Patent Publication Number: US-11027307-B2

Title: Nozzle tip and method for dispensing onto a panel edge

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of pending prior application Ser. No. 15/548,617, filed Aug. 3, 2017, which is a national stage filing under 35 U.S.C. 371 of PCT/US2016/021464, filed Mar. 9, 2016, which claims the benefit of US Provisional Patent Application No. 62/132,823, filed Mar. 13, 2015, the disclosures of which are incorporated by reference in their entirety herein. 
    
    
     FIELD OF THE DISCLOSURE 
     This disclosure relates to nozzles for applying setting resins onto the edge of a panel and methods of applying setting resins onto the edge of a panel. 
     BACKGROUND OF THE DISCLOSURE 
     The following references may be relevant to the general field of technology of the present disclosure: U.S. Pat. Nos. 5,250,145, 6,276,858, US 2009/0294489 A1, and US2012/0091172 A1. 
     SUMMARY OF THE DISCLOSURE 
     Briefly, the present disclosure provides nozzles for applying setting resins onto the edge of a panel. The nozzle comprises a connector portion and an application head, wherein the connector portion is adapted to receive setting resin from a resin dispensing device and deliver the setting resin to the application head. The application head comprises: a) a supporting wall, and b) a curved finish wall joining the supporting wall along an edge at an angle of greater than 92 degrees and less than 120 degrees. The connector portion is adapted to deliver the setting resin to the application head in the interior of the angle formed between the supporting wall and the curved finishing wall. In some embodiments, the nozzle comprises a single supporting wall. In some embodiments, the nozzle comprises no component which makes contact with the panel other than the supporting wall and the curved finish wall during application of a setting resin onto the edge of a panel. In some embodiments, the curved finish wall has a curve radius which remains between 1.0 and 7.0 cm throughout the length of the curved finish wall. In some embodiments, the curved finish wall has a curve radius which remains between 1.0 and 7.0 cm throughout the first 1.6 cm of the curved finish wall, i.e., the 1.6 cm of the curved finish wall closest to supporting wall. In some embodiments, the curved finish wall has a curve radius which remains between 1.5 and 5.0 cm throughout the first 1.6 cm of the curved finish wall. In some embodiments, the curved finish wall has a curve radius which is longer closer to the joining between the curved finish wall and the supporting wall and shorter farther from the joining between the curved finish wall and the supporting wall. In some embodiments, the curved finish wall has a trailing edge profile which is smoothly curved and a leading edge profile which is scalloped. In some embodiments, the nozzle is a one-piece, integrally formed article. In some embodiments, the nozzle is optically translucent or transparent. 
     In another aspect, the present disclosure provides methods of applying a setting resin onto the edge of a panel, comprising the steps of: a) bringing the connector portion of a nozzle according to the present disclosure into connection with an output of a resin dispensing device; b) bringing the application head of the nozzle into contact with the edge of a panel; and c) dispensing the setting resin through the nozzle to the edge of the panel while the nozzle is moved in a lateral direction relative to the panel so as to apply resin to the panel edge. In some embodiments, the step of bringing the application head of the nozzle into contact with the edge of a panel comprises positioning the supporting wall of the nozzle plane parallel to and in contact with a top surface layer of the panel. In some embodiments, the step of bringing the application head of the nozzle into contact with the edge of a panel comprises positioning the nozzle such that the angle formed between the supporting wall and the finish wall rides on an outer edge of a top surface layer of the panel. In some embodiments, the panel is a honeycomb panel. In some embodiments, the setting resin is an adhesive. In some embodiments, the setting resin is a low density void filler. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIGS. 1A, 1B and 1C  are views of a first embodiment of a nozzle according to the present disclosure. 
         FIGS. 2A, 2B and 2C  are views of a second embodiment of a nozzle according to the present disclosure. 
         FIGS. 3A, 3B, and 3C  are cross sections of a first embodiment of a nozzle according to the present disclosure positioned for use with three different sizes of cut panels. 
         FIG. 4  is a photograph of a cut honeycomb panel bearing low density void filler on one cut edge which was applied from a nozzle according to the present disclosure, by a method according to the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     This disclosure relates to nozzles for applying setting resins onto the edge of a panel or a cut edge of a panel and methods of applying setting resins onto the edge of a panel or a cut edge of a panel. In some embodiments, interior layers of the panel are undercut relative to the surface layers. 
