Patent Publication Number: US-2018036765-A1

Title: Screen Repair Apparatus and Method of Use

Description:
FIELD OF THE DISCLOSURE 
     The invention relates generally to the field of repair apparatus for screens used on electronic devices. 
     BACKGROUND 
     Many electronic devices have screens on one or more portions of the device. These screens are typically glass (or glasslike) pieces facilitating a visual display section of the device. Often these screens are touch screens that allow a user to operate the device through touching the screen. 
     At times, these screens may be broken creating one or more cracks in the screen itself. When the screen is broken, the cracks may have sharp and/or jagged edges that may cause injury to a user, the device to be unpleasant to operate and/or the device to be effectively inoperable. To repair the device, the screen is removed and replaced with a new screen. 
     SUMMARY 
     The present disclosure provides a way to repair a cracked display screen without replacing the screen. 
     Embodiments of the present disclosure use a sodium metasilicate solution, sometimes referred to as a sodium silicate solution, to fill in the cracks of a broken screen. The sodium metasilicate solution has a sufficient viscosity to flow or be pressed into the cracks of a broken screen during application. Some embodiments of the present disclosure provide a kit including a container having a sodium metasilicate solution and an applicator. 
     Embodiments of the container include a seal covering a container output. In some embodiments, a cap is used as the seal for the container output. Some embodiments of the seal are replaceable, allowing for multiple uses. Other embodiments of the seal may not be replaceable. 
     Embodiments of the container output include openings designed to allow the sodium metasilicate solution to flow out of the container. In some embodiments, the container output may operate to direct the flow of the sodium metasilicate solution to specific locations. In some embodiments, the container output may operate to control the flow of the sodium metasilicate solution from the container. 
     Embodiments of the container may be designed for single-use applications or multiuse applications. Some embodiments of the container may be deformable to provide additional pressure within the container for moving the sodium metasilicate solution out of the container. In some embodiments, the container may be flexible such that the container resumes a default shape after being compressed. 
     Embodiments of the applicator include stick applicators with a broadened head to apply the sodium metasilicate solution into the cracks in the screen. In some embodiments, the stick applicator is made from a hard or semi-hard plastic. In some embodiments, the stick applicator may comprise multiple portions including a hard stick portion with a soft application portion. For example, the applicator may comprise a plastic stick with a foam head designed to apply the sodium metasilicate solution. Some embodiments of the applicator may be small foam or soft material blocks that may be used to spread the sodium metasilicate solution over the cracks of the screen. 
     In some embodiments, the applicator may be attached to the container. For example, a container may include a breakaway applicator connected to the side for use during application. Some embodiments may incorporate the applicator into a cap used on the container. In other embodiments, the applicator may be incorporated into the output of the container. 
     To repair a cracked screen, the sodium metasilicate solution may be applied out of the container onto the broken area of the display screen. An applicator may then be used to spread the sodium metasilicate solution over the cracked area of the broken screen. In some embodiments, the applicator may also be used to press the sodium metasilicate solution into the cracks. Once the sodium metasilicate solution is smoothed out over the broken surface of the screen, the sodium metasilicate solution is allowed to dry. Once completely dry, the screen is repaired and may be used again. 
    
    
     
       A BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments will now be described, by way of example only, with references to the accompanying drawings in which: 
         FIG. 1  shows an embodiment of a bottle and an electronic device with a damaged display; 
         FIG. 2  shows an embodiment of an applicator and an electronic device with a damaged display; 
         FIG. 3  shows an embodiment of a container; 
         FIG. 4  shows an exploded view of an embodiment of a container; 
         FIG. 5A  shows an embodiment of a container; 
         FIG. 5B  shows two views of an embodiment of a container tip; 
         FIG. 5C  shows an embodiment of a cap with an applicator portion; 
         FIG. 6A  shows an embodiment of an applicator; and 
         FIG. 6B  shows another embodiment of an applicator. 
     
    
    
     DETAILED DESCRIPTION 
     While this invention may be embodied in many different forms, there will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspects of the invention to the embodiments illustrated. It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. 
       FIGS. 1 and 2  illustrate an application of a sodium metasilicate solution for repairing displays on electronic devices using a container and applicator.  FIGS. 1 and 2  shows a smart phone  102  having a display  104 . The smart phone  102  is shown as an illustrative electronic device. The screen repair process and elements described herein may be applied to other electronic devices having display screens. The display  104  may be a visual output only display or an input/output display, such as a touchscreen display element. The display  104  is shown with a damaged screen as illustrated by the cracks in damaged area  106 . The cracks in the screen may be hairline fractures less than 1 mm wide or larger fissures such as 1 mm to 3 mm wide or larger. 
