Polymer bonding process

The present application provides methods and compositions for patching a polymer or a non-polymer substrate surface by producing a bond between a polymer patch surface and the substrate surface. The application also provides kits having instructions for patching a polymer or a non-polymer substrate surface by producing a bond between a polymer patch surface and the substrate surface.

FIELD OF INVENTION

The present invention relates to the field of compositions and methods, particularly a method and kit for affixing a polymer patch to a polymer or non-polymer substrate surface.

BACKGROUND

A polymer is a substance or material consisting of very large molecules, or macromolecules, composed of many repeating subunits. Due to their broad spectrum of properties, both synthetic and natural polymers play essential and ubiquitous roles in everyday life. Polymers range from familiar synthetic plastics such as polystyrene to natural biopolymers such as DNA and proteins that are fundamental to biological structure and function. Polymers, both natural and synthetic, are created via polymerization of many small molecules, known as monomers. Their consequently large molecular mass, relative to small molecule compounds, produces unique physical properties including toughness, high elasticity, viscoelasticity, and a tendency to form amorphous and semicrystalline structures rather than crystals.

The term polymer is often used to describe plastics, which are synthetic polymers. A wide variety of synthetic polymers are available. Some familiar household synthetic polymers include: Nylons in textiles and fabrics, Teflon in non-stick pans, Bakelite for electrical switches, polyvinyl chloride (PVC) in pipes, etc. Popular polymers for manufacturing include polyethylene and polypropylene.

Often times synthetic polymers break or fracture which require some type of repair, for example, auto plastic often requires some type of repair after an accident or a plastic household decor item will need repair after a fall. Currently, the only means of repair is by way of adhesives or glues which provide a limited, temporary glue joint between the polymer surfaces. The adhesive does not provide an actual chemical bond between the surfaces of the polymer or to the glue itself. The glue molecules simply stick to the polymer surface molecules in order to provide the connection—thereby limiting the strength and longevity of the bond.

SUMMARY

The present application provides methods and compositions for patching a polymer or a non-polymer substrate surface by producing a bond between a polymer patch surface and the substrate surface. The application also provides kits having instructions for patching a polymer or a non-polymer substrate surface by producing a bond between a polymer patch surface and the substrate surface.

In a version of the application, a method of patching a polymer substrate surface by producing a bond between a polymer patch surface and the polymer substrate surface generally comprises the steps of: roughing the polymer substrate surface; cleaning the polymer substrate surface; applying a synthetic polymer preparation solution to the polymer substrate surface; allowing the applied synthetic polymer preparation solution to dry; applying a polymerization catalyst to the polymer substrate surface; allowing the applied polymerization catalyst to dry; applying heat to warm the polymer substrate surface until surface temperatures reach between about 114°-120° Fahrenheit; applying a surface insensitive cyanoacrylate structural adhesive to the polymer patch surface; and urging contact between the polymer patch surface and the polymer substrate surface.

In another version of the application, a method of patching a non-polymer substrate surface by producing a bond between a polymer patch surface defined within a perimeter and a non-polymer substrate surface is disclosed. The method generally comprising the steps of: roughing the non-polymer substrate surface; polishing the non-polymer substrate surface; cleaning the non-polymer substrate surface; applying a polymerization catalyst to the non-polymer substrate surface; allowing the applied polymerization catalyst to dry; applying a first amount of surface insensitive cyanoacrylate structural adhesive to the polymer patch surface; and urging contact between the polymer patch surface and the non-polymer substrate surface.

In yet another version of the application, a method of patching a non-polymer substrate surface by producing a bond between a polymer patch surface defined within a perimeter, an intermediate reinforcement substrate having a first surface and a second opposing surface, and the non-polymer substrate surface is disclosed. The method generally comprises the steps of: roughing the non-polymer substrate surface; polishing the non-polymer substrate surface; roughing the first surface and the second surface of the intermediate reinforcement substrate; cleaning the non-polymer substrate surface, the first surface of the intermediate reinforcement substrate, and the second surface of the intermediate reinforcement substrate; applying a polymerization catalyst to the non-polymer substrate surface; allowing the applied polymerization catalyst applied to the non-polymer substrate surface to dry; applying a surface insensitive cyanoacrylate structural adhesive to the intermediate reinforcement substrate first surface; urging contact between the intermediate reinforcement substrate first surface and the non-polymer substrate surface; applying a polymerization catalyst to the intermediate reinforcement substrate second surface; allowing the applied polymerization catalyst applied to the intermediate reinforcement substrate second surface to dry; applying a surface insensitive cyanoacrylate structural adhesive to the polymer patch surface; and urging contact between the polymer patch surface, the intermediate reinforcement substrate second surface and the surrounding exposed non-polymer substrate surface.

DETAILED DESCRIPTION

In the following description, for purposes of explanation and not limitation, specific details are set forth such as particular compositions, kits, methods, techniques, etc. in order to provide a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced in other versions that depart from these specific details. In other instances, detailed descriptions of well-known devices and methods are omitted so as not to obscure the description of the present invention with unnecessary detail.

Moreover, the description is not to be taken in the limiting sense but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims. Various inventive features and methods are described below that can each be used independently of one another or in combination with other features.

Unless otherwise defined, all technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. As used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Any reference to “or” herein is intended to encompass “and/or” unless otherwise stated.

The term “polymer” or “synthetic polymer” as used herein refers primarily to synthetic, oil-based polymers, co-polymers and polyolefins, known as poly-plastics. Plastics are typically produced by the conversion of natural products or by the synthesis from primary chemicals generally coming from oil, natural gas, or coal. Relevant poly-plastics may include low-density polyethylene (LDPE), high density polyethylene (HDPE), polypropylene (PP), Polyvinyl chloride (PVC) Polystyrene (PS), Nylon, Teflon (Polytetrafluoroethylene), Thermoplastic polyurethanes (TPU), Polytetrafluoroethylene (PTFE), Silicones, Polysiloxanes, etc. Relevant copolymers may include acrylonitrile butadiene styrene (ABS), styrene/butadiene co-polymer (SBR), nitrile rubber, styrene-acrylonitrile, styrene-isoprene-styrene (SIS) and ethylene-vinyl acetate as well as nylon.

