Abstract:
The present invention is a new resin chamber construction, a kit and method for the repair of large selection of breaks in a lens or an automobile light bulb housing and even plate glass. The kit and method enable an inexpensive in situ repair including a bead overriding the break substantially maintaining light diffusions patterns. The bead forms an environmentally impervious repair which can match the color of the housing or lens including a substantially matching light diffusion pattern to diffuse light substantially similar to that of the unbroken article. The kit includes parts enclosable in a blister pack. The blister cover may include a resin chamber construction which can be cut out from it.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates to a resin chamber construction, kit and method for repairing a selected break from the surface, of a transparent automobile light bulb housing, an automobile light lens, or a plate of glass or plastic.  
           [0002]    The repair of plate glass and automobile light housings whether lenses or housings and plate glass is complex, expensive and frought with permutations and combinations of physical and visual problems. A spectrum of the situations can be found in Jacino U.S. Pat. Nos. 4,200,478, 4,961,883, 5,209,935, 5,401,152, 6,074,852 and PCT Application PCT/US99/25472, all incorporated by reference.  
           [0003]    The present invention including a new resin chamber construction, enables a new ability for the repair of plate glass and automobile light housings whether lenses or housings and plate glass. The repair is effected on a surface and adapts to the provision of grid patterns and color.  
           [0004]    Another unexpected aspect of the present invention is that the repair can be effected in situ without physical removal of the repaired object such as a lightbulb housing, lens or pane of plate glass.  
         DESCRIPTION OF THE RELATED ART  
         [0005]    In the past, automobile light bulb housings lenses have been repaired by covering the housings with tape just to protect them from the atmosphere.  
           [0006]    The tape has been either opaque or translucent. Tapes used in such repair have even been selected to match the color of the broken part of the lens. To repair voids, repairs have been made by the flush filling of the broken spaces; plastic castings were also made to fill breaks. Many different techniques were used.  
           [0007]    U.S. Pat. No. 4,497,755 discloses a kit for the repair of automobile light bulb housing lenses by casting the repair. The repair method includes the use of flush tapes to form a releasable form for molding an exothermic adhesive resin to make a repair. Colored resin was used to match colors in the automobile plastic light bulb housing and glass bead were used to simulate the facets in the broken diffuse area.  
           [0008]    As shown in U.S. Pat. No. 5,401,157, breaks through glass have been repaired by providing a gasket with a cover to form a mold for a casting including a bead surrounding a repaired area. The gasket and cover define the shape of the repair casting.  
           [0009]    U.S. Pat. No. 4,200,478 discloses a pedestal adapted to create a casting to override and surround a break in glass.  
           [0010]    U.S. Pat. No. 3,887,413 discloses a method for repairing plastic materials, using an insert backing material, protective paste and graining paper and uses a hot surface, such as iron. See FIG. 1. A flat backing material is used to hold the heat responsive elastic repair material flush with the surface of the patched area.  
           [0011]    U.S. Pat. No. 3,772,114 discloses a process for mending fabrics, including the use of an adhesive which contains a color additive to match the area around the repair. The invention is involved with fitting in a flush patch supported on one side.  
           [0012]    U.S. Pat. No. 3,388,016 discloses a method and apparatus for patching articles. The method and apparatus are a complex set to apply a fiber glass patch to one surface. Flush liners may be used.  
           [0013]    U.S. Pat. No. 3,109,765 discloses a method for repairing surfaces, wherein a textured backing is used. A textured backing hold holds a composition applied from an outer surface of a rupture.  
           [0014]    U.S. Pat. No. 4,961,883 discloses a pedestal and a seal surrounding an opening and forming a chamber for the introduction of a repair plastic, forming an irregular bead, which has to be cut off flush. The bead is formed in the central opening  20 .  
           [0015]    U.S. Pat. No. 4,473,419 discloses the use of a flush patch to a contoured surface for the purpose of making a repair.  