     In  FIG. 1 , a container  110  having a sodium silicate solution is shown over the smart phone  102 . The sodium silicate solution comprises a mixture of sodium silicate and water. The sodium silicate may be mixed to a consistency ranging from a liquid to a gel. For example, the sodium silicate solution may be approximately 40% water and 60% sodium silicate to provide a semi-viscous liquid that will flow into small openings and spread over the surface. As another example, the sodium silicate solution may be approximately 10% water and 90% sodium silicate to provide a gel that can be spread over damaged surfaces and pressed into openings. Preferred embodiments of the sodium silicate solution may contain between 10% and 40% water. However, other embodiments may contain more than 40% water or less than 10% water. The sodium silicate solution may be tailored for specific uses. For example, a solution having 35% water and 65% sodium silicate may be used for damaged screens that predominantly have thin cracks. Alternatively, a solution having 13% water and 87% sodium silicate may be used for damaged screens with larger cracks and/or pits in the surface of the screen. 
     An output  112  of the container  110  is directed to the damaged area  106  of the screen. The sodium silicate solution is then applied to the damaged area  106  of the screen including the cracks. In some embodiments, the output  112  is designed to allow the sodium silicate solution to pour or drip from the container when the output is turned downward. In some embodiment, the output  112  is designed to hold the sodium silicate solution within the container  110  until an external force is applied to the container  110 . For example, a user may hold the container  110  upside down over the damaged area and squeeze the container  110  when ready to apply the sodium silicate solution. The design of the output  112  may vary depending on the viscosity of the sodium silicate solution to achieve the desired output characteristics. 
     Once the sodium silicate solution is applied from the container  110  onto the damaged area  106 , the sodium silicate solution is spread over the damaged area  106  using an applicator  120  as shown in  FIG. 2 . In this embodiment, the applicator  120  includes an application surface adjacent to the screen of the display  104 . In some embodiments, the application surface may be a foam portion that is placed against the surface of the screen and moved over the damaged area  106  to ensure the sodium silicate solution covers the entire damaged area  106 . Other applicator embodiments may use alternative materials for the application surface, such as plastic, nylon, cotton, metal or other materials. In some embodiments, the application surface may be designed as a brush, a flat edge, a solid flat application surface or other design. The selection of the material and design of the application surface may correlate to the consistency of the sodium silicate solution and/or the characteristics of the screen of the electronic device. 
     Some applicators may also include a handle portion that may be any design used to hold the applicator  120  during application of the sodium silicate solution. In some embodiments, the handle portion may be designed to attach to the container  110 . For example, the handle portion may fit over the output  112  of the container  110  as a cap. For another example, the handle portion may be designed to snap onto the side of the container  110 . 
     Once the sodium silicate solution is spread over the damaged area  106  with the applicator  120 , the sodium silicate solution is allowed to dry. In some embodiments, a heat source and/or fan may be used to speed the drying process. Once dry the sodium silicate solution provides a solid seal smoothing out the rough edges of the cracks in the damaged area  106 . The dry sodium silicate solution is safe to touch and allows the smart phone  102  to be used as a phone and for other purposes. 
     In some embodiments, the repair using the sodium silicate solution is designed as a temporary repair to allow the user to safely use the device for a limited timeframe until the screen or the device is replaced. In some embodiments, while allowing the display  104  to be fully visible through the damaged area  106 , the dried sodium silicate solution may have a cloudy visual characteristic. In other embodiment, the sodium silicate solution may not be apparent on the screen once it has dried. 
       FIG. 3  shows a sleeve container  200  for holding a sodium silicate solution as described above. For example, the sodium silicate solution may comprise 37.5% sodium silicate and 63.5% water. For another example, the sodium silicate solution may comprise 55% sodium silicate and 45% water. The sleeve container  200  may also be referred to as a tube container. In this embodiment, the sleeve container  200  includes a container body  202  with a container output  204  located at one end of the sleeve container body  202 . At the other end of the container body  202  is a seal  208 . In this embodiment, the seal is shown as a crimped section at the base of the container body  202 . The crimped section may be sealed in a variety of ways including compression seals, adhesives, heat seals and/or other seals. In some embodiments, the crimped section may be replaced with an alternative sealing component, such as a second removable cap, a plug or another sealing component. 