The term “substrate” as used herein refers primarily to objects having all types of surface materials including polymers and non-polymers.

The term surface as used herein refers primarily to uppermost layer of an object that will be utilized in the bonding and polymerization process. Surfaces may have a smooth, rough or irregular profile. For example, the surfaces can be a smooth flat surface, an irregular rough surface, or displaying broken ridges including forming broken edges. Typically, the exposed surfaces formed by a break in a plastic or other substrate forms the relevant surfaces to be bonded.

The present application provides a method of use of chemical compositions and kits having instructions for using the chemical compositions for producing a permanent bond between a polymer-plastic surface and a substrate surface. A version of the application utilizes a synthetic polymer preparation solution to prepare the synthetic polymer surface for the bonding process, a polymerization catalyst as well a heating source for activating and accelerating the bonding process, and a cyanoacrylate adhesive for interacting with the synthetic polymer preparation solution and the polymerization catalyst for sustaining the permanent bond between surfaces.

The cyanoacrylate adhesive is utilized in the process to bond the synthetic polymer surface with the substrate surface. Generally, cyanoacrylates are a family of strong fast-acting adhesives with industrial, medical, and household uses. Cyanoacrylates include methyl 2-cyanoacrylate, ethyl-2-cyanoacrylate (commonly sold under trade names such as “Super Glue” and “Krazy Glue”™, of Toagosei), n-butyl cyanoacrylate and 2-octyl cyanoacrylate. Cyanoacrylate adhesives are sometimes known generically as instant glues, power glues or superglues. The abbreviation “CA” is commonly used for industrial grades. The active ingredient in cyanoacrylate adhesives is cyanoacrylate ester. Typical Cyanoacrylate adhesive compounds comprise 90-99% of cyanoacrylate ester.

Ideally, the cyanoacrylate adhesive is a surface insensitive adhesive which is formulated to react much faster than traditional CA's on inactive and active surfaces, even in dry climates, for a more consistent, reliable bond. This effect is magnified when a surface insensitive CA is used in combination with the synthetic polymer preparation solution and the polymerization catalyst. The speed and intensity of the polymerization process is critical to bond formation.

The synthetic polymer preparation solution is a chemical composition which prepares the poly-plastic surface for the bonding process. More specifically, the synthetic polymer preparation solution comprises chemical compounds which allow the achievement of high strength bonds when utilized in conjunction with cyanoacrylate adhesives. More specifically, the chemical compounds in the synthetic polymer preparation solution rapidly dries (relatively short flash off period) and removes oil from the poly-plastic surface and etches the surface. This etching of the surface provides increased and irregular shaped surface area which provides an ideal framework for the bonding process.

Generally, the synthetic polymer preparation solution is applied/saturated to the poly-plastic surfaces in the form of a spray, brush, and/or by dipping the surfaces. The synthetic polymer preparation solution treated surfaces are allowed to quickly and completely dry. Thereby, providing a poly-plastic surface that will yield a permanent, high strength bond that is resistant to aging and deterioration. It will be known that the synthetic polymer preparation solution treated poly-plastic surfaces do not have to be bonded immediately—the treated surfaces may be stored for significant periods of time including several years without losing the potential of providing a strong, permanent bond through the polymerization bonding process.

In a preferred version of the application, it is desirable that the synthetic polymer preparation solution provides a composition that has a quick “flash off” period in order to provide the best results. Through applicant's research and testing, preferably, the synthetic polymer preparation solution (PPS) is a solution comprising quantities of hydrotreated light naphtha, isopropanol, and triethylenediamine.

Ideally, the synthetic polymer preparation solution comprises 95%-99% hydrotreated light naphtha by volume. Naphtha is a flammable liquid hydrocarbon mixture and is known as Petroleum ether. It belongs to the product category of UVCB s-Organic. Naphtha is a group of various volatile, highly flammable, liquid hydrocarbon mixtures used chiefly as nonpolar solvents. Chemically, it is not an ether like diethyl ether, but a light hydrocarbon. Naphtha (petroleum), hydrotreated light is obtained from petroleum refineries as the portion of the distillate which is intermediate between the lighter naphtha and the heavier kerosene. Naphtha (petroleum), hydrotreated light consists mainly of pentane, and is sometimes used instead of pentane due to its lower cost.

For purposes of the application, the hydrotreated light naphtha assists with drying and providing a quick flash off of the treated surface while removing oils and carries and stabilizes the other active ingredients in the PPS, for example, the isopropanol and the triethylene diamine.

Preferably, the solution comprises 3-5% of isopropanol or isopropyl alcohol by volume which is a compound with the chemical formula C3H8O. Isopropyl alcohol is a colorless, flammable chemical compound with a strong odor. As an isopropyl group linked to a hydroxyl group, it is the simplest example of a secondary alcohol, where the alcohol carbon atom is attached to two other carbon atoms. It is a structural isomer of 1-propanol. The isopropyl compound is preferred because it is a solvent in regard to non-polar materials such as poly-plastics, thus when applied to the poly-plastic surface, the compound preferably etches the surface providing a superior surface structure framework for the bonding process.

Further, the preferred PPS comprises 0.1-1% of triethylenediamine which is an organic compound with the formula N2(C2H4)3, a highly nucleophilic amine, which is used as a catalyst and reagent in polymerization and organic synthesis. The triethylenediamine is an active ingredient in the PPS which provides a catalyst during the polymerization bonding process.

