MXPA99007635A - Method and apparatus for repairing plastic parts - Google Patents

Abstract

A method and apparatus for eliminating blemishes (14) in the outer surface (12) of a plastic member (10) of a particular color and wherein such blemishes are removed by using an applicator device (16) provided with a one-component, water-borne material (22) of the same color as the particular color and having a fibrous tip (40) which is capable of being saturated with the water-borne material.

Description

METHOD AND APPARATUS FOR REPAIRING PLASTIC PARTS DESCRIPTION OF THE INVENTION This application is based on United States Provisional Application Serial No. 60/038, 089 filed on February 18, 1997. This invention relates to a method and apparatus for repair the surfaces of plastic parts, for example, those that appear inside a car or other places. Several parts of a car are made as hard plastic members or are provided with an external plastic skin or coating, which serves to cover a substrate with a foam material therebetween. In any case, the external surface of the plastic part serves as a wear surface as well as a surface that is aesthetically attractive. In the manufacture of such parts, sometimes the appearance or external surface of the plastic member may be scratched or have a slight discoloration which causes the part to be rejected during the final inspection, and as a result, to be discharged. Obviously, if such a part can be repaired and saved, the total cost of manufacturing can be reduced. In order to prevent the finished plastic parts from being rejected and discarded, due to imperfections of the kind described above, we have found, after many experiments, that by using an applied device, specially developed in a predetermined manner, such imperfections can be hidden with the naked eye . This allows the part to be saved and used as original equipment for a new car. In this regard, the applicator used to accomplish this achievement takes the form of a pen and includes a dispenser assembly attached to a tubular member that serves as a reservoir containing a filler / coater material preferably made of a vinyl transported in component water. liquid. For the purposes of this specification, a single component waterborne material has at least one polymer dispersed in water as the primary carrier. Water is the main carrier where its percentage by weight is greater than that of any other carrier in which the polymer or polymers can be dispersed, or where water is the only carrier. In this case, the preferred polymer is vinyl. More specifically, the dispenser assembly has an outer housing that includes a cylindrical body portion that serves as a reservoir for the filler / coater material. A fluid control device is located within the dispenser assembly and includes a spring tightening valve which is normally in the closed position.

In addition, the dispenser assembly includes a dispensing tip made of fibrous material that is slidably supported within the assembly. In order to saturate the dispensing tip with the filler / coater material so that the applicator device can be used in accordance with the present invention, the dispensing tip must be moved inwardly to cause the trailing end of the dispensing tip to remove the valve. This is achieved manually by holding the applicator device by its tubular body and strongly pressing the dispensing tip against the imperfection in the plastic surface to be repaired. In order to be able to repair the imperfection on the appearance surface of a plastic member according to the present invention, the imperfection is first cleaned using a clean, damp, clean cloth with a cleaning fluid such as isopropyl alcohol if the plastic member is made of polyvinyl chloride (PVC). The plastic member is made of thermoplastic olefin (TPO), thermoplastic urethane (TPU), styrene acrylonitrile-butadiene (ABS), or thermoplastic elastomers (TPE), the cleaning fluid would be a 50/50 mixture of methyl ethyl ketone / oluol (MEK / Toluol ). Toluene is also known as toluene. After cleaning the area to be repaired, the plastic member is allowed to dry. If the plastic member is made of TPO, TPU, TPE or ABS, an adhesion promoter will need to apply the imperfection first. If the plastic material is PVC, there is no need to apply any adhesion promoter. Then, the applicator device is used to fill the imperfection with the filler / coater material by first placing the dispensing tip at one end of the imperfection. After a downward pressure is applied to the applicator device to cause the spring-loaded valve to open and cause the filler / coater material to flow into the tip body, the applicator device moves along the imperfection allowing the the filler / coater material covers and hides it. Then, the filler / coater material is cured at room temperature before the plastic member is released for production use. Accordingly, an object of the present invention is to provide a new and improved method and apparatus for repairing the appearance surface of a plastic part that may have undesirable flaking, scratching, scratching, damage, staining, or localized discoloration. Another object of the present