     A cap  210  is included in this embodiment to cover the output  204  when the sleeve container  200  is stored or otherwise not in use. In this embodiment, the output  204  includes a threaded section  206  compatible with an interior section of the cap  210 , wherein the cap  210  may be removably secured to cover the output  204  by threading or screwing the cap  210  down on the threaded section  206  of the sleeve container body  202 . In some embodiments, alternative connection or attachment components may be used to connect the cap  210  to the container body  202 . For example, the cap may be connected to the container body  202  by a friction seal, a breakaway component and/or another connection. 
     In some embodiments, the sleeve container  202  may be intended to be a single use container having a select amount of a sodium silicate solution for a given project. In such embodiments, the cap  210  may be attached to the container body  202  by a single use connection. For example, the cap  210  may be attached by a breakaway plastic component, whereby when the cap  210  is removed it cannot be replaced on the container body  202 . 
     In some embodiments, the sleeve container  202  may be compressible to allow a user to push the sodium silicate contents from the sleeve container  200  by compressing the container body  202 . As the space within the container body  202  decreases, the internal pressure of the container body  202  will increase moving the sodium silicate solution through the output  204 . In some embodiments, the output  204  may be designed to limit the release of the sodium silicate solution unless an increased pressure is applied to the container body  202 . For example, the output  204  may comprise a fenestrated opening with slits to limit the release of the sodium silicate solution. 
       FIG. 4  illustrates a container  300  for holding a sodium silicate solution as described above. In this embodiment, the container  300  is shown as a bottle container. The container  300  includes a container body  302  with a container output  312  located at one end of the container body  302 . In this embodiment, the container body only has the one opening at output  312 . 
     A cap  304  is included in this embodiment to cover the output  312  when the container  300  is stored or otherwise not in use. In this embodiment, the output  312  includes a threaded section  306  compatible with an interior section of the cap  304 , wherein the cap  304  may be removably secured to cover the output  312  by threading or screwing the cap  304  down on the threaded section  306  of the container body  302 . In some embodiments, alternative connection or attachment components may be used to connect the cap  304  to the container body  302 . For example, the cap  304  may be connected to the container body  302  by a friction seal, a breakaway component and/or another connection. 
     In this embodiment, the container body  302  includes a section of protrusions  308  below the threaded section  306 . The protrusions  308  extend radially outward from the container body  302 . In this embodiment, the interior of the cap  304  contains one or more detents corresponding to the protrusions  308 . When the cap  304  is threaded onto the top of the container body  302  in a first direction (e.g. clockwise), the protrusions  308  and corresponding detents do not engage and allow rotation. When the cap  304  is rotated in the second direction, the protrusions  308  catch the detents preventing or increasing the difficulty to rotate the cap  304  in the second direction. In some embodiments, the section of the cap  304  having the detents may be designed to breakaway when a sufficient rotational pressure is applied to the cap  304 . In other embodiments, the user may compress the section of the cap  304  having the detents at specific locations while the cap  304  is rotated to keep the detents from engaging during rotation in the second direction. 
     This embodiment also includes a reducer  310  that fits into the output  312  and provides a modified narrower output  316 . The reducer base  314  is designed to correspond with the output  312  in this embodiment, such that the exterior circumference of the reducer base  314  creates a friction seal with the interior of the output  312 . When a person uses the container  300  with reducer  310 , the sodium silicate solution will pass through output  312 , the reducer  310  and out through the modified narrower output  316 . In some embodiments, the reducer  310  may be placed in the output  312  after the container body  302  is filled. In some embodiments, the reducer  310  may be removable to allow refilling the container  300  and/or pouring the sodium silicate solution. In other embodiments, the reducer  310  may be designed to prevent or hamper removal. 
     In some embodiments, the container  300  may be intended to be a single use container having a select amount of a sodium silicate solution for a given project. In such embodiments, the cap  304  may be attached to the container body  302  by a single use connection. For example, the cap  304  may be attached by a breakaway plastic component, whereby when the cap  304  is removed it cannot be replaced on the container body  302 . 
     In some embodiments, the container  300  may be intended to be a multi-use container having an amount of a sodium silicate solution for multiple uses. In such embodiments, the cap  304  may be attached to the container body  302  by a connection that may be opened and closed. For example, the cap  304  may be attached by a threaded connection with a safety lock, whereby when the cap  304  is removed properly it can be replaced on the container body  302 . While the container  300  may be designed as a multi-use container, it is possible that the type of project and extent of damage will affect the number of uses. For example, a container  300  designed for multiple uses in fixing minor damage to the screen of a mobile phone may only contain enough solution for fixing major damage to the screen of a tablet device. 