The polymerization catalyst is a chemical composition comprising an amine for activating, accelerating, and intensifying the polymerization bonding process of the cyanoacrylate adhesive. Preferably, the amine is N,N-Dimethyl-p-toluidine which has the chemical formula C9H13N and is miscible with alcohol, ether, and chloroform as a carrier substance. Ideally, polymerization catalyst solution comprises 1-5% of the amine by volume, preferably about 3%.

The polymerization catalyst enhances the alkaline conditions on the treated surface in order to activate and accelerate the intensity of the polymerization of the cyanoacrylate adhesive or formation of covalent bonds. Thus, it is preferable that the polymerization catalyst is a cyanoacrylate activator and accelerator comprising an amine. Moreover, it is important to provide a polymerization catalyst because there is a limited window of time after the application of the cyanoacrylate adhesive to form a superior quantity of covalent bonds—the catalyst in conjunction with heat ensure that throughout this small timeframe, the maximum number of covalent bonds are formed, thereby yielding a strong, permanent bond after the process is complete.

Referring specifically now toFIG.1-FIG.3, the present application provides a method100of producing a permanent bond between a synthetic polymer first surface10and a substrate second surface12. The method generally comprises the steps of: a) applying a synthetic polymer preparation solution to the synthetic polymer first surface10and, if the second substrate second surface12is a synthetic polymer, to the substrate second surface12(Step110); b) allowing the applied synthetic polymer preparation solution to dry on each applied surface (Step120); c) applying a polymerization catalyst to the synthetic polymer first surface10(Step130); d) allowing the applied polymerization catalyst to dry on the synthetic polymer first surface10(Step140); e) applying heat to warm the surfaces made of synthetic polymers until surface temperatures reach between about 114°-120° Fahrenheit (Step150); f) applying a surface insensitive cyanoacrylate structural adhesive to the substrate second surface12which has not been treated with the polymerization catalyst (Step160); g) urging contact between the first surface10and the second surface12(Step170); and h) applying heat to warm the seam14formed between the first and second surface.

Preferably, prior to initiating the method100, the synthetic polymer first surface10and the substrate second surface12is cleaned (step105) in order to reduce quantities of foreign substances that could contaminate or mitigate the polymerization process. Cleaning may be performed by way of a moist paper towel or other means applied to the surfaces to remove dirt and grime. Any residual water on the surfaces is allowed to completely dry before beginning the method100.

Referring to Step110, the synthetic polymer preparation solution is applied only to the synthetic polymer surfaces to be bonded. Thus, the synthetic polymer preparation solution is not applied to non-poly plastic substrates, such as wood. The synthetic polymer preparation solution can be applied by way of spray bottle, brush, or even dipping the object surface into the solution. Once the synthetic polymer surfaces are completely saturated with PPS, the surfaces are allowed to completely dry (Step120).

Thereafter, in step130, the polymerization catalyst is applied to the synthetic polymer first surface10and not the substrate second surface12. The polymerization catalyst can be applied by way of spray bottle, brush, or even dipping the object surface into the solution. Once the synthetic polymer first surface10is completely saturated with the polymerization catalyst, the surfaces are allowed to completely dry (Step140).

Thereafter, in step150, heat is evenly applied to warm the first and second surfaces10,12until surface temperatures preferably reach 114°-120° Fahrenheit, more preferably about 118° Fahrenheit. The application of heat can be provided by a means for heating such as a blow dryer or heat gun. The application of heat primes each surface for the application of the SI adhesive and the bonding process at the molecular level. When heat is added to the surface of an object, the molecules and atoms vibrate faster. As atoms vibrate faster, the space between atoms increases. The result of increased molecular motion and greater spaces is the dramatic increase in the quantity, durability, and strength of resulting covalent bonds formed between the surfaces10,12. Thus, during the polymerization and bonding step170, the heated surface provides a molecular excitation which dramatically increases the quantity, durability, and strength of resulting covalent bonds formed between the surfaces is increased. In essence, through testing, the addition of heat provides additional surface area which allows the bonds to react and form more quickly.

Temperatures exceeding 120° have been found through applicant's testing to cause the cyanoacrylate adhesive to polymerize prematurely. Applicant's testing has shown that surface temperatures falling below 110° fail to provide adequate molecular motion. Testing has shown that the ideal surface temperature prior to applying the SI cyanoacrylate adhesive and facilitating the bonding process is about 118°.

Referring to step160inFIG.1, a cyanoacrylate structural adhesive, preferably a fast-active surface insensitive cyanoacrylate structural adhesive is applied to the substrate second surface12which has not been treated with the polymerization catalyst. The application of the adhesive may be by way of brush or beading directly onto the surface12from the adhesive container nozzle. The adhesive is not applied to the treated first surface10because it would cause the polymerization process to begin prematurely. Thereafter, in step170, the first and second surfaces10,12are urged together (FIG.3) in order to initiate the bonding of the first and second surface10,12. Ideally, the urging together of the surfaces is performed for 15-20 seconds, allowing the prepped synthetic polymer surface(s), the polymerization catalyst, and the surface insensitive adhesive to rapidly work synergistically together to form a strong, permanent bond.

Thereafter, in step180, heat is applied to warm the seam14formed between the first and second surface10,12, thereby further sealing and strengthening the resulting bond between the first and second surface10,12, thereby bonding the objects together (FIG.3). This additional heat maintains the increased distance and increased action of the polymer substrate allowing for the maximum number of bonds to form.

Optionally, but not critical to the above method100, in step190, the bonded surfaces are allowed to cure for approximately 7-30 days in order to realize the strongest bond—further providing strength and resilience. However, it will be known that the resulting bond is at operational strength—able to handle normal wear and tear—immediately after the bonding process.

It has been determined through testing that the above fast-acting polymerization process provides the strongest resulting bonds. The combination of the above steps and materials provide a superior bond within a minute of urging the surfaces together, which is unexpected and superior to any other bonding process known.

