2. Description of the Prior Art The prior art related to packaging for multi-component materials is relatively crowded. Representative patents generally related to packaging for dual component materials include U. S. Patent No. 1,698,404, issued January 8,1929 to N. M. Hopkins ; U. S. Patent No. 3,266,671, issued August 16,1966 to K. Gelpey; U. S. Patent No.

3,302,832, issued February 7,1967 to K. V. Hardman et al.; U. S. Patent No. 3, 323,682, issued June 6,1967 to A. M. Creighton, Jr., et al.; U. S. Patent No. 3,813,011, issued May 28,1974 to Harrison et al.; U. S. Patent No. 3,976,223, issued August 24,1976 to Jass et al.; U. S. Patent No. 4,014,463, issued March 29,1977 to Hermann, U. S. Patent No.

4,147,282, issued April 3,1979 to Levy; U. S. Patent No. 4,240,566, issued December 23, 1980 to Bergman; U. S. Patent No. 4,340,154, issued July 20,1982 to VanManen; U. S.

Patent No. 4,366,919, issued January'4,1983 to Anderson; U. S. Patent No. 4, 370,062, issued January 25,1983 to Moody; U. S. Patent No. 4,432,469, issued February 21,1984 to Eble et al.; U. S. Patent No. 4,846, 373, issued July 11,1989 to Penn et al.; U. S. Patent

No. 4,901,888, issued February 20,1990 to Standlick; and U. S. Patent No. 5,004,125 issued April 2,1991 to Standlick.

The entire disclosures of each of the foregoing patents is hereby incorporated herein by this reference thereto.

The aforementioned U. S. Patent No. 3,323,682, issued June 6,1967 to A. M.

Creighton, Jr., et al. discloses a disposable cartridge adapted for use with a conventional caulking gun and including a cylindrical exterior shell enclosing two collapsible tubes each of semi-cylindrical shape and filled with and separately containing two diverse dispensable ingredients, such as an epoxy resin and a hardener.

SUMMARY OF THE INVENTION The present invention provides an improved cartridge for the storage, packaging, and dispensing of multi-component systems such as dual component adhesives, sealants, and the like which includes a support member preferably secured to end portions of a pair of flexible bags disposed within a shell member of the cartridge, with openings of the support member disposed in alignment with end portions of the flexible bag and dispensing openings in an end cap of the cartridge to enable a user to dispense the contents of the flexible bags from the cartridge for mixing in a static mixing nozzle. The cartridge may employ various alternative plunger configurations designed to afford clearance space for the collapsible flexible bags during use and to maintain proper orientation of the plunger with the shell member of the cartridge. In a method of filling the cartridge, a vacuum fixture applies a vacuum to one end of the flexible bag in the cartridge, while the flowable material is introduced through an opposite open end of the

bag. In contrast to conventional methods of filling cartridges from the lower end while an upper end cap is secured to the cartridge, the present method permits the bag to be filled at an upper end of the cartridge and thereafter installing the end cap.

These and various other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view, partially cut-away and in cross-section, illustrating a dual component cartridge according to a first embodiment of the present invention.

Figure 2 is an explodedperspectiveview illustratingthe dual component cartridge of Figure 1.

Figure 3 is a perspective view, partially cut-away and in cross-section, illustrating a dual component cartridge according to a second embodiment of the present invention.

Figure 4 is an exploded perspective view illustrating the dual component cartridge of Figure 3.

Figure 5 is a perspective view, partially cut-away and in cross-section, illustrating a dual component cartridge according to a third embodiment of the present invention.

Figure 6 is an exploded perspective view illustrating the dual component cartridge of Figure 5.

Figure 7 is a perspective view, partially cut-away and in cross-section, illustrating a dual component cartridge according to a fourth embodiment of the present invention.

Figure 8 is an exploded perspective view illustratingthe dual componentcartridge of Figure 7.

Figure 9 is a bottom plan view of a nozzle connection end cap portion of a dual component cartridge according to the present invention.

Figure 10 is a longitudinal cross-sectional view taken along line 10-10 of Figure 9.