           [0016]    U.S. Pat. No. 3,138,505 discloses means for mending fabric, using a heat responsive thermoplastic adhesive backed by a substrate which may be stripped, then bonding a matching patch to the fabric and the adhesive. The patch is ironed on.  
           [0017]    U.S. Pat. No. 3,841,932 discloses a surface patch for windshield glass, which leaves a superficial dam which is removed.  
           [0018]    U.S. Pat. No. 3,914,145 discloses a flush patch casting for the repair of plate glass.  
           [0019]    U.S. Pat. No. 4,147,576 is a substantially invisible PVC auto body non transparent repair over a damaged area.  
           [0020]    U.S. Pat. No. 4,094,316 is a decorative applique overlay adherable to bandage.  
           [0021]    U.S. Pat. No. 4,588,619 is a reflective panel for diffusion of light in an automotive lens housing.  
           [0022]    U.S. Pat. No. 4,221,465 is a patching tape to alter the light transmissive characteristics of a view graph.  
           [0023]    U.S. Pat. No. 4,661,182 is a non transparent substantially invisible surface repair of the damaged glossy surface of an auto body.  
           [0024]    U.S. Pat. No. 2,833,327 is a laminated tire patch with an adhesive layer.  
           [0025]    U.S. Pat. No. 3,939,337 is an elastomeric gasket for a light housing assembly for mounting a lens.  
         SUMMARY OF THE INVENTION  
         [0026]    According to the present invention, a resin chamber construction, and a kit and method are provided for repairing for repairing a break from a selected surface, particularly a transparent surface such as the lens of an automobile light bulb housing, an automobile light lens, a plate of glass or plastic, in situ substantially maintaining the selected light diffusion characteristics of the original article.  
           [0027]    The resin chamber is the enablement when used with a cover to seal a surface break. The resin chamber construction includes, the chamber, a flange portion, to be sealed around the break, at least one air vent and a pouring spout.  
           [0028]    In its simplest form, a repair can be performed with a cover sealing the outer surface of the break and the chamber portion of the resin chamber construction sealed, spaced away from the sealing cover and surrounding its outer periphery.  
           [0029]    The kit includes the resin chamber construction, sealing cover, a peripheral adhesive sealing gasket, a push pin and a resin container. The kit is preferably mounted on a display card with blister pack. In other variations the kit may include a selection of pigment colors.  
           [0030]    The resin chamber construction can be an integral part of an enclosing blister on the kit package. The resin chamber construction can also include a diffusion pattern to match the pattern of the lens or housing repaired.  
           [0031]    The method includes the steps of sealing a break with a sealing cover, selecting a resin chamber construction to form a mold for the resin that effects the repair, filling the resin into the resin chamber construction. It is important for the resin chamber construction to extend beyond the periphery of the cover over the break. A sealing gasket may be used for convenience, particularly when the resin chamber construction is an integral part of the kit blister pack, and it is cut out of the blister for use. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0032]    Although such novel feature or features believed to be characteristic of the invention are pointed out in the claims, the invention and the manner in which it may be carried out may be further understood by reference to the description following and the accompanying drawings.  
         [0033]    [0033]FIG. 1 is a plan view of the resin chamber construction of the present invention.  
         [0034]    [0034]FIG. 2 is a top view of FIG. 1.  
         [0035]    [0035]FIG. 3 is a left side view of FIG. 1  
         [0036]    [0036]FIG. 4 is a detail showing a front elevation of a bullseye break in a glass headlight housing.  
         [0037]    [0037]FIG. 5 is a detail view of the bulls eye break as shown in FIG. 4 overlain with a transparent adhering cover.  
         [0038]    [0038]FIG. 6 is a detail section of FIG. 5 at lines  6 - 6 .  
         [0039]    [0039]FIG. 7 Is a detail of a headlight repair with a resin chamber construction of the present invention engaged over the transparent adhering cover of FIG. 6 and filled with resin.  