Polymers are greatly diverse which can impact the Polymer Bonding Process described above. For example, sulfone polymers such as polyphenylsulfone (PPSU) need every step of the process, polymer preparation, use of the polymerization catalyst, heat and the surface insensitive structural cyanoacrylate in order to generate a bond. Omit the heat and a very weak glue joint is formed. With another type of polymer, Fluorosilicone (FVMQ) the heat step may not be required in order for a bond to form. While not strictly needed in every application, heat, in every case will produce a stronger bond.

The present application may further comprise a kit for producing a permanent bond between a synthetic polymer first surface and a substrate second surface. Generally, the kit comprises a quantity of synthetic polymer preparation solution; a quantity of a polymerization catalyst; a quantity of surface insensitive cyanoacrylate structural adhesive; and instructions to use the synthetic polymer preparation solution, a polymerization catalyst, and the surface insensitive cyanoacrylate structural adhesive and heat to produce the permanent bond between the synthetic polymer first surface and the substrate second surface.

The instructions contained in the kit may comprise instructions similar to the method100outlined above which comprise the following: a) apply the synthetic polymer preparation solution to the synthetic polymer first surface and, if the second substrate second surface is a synthetic polymer, to the substrate second surface; b) allow the applied synthetic polymer preparation solution to dry on each applied surface; c) apply the polymerization catalyst to the synthetic polymer first surface; d) allowing the applied polymerization catalyst to dry on the synthetic polymer first surface; e) applying heat to warm the surfaces made of synthetic polymers until surface temperatures reach between about 114°-120° Fahrenheit; f) apply the surface insensitive cyanoacrylate structural adhesive to the second surface; g) urge contact between the first surface and the second surface; and h) apply heat to warm the seam formed between the first and second surface.

Referring specifically now toFIG.4-FIG.15, the present application further provides patch application methods200,300and400for sealing a fractured or broken synthetic polymer or non-polymer substrate surface, such as a pipe, tank, or other container. The patch application methods200,300, and400generally utilize a strip of a synthetic polymer defining a patch which is adhered over a discontinuity and onto the substrate surface in a permanent manner. The synthetic polymer patch20is generally impervious or highly resistant to fuel, oil, water, chemicals, and weather. The synthetic polymer patch20as utilized in the patch application methods200,300, and400have many useful applications—and may be utilized to fix or patch most synthetic polymer and non-polymer surfaces including PVC, copper, galvanized steel, cast iron, and plastics. Generally, through research and testing, the synthetic polymer patch20as applied in methods200,300, and400may withstand pressurized contents of up to 240 PSI before failing.

As shown inFIG.4, the patch20is generally a thin strip of a synthetic polymer material having sufficient dimensions to overlay a substrate surface comprising a discontinuity, break, or fracture24. Thus, the size, shape, and dimension of each patch20may vary for each specific application. However, preferably, the patch20is defined in a rectangular shape having a length L and a width W providing a wide range of coverage. Preferably, the size of the patch is sufficient of overlay and form a boundary which is at least one inch around the discontinuity, break, or fracture24of the substrate surface22.

Preferably, the patch is manufactured of fluorosilicone (FVMQ) which is highly resistant to both chemicals and weather. Fluorosilicone is the polymer of choice for high-stress environments and applications. During the manufacturing process of fluorosilicone, the surface of fluorosilicone is infused with polyfluoroalkyl substances which further improves the imperviable nature of the fluorosilicone. Due to these properties, the patches20made of fluorosilicone have excellent fuel, oil, water, and weather resistant properties, along with excellent chemical resistance for most common chemicals. Further, fluorosilicone has a service temperature range from −50 degrees F. to 200 degrees F. which is ideal for outdoor applications.

In some applications, it is ideal to abrade at least one side of a patch20which has been treated with polyfluoroalkyl substances, leaving behind a surface that has improved adhesion characteristics, which improves the overall strength of the patches during application as utilized in methods200,300, and400. The unabraded surfaces of the patches generally visually provide a glossy finish while the abraded surfaces visually provide a matte finish. Preferably, during application of the patch20, the abraded side or interior application surface26of the patch20is utilized to adhere to the substrate surface22and the unabraded side or exterior surface32of the patch is exposed outward, providing a barrier resistant to fuel, oil, weather, etc.

Referring now toFIG.4-FIG.7, the method200generally defines the application of the polymer patch20for adhering to and sealing over a fractured or broken polymer substrate surface22, for example, a synthetic polymer such as a plastic pipe or a plastic container.

The method200of patching a polymer substrate surface by producing a bond between the polymer patch20and the polymer substrate surface22generally comprises the steps of: a) roughing the polymer substrate surface22(Step205); b) cleaning the polymer substrate surface22(Step210); c) applying a synthetic polymer preparation solution to the polymer substrate surface22(Step220); d) allowing the applied synthetic polymer preparation solution to dry (Step230); e) applying a polymerization catalyst to the polymer substrate surface22(Activator/Accelerator) (Step240); f) allowing the applied polymerization catalyst to dry (Step245); g) applying heat to warm the polymer substrate surface22until surface temperatures reach between about 114°-120° Fahrenheit (Step250); h) applying a surface insensitive cyanoacrylate structural adhesive to the synthetic polymer patch20application surface26(Step255); and i) urging contact between the synthetic polymer patch20application surface26and the polymer substrate surface22(Step260), thereby adhering the synthetic polymer patch20over the discontinuity24and bonding with the polymer substrate surface22.

In Step205, the polymer substrate surface22around the discontinuity24is roughed by way of a means for roughing, for example, sandpaper. Preferably, a fine to medium grade sandpaper is used to rough or make the substrate surface22uneven about the substrate discontinuity24. Thereafter, in Step210, the synthetic polymer substrate surface22is cleaned in order to reduce quantities of foreign substances that could contaminate or mitigate the bonding process, preferably, with a cloth and mild cleaner—wiping the surfaces to remove any dirt, grime, and/or residue.