Figure 11 is a longitudinal cross-sectional view taken along line 11-11 of Figure 9.

Figure 12 is a top plan view of a cartridge according to the present invention.

Figure 13 is a longitudinal cross-sectionalview taken along line 13-13 of Figure 12.

Figure 14 is a longitudinal cross-sectional view taken along line 14-14 of Figure 12.

Figure 15 is a perspective view illustrating the cartridge end portion shown in Figure 12.

Figure 16 is a perspective view illustrating the nozzle connection end cap shown in Figure 9.

Figure 17 is an exploded perspective view illustratingthe manner of assembly of a dual component cartridge and nozzle connection end cap according to the present invention.

Figure 18 illustrates a vacuum filling fixture for use in a method of filling a dual component cartridge according to the present invention.

Figure 19 is a perspective view illustrating a grooved plunger for use in connection with the present invention.

Figure 20 is a partial perspective view illustrating an alternative cartridge construction including internal plunger guide rails for use with the grooved plunger of Figure 19.

Figure 21 is a longitudinal cross-sectional view illustrating another alternative plunger for use with the present invention.

Figure 22 is a perspective view illustrating still another alternative plunger for use with the present invention.

Figure 23 is an exploded perspective view illustrating a dual component cartridge according to a further alternative of the invention, employing an integral dual-component flexible interior bag.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT (S) Referring now to the drawings, wherein like reference numerals designate corresponding structure throughout the views, and referring in particular to Figures 1 and 2, a cartridge 10 for dispensing dual component products such as adhesives and sealants according to a first embodiment of the invention includes a substantially cylindrical outer shell member 12 terminating at a distal end in a circular annular end face 14 formed with a central circular aperture 16. A substantially circular forward end cap 18 includes a generally cylindrical tubular connection member 20 upstanding centrally from a circular

planar surface 19 and subdivided internally by a diametrically extending central web 22 forming separated discharge passages 24 and 26, each having a substantially semi- circular cross-sectional shape, and adapted to dispense two separate components, for example, resin and hardener components of a conventional epoxy. The connection member 20 includes a threaded portion 28 adapted for selective connection to a mating threaded portion on a mixing nozzle during use of the cartridge 10.

A support ring 30 includes a central rib 32, extending across a diameter of the ring 30, forming two substantially symmetrical semi-circularopenings 34 and 36 disposed in alignment with respective generally semi-circular open forward ends 44 and 46 of a pair of generally semi-cylindrical flexible bags 40 and 42 disposed within the shell member 12.

The support ring 30 and rib 32 are preferably secured to edge portions of the bags 40 and 42 adjacent the open ends 44 and 46 of the bags 40 and 42 by heat welding, radio frequency welding, adhesives, mechanical fasteners, or by other suitable means. The upper surface of the rib 32 is preferably disposed in abutting alignment with the web 22, and is preferably also secured thereto, for example by heat welding, radio frequency welding, adhesives, mechanical fasteners, or by other suitable means. The end cap 18 may include an annular rim or shoulder 38 dimensioned for a close-conforming engagement with an outer peripheral surface of the support ring 30, and may be secured thereto by heat welding, radio frequency welding, adhesives, mechanical fasteners, or by other suitable means.

A cylindrical disk-shaped plunger 52 is received for longitudinal sliding movement within an open proximal end 13 of the shell 12, and is adapted for engagement

with a movable rod of a conventional caulking gun or other similar dispensing apparatus such that the exertion of axially directed force on the plunger 52 will dispense the contents of the flexible bags 40 and 42 through the forward open ends 44 and 46, through support ring openings 34 and 36, through the connection member passages 24 and 26, and subsequently through an open tip portion of a mixing nozzle. In the embodiment shown in Figure 1, the plunger 52 includes a conical recess 53 dimensioned and disposed to provide some degree of clearance space to receive at least a portion of the bags 40 and 42 as they collapse during dispensing.

The various components of the cartridge 10 may be formed from a variety of plastic fabrication techniques, including casting, extrusion, injection molding, blow molding, and rotational molding.

