Abstract:
A repair kit ( 10 ) includes a sealed package ( 12 ) having a plurality of isolated compartments ( 32, 42, 44 ) for holding substances ( 50, 52 ) that, when mixed together, form an adhesive, and for holding a flexible substrate ( 54 ). Pull tabs ( 60, 66, 80, 86 ) are arranged on the package ( 12 ) to aid in opening fluid communication between the compartments to permit adhesive mixture and to permit adhesive flow onto the substrate ( 54 ) for subsequent repair purposes.

Description:
FIELD OF THE INVENTION 
     The present invention is directed to a method and apparatus for repairing a surface defect and is more particularly directed to a method and apparatus for repairing a surface defect that would be self contained within a repair kit package. 
     BACKGROUND 
     Many items become damaged due to unexpected accidents or corrosion. For example, vehicles, boats, surf boards, etc., may become damaged through use wherein the surface of the object is dented or punctured. One way to repair such damage in these objects is to mix together epoxy which is a two part chemical comprising a resin and a catalyst. Once these two materials are mixed together they form an adhesive which is then paddled into the dent. The material is smoothed with the paddle and the material allowed to dry. The hardened material is then sanded smooth and finished such as by painting. During the repair, the user is in contact with the epoxy material during mixing and during application using the paddle. 
     Sometimes, a repair of an object requires the use of a supporting material such as volan or fiberglass cloth. For such repairs, the epoxy mixture is spread over the dent and the volan cloth is placed over the epoxy covering the dent. More epoxy is then spread over the volan cloth. However, it is difficult to keep the volan cloth from moving when the epoxy is being spread over the volan cloth. The material is then smoothed, allowed to dry, sanded, and finished. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention, a repair kit includes a sealed package having a plurality of isolated compartments for holding substances that, when mixed together, form an adhesive, and for holding a flexible substrate. Pull tabs are arranged on the package to aid in opening fluid communication between the compartments to allow for adhesive mixture and to allow for adhesive flow onto the substrate for subsequent repair purposes. 
     In accordance with one example embodiment of the present invention, a repair kit is provided comprising a sealed package having a plurality of isolated compartments, at least two of the plurality of isolated compartments holding substances that, when mixed together, form an adhesive, and a third of the plurality of isolated compartments holding a flexible substrate. A plurality of pull tabs are arranged on an outside of the package so that when the pull tabs are pulled, they open fluid communication between the compartments. Certain of the pull tabs, when pulled, allow the plurality of substances to be mixed to form the adhesive. Certain others of the pull tabs, when pulled, allow the adhesive to cover the substrate for a subsequent repair purposes. 
     In accordance with another example embodiment of the present invention an apparatus for is provided making a repair comprising a sealed package having a plurality of isolated compartments including, a first compartment for storing a resin, and a second compartment for storing a catalyzing agent, the resin and the catalyzing agent, when mixed together, forming an adhesive, and a third compartment for storing a flexible substrate. Separable isolation seals are located between the first and second compartments and are also located between the first, second, and the third compartments to keep the three compartments isolated from each other. A plurality of pull tabs are located on opposite sides of the package and positioned so that pulling of selected pull tabs permits fluid communication between the first and second compartments and allows mixing of the resin and the catalyzing agent so as to form the adhesive. Pulling of other selected tabs permits fluid communication of the adhesive with the flexible substrate to allow the substrate to be covered with the adhesive. 
     In accordance with yet another example embodiment of the present invention a repair kit for making a fiberglass patch repair is provided comprising a flexible package having a plurality of isolated compartments, one compartment holding a resin, one compartment holding a catalyzing agent, and one compartment holding a fiberglass cloth material. A first pull tab arrangement is mounted between the compartments having the resin and the catalyzing agent so that applied force to the first pull tab arrangement permits fluid communication therebetween and allows the resin and catalyzing agents to be mixed. A second pull tab structure is mounted between at least one of the compartments having the resin and the catalyzing agent and the compartment holding the fiberglass cloth material so that applied force to the second pull tab arrangement permits fluid communication with the mixture and the fiberglass cloth. 
     In accordance with another example embodiment of the present invention, a method is provided for making a repair kit comprising the steps of sealing a two layer package so that the package has a plurality of isolated compartments, storing a resin material in a first compartment of the package, storing a catalyzing agent in a second compartment of the package, storing a flexible substrate in a third compartment of the package, and applying pull tabs to the package at locations so that when the pull tabs are pulled, fluid communication between the selected compartments is enabled. 