invention is to provide a new and improved method and apparatus for removing imperfections of the outer surface of a particular colored plastic sheet covering a part and wherein such imperfections are promoted using an applicator device provided with a material of vinyl transported in water of unique component of the same color as the particular color and having a fibrous tip which is capable of being saturated with the vinyl material transported in water. Another object of the present invention is to provide a new and improved method and apparatus which takes the form of a boom having a plastic reservoir containing a liquid filler / coater material and being selectively transported to an applicator tip made of a fiber material acrylic having a density which allows the liquid material to flow through the tip at a desired speed on the skin while the tip is manually pressed against the outer surface of the plastic sheet to fill and repair the damaged area of such surface . Yet another object of the present invention is to provide a new and improved method and apparatus for repairing the outer surface of a plastic member using a single component waterborne vinyl material, which is applied to the damaged area through a device. with boom, which has a reservoir containing the waterborne material of the single component which is selectively fluid connected to a spring-loaded dispensing tip by being manually depressed to mate with the damaged area, to cause the material transported in water to flow of the deposit and again of the dispensing tip to fill and repair the damaged area of the plastic member. BRIEF DESCRIPTION OF THE DRAWINGS The foregoing and other objects, features and advantages of the present invention will now be more apparent from the following detailed description together with the accompanying drawings in which: Figure 1 is a pictorial view showing an applicator device especially made to practice the present invention and which is used to repair a scratch located on the outer appearance surface of a plastic member; Figure 2 is a cross-sectional view of the applicator device seen in Figure 1; Figure 3 is an end view of the guide section of the dispensing assembly of the applicator device taken on line 3-3 of Figure 2; and Figure 4 is an enlarged elevation view showing the dispensing tip pressed against the outer surface of the plastic member to release the liquid filler / coater material within the applicator device to fill and hide the cavity created by the grated view seen in Figure 1. Referring to the drawings and more particularly to Figure 1 thereof, a plastic member 10 is shown which can be either a hard plastic member or a flexible cover sheet or a lower trim panel lining of an automobile or a Instrument panel or a panel of exterior ornament or a defense. The cover sheet can be made of polyvinyl chloride (PVC), thermoplastic olefin (TPO), thermoplastic urethane (TPU), acrylonitrile-butadiene styrene (ABS), or thermoplastic elastomers (TPE). This list of plastic materials is intended to be illustrative, and not limiting. With respect to forming methods, the plastic member 10 can be produced by any plastic forming method known in the art. The plastic member 10 has a surface of external appearance 12 which in this case has a gradation 14 and a depth and type which would classify the automobile part formed with this cover sheet as aesthetically unacceptable. In this case, however, by using an applicator device 16 and a repair method in accordance with the present invention, the grater 14 can be hidden so that it is not easily visible to the observer.

As seen in Figure 2, the applicator device 16 takes the form of a pen and includes a dispenser assembly 18 connected to a tubular member 20 which serves as a reservoir containing a filler / coater material 22 to be described in its entirety. later . More specifically, the dispenser assembly 18 has an outer housing which includes a cylindrical body portion 24, the outer periphery of which is integrally formed with an annular collar 25. The rear end of the cylindrical body portion 24 extends (limited by the collar 25) to the front open end of the tubular member 20 and sealingly secured thereto. The front portion of the outer housing tapers inwardly from the body portion 24 and is integrally formed as a cylindrical guide section 26 of reduced diameter. Also, a fluid control device 28 is rigidly supported by and is located within the cylindrical body portion 24 and includes a cylindrical housing 30 having an inner chamber containing a spring tightening valve 34 in a closed position with relation to the circular opening 36 centrally formed at the front end of the housing 30. A plurality of identical elongated openings or holes 38 (only two of which are shown in Figure 2) are provided around the housing 30 adjacent to the trailing end thereof . The openings 38 provide communication between the reservoir formed in the tubular member 20 and the interior of the housing 30 of the fluid control device 28. In addition, the dispenser assembly 18 includes a dispensing tip 40 which is made of a fibrous material and is slidably supported within the guide section 