         [0040]    [0040]FIG. 8 shows the molded bead formed in FIG. 7 with the resin chamber construction removed.  
         [0041]    [0041]FIG. 9 is a section of FIG. 8 at lines  9 - 9  showing the completed repair.  
         [0042]    [0042]FIG. 10 is a section of an alternate repair configuration particularly for use with plate glass.  
         [0043]    FIGS.  11 - 17  are the elements of a kit of the present invention for repairing a break in a headlight housing or a lens.  
         [0044]    [0044]FIG. 11, is an isometric view of a resin chamber construction including a grid pattern molded into the resin chamber.  
         [0045]    [0045]FIG. 12 is a front elevation of a gasket for use with the resin chamber construction of FIG. 11.  
         [0046]    [0046]FIG. 13 is a detail schematic right side elevation of the gasket of FIG. 12.  
         [0047]    [0047]FIG. 14 is a cover for the sealing of the outer opening of a break through the transparent surface particularly of a lens or a glass bulb housing, shown mounted on a release sheet.  
         [0048]    [0048]FIG. 15 is a detail schematic right side elevation of FIG. 14.  
         [0049]    [0049]FIG. 16 is a push pin for a kit of the present invention.  
         [0050]    [0050]FIG. 17 is a resin container for a kit of the present invention.  
         [0051]    [0051]FIG. 18 is a blister pack kit of the present invention mounted on a cut away display card including all the elements shown in FIGS.  11 - 17 .  
         [0052]    FIGS.  19 - 26  are the elements of another kit of the present invention.  
         [0053]    [0053]FIG. 19 is another embodiment of a resin chamber construction of the present invention including a grid pattern.  
         [0054]    [0054]FIG. 20 is a right side elevation of a FIG. 19.  
         [0055]    [0055]FIG. 21 is a cover for the sealing of the opening of a break through a transparent surface, mounted on a release sheet.  
         [0056]    [0056]FIG. 22 is a right side elevation of a FIG. 21.  
         [0057]    [0057]FIG. 23 is a front elevation of gasket for use with the resin chamber construction of FIG. 19.  
         [0058]    [0058]FIG. 24 is a right side elevation of a FIG. 23.  
         [0059]    [0059]FIG. 25 is a pair of syringes for a selected sealing resin for a repair of the present invention.  
         [0060]    [0060]FIG. 26 is a pair of syringes for selected pigments for the sealing resin of the present invention.  
         [0061]    [0061]FIG. 27 shows the mounting of the cover of FIG. 21 over a break to be repaired.  
         [0062]    [0062]FIG. 28 shows cutting the cover to remove the excess.  
         [0063]    [0063]FIG. 29 shows the placing of the gasket of FIG. 24 around the cover.  
         [0064]    [0064]FIG. 30 shows mounting the resin chamber construction on the mounted gasket of FIG. 29.  
         [0065]    [0065]FIG. 31 shows the filling of a syringe from a mixing receptacle.  
         [0066]    [0066]FIG. 32 shows the injection of the resin into the resin chamber construction of FIG. 19. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0067]    Referring now to the figures in greater detail, where like reference numbers denote like parts in the various figures.  
         [0068]    The resin chamber construction  10  as shown in FIG. 1 comprises an integral peripheral flange portion  11 , a resin chamber  12 , a flange portion  11 , a tab  13 , a pouring spout  14  and at least one vent  15 . The flange portion  11  includes an adhesive layer  16 .  
         [0069]    At least the resin chamber  12  is preferably transparent. As shown in FIG. 1, the resin chamber construction  10  is a unitary molded transparent plastic. The vents  15  and pouring spout  14  open into the resin chamber  12 . The vents  15  have openings  17  to the atmosphere. The pouring spout  14  has an opening  18  open to the atmosphere.  