Referring to Step220, the synthetic polymer preparation solution is applied to and around the polymer substrate surface22discontinuity24. The synthetic polymer preparation solution can be applied by way of spray bottle, brush, or even dipping the object surface into the solution. Thereafter, the polymer substrate surface22is allowed to completely dry (Step230).

Thereafter, in Step240, the polymerization catalyst is applied to the polymer substrate surface22. The polymerization catalyst can be applied by way of spray bottle, brush, or even dipping the subject surface into the solution. Once the polymer substrate surface22is completely saturated with the polymerization catalyst, the polymer substrate surface22is allowed to dry (Step245).

Thereafter, in Step250, heat is evenly applied to warm the polymer substrate surface22until surface temperatures preferably reach 114°-120°, more preferably about 118°. The application of heat can be provided by a means for heating such as a blow dryer or heat gun. The application of heat primes the polymer substrate surface22for the application of the SI adhesive and the bonding process at the molecular level.

Referring to Step255, a cyanoacrylate structural adhesive, preferably a fast-active surface insensitive cyanoacrylate structural adhesive is applied to the application surface26of the synthetic polymer patch20which has not been treated with the polymerization catalyst. The application of the adhesive may be by way of brush or beading directly onto the application surface26.

Preferably, the SI adhesive is applied to the synthetic polymer patch20application surface26in a continuous loop or circular pattern covering the entire application surface26except for small fingertip sized surfaces adjacent to selected opposing diagonal corners28,30, assuming that the synthetic polymer patch20is rectangular in dimension. Preferably, additional adhesive is applied to the synthetic polymer patch20application surface26where it is likely to contact the discontinuity24of the polymer substrate surface22. If the synthetic polymer patch20is not rectangular, then opposing fingertip sized surfaces can be positioned at the synthetic polymer patch20outer perimeter34.

Thereafter, in step260, the synthetic polymer patch20application surface26and the polymer substrate surface22are urged together (FIG.6) in order to initiate the bonding of the application surface26or polymer patch surface and the polymer substrate surface22near the discontinuity24.

Preferably, the diagonal corners28,30that lack adhesive are utilized as grab points, namely, the corners28,30are grabbed by hand, gently stretching the polymer patch20while simultaneously applying the application surface26to the polymer substrate surface22. Ideally, the urging together of the surfaces22,26is performed for 15-20 seconds, allowing the prepped synthetic polymer substrate surface22, the polymerization catalyst, and the surface insensitive adhesive to rapidly work synergistically together to form a strong, permanent bond.

Preferably, a glue squeegee or putty knife is utilized to apply firm pressure working from the interior of the polymer patch20exterior surface32to the outer perimeter34thereof. Further, adhesive is applied to the opposing diagonal corners28,30of the application surface26that lack adhesive. Thereafter, each of the diagonal corners28,30are urged towards the polymer substrate surface22in order to complete the seal.

Thereafter, the synthetic polymer patch20is inspected to assure that there is continual contact between the patch20application surface26and the polymer substrate surface22, particularly at the outer perimeter34of the synthetic polymer patch20. In certain instances, multiple patches20may be fabricated to overlap previously attached patches20in order to assure that the discontinuity24is completely sealed.

Optionally, it is recommended that adhesive is applied along the complete outer perimeter34of the polymer patch20. Thereafter, the polymerization catalyst is applied to the synthetic polymer patch20outer perimeter34.

Lastly, the patch20and polymer substrate surface22are visually inspected for any discontinuities, breaks, or gaps around the outer perimeter34of the polymer patch20, indicating that the patch20may allow a leak. If a discontinuity is discovered, more adhesive should be applied and the polymerization catalyst applied thereafter until a complete seal is achieved.

The present application may further comprise a kit for patching a polymer substrate surface by producing a bond between a polymer patch surface and the polymer substrate surface. Generally, the kit may include a polymer patch providing a polymer patch surface, a means for roughing such as a quantity of sandpaper; a quantity of synthetic polymer preparation solution; a quantity of a polymerization catalyst; a quantity of surface insensitive cyanoacrylate structural adhesive; and a glue squeegee (or putty knife). The kit may further include instructions to use the polymer patch, means for roughing, synthetic polymer preparation solution, a polymerization catalyst, the surface insensitive cyanoacrylate structural adhesive, glue squeegee and heat to produce a bond between the polymer patch surface and the polymer substrate surface.

The instructions contained in the kit may comprise instructions similar to the method200outlined above which may comprise the following: roughing the polymer substrate surface with the means for roughing; cleaning the polymer substrate surface; applying an amount of synthetic polymer preparation solution to the polymer substrate surface; allowing the applied synthetic polymer preparation solution to dry; applying an amount of polymerization catalyst to the polymer substrate surface; allowing the applied polymerization catalyst to dry; applying heat to warm the polymer substrate surface until surface temperatures reach between about 114°-120° Fahrenheit; applying an amount of surface insensitive cyanoacrylate structural adhesive to the polymer patch surface; and urging contact between the polymer patch surface and the polymer substrate surface by utilizing the glue squeegee.

Referring specifically now toFIG.4,FIG.8-FIG.10, the present application further provides the method300for patching or sealing over a discontinuity50in a non-polymer substrate surface48, such as copper, galvanized steel, cast iron, etc. Ideally, a thin-layered synthetic polymer patch20, preferably manufactured of fluorosilicone is utilized to adhere over the discontinuity50and onto the non-polymer substrate surface48surrounding the discontinuity50. Research and testing have shown that the application of the synthetic polymer patch20as it relates to the attachment to non-polymer substrates can resist up to 120 PSI before the patch fails.