26 of the dispenser assembly 18 by spaced-apart radially inwardly spaced arrangement 42 as seen in Figure 3. The extensions 42 extend longitudinally along the length of the guide section 26 and provide passages therebetween for a fluid connection with a chamber 43 located adjacent the rear end of the dispensing tip 40. The dispensing tip portion 40 is located within the guide section 26 of the dispenser assembly 18 generally cylindrical in its section cross section with the front exposed end of the dispensing tip 40 being generally rectangular in its cross section of a gradually decreasing size to present a pair of parallel straight edges spaced apart 44 at its terminal end. The filler / coater material 22 located within the reservoir of the applicator device 16 will normally substantially fill the interior of the housing 30 of the flow control device 28 by flowing through the openings 38. In order to saturate the dispensing tip 40 with the filler material / casing 22 so that the applicator device 16 can be used in accordance with the present invention, the dispensing tip 40 must be moved inwardly from the guide section 26 to cause the trailing end of the dispensing tip 40 to replace the valve 34 against the opening 36. This can be achieved by having a person manually grip the applicator device 16 by its tubular body 20 and strongly pressing the dispensing tip 40 against the plastic surface 12 to be repaired. This action causes the dispensing tip 40 to move further from the guide section 26 of the dispenser assembly 18 so that the trailing end of the dispensing tip 40 removes the spring valve 34 from the spring 32. This then allows the filler / coater material to be removed. 22 inside the housing 30 flows down into the chamber 43 and then along the passages between the projections 42 within the fibrous body of the dispensing tip 40 and finally flows outwardly from the edges 44 on the surface to be repaired. The tubular member 20, the body portion 24 including the guide section 26, and the housing 30 are made of a plastic material and are provided by Moha Kood Coatings Group, located at 47158 STH and 30, Amsterdam, New York 12010-7417. Dispatcher assembly 18 contains an identification code number QO5-0017-0 and is made by Flocon Inc., located at 1111 Lions Drive, Barrington, Illinois 60010. The dispensing tip 40 is made of an acrylic fiber and is identified by the code number Q10-0210-076. The tubular member 20 is identified by the code number BNPV2. Both the dispensing tip 40 and the tubular member 20 are also supplied by Flocon Inc. The filler / coater material 22 preferably used with the applicator device 16 is manufactured by Estfield Coatings Corporation, 221 Union St., P.O. Box 815, Westfield, Mass. 01086 and is a single component waterborne vinyl material. The filler / coater material 22 can be found in different colors which agree identically with the various colors of the plastic members that are currently being manufactured. In this way, when repairing a plastic member, the final color of the filler / coater material 22 will be identical to the color of the plastic member. For example, if the plastic member 10 seen in Figure 1 is identified as having the color "lapizlazuli", then the particular filler / coater material selected to repair the scratch 14 in the plastic member 10 and having corresponding color will be the material Westfield filler / coater, identified by product code 332WSL23747. However, before placing this vinyl material transported to the particular water within the reservoir of the applicator device 16, it would first have to be diluted to obtain the proper viscosity which allows the filler / coater material to flow at an acceptable rate through of the fibrous tip 40 and on the surface 12 to be repaired. After many experiments, it has been found that the viscosity of the Westfield filler / coater material with the aforementioned product code must be reduced by approximately ten percent by adding water to the material. In order to obtain the proper viscosity of the Westfield filler / coater material identified above for use in the applicator device 16, a viscosity measuring instrument was used manufactured and sold by Paul N. Gardner Company, Inc., 316 NE lst. St. , Pompano Beach, FL 33060 and meets the requirements of ASTM D 4212. The instrument used is known as the EZ Dip Viscosity Cup Series (EZ Bath Viscosity Cup Series). These series consist of five Numbers 1-5 cups, and the particular EZ cup is used to determine the proper viscosity of the Westfield filler / coater material was the EZ No. 2 cup. Using this cup, it was found that the preferable and acceptable viscosity of the Westfield filler / coater material was made when the first break in the spill jet occurred between 16 and 20 seconds at a temperature of approximately 70 degrees Fahrenheit plus or minus two degrees. In practicing the method according to the present invention to repair the scratch 14 of the plastic member 10 as seen in Figure 1, the following is required: 1. An HP-21054-4wl adhesion promoter made by Morton International Inc. located at 2700 E. 170th Street, Lansing, Illinois 60433-1107 2. The applicator device 16 described above. 