, and the pre-formed polymer sheath (or sleeve)132melted so as to surround the line segments142,144and join them together.

Looking next atFIGS. 7A-7C, there is shown a perspective view and cross-sectional views of a further exemplary embodiment of the present invention. InFIG. 7A, there can be seen a pair of line segments142,144that are intended to be joined together. In this embodiment of the invention, the line segments142,144are encircled by a pre-formed meltable polymer construct145that comprises at least two pre-formed polymer sheaths (or sleeves)146,148, such that the polymer melts at a temperature that is lower than the melting temperature of the line segments142,144. The pre-formed polymer sheaths (or sleeves)146,148can have reinforcing braids150within the material of the pre-formed polymer sheaths (or sleeves)146,148so as to strengthen the material (and hence the final construct).

As seen inFIG. 7B, the braided material of the pre-formed polymer sheaths (or sleeves)146,148encircles the line segments142,144as they extend alongside each other awaiting the heating step. InFIG. 7C, the polymer of the pre-formed sheaths (or sleeves)146148have been heated so that the meltable or flowable material of the pre-formed polymer sheaths (or sleeves)146,148has melted and created a seal surrounding the line segments142,144, with the braids150embedded therein, thereby joining the line segments142,144together in a junction with enhanced strength.

Thus it will be seen that with the embodiments ofFIGS. 5A-5D, 6A-6C and 7A-7C, a pre-formed adhesive or flowable polymer (or other flowable material) sleeve is provided, the line segments which are to be joined are positioned in the pre-formed adhesive or flowable polymer (or other flowable material) sleeve, and then the pre-formed adhesive or flowable polymer (or other flowable material) sleeve is transformed (e.g., by the application of heat) so some or all of the pre-formed adhesive or flowable polymer (or other flowable material) sleeve becomes flowable, whereby to cause the adhesive or flowable polymer (or other flowable material) to form an encasing structure about the line segments and thereby lock them in position relative to one another.

Turning next toFIG. 8, there is shown a side view illustrating a still further embodiment of the present invention wherein two line segments152,154are being joined together with the use of a hand-held device156that melts an adhesive or flowable polymer (or other flowable material). Again, the particular adhesive or flowable polymer (or other flowable material) used in the hand-held device156is selected so as to have a melting temperature that is lower than the melting temperature of the line segments152,154, such that the adhesive or flowable polymer (or other flowable material) can be laid along the junction of the line segments152,154so as to join the line segments152,154together.

It should also be appreciated that with this embodiment of the invention, the line segments152,154may also be aligned in a pre-formed meltable or flowable polymer sheath (or sleeve), e.g., as illustrated inFIG. 6A, and a hand-held heater, similar to the device ofFIG. 8, can be used to heat the polymer and melt the polymer so as to mold the sheath (or sleeve) about the line segments and thereby join the line segments together.

FIGS. 9A-9Dshow an alternative hand-held device200that molds a polymer sheath (or sleeve) fastener about a plurality of line segments so as to join those line segments together.

Looking now atFIGS. 9A-9D, and also10A-10F, with hand-held device200, a latch201is released so as to open a mold door202(FIG. 10A), line segments203A,203B are extended across the cavity204of a mold205(FIG. 10B), and then mold door202is closed (FIG. 10C). Then, as seen inFIGS. 10D-10F, a stick206of flowable polymer (or other flowable material) is loaded into hand-held device200and then trigger207is depressed, causing injection assembly210to inject or administer the flowable polymer into mold cavity204, whereby to create, in situ, the polymer sheath (or sleeve) that encapsulates the line segments. Note that hand-held device200is configured so as to hold the line segments203A,203B spaced apart from one another so as to increase the bond strength between the polymer sheath (or sleeve) and the line segments. This bonding process and design does not impair the integrity of the line segments because it avoids crimping, compressing, deforming, or unwantedly abrading of the line segments, which has been shown to reduce the tensile strength of the joined line.

FIG. 11shows details of the mold205which defines mold cavity204(and hence the configuration of the molded polymer sheath or sleeve).