         [0070]    As shown in the detail in FIGS.  4 - 9 , a bulls eye break  20 , particularly as in a glass bulb housing for and automobile (not shown) has a surface pit  21 . In making a repair of the bulls eye break  20  a cover  22  with an adhesive back  23  is engaged over the pit  21  as shown in FIGS.  6 - 9 .  
         [0071]    The resin chamber construction  10  is engaged over the pit  21  with the cover  22  in place. The adhesive layer  16  holds the resin chamber construction  10  in place so that a selected resin, well known in the art, can be pour or injected into the resin chamber  12 , where it cures or is cured by means well known in the art. The resin is poured or injected through the opening  18  in the pouring spout  14 . Air and/or bubbles escape through the vents  15 , through the openings  17 . The resin chamber  12  is selected to have a depth to allow the formation of a bead  26  of sufficient thickness to protect the light bulb housing  24  and allow light to pass through the bead  26  and the cover  22  with a minimum of attenuation.  
         [0072]    As shown in FIGS. 7 and 8, the light diffusion pattern lines  25  of the unbroken portion of the light bulb housing  24  show through the repair with a minimum of attenuation. As shown in FIG. 8 with the resin chamber construction  10  removed, the bead  26 , though extending beyond the outer surface of the light bulb housing  24 , substantially maintains the appearance of the light bulb housing  24 .  
         [0073]    As shown in FIG. 9, the bulls eye break  20  does not have to be filled in order to restore the light bulb housing  24  to usability. The cover  22  with the adhesive back  23  are all contained within the bead  26 .  
         [0074]    The resin chamber construction  10  is a great advance in the art. It enables an effective repair of a light bulb housing  24  break or lens break, without the difficult task of having to remove it.  
         [0075]    The integral pouring spout  14 , opening into the resin chamber  12  and to the atmosphere, from outside the resin chamber construction  10  and the vents  15  opening into the resin chamber  12 , openings  17  opening to the atmosphere, enable the repair.  
         [0076]    The method includes adhering a cover  22  over the pit  21  or over any open break with an appropriate sized cover, emplacing a resin chamber construction  10  and molding a resin over the surface of the broken object. This repairs the break and maximizes the normal light diffusion.  
         [0077]    As shown in FIG. 10, the resin chamber construction  10  also can be used for an effective in situ repair of a plate of glass  27 . The cover  22  is applied at the pit  21  only on the outside portion of the plate of glass  27 . The resin chamber construction  10  is engaged on the inside of the plate of glass  27 . The resin is conventionally used, in this instance the entire break or bulls eye break  20  is filled with the resin.  
         [0078]    FIGS.  11 - 18  show the parts of a kit for the repair of breaks in transparent automobile light bulb housings and lens.  
         [0079]    [0079]FIG. 11 shows a resin chamber construction  30 . The resin chamber construction  30  is part of a plastic base  49  which includes a peripheral flange portion  31 , a resin chamber  32 , a tab  33 , a pouring spout  34 , vents  35 , vent opening  37 , and a grid pattern  39 .  
         [0080]    [0080]FIGS. 12 and 13 show the gasket  50  with a release cover  51 , tab portion  52 , vent inset  53 , vent inset  54 , pouring spout inset  55 , adhesive layer  56 , working gasket  57 , adhesive layer  58  and release paper  59 .  
         [0081]    [0081]FIGS. 14 and 15 show the cover  42  with a adhesive back  43  and a release sheet  44 .  
         [0082]    [0082]FIGS. 16 and 17 show a push pin  48  and resin container  47 .  
         [0083]    [0083]FIG. 18 shows a cut away of a kit of the present invention mounted on a display card  60  with a blister cover  61 . The blister cover  61  includes a push pin blister  62  and a resin container blister  63  to contain the respective push pin  48  and resin container  47 . The blister cover  61  includes an integral impression of the resin chamber construction  30  which is shown cut out of the blister cover  61  in FIG. 11.  