As shown inFIG.10, the method300generally comprises the steps of: a) roughing the non-polymer substrate surface (Step305); b) polishing the non-polymer substrate surface (Step310); c) cleaning the non-polymer substrate surface (Step320); c) applying a polymerization catalyst to the non-polymer substrate surface (Step330); d) allowing the applied polymerization catalyst to dry (Step340); e) applying a surface insensitive cyanoacrylate structural adhesive to the polymer patch surface (Step350); and f) urging contact between the polymer patch surface and the substrate surface (Step360).

The method300starts with Step305, wherein the area around the discontinuity50in the non-polymer substrate surface48is roughed by a means for roughing. Preferably, the means for roughing is a course grade sandpaper which is used to aggressively rough or make the surface uneven about the non-polymer substrate surface48discontinuity50. Further, the edges of the discontinuity50should be roughed to adequately remove corrosion if present.

Thereafter, in Step310, a fine to medium grade sandpaper, preferably 400 to 600 grit, is utilized to polish the non-polymer substrate surface48, for example, in order to polish copper, metal, cast iron, etc. If the non-polymer substrate surface48is steel, polishing is ideally achieved by way of sandblasting or other means of polishing.

Thereafter, the non-polymer substrate surface48is cleaned in order to reduce quantities of foreign substances that could contaminate or mitigate the bonding process, preferably, with a cloth and mild cleaner—wiping the surfaces to remove any dirt, grime, and/or residue. Any residual water on the surface is allowed to completely dry.

In step330, a polymerization catalyst is applied to the non-polymer substrate surface48. Once the non-polymer substrate surface48is completely saturated with the polymerization catalyst, the non-polymer substrate surface48is allowed to dry (Step340).

Referring to step350inFIG.10, a cyanoacrylate structural adhesive, preferably a fast-active surface insensitive cyanoacrylate structural adhesive is applied to the application surface26of the synthetic polymer patch20. The application of the adhesive may be by way of brush or beading directly onto the surface26from the adhesive container nozzle. Preferably, the adhesive is applied to the polymer patch20application surface26in a continuous loop or circular pattern covering the entire surface26. Preferably, adhesive is not applied to two opposing fingertip size diagonal corners28,30. Preferably, additional adhesive is applied to the patch20application surface26where it is likely to contact the discontinuity50of the non-polymer substrate surface48.

Thereafter, in step360, the patch20application surface26and the non-polymer substrate surface48are urged together (FIG.9) in order to initiate the bonding of the patch20application surface26and the non-polymer substrate surface48near the discontinuity50. In further detail, preferably, the diagonal corners28,30(FIG.4) that lack adhesive are utilized as grab points, namely, the corners28,30are grabbed by hand, gently stretching the patch20while simultaneously applying the patch20application surface26to the non-polymer substrate surface48. Ideally, the urging together of the application surface26and non-polymer substrate surface48is performed for 15-20 seconds, allowing the non-polymer substrate surface48, the polymerization catalyst, and the surface insensitive adhesive to rapidly work synergistically together to form a strong, permanent bond.

Preferably, thereafter in Step370, a glue squeegee or putty knife is utilized to apply firm pressure working from the interior of the synthetic polymer patch20exterior surface32to the outer perimeter34thereof. Further, adhesive is applied to the opposing diagonal corners28,30surfaces that lack adhesive. Thereafter, each of the diagonal corners28,30are urged towards the non-polymer substrate surface48in order to complete the seal.

Thereafter, the synthetic polymer patch20is inspected to assure that there is continual contact between the patch20application surface26and the non-polymer substrate surface48, particularly at the perimeter34of the synthetic polymer patch20. In certain instances, multiple patches20may be fabricated to overlap previously attached patches20in order to assure that the discontinuity50is completely sealed.

Optionally, in Step380, it is recommended that adhesive is applied along the complete outer perimeter34of the synthetic polymer patch20extending to the surrounding non-polymer substrate surface48. Thereafter, in Step390, the polymerization catalyst is applied to the synthetic polymer patch20outer perimeter34and surrounding non-polymer substrate surface48.

Lastly, in Step395, the synthetic polymer patch20and non-polymer substrate surface48are visually inspected for any discontinuities, breaks, or gaps around the outer perimeter34of the synthetic polymer patch20, indicating that the patch20may allow a leak. If a discontinuity is discovered, more adhesive should be applied and the polymerization catalyst applied thereafter until a complete seal is achieved.

The present application may further comprise a kit for patching a non-polymer substrate surface by producing a bond between a polymer patch surface and the non-polymer substrate surface. Generally, the kit may include a polymer patch providing a polymer patch surface, a means for roughing such as a quantity of sandpaper; a means for polishing such as a fine grade sandpaper; a quantity of a polymerization catalyst; a quantity of surface insensitive cyanoacrylate structural adhesive; and a glue squeegee. The kit may include instructions to use the polymer patch, synthetic polymer preparation solution, a polymerization catalyst, the surface insensitive cyanoacrylate structural adhesive, and glue squeegee to produce a bond between the polymer patch surface and the non-polymer substrate surface.

The instructions contained in the kit may comprise instructions similar to the method300outlined above which may comprise the following: roughing the non-polymer substrate surface with the means for roughing; polishing the non-polymer substrate surface with the means for polishing; cleaning the non-polymer substrate surface; applying an amount of polymerization catalyst to the non-polymer substrate surface; allowing the applied polymerization catalyst to dry; applying an amount of surface insensitive cyanoacrylate structural adhesive to the polymer patch surface; and urging contact between the polymer patch surface and the non-polymer substrate surface by utilizing the glue squeegee.

Referring specifically now toFIG.4,FIG.11-FIG.15, the present application further provides a method400for patching or sealing over a discontinuity54in a non-polymer substrate52such as copper, galvanized steel, cast iron, etc. In method400, a thin-layered synthetic polymer patch20, preferably manufactured of fluorosilicone is utilized to adhere over the discontinuity54and onto the non-polymer substrate surface52. Unique to method400, an additional thin layer of an intermediate reinforcement substrate36, preferably a metal foil or a piece of cloth tape is utilized and positioned between the synthetic polymer patch20and the non-polymer substrate surface52in order to achieve improved structural integrity of up to 240 PSI before the patch20fails.

The intermediate reinforcement substrate36is generally a thin piece of material which is positioned between the polymer patch20and the non-polymer substrate surface52in order to provide more structural reinforcement to the affixation of the polymer patch20onto the non-polymer substrate surface52. Preferably, the intermediate reinforcement substrate36is either a strip of porous cloth material or a metal foil. Ideally, the strip of porous cloth is similar to surgical adhesive tape which provides a porous material made of cotton which is ready to absorb SI adhesive. The use of a strip of porous cloth as the intermediate reinforcement substrate36is beneficial because it absorbs the application of the SI adhesive, and after the SI adhesive cures within the pours of the cloth, a strong and durable reinforcement of the polymer patch20results.

The thin piece of metal or metal foil can preferably be manufactured of copper, tin, aluminum, gold, etc. Preferably, the thickness of the intermediate reinforcement substrate36is between 10 mil to 20 mil, most preferably, about 10 mil. In the application, the intermediate reinforcement substrate36provides a rectangular dimension, preferably having dimension which are less than the rectangular dimensions of the polymer patch20and great enough to surround the discontinuity54within the non-polymer substrate surface52.

The method400generally comprises the steps of: a) roughing the non-polymer substrate surface52(Step405); b) polishing the non-polymer substrate surface52(Step410); c) roughing the opposing surfaces38,40of the intermediate reinforcement substrate36(Step415); d) cleaning the non-polymer substrate surface52, the first surface38of the intermediate reinforcement substrate36, and the second surface40of the intermediate reinforcement substrate36(Step420); e) applying a polymerization catalyst to the non-polymer substrate surface52(Step425); f) allowing the applied polymerization catalyst to dry (Step430); g) applying a surface insensitive cyanoacrylate structural adhesive to the intermediate reinforcement substrate36first surface38(Step435); h) urging contact between the intermediate reinforcement substrate36first surface38and the non-polymer substrate surface52(Step440); i) applying a polymerization catalyst to the intermediate reinforcement substrate36second surface40(Step445); j) allowing the applied polymerization catalyst to dry (Step450); k) applying a surface insensitive cyanoacrylate structural adhesive to the polymer patch20application surface26(Step455); and l) urging contact between the polymer patch20application surface26, the intermediate reinforcement substrate36second surface40, and the exposed surrounding non-polymer substrate surface52surrounding the intermediate reinforcement substrate36second surface40, thereby adhering the polymer patch20over the intermediate reinforcement substrate36and surrounding exposed non-polymer substrate surface52(Step460).

With reference toFIG.14, the method400starts with Step405, wherein the area around the discontinuity54in the non-polymer substrate surface22is roughed by way of a means for roughing. Preferably, a course grade sandpaper is used to aggressively rough or make the surface uneven about the non-polymer substrate surface52discontinuity54. Further, the edges of the discontinuity54should be roughed to adequately remove corrosion if present.

Thereafter, in Step410, a fine to medium grade sandpaper, preferably 400 to 600 grit, is utilized to polish the non-polymer substrate surface52, for example, copper, metal, cast iron, etc. If the non-polymer substrate surface52is steel, polishing is ideally achieved by way of sandblasting or other means of polishing.

In Step415, each of the first surface38and the second surface40of the intermediate reinforcement substrate36are roughed, preferably by the use of sandpaper or other roughing means.

Thereafter, in Step420, both sides of the intermediate reinforcement substrate36or metal foil surfaces and the non-polymer substrate surface52are cleaned in order to reduce quantities of foreign substances that could contaminate or mitigate the bonding process, preferably, with a cloth and mild cleaner—wiping the surfaces to remove any dirt, grime, and/or residue. Any residual water on the surface is allowed to completely dry.

Thereafter, in step425, the polymerization catalyst is applied to the non-polymer substrate surface52. Once the non-polymer substrate surface52is completely saturated with the polymerization catalyst, the non-polymer substrate surface52is allowed to completely dry (Step430).

Referring to step435inFIG.14, a cyanoacrylate structural adhesive, preferably a fast-active surface insensitive cyanoacrylate structural adhesive is applied to the first surface38of the intermediate reinforcement substrate36. The application of the adhesive may be by way of brush or beading directly onto the first surface38from the adhesive container nozzle. Preferably, the adhesive is applied in a continuous loop or circular pattern covering the entire first surface38. Preferably, adhesive is selectively not applied to two opposing diagonal corners42,44. Preferably, additional adhesive is applied to the intermediate reinforcement substrate36first surface38where it will likely contact the discontinuity54of the non-polymer substrate surface52.

Thereafter, in step440, the first surface38of the intermediate reinforcement substrate36and the non-polymer substrate surface52are urged together (FIG.12) in order to initiate the bonding of the intermediate reinforcement substrate36first surface38and the non-polymer substrate surface52near the discontinuity54. In further detail, preferably, the diagonal corners42,44that lack adhesive are utilized as grab points, namely, the corners42,44are grabbed by hand, gently providing the intermediate reinforcement substrate36under tension while simultaneously applying the intermediate reinforcement substrate36first surface38to the non-polymer substrate surface52. Ideally, the urging together of the surfaces is performed for 15-20 seconds.

Preferably, a glue squeegee or putty knife is utilized to apply a firm pressure working from the interior of the intermediate reinforcement substrate36second surface40to the outer perimeter46thereof. Thereafter, the intermediate reinforcement substrate36is inspected to assure that there is continual contact between the intermediate reinforcement substrate36first surface38and the substrate surface22, particularly at the outer perimeter46thereof. Adhesive is applied to the opposing diagonal corners42,44of the intermediate reinforcement substrate36first surface38that lack adhesive. Each of the diagonal corners42,44are urged towards the non-polymer substrate surface52in order to complete the seal.

Thereafter, in step445, the polymerization catalyst is applied to the second surface40of the intermediate reinforcement substrate36and the surrounding non-polymer substrate surface52. The polymerization catalyst can be applied by way of spray bottle, brush, etc. Once the intermediate reinforcement substrate36second surface40is completely saturated with the polymerization catalyst, the second surface40is allowed to completely dry (Step450).

Referring to step455inFIG.15, a cyanoacrylate structural adhesive, preferably a fast-active surface insensitive cyanoacrylate structural adhesive is applied to the application surface26of the synthetic polymer patch20. The application of the adhesive may be by way of brush or beading directly onto the surface26from the adhesive container nozzle. Preferably, the adhesive is applied to the polymer patch20application surface26in a continuous loop or circular pattern covering the entire application surface26. Preferably, adhesive is selectively not applied to two opposing diagonal corners28,30(FIG.4).

Thereafter, in step460, the patch20application surface26, the intermediate reinforcement substrate36second surface40, and the exposed surrounding non-polymer substrate surface52are urged together (FIG.13). The urging together of surfaces initiates the bonding of the patch20application surface26with over the intermediate reinforcement substrate36second surface40and surrounding exposed non-polymer substrate surface52. In further detail, preferably, the diagonal corners28,30that lack adhesive are utilized as grab points, namely, the corners28,30are grabbed by hand, gently stretching the patch20while simultaneously applying the patch20application surface26to the intermediate reinforcement substrate36second surface40and the non-polymer substrate surface52. Ideally, the urging together of the surfaces52,26, and40is performed for 15-20 seconds, allowing the prepped non-polymer substrate surface52, the polymerization catalyst, and the surface insensitive adhesive to rapidly work synergistically together to form a strong, permanent bond.

Preferably thereafter in Step465, a glue squeegee or putty knife is utilized to apply firm pressure working from the interior of the synthetic polymer patch20exterior surface32to the outer perimeter34thereof. Further, adhesive is applied to the opposing diagonal corners28,30surfaces that lack adhesive. Thereafter, each of the diagonal corners28,30are urged towards the non-polymer substrate surface52in order to complete the seal.

In Step470, the synthetic polymer patch20is inspected to assure that there is continual contact between the patch20application surface26and the non-polymer substrate surface52, particularly at the outer perimeter34of the synthetic polymer patch20. In certain instances, multiple patches20may be fabricated to overlap previously attached patches20in order to assure that the discontinuity54is completely sealed.

Optionally, in Step475, it is recommended that adhesive is applied along the complete outer perimeter34of the synthetic polymer patch20. Thereafter, in Step480, a polymerization catalyst is applied to the adhesive at the outer perimeter34of the synthetic polymer patch20and allowed to dry (Step485).

Lastly, in Step490, the synthetic polymer patch20and non-polymer substrate surface52are visually inspected for any discontinuities, breaks, or gaps around the outer perimeter34of the synthetic polymer patch20, indicating that the patch20may allow a leak. If a discontinuity is discovered, more adhesive should be applied and the polymerization catalyst applied thereafter until a complete seal is achieved.

The present application may further comprise a kit for patching a non-polymer substrate surface by producing a bond between a polymer patch surface, an intermediate reinforcement substrate having a first surface and a second surface, and a non-polymer substrate surface. Generally, the kit may include a polymer patch providing a polymer patch surface, a piece of intermediate reinforcement substrate, a means for roughing such as a quantity of sandpaper; a means for polishing such as a fine grade sandpaper; a quantity of a polymerization catalyst; a quantity of surface insensitive cyanoacrylate structural adhesive; and a glue squeegee. The kit may include instructions to use the polymer patch, intermediate reinforcement substrate, synthetic polymer preparation solution, a polymerization catalyst, the surface insensitive cyanoacrylate structural adhesive, means for roughing, means for polishing, and glue squeegee to produce a bond between the polymer patch surface, intermediate reinforcement substrate, and the non-polymer substrate surface.

The instructions contained in the kit may comprise instructions similar to the method400outlined above which may comprise the following: roughing the non-polymer substrate surface with the means for roughing; polishing the non-polymer substrate surface with the means for polishing; roughing the first surface and the second surface of the intermediate reinforcement substrate with the means for roughing; cleaning the non-polymer substrate surface, the first surface of the intermediate reinforcement substrate, and the second surface of the intermediate reinforcement substrate; applying an amount of the polymerization catalyst to the non-polymer substrate surface; allowing the applied polymerization catalyst applied to the non-polymer substrate surface to dry; applying an amount of the surface insensitive cyanoacrylate structural adhesive to the intermediate reinforcement substrate first surface; urging contact between the intermediate reinforcement substrate first surface and the non-polymer substrate surface by utilizing the glue squeegee; applying an amount of the polymerization catalyst to the intermediate reinforcement substrate second surface; allowing the applied polymerization catalyst applied to the intermediate reinforcement substrate second surface to dry; applying an amount of surface insensitive cyanoacrylate structural adhesive to the polymer patch surface; urging contact between the polymer patch surface and the intermediate reinforcement substrate second surface and the exposed non-polymer substrate surface by utilizing the glue squeegee.

Preferably, the bonds formed between the polymer patch20and the respective substrates as described by method200,300, and400are allowed to cure for at least twenty-four hours.

The invention does not require that all the advantageous features and all the advantages need to be incorporated into every version of the invention.

Although preferred embodiments of the invention have been described in considerable detail, other versions and embodiments of the invention are certainly possible. Therefore, the present invention should not be limited to the described embodiments herein.

All features disclosed in this specification including any claims, abstract, and drawings may be replaced by alternative features serving the same, equivalent or similar purpose unless expressly stated otherwise.