     In some embodiments, the container body  302  may be compressible to allow a user to push the sodium silicate contents from the container  300  by compressing the container body  302 . As the space within the container body  302  decreases, the internal pressure of the container body  302  will increase moving the sodium silicate solution through the output  312  and the reducer output  316 . In some embodiments, the reducer output  316  may be designed to limit the release of the sodium silicate solution unless an increased pressure is applied to the container body  302 . For example, the reducer output  316  may comprise a fenestrated opening with slits to limit the release of the sodium silicate solution. 
       FIG. 5A  shows another embodiment of a container  400  for holding a sodium silicate solution as described above. In this embodiment, the container  400  is shown as another bottle container. The container  400  includes a container body  402  with a container output  404  located at one end of the container body  402 . In this embodiment, the container body  402  only has the one opening at output  404 . As discussed with other embodiments, the container  400  may be designed as a single use container or a multi-use container. 
     A cap is not shown in  FIG. 5A . In some embodiments, a cap such as those discussed elsewhere herein may be included to cover the output  404  when the container  400  is stored or otherwise not in use. In this embodiment, the container  400  includes a threaded section  406  that may be compatible with an interior section of a cap. In some embodiments, alternative connection or attachment components may be incorporated in the design of the container  400 . 
     In some embodiments, the container body  402  may be compressible to allow a user to push the sodium silicate contents from the container  400  by compressing the container body  402 . As the space within the container body  402  decreases, the internal pressure of the container body  402  will increase moving the sodium silicate solution through the output  404 . In some embodiments, the output  404  may be designed to limit the release of the sodium silicate solution unless an increased pressure is applied to the container body  402 . For example, the output  404  may comprise a sufficiently small opening that the sodium silicate solution will not pass through without additional applied pressure. 
       FIG. 5B  illustrates a front view and a side view of an alternative container output  420 . In this embodiment, the alternative output  420  includes the output opening  422  in an angled section  424  of the alternative output  420 . The output opening  422  is fluidly connected to the internal opening of a container and allows the sodium silicate solution to be applied from the container through the output opening  422  onto an application surface. The angled section  424  may operate as an applicator to direct the sodium silicate solution to selected areas as the sodium silicate solution is applied from the output opening  422 . In some embodiments, this operates as an initial application step with a separate applicator to conduct a subsequent application step for moving and smoothing the applied sodium silicate solution into the damaged area of a screen. 
     In some embodiments, the alternative output  420  may replace a container output, such as output  404  in  FIG. 5A . In other embodiments, a user may cut a container output to create the angled section  424  of the alternative output  420 . In such embodiments, a person may elect to create any desired angle for the angled section  424 , whereby the user may customize the alternative output  420  for the specific application. In some designs, the container output may contain suggested angles for a user to cut. In some embodiments, the container may not have an output until a user cuts the tip of the container to create an output. In such embodiments, a cap and/or connections for a cap may not be necessary for single use designs. 
       FIG. 5C  shows an embodiment of an applicator  410 . The applicator  410  includes an application surface  416  and a base section  414 . The application surface  416  may comprise a material that can smooth a sodium silicate solution into a damaged area of the screen. The material may be selected or designed to prevent or limit the likelihood of damage to the screen surface while facilitating the application of the sodium silicate solution. In some embodiments, the material may be a foam composite, a rubber, a plastic, a nylon and/or another material or combination of materials. In addition, alternative designs for the application surface  416  may be used in some embodiments. For example, the application surface  416  may be a solid or semi-solid flat surface. For another example, the application surface  416  may be a brush surface comprising a plurality of bristles. 
     The base section  414  may operate as a handle for a user to hold while applying the sodium silicate solution to the damaged area. In some embodiments, the base section  414  may include an internal opening with threads or other connection components and operate as a cap for a container, such as container  400 . In such embodiments, the user may hold the container body with the applicator  410  connected thereto when spreading and smoothing the sodium silicate solution in the damaged area of a screen. In some embodiments, the applicator  410  may be combined with a container (e.g. container  400 ) as a single screen repair kit. 
     The applicator  410  also includes an interface section  412  that facilitates the connection to the application section  416 . In some embodiments, the interface section  412  may also operate to allow an applicator cap (not shown) to be connected over the application section  416 . 