The injection assembly210of hand-held device200is shown in great detail inFIGS. 12A and 12B. Injection assembly210generally comprises a plunger mechanism215and an injector mechanism220. The plunger mechanism215is used to advance the stick206of the flowable polymer material through the injector mechanism220such that a heater230in the injector mechanism is able to melt the flowable polymer so it can be molded in cavity204of mold205, thereby encapsulating the line segments that are supported by mold205in a spaced orientation so as to create a resulting polymer sheath (or sleeve) that secures the line segments together.

FIG. 13shows a polymer sheath (or sleeve)235created by the hand-held device200. InFIG. 13, the polymer sheath (or sleeve)235is shown being used to bond line segments that secure a fishing hook240(or other component), with the line being looped through an eyelet245in the hook (or other component).

The polymer sheath/sleeve235may be fabricated with an elongated orientation as shown inFIGS. 14A through 14I. In one preferred form of the invention, the polymer sheath (or sleeve)235holds the line segments in parallel, spaced-apart relation. In one preferred form of the invention, polymer sheath (or sleeve)235is beveled, e.g., as shown at250, so as to facilitate passing polymer sheath (or sleeve)205through a constrained opening such as the eye of a fishing rod, and to minimize abrasion with line segments or other components, etc.

Alternatively, as described previously, the line segments may be secured in the polymer sheath (or sleeve) with a non-parallel orientation, and/or multiple segments from a single line, or multiple lines, may be secured in the polymer sheath (or sleeve). In addition, the polymer sheath (or sleeve) may be used to secure a hook or other component directly to a line segment without having to loop the line. The polymer sheath (or sleeve) may also incorporate any other shape defined by the mold cavity204through which the line segments (and hook or other component, for embodiments in which a portion of the hook or other component are to be encapsulated) can be inserted. This geometry may consist of a T-shape (to position hooks orthogonal to the line segments) or any other shape to support the needs for mounting and configuring multiple lines in a non-linear orientation.

An alternative hand-held device255, shown inFIGS. 15A to 15Eand generally similar to the aforementioned hand-held device200except as otherwise stated, incorporates a polymer cartridge system for injecting polymer sheath material into a mold so as to secure line segments. A replaceable cartridge260for releasably containing the polymer, and for insertion into the hand-held device255, is shown inFIGS. 16A-16C. The replaceable cartridge260can house the raw polymer material in the form of a fluid, powder, pellet, or solid. A plunger, compressible roller, or other mechanism may be used by hand-held device255to expel the raw polymer material out of the cartridge, through the injector mechanism220, and into the mold cavity204of mold205to mold the polymer sheath (or sleeve) around the oriented line segments. The heater230may be used to melt the polymer raw material so as to facilitate injecting the polymer into the mold cavity, especially when the polymer is maintained as a powder, pellet or solid form in the cartridge260. Alternatively, the cartridge260may incorporate an internal spring mechanism, or be pressurized, to enable the raw polymer material to be ejected from the cartridge260without requiring an actuating mechanism associated with the hand-held device255. In those hand-held embodiments, the heating mechanism melts the raw polymer material to enable flowing the polymer material into the mold cavity204where molding around the line segments is achieved. Whether it is these or other cartridge injection concepts, the key is to provide a replaceable cartridge that can easily and cleanly inject the raw polymer material into the mold cavity204, and to allow the user to quickly switch cartridges, whereby to change the material type, viscosity, color, additive, or other feature, so that the polymer sheath (or sleeve) can be customized to the application.

Just as the cartridge260may be replaceable, the mold205(and hence mold cavity204) may also be replaceable in order to accommodate different line segment sizes, different numbers of line segments, the orientation of line segments in parallel or non-parallel orientations, or encapsulation of hooks or other components within the polymer sheath (or sleeve), as described above.