         [0084]    Shown within the blister cover  61  are the gasket  50 , cover  42 , push pin  48 , and resin container  47 .  
         [0085]    The resin chamber construction  30  is physically cut out of the blister cover  61  as shown in FIG. 11. peripheral flange portion  31  is shallower than the resin chamber construction  10  and includes a grid pattern  39  for light diffusion.  
         [0086]    In the method of making a repair the cover  42  has its release sheet  44  removed. The cover  42  is then placed over the break. The resin chamber construction  30  can be selected to match the diffusion pattern of the broken lens. The gasket  50  has the release paper  59  removed and is placed around the break and the cover  42 , with the adhesive layer  58  adhering to the surface of the lens or glass to be repaired with the tab portion  52  substantially vertical. The release cover  51  is then removed and resin chamber construction  30  is then engaged over the gasket  50  and adhered to the adhesive layer  56 .  
         [0087]    The vents  35  must be aligned with the vent inset  53  and vent inset  54  and the pouring spout  34  aligned with the pouring spout inset  55 . The push pin  48  is then used to puncture the pouring spout  34 . The push pin  48  is also used to puncture the resin container  47 . Resin from the resin container  47  is the put into the pouring spout  34  at the puncture to fill the resin chamber  32 .  
         [0088]    In the event the openings  37  are not exposed the push pin  48  can be used to open the vents  35 . The repair is substantially identical to the repair as shown in FIGS.  7 - 9  with the thickness of the bead  26  defined by the thickness of the resin chamber  32  and of the working gasket  57 .  
         [0089]    As shown in FIG. 19- 24  another resin chamber construction  70  has a flange portion  71 , resin chamber  72 , pouring spout  74 , vents  75 , openings  77 , and a grid pattern  79 . The shape and contour is shown in FIG. 20. There is a cover  82  with an adhesive back  83  and a release sheet  84 . A gasket  90 , as shown in FIG. 24, has a cover  91 , a adhesive layer  96 , a working gasket  97 , an adhesive layer  98  and a release paper  99 . As part of a kit a FIG. 25 shows a pair of syringes, syringe  101  for resin and syringe  102  for hardener. In FIG. 26 a pair of syringes are shown for pigment. Syringe  103  for red and syringe  104  for amber.  
         [0090]    As shown in FIG. 27, a transparent cover  82  with release sheet  84  removed is adhered over a ragged break  110  in a light bulb housing  111 . As shown in FIG. 28, the cover  82  is trimmed to overlap the break  110 . As shown in FIG. 29, the working gasket  97  is affixed to the light bulb housing  111  surrounding the trimmed cover  82 . As shown in FIG. 30, the resin chamber construction  70  is engaged on the working gasket  97  (not shown). As shown in FIG. 31 the resin is mixed, as is well known in the art, optionally including a selected pigment and withdrawn into a syringe  101 . As shown in FIG. 32, the resin is injected into the pouring spout  74  to complete the repair. The repair includes a mold of the grid pattern  79 , which is selected to simulate the diffusion pattern of the basic lens light bulb housing  111 .  
         [0091]    The configuration of the resin chamber construction  70  maintains the combination of novel elements of the present invention, the combination of resin chamber construction  70  including a chamber  72  engagable on the outside of a lens or housing, in situ, or even on the inside of plate glass in situ. A basic pouring spout  74  must open to the chamber  72 . The chamber  72  must also be vented on the same plane so that the entire repair can be poured and vented from the same side.  
         [0092]    The resin chamber construction enables an in situ repair maximizing the security of a housing or of a lens. The resin chamber construction of the present invention also facilitates an improved repair of plate glass.  
         [0093]    The terms and expressions which are employed are used as terms of description; it is recognized, though, that various modifications are possible.  
         [0094]    It is also understood the following claims are intended to cover all of the generic and specific features of the invention herein described; and all statements of the scope of the invention which as a matter of language, might fall therebetween.