       FIGS. 6A and 6B  illustrate additional embodiments of applicators.  FIG. 6A  shows a wedge applicator  502 . The wedge applicator  502  has a wide section  504  on one end with a narrow section  506  on the opposite end. In this embodiment, the wedge applicator  502  is shown having a consistent material throughout. The material may be selected or designed to prevent or limit the likelihood of damage to the screen surface while facilitating the application of the sodium silicate solution. In some embodiments, the material may be a foam composite, a rubber, a plastic, a nylon and/or another material or combination of materials. In some embodiments, the wedge applicator  502  may provide a variety of surface attributes that may be used to spread and smooth a sodium silicate solution on a screen. In addition, the dimensions of the applicator  502  may vary based upon various factors, such as the intended use of the applicator  502 , the intended packaging for the applicator  502  (or a kit including the applicator  502 ) and/or other considerations. 
     A user may hold the wedge applicator  502  in a variety of manners depending on the selected application surface. In other words, a user may hold the wide section  504  when using the narrow section  506  or another surface to spread and smooth the sodium silicate solution. Alternatively, a user may hold the narrow section  506  when using the wide section  504  or another surface to spread and smooth the sodium silicate solution. During use, a person may wipe the wedge applicator  502  over the damaged area of the screen to smooth the sodium silicate solution across the damaged area. During the process, the wedge applicator  502  may remove excess sodium silicate solution. In addition, the wedge applicator  502  material may be selected to absorb excess sodium silicate solution. 
     In some embodiments, the sodium silicate solution may be applied to the wedge applicator when the material of the wedge applicator  502  allows absorption. The wedge applicator  502  may then transfer the sodium silicate solution to the damaged area of the screen as part of the application process. 
     In some embodiments, a user may use the wedge applicator  502  to apply a sufficient amount of water or other fluid to a previously repaired area having a dried sodium silicate solution. The water or other fluid may allow the sodium silicate solution to be further smoothed or removed. For example, a user may dip the wedge applicator  502  in water and apply the wet wedge applicator  502  to a section of the sodium silicate solution that dried in an uneven manner. The wedge applicator  502  may then be used to wipe the surface smoothing the sodium silicate solution and even removing excess sodium silicate solution. 
       FIG. 6B  shows a stick applicator  510 . The stick applicator  510  has a handle section  512  on one end with an application section  514  on the opposite end. In some embodiments, the handle section  512  is rigid with a softer material as the application section  514 . In some embodiments, the handle section  512  may be a semi-rigid design. The material for the handle section  512  may be comprised of rubber, plastic, wood, papers or other composites. The material for the application section  514  may be selected or designed to prevent or limit the likelihood of damage to the screen surface while facilitating the application of the sodium silicate solution. In some embodiments, the material may be a foam composite, a rubber, a plastic, a nylon, fabrics and/or another material or combination of materials. In addition, the dimensions of the applicator  510  may vary based upon various factors, such as the intended use of the applicator  510 , the intended packaging for the applicator  510  (or a kit including the applicator  510 ) and/or other considerations. 
     The handle section  512  comprises the substantial majority of the stick applicator  510  in this embodiment. In some embodiments, the stick applicator  510  may have a consistent material throughout for the handle section  512  and the application section  514 . 
     A user may hold the handle section  512  of the stick applicator  510  and use the application section  514  to spread and smooth the sodium silicate solution. During use, a person may wipe application section  514  of the stick applicator  510  over the damaged area of the screen to smooth the sodium silicate solution across the damaged area. The stick applicator  510  may remove excess sodium silicate solution. 
     In some embodiments, the sodium silicate solution may be applied to the stick applicator  510  when the material of the application section  514  allows absorption. The stick applicator  510  may then transfer the sodium silicate solution to the damaged area of the screen as part of the application process. In some embodiments, a user may dip the application portion  514  of the stick applicator  510  into a container holding the sodium silicate solution and allow the application portion  514  to absorb the sodium silicate solution for transfer to a damaged screen. 
     The screen repair system may be provided as a kit containing one or more of the applicators and the containers of the sodium silicate solution. For example, a kit may comprise a container  300  with a stick applicator  510 . The stick applicator  510  may be attached to container  300  to provide a simple kit with everything needed to repair a damaged screen. In some single use embodiments, the stick applicator  510  may be connected by a break away element to allow a single use of the stick applicator  510 . In some multi-use embodiments, the stick applicator  510  may be connected by a connection that allows the stick applicator  510  to be reconnected. In some multi-use embodiments, multiple stick applicators  510  may be connected to the container  400  by connections that break away to allow a single use of each stick applicator  510  provided. 
     As another embodiment of a screen repair kit, an applicator  502  may be provided with multiple containers  200 . The same applicator  502  may be reused for each application from one of the container  200  provided in the kit. 
     The invention being thus described and further described in the claims, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the apparatuses and methods described.