     Any suitable panels may be used in the practice of the present disclosure. Typically, the panel comprises a top surface layer, at least one core layer, and a bottom surface layer. In some embodiments, the panel comprises a core material which presents voids or ragged or uneven surfaces when cut. In some embodiments, the panel is a honeycomb panel comprising a core layer of honeycomb support material. The honeycomb support material may be of any suitable geometry or material, including standard honeycomb and overexpanded honeycomb. Suitable materials may include metal or alloys, paper or card, plastic resins, fiber, or combinations thereof such as fiberglass or NOMEX® aramid resin-treated paper. In some embodiments, the panel is a foam core panel comprising a core comprising one or more layers of foam material. The surface layers may be single layers or may be comprised of two or more plies. The surface layers may be of any suitable material, which may include one or more of aluminum or other metals or alloys, plastic resins, such as phenolic resin, optionally incorporating glass fibers, aramid fabrics such as KEVLAR®, paper, resin, or veneer. 
       FIG. 4  is a photograph of a honeycomb core panel  100  comprising top surface layer  110 , bottom surface layer  140  and honeycomb core  130 . A setting resin, in this case a low density void filling resin, has been applied to one edge of panel  100  using a nozzle and method of the present disclosure. The resin was allowed to cure in place to form edge fill  150 . 
     Any suitable setting resins may be used in the practice of the present disclosure. Suitable materials may include adhesives, including one-part or two-part adhesives, and void filler materials, including low density void fillers. 
       FIGS. 1A-C  and  FIGS. 3A-C  depict certain embodiments of nozzles  200  according to the present disclosure. Arrows  205  represent the direction of movement of the nozzle in use, herein the “lateral axis.” In  FIGS. 2A-C , the direction of movement of the nozzle in use (the lateral axis) is orthogonal to the page, away from the viewer. The “vertical axis,” as used herein, is the axis orthogonal to the panel when the nozzle is positioned next to the panel for use, as depicted in  FIGS. 3A-C .  FIG. 3A  depicts an embodiment of a nozzle  200  according to the present disclosure positioned for use with a cut panel  160  ¼″ (0.64 cm) in thickness.  FIG. 3B  depicts an embodiment of a nozzle  200  according to the present disclosure positioned for use with a cut panel  170  ½″ (1.27 cm) in thickness.  FIG. 3C  depicts an embodiment of a nozzle  200  according to the present disclosure positioned for use with a cut panel  180  ⅝″ (1.59 cm) in thickness. Panels  160 ,  170  and  180  each comprise top surface layer  110 , bottom surface layer  140  and honeycomb core  130 . In each of  FIGS. 3A-C , honeycomb core  130  has been undercut relative to top and bottom surface layers  110 ,  140 , leaving gap  190 . 
       FIGS. 2A-C  depict certain alternate embodiments of nozzles  200  according to the present disclosure. Arrows  205  represent the direction of movement of the nozzle in use, herein the “lateral axis.” The “vertical axis,” as used herein, is the axis orthogonal to the panel when the nozzle is positioned next to the panel for use. 
     With reference to  FIGS. 1A-C ,  FIGS. 2A-C , and  FIGS. 3A-C , nozzles  200  according to the present disclosure comprise connector portion  210  adapted to engage with a setting resin dispensing apparatus (not shown) so as to receive setting resin (not shown). Connector portion  210  may be adapted to engage any suitable setting resin dispensing apparatus. Suitable setting resin dispensing apparatus may include the output of a pump, tube, or gun, or the output of a mixing head. In some embodiments, the mixing head has an outer diameter of 10 or 13 mm, and thus connector portion  210  may have an inner diameter of 10 or 13 mm adapted for friction fit to such an apparatus. In some embodiments, the mixing head has a polygonal profile, and thus connector portion  210  may have a corresponding polygonal profile. In various embodiments, connector portion  210  may be adapted to engage a setting resin dispensing apparatus by friction fit, threaded connection, bayonet mount, or similar mechanism. 
     Passage  220  allows setting resin (not depicted) to enter application head  230 . In some embodiments passage  220  is elongated in the lateral direction to allow for increased resin flow. In some embodiments, passage  220  passes through curved finish wall  250  of application head  230 . 