A variety of modifications and options may be employed in connection with the dual component cartridge according to the present invention. The various openings 24, and open ends 44,46 may be varied in size and/or shape to regulate the amount and relative proportions of product components dispensed from the bags 40 and 42. The various parts of the cartridge 10 are preferably formed from suitable plastic materials so as to be of a low-cost construction, and suitable for recycling. All or some of the various components and 52 of the cartridge 10 may be reusable, or all or some may be designed to be discarded or recycled after use.

Figures 3 and 4 illustrate a dual component cartridge 10'according to a second embodiment of the invention, which differs from the cartridge 10 shown in Figures 1 and 2 principally in the provision of closed end faces 44'and 46'on the forward ends of the bags 40 and 42 and the omission of the support ring 30. Instead, the cartridge 10'

employs a direct interface of the end faces 44'and 46'of the bags 40 and 42 with the end cap 18. This may be accomplishedin a variety of differentways within the scope of the present invention. The central web 22 of the connection member 20 may extend slightly into a space 47 between the bags 40 and 42, with the inner surface of the end cap 18 and the annular shoulder 3 8 engaging the bag faces 44'and 46'. Additionally, all or parts of the end cap 18, web 22, and shoulder 38 may be secured to the bags 40 and 42 by heat welding, radio frequency welding, adhesives, mechanical fasteners, or by other suitable means. With reference to Figure 4, the web 22 may have a stepped width or T-shaped configuration, with a reduced width portion disposed within the connection member 20 and an enlarged width portion spanning all or a substantial portion of the diametrical extent or length of the slight gap or space 47 between the bags 40 and 42.

A suitable tool may be provided for puncturing the forward end faces 44 and 46 of the bags 40 and 42 prior to use to allow dispensing of the contents thereof.

Alternatively, the end cap 18 or mixing nozzle (not shown) may include projections or sharpened edges adapted to automatically puncture the end faces 44'and 46'upon use of the cartridge 10. Alternatively, the end faces 44'and 46'may be formed of a reduced thickness material or with preformed perforations such that all or portions of the end faces 44'and 46'tear open upon application of pressure to the bags 40 and 42 by the plunger 52.

The dual component cartridge according to the present invention may be employed with a variety of conventional static mixing nozzles. Examples of suitable static mixing nozzles include those sold under the trademark STATOMIX by ConProTec,

Inc. of Salem, New Hampshire and those sold under the trademark Sulzer Quadro by Sulzer Chemtech Ltd of Winterhur, Switzerland.

Figures 5 and 6 illustrate a dual-component cartridge 10"according to a third embodiment of the invention, having as a principal distinctive feature the disposition of flexible bags 40'and 42'in coaxial relation within the shell 12. Toward this end, the inner 42'and outer 40'bags may each comprise substantially cylindrical tubes having different diameters, with the outer bag 40'formed as double walled annular section of a cylinder, having a hollow core portion dimensioned for reception of the inner bag 42' therein.

In this construction, the cartridge 10"includes a modified support ring 30'which additionally includes a reduced diameter inner ring 33 supported centrally from the outer ring 30'by a plurality of radial struts 35,37, and 39. As shown in Figure 5, the outer ring 30'is dimensioned and disposed for alignment with the distal end face 44"of the outer bag 40'and the inner ring 33 is dimensioned and disposed for alignment with the distal end face 46"of the inner bag 42'. As in the previously described embodiments, all or portions of the parts 33,40'and 42'may be secured by heat welding, radio frequency welding, adhesives, mechanical fasteners, or by other suitable means.

To facilitate even dispensing of the components from the outer 40'and inner 42' bags, the end cap 18 may optionally include baffles or additional web or rib portions adapted and disposed for directing materials flowing through the outer 30'and inner 33 support rings to the nozzle connection member 20.

Figures 7 and 8 illustrate a dual component cartridge 10"'according to a fourth embodiment of the present invention which differs from the embodiment 10 shown in

Figures 1 and 2 principally in that the shell member 12 terminates at a distal end in a circular open end portion 14', instead of a partially closed