3. Isopropyl alcohol and MEK / Toluol (50/50%) 4. Particle Free cloth (technical cloth 11 made by The Texwipe Company, located in Upper Saddle River, New Jersey 07458. With reference to Figure 4, the procedure to repair the scratch 14 on the appearance surface 12 of the plastic member 10 is as follows: First, clean the area to be repaired with a clean cloth of the aforementioned type using a cleaner appropriate recommended and applying moderate pressure in a cleaning movement. If the plastic member made of PVC, the cleaning fluid used would be isopropyl alcohol. If the plastic member is made of TPO, TPU, TPE or ABS, the cleaning fluid will be a 50/50 mixture of MEK / Toluol. After cleaning the area to be repaired, allow the plastic member to air dry for a minimum of 30 seconds at an ambient temperature of approximately 72 degrees Fahrenheit. If the plastic member is made of TPO, TPU, TPE or ABS, the Morton adhesion promoter identified above will have to be applied to the zest 12 and cured as recommended by Morton. At an ambient temperature of about 72 degrees Fahrenheit, the curing time for the Morton adhesion promoter has been found to be about twenty minutes. If the plastic material is PVC, the Morton adhesion promoter does not need to be applied. Then, the applicator device 16 will now be used to fill the grating 12 with the filler / coater material 22. Before continuing to use the applicator device 16, first manually shake the applicator device 16 up and down for approximately 30-60 seconds to causing the metal balin inside the device of the tubular member 20 to mix the filler / coater material. Then, place the applicator device 16 so that one of the wide straight edges 44 of the dispensing tip 40 is flat on the surface 12 and extends over the grating 14. While manual downward pressure is applied on the applicator device 16 in the direction of arrow "A" to cause the valve 34 to open and cause the filler / coater material 22 to flow into the tip body 40, the applicator device 16 moves in the direction of the arrow "B" "from the left start point of the grated 14 towards the right end point of the grated 14 allowing the filler / casing material 22 to fill and cover the grated 14. After filling the grated 14 a curing time of twenty minutes to a Ambient temperature of about 72 degrees Fahrenheit will be required before the plastic member 10 can be released for use in production. By using the above applicator device 16 in the manner described, it has been found that the repaired area will comply with the specification of the Ford Motor Company ESA-M99J263-A. If for some reason, the procedure described above needs to be repeated because the repair was not performed properly, the filler / coater material 22 deposited on the surface 12 can be removed using the isopropyl alcohol mixture identified above. Although the present invention has been described in conjunction with a flexible plastic sheet or a liner covering an automobile part such as a decorative board or an instrument board, it will be understood that the plastic member can take the form of a hard plastic or a part in flexible plastic as found in furniture, meeting structures, or other plastic parts that are not used in a car. Also, it can be understood that the dispensing tip 40 must be made of a fibrous material which has sufficient stiffness to withstand the downward pressure applied to open the valve 34 while at the same time having a sufficient porosity and density of the type which allows the filler / coater material 22 to flow through the body of the dispensing tip 40 and toward the terminal end of the tip 40 to apply a uniform coating on the damaged area of the plastic member. further, depending on the depth of the scratch, the applicator device 16 will have to pass more than once along the repair area to fill in the scratch and hide the damaged area. Various changes and modifications can be made in the apparatus and method described herein without departing from the spirit of the invention. Such changes and modifications are contemplated by the inventors and do not wish to limit it except for the scope of the appended claims.

Claims (21)

1. CLAIMS 1. A method for removing imperfections such as chipping, scratches, scratches, and discolorations located on the outer surface of a plastic member of a particular color using an applicator having a fibrous tip characterized by comprising the steps of: a. providing in the applicator a material transported in water of a single component of the same color as the particular color; b. select the part that has an imperfection; c. clean the imperfection with a damp cloth with a cleaning fluid in a way that leaves part of the cleaning fluid deposited on the imperfection; d. let the cleaning fluid deposited in the imperfection dry; and. filling the fibrous tip of the applicator with the material transported in water; F. moving the fibrous tip along the imperfection so that the material transported in water flows on the outer surface of the plastic member and completely covers the imperfection; and g. allow the material transported in water to heal and hide the imperfection.