     Connector portion  210  may engage application head  230  at any suitable angle. In some embodiments, such as depicted in  FIGS. 1A-C  and  FIGS. 3A-C , connector portion  210  may engage application head  230  at approximately 60 degrees from vertical (relative to the vertical axis) and 45 degrees from lateral (relative to the lateral axis). In some embodiments, such as depicted  FIGS. 2A-C , connector portion  210  may engage application head  230  at approximately 90 degrees from vertical (relative to the vertical axis) and 45 degrees from lateral (relative to the lateral axis). In some embodiments, connector portion  210  may engage application head  230  at angles of from 0 degrees to 90 degrees from vertical and from 0 degrees to 180 degrees from lateral. In some embodiments adapted to hand application, connector portion  210  engages application head  230  at angles of from 15 degrees to 75 degrees from vertical and from 15 degrees to 165 degrees from lateral. In some embodiments adapted to automated application, connector portion  210  engages application head  230  at angles of from 0 degrees to 45 degrees from vertical and from 45 degrees to 135 degrees from lateral. 
     Application head  230  comprises supporting wall  240 . Supporting wall  240  joins with curved finish wall  250  to form an angle which, in use, rides on the outer edge of top surface layer  110  to contact, alignment and support of nozzle  200 , as depicted in  FIGS. 3A, 3B, and 3C . In use, supporting wall  240  may be plane parallel to and ride on top surface layer  110  to provide additional contact, alignment and support of the nozzle, as depicted in  FIG. 3C . Alternately, when used with thinner panels, such as panels  160  and  170  depicted in  FIGS. 3A and 3B , supporting wall  240  may angle upward from top surface layer  110 . In some embodiments, “supporting wall” means a nozzle component which, when the nozzle is in use to apply resin to a panel, may be in contact with and plane parallel to a portion of the panel. In some embodiments, “supporting wall” means a nozzle component which, when the nozzle is in use to apply resin to a panel, may form an angle with curved finish wall  250  which angle rides on an outer edge of the panel. In some embodiments, application head  230  comprises a single supporting wall  240 ; i.e., no more than one supporting wall  240 . In some embodiments, application head  230  comprises no component which, during use, makes contact with the bottom surface layer other than at the outer edge of the bottom surface layer. In some embodiments, application head  230  comprises no component other than curved finish wall  250  which, during use, makes contact with the bottom surface layer. In some embodiments, application head  230  comprises no component which, during use, makes contact with the panel other than supporting wall  240  and curved finish wall  250 . 
     Curved finish wall  250  is curved toward the panel so as to allow the nozzle to be used with to panels of different nominal thickness, so as to allow that nozzle to adapt to variability in thickness of a single panel, and so as to provide a smoothly curved finish in the applied resin (not shown) after application. In some embodiments, the curve radius of curved finish wall  250  is constant. In some embodiments, the curve radius of curved finish wall  250  varies over the length of curved finish wall  250 . In some embodiments, the curve radius of curved finish wall  250  is longer closer to the joining between curved finish wall  250  and supporting wall  240  and shorter farther from the joining between curved finish wall  250  and supporting wall  240 . In some embodiments, the curve radius of curved finish wall  250  remains between 1.0 and 7.0 cm throughout the curve, in some embodiments between 1.5 and 7.0 cm, in some embodiments between 1.5 and 5.0 cm, and in some embodiments between 1.5 and 3.0 cm. In some embodiments, the curve radius of the first 1.6 cm of curved finish wall  250  (the 1.6 cm nearest to supporting wall  240 ) remains between 1.0 and 7.0 cm throughout the curve, in some embodiments between 1.5 and 7.0 cm, in some embodiments between 1.5 and 5.0 cm, and in some embodiments between 1.5 and 3.0 cm. As used herein, “curve radius” refers to the inner face of curved finish wall  250  and is measured for a curve existing in a plane orthogonal to the lateral axis. In some embodiments, such as depicted  FIGS. 1A-C  and  FIGS. 3A-C , supporting wall  240  joins curved finish wall  250  along an edge at an angle of greater than 90 degrees, in some embodiments greater than 92 degrees, in some embodiments greater than 94 degrees, and in some embodiments greater than 96 degrees. In some embodiments, supporting wall  240  joins curved finish wall  250  along an edge at an angle of 92 degrees or greater and less than 120 degrees; in some embodiments greater than 94 degrees and less than 120 degrees, and in some embodiments greater than 96 degrees and less than 120 degrees. In some embodiments, curved finish wall  250  includes scoring (not shown) on the back side of curved finish wall  250  enabling the user to break off distal portions of curved finish wall  250  not necessary for use with thinner panels. The length of finish wall  250 , measured along the vertical axis from the joining between finish wall  250  and supporting wall  240  to the end of finish wall  250 , is greater than the width of the panel. In some embodiments, the length of finish wall  250  is at least 120% of the width of the panel, so as to aid in acquiring position on the panel; on some embodiments at least 140%, and in some embodiments at least 160%. 