FIG. 17shows preferred relationships between the dimensions of the polymer sheath (or sleeve)235and the secured line segments so as to optimize the bond strength while maintaining the integrity of the line segments. In one preferred form of the invention, the individual line segments are separated such that the spacing (L1) is at least 0.5 times, and preferably 2.5 times, the diameter (D1) of the smallest diameter line segment so as to ensure that the mold encapsulates the entire surface of the line segment and avoids compressing individual line segments. Optimizing tensile strength is obtained when the wall thickness of the polymer sheath (or sleeve)235is designed such that the outer diameter, or width for non-circular cross-sections, is at least 2 times, and preferably 4 times, the diameter of the line segment which is being encapsulated.

FIG. 18is a graph showing performance characteristics for the present invention.

FIG. 19is a graph showing the tensile strength of joined lines as a plot of sleeve length vs. line diameter.

In the foregoing discussion, it was noted that the line segments may extend in parallel or non-parallel, spaced relation within the molded sheath (or sleeve) construct. In this respect it should be appreciated that various strategies may be employed to increase the surface area of the line segments engaged by the molded sheath (or sleeve), and/or to adjust the pathway of the line segments engaged by the molded sheath (or sleeve), whereby to increase the strength of the bond. See, for example,FIG. 20, where the line segments302,304extend in a serpentine manner through the molded sheath (or sleeve) construct306.

It is also possible to have the line segments contact one another within the molded sheath. See, for example,FIG. 21, which shows a loop308of a line310and a loop312of a line314, where loop308and loop312are passed through one another. This approach can provide a superior bond, particularly where one line is braided line and the other line is monofilament line. See also, for example,FIG. 22, where line314is knotted (e.g., at316) within the molded sheath. Again, this can provide a superior bond, particularly where one line is braided line and the other line is monofilament line. Still other configurations for the line segments will be appreciated by those skilled in the art in view of the present disclosure.

In addition to the embodiments discussed above, the devices of the present invention may attach line segments for applications other than fishing. In particular, any application in which two segments of line, thread, yarn, suture, wire, or other flexible elongated material are bonded together may benefit from the embodiments of the present invention, which secure at least two line segments together such that they are spaced apart to improve bond strength and profile of the bond while preserving the physical integrity of the raw line material.

Thus it will be seen that, in one preferred form of the invention, the invention comprises the provision and use of a molded fastener, formed at least in part out of a flowable material, to secure two or more line segments in position relative to one another. In use, the line segments are positioned with a desired orientation (e.g., in a parallel or non-parallel, spaced relationship), the flowable material is flowed about the line segments so as to engulf the line segments, and then the flowable material is set so as to form an encasing structure about the line segments, whereby to lock the line segments in position relative to one another.

In one form of the invention, the molded fastener is formed in situ, e.g., the line segments are positioned in a mold with the desired orientation, the flowable material is flowed into the mold and about the line segments, and then the flowable material is set so as to form the encasing structure about the line segments, whereby to lock the line segments in position relative to one another.

In another form of the invention, the molded faster is at least partially pre-formed, and then the final configuration of the molded fastener is effected in situ, e.g., the line segments are positioned in the at least partially pre-formed molded fastener, the flowable material is flowed about the line segments, and then the flowable material is set so as to form the encasing structure about the line segments, whereby to lock the line segments in position relative to one another.

The flowable material may comprise any material capable of performing the desired function. In one form of the invention, the flowable material forms a mechanical bond with the line segments when set. In another form of the invention, the flowable material forms a chemical bond with the line segments when set. And in another form of the invention, the flowable material forms both mechanical and chemical bonds with the line segments when set. The flowable material may comprise an adhesive (including a hot melt adhesive) and/or a flowable polymer and/or any other appropriate material, and flowing/setting of the flowable material may be effected according to the nature of the flowable material, e.g., heating/cooling, the absence or presence of UV light, the absence or presence of a reactant, etc.

Modifications of the Preferred Embodiments

While the present invention has been set forth in terms of a specific embodiment or embodiments, it will be understood that the method and apparatus for joining lines together herein disclosed may be modified or altered by those skilled in the art to other configurations. Accordingly, the invention is to be broadly construed and limited only by the scope and spirit of the claims appended hereto.