2. 2. The method according to claim 1, characterized in that the single component water transported material contains a polymer such as vinyl.
3. 3. The method according to claim 2, characterized in that the plastic member is made of polyvinyl chloride. . The method according to claim 3, characterized in that the cleaning fluid is isopropyl alcohol. 5. The method of compliance with the claim 1, characterized in that the cleaning fluid is a 50/50 mixture of MEK / Toluol. 6. The method of compliance with the claim 5, characterized in that the adhesive promoter is deposited on the imperfection after the cleaning fluid deposited in the imperfection has dried. 7. The method of compliance with the claim 6, characterized in that the plastic member is made of thermoplastic olefin. 8. The method of compliance with the claim 6, characterized in that the plastic member is made of acrylonitrile-butadiene styrene. The method according to claim 6, characterized in that the plastic member is made of thermoplastic elastomer. 10. A method for removing imperfections such as chips, scratches, scratches and discolorations located on the outer surface of a plastic member of a particular color, which uses an applicator device having a fibrous tip which allows the material transported in water to flow into the tip when pressure is applied to it characterized in that it comprises the steps of: a. providing in the applicator a material transported in water of a single component of the same color as the particular color; b. select the part that has an imperfection; c. clean the imperfection with a damp cloth with a cleaning fluid in a way that leaves part of the cleaning fluid deposited on the imperfection; d. let the cleaning fluid deposited in the imperfection dry; and. pressing the fibrous tip of the applicator against the imperfection to cause the material transported in water to flow into that fibrous tip; F. moving the fibrous tip along the imperfection so that the material transported in water flows on the outer surface of the plastic member and completely covers the imperfection; and g. allow the material transported in water to heal and hide the imperfection. The method according to claim 10, characterized in that the waterborne material of the single component comprises a polymer such as vinyl; The method according to claim 10, characterized in that the plastic member is an interior decoration part of the automobile. The method according to claim 10, characterized in that the plastic member is made of polyvinyl chloride. The method according to claim 13, characterized in that the cleaning fluid is isopropyl alcohol. 15. The method of compliance with the claim 10, characterized in that the cleaning fluid is a 50/50 mixture of MEK / Toluol. 16. The method of compliance with the claim 15, characterized in that an adhesive promoter is deposited on the imperfection after the cleaning fluid has dried on the imperfection; 17. The method of compliance with the claim 16, characterized in that the plastic member is made of thermoplastic olefin. 18. The method according to claim 16, characterized in that the plastic member is made of acrylonitrile-butadiene styrene. 19. The method according to claim 16, characterized in that the plastic member is made of thermoplastic elastomer. 20. In combination with an applicator device for hiding imperfections in the external appearance surface of a plastic member, such an applied device includes a dispenser assembly, a plastic tubular member connected to the dispenser assembly and serving as a reservoir, a material transported in water of single component is located in the reservoir, the dispenser assembly has a plastic cylindrical body portion, the rear end of which is secured to the tubular member, the front end of the body portion has the inner part which is formed with a section of guide, a dispensing tip made of a fibrous material located within the guide section and having a portion thereof extending outwardly from the front end of the cylindrical body portion, a fluid control device placed in the body portion cylindrical and having a spring-loaded valve to control the flow of the material transported in water from the reservoir to the guide section, the inner end of the dispensing tip makes contact with the valve and causes the valve to open so that the material transported in water flows from the reservoir to the guide section and saturates the dispensing tip when the outer end of the tip is pressed against the imperfection in the appearance surface of the plastic member, the viscosity of the material transported in water and the density and porosity of the fibrous material is such that the material transported in water flows to through the tip at a desired speed on the liner of the plastic member while the tip is manually pressed against the imperfection and at the same time the dispensing tip has sufficient rigidity to withstand the applied downward pressure to open the valve. 21. The combination according to claim 20, characterized in that the single component water transported material contains a polymer such as vinyl.