     In some embodiments, such as depicted in  FIGS. 2A-C , the trailing edge of curved finish wall  250  is curved toward the panel however the leading edge of curved finish wall  250  has a scalloped profile. The scalloped profile provides guide edges  252 ,  254  for panels of certain thicknesses smaller than the maximum panel thickness for which the nozzle may be used. For example, nozzle  200  depicted in  FIGS. 2A-C  may be used with ⅝″ (1.59 cm) panels at full width and additionally incorporates guide edges  254  for use with ¼″ (0.64 cm) panels and guide edges  252  for use with ½″ (1.27 cm) panels. Optionally, nozzle  200  incorporating guide edges  252 ,  254  may additionally comprise a second support wall  242  used with maximum width panels—in this embodiment, ⅝″ (1.59 cm) panels—or nozzle  200  may include only a single support wall  240 . In embodiments where the leading edge of curved finish wall  250  has a scalloped profile, the profile of curved finish wall  250  varies from scalloped to smoothly curved from leading edge to trailing edge, (see, e.g.,  FIGS. 2A-C ), so as to provide a smoothly curved finish in the applied resin (not shown) after application. In some embodiments, the curve radius of the trailing edge of finish wall  250  is constant, while in other embodiments the curve radius of the trailing edge of finish wall  250  varies over the length of the trailing edge. In some embodiments, the curve radius of the smoothly curving trailing edge of finish wall  250  remains between 1.0 and 7.0 cm throughout the curve, in some embodiments between 1.5 and 7.0 cm, in some embodiments between 1.5 and 5.0 cm, and in some embodiments between 1.5 and 3.0 cm. 
     The nozzles according to the present disclosure may be made of any suitable material. Suitable materials may include ceramics, metals or plastic resins, such resins potentially ABS, acrylics, polyetheramides such as ULTEM™, and optionally incorporating fibers or fillers. In some embodiments the nozzle material is optically clear or translucent so as to allow observation of the setting resin within the nozzle during preparation, use, and cleaning. The nozzles according to the present disclosure may be made by any suitable process. Suitable processes may include machining, additive processes such as 3D printing, molding processes such as injection molding. In some embodiments, the nozzles according to the present disclosure are one-piece, integrally formed articles. In some embodiments, the nozzles according to the present disclosure are integrally formed with or permanently attached to setting resin dispensing apparatus. 
     With reference to  FIGS. 3A-C , in a method according to the present disclosure, connector portion  210  of a nozzle  200  according to the present disclosure is brought into connection with the output of a resin dispensing device (not shown). Application head  230  of nozzle  200  is brought into contact with the edge of panel  160 ,  170 , or  180  such that supporting wall  240  is plane parallel to and rides on top surface layer  110  to provide contact, alignment and support of nozzle  200 , or such that the angle formed between supporting wall  240  and finish wall  250  rides on the outer edge of top surface layer  110  to provide contact, alignment and support of nozzle  200 , or both. Setting resin (not shown) is dispensed from the resin dispensing device through nozzle  200  to the edge of panel  160 ,  170 , or  180  while the nozzle is moved in the lateral direction relative to the panel so as to apply resin to the panel edge. It is to be understood that motion of the nozzle relative to the panel may be achieved by motion of the nozzle, motion of the panel, or both. The setting resin is allowed or caused to set. Dispensing of the resin may be motivated by any suitable method, including manual and mechanical methods, and controlled by any suitable methods, including human or automated methods. Support and motion of the panel and nozzle may be accomplished by any suitable methods, including manual and mechanical methods, and controlled by any suitable methods, including human or automated methods. 
     Various modifications and alterations of this disclosure will become apparent to those skilled in the art without departing from the scope and principles of this disclosure, and it should be understood that this disclosure is not to be unduly limited to the illustrative embodiments set forth hereinabove.