     In accordance with another example embodiment of the present invention, a method is provided for making a repair comprising the steps of using a package having a plurality isolated compartments for storing a resin material in a first compartment of the package, for storing a catalyzing agent in a second compartment of the package, and for storing a flexible substrate in a third compartment of the package. The method further including the steps of pulling tabs on the package to permit the resin material and catalyzing agent to be mixed together, mixing the resin material and the catalyzing agent together to form an adhesive, pulling tabs on the package to permit the adhesive to flow into the compartment having the flexible substrate, moving the adhesive to cover the flexible substrate, opening the package, and placing the adhesive covered substrate against an object to be repaired. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other features and advantages of the present invention will become apparent to those skilled in the art to which the present invention relates upon reading the following description with reference to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a repair kit made in accordance with one example embodiment of the present invention; 
         FIG. 2  is a top view of the repair kit of  FIG. 1 ; 
         FIG. 3  is side sectional view taken along lines  3 - 3  of  FIG. 2 ; 
         FIG. 4  is side sectional view taken along lines  4 - 4  of  FIG. 2 ; 
         FIG. 5  is a perspective view of the repair kit of  FIG. 1  showing two compartments in fluid communication for mixing an adhesive; 
         FIG. 6  is a perspective view of the repair kit of  FIG. 1  showing two compartments in fluid communication for moving mixed adhesive onto a flexible substrate; 
         FIG. 7  is a perspective view of the repair kit of  FIG. 1  showing opening of the compartment having the flexible substrate; 
         FIG. 8  is side sectional view similar to  FIG. 3  of an alternative embodiment of the present invention; and 
         FIG. 9  is side sectional view similar to  FIG. 4  of an alternative embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 1-4 , a surface repair kit  10 , made in accordance with one example embodiment of the present invention, is shown. The surface repair kit  10  includes a multi-compartment package  12  made from a two flexible, spaced apart sheets  14 ,  16  of plastic. The plastic sheets  14 ,  16  can be made from various plastic materials such as polyvinyl chloride (“PCV”) or polyvinyl alcohol (“PVA”). The package  12  is formed by heat sealing the outer peripheral edges  18 ,  20 ,  22 ,  24  of the two sheets  14 ,  16 . The heat sealing of the package  12  is accomplished by applying pressure in combination with heat. For example, applying a heat of 127 degrees Fahrenheit at a pressure of 5-7 psi will seal the two sheets  14 ,  16  of PVA together. By heat sealing the package  12  around the entire outer peripheral edge, one large compartment is formed. 
     The flexible package  12  is then divided into a plurality of individual compartments to maintain elements that make up the repair kit  10  isolated from each other until ready for use. Specifically, a heat seal  30  extends from the heat seal  20  to the heat seal  24  and divides the package  12  into two compartments  32 ,  34 . A second heat seal  40  extends from the heat seal  18  to the heat seal  30  so as to divide the compartment  34  into two compartments  42 ,  44 . The result of the two heat seals  30  and  40  results in a three compartment flexible package  12 . These three compartments are fluid tight and fluid isolated from each other. 
     In accordance with one example embodiment of the present invention, the first compartment  42  stores a premeasured amount of a liquid epoxy resin  50 . Stored in the second compartment  44  is a premeasured amount of a liquid catalyzing agent  52 . Stored in the compartment  32  is a fiber reinforced material  54  such as volan or fiberglass cloth. The size and shape of the material  54  may be varied in accordance with the size and shape of the repair desired. For example, if a small round hole is to be patched, the material  54  can be sized so as to be small and round and the amount of epoxy resin  50  and catalyzing agent  52  would commensurately be adapted, i.e., the entire kit  10  (package  12 ) size would be adjusted accordingly. If the repair is for a large rectangular or triangular shaped, the size of the kit  10  (package  12 ) could be adapted to have a similarly shaped material  54  with a commensurate amount of resin  50  and catalyzing agent  52 . The amount of the epoxy resin  50  and catalyzing agent  52  are selected so as to properly mix together to form a good adhesive and to result in an adequate amount to fully cover and impregnate the fiberglass cloth  54  of the kit  10 . 
     The heat seals  18 ,  20 ,  22 ,  24 , and  30 , and  40  keep the three kit materials, i.e., epoxy resin  50 , catalyzing agent  52  and fiberglass cloth  54 , isolated from each other and within the package  12  until the kit  10  is ready for use. 
     The package  10  further includes a first pull tab  60  located on side  14  of the package  12  and connected at locations  62 ,  64  to compartments  42 ,  44 , respectively, adjacent to but slightly spaced from the heat seal  40 . A second pull tab  66  is located on side  16  of the package  12  and connected to locations  68 ,  70  on compartment  42 ,  44 , respectively, adjacent to but slightly spaced from the seal  40  and approximately opposite from where the pull tab  60  is located. 
     A third pull tab  80  is located on side  14  of the package  12  and connected at locations  82 ,  84  to the compartments  42 ,  32 , respectively, adjacent to but slightly spaced from the heat seal  40 . A fourth pull tab  86  is located on side  16  of the package  12  and connected at locations  88 ,  90  to the compartment  42 ,  32 , respectively, adjacent to but slightly spaced from the heat seal  40  and approximately opposite from where the pull tab  80  is located. Each of the pull tabs  60 ,  66 ,  80 ,  86  forms a loop large enough to accept a finger of the user of the repair kit  10 . 
     Within the heat seals  20 ,  22 ,  24 , as they define three sides of the compartment  32  holding the fiberglass material  54 , are rip strings  92 ,  94 ,  96 , respectively. The rip strings are positioned between the layers  14 ,  16  when the heat seals  20 ,  22 ,  24  are formed so that the strings become embedded within the seal. When it is desired to access the fiberglass material and open the compartment  32 , the strings  92 ,  94 ,  96  are pulled and rip open their associated heat seal thereby permitting separation of the layers  14 ,  16 . 
     The repair kit  10  further includes a paddle  100  having a flat working surface  102  and a concave area that is useful for finger placement by the kit user. The paddle  100  could be made from a semi-rigid plastic. 
     When it is desired to use the kit  10  to make a repair, the user must first mix the epoxy resin  50  with the catalyzing agent  52 . Referring to  FIGS. 5-7 , the user of the kit  10  inserts his fingers into the loops of tabs  60  and  66  and gently pulls in opposite directions as indicated by arrows  110 ,  112 . Alternatively, rather than inserting a finer into each of the loops, the taps  60 ,  66  could just be grabbed and pulled apart in the direction of arrows  110 ,  112 . Sufficient force is applied until the heat seal  40  is torn open allowing fluid communication between compartments  42  and  44  so that the epoxy resin  50  can be mixed with the catalyzing agent  52 . The two chemicals can be mixed together by the user applying hand kneading force back-and-forth between the two compartments with his hands or the paddle  100  can be used in a back-and-forth motion across the two compartments until a good mixture of the resin  50  and catalyzing agent  52  is achieve thereby forming a good adhesive. 
     Once the good adhesive is mixed, the user applies an equal and opposite force to the taps  80  in the direction of arrow  114  and  86  in the  15  opposite direction by either grabbing the associated tabs or by placing associated fingers in the tab loops. A sufficient gentle force is applied to tear open the heat seal  30  and thereby permit fluid communication between the compartment  34  and the compartment  32 . The adhesive mix is then squeegeed into the compartment  32  so as to cover and impregnate  20  the fiberglass cloth  54 . The paddle  100  aids in moving the adhesive mix in the process as shown in  FIG. 6 . 
     Once the fiberglass cloth  54  is fully covered and ready to be applied to the surface to be repaired, the strings  92 ,  94 , and  96  are pulled so as to break the heat seals  20 ,  22 ,  24 . The one layer  14  can then be peeled back to expose the impregnated fiberglass cloth  54 . The kit  10  is picked-up from the back side touching the layer  16 , the fiberglass cloth is placed against the surface to be repaired, and then the layer  16  of the package  12  is peeled away. The fiberglass cloth  54  is then allowed to dry on the object being repaired and hardened for later finishing of the repair. The kit  10  can then be properly disposed of without the user ever coming in contact with any of the materials. 
     Referring to  FIGS. 8 and 9 , an alternative embodiment of the present invention is shown. Rather than pull tabs  60 ,  66 ,  80 ,  86  formed into loops as described above, individual pull tabs  200 ,  202 ,  204 ,  206 ,  208 ,  210 ,  212 , and  214  are secured to the package  12  at appropriate locations spaced away from the heat seals in a similar manner as described above. These individual pull tabs can be held between individual fingers for pulling. Those skilled in the art will also appreciate that in accordance with another possible embodiment, it is possible to have individual combinations of pull tabs such as ( 200  and  206 ) OR ( 200  and  204 ) OR ( 202  and  204 ) OR ( 202  and  206 ) to pull heat seal  40  apart. Similarly, it is possible to have individual combinations of ( 208  and  214 ) OR ( 210  and  212 ) OR ( 208  and  212 ) OR ( 210  and  214 ) to be used to pull heat seal  30  apart. These alternatives would reduce the number of pull tabs required. 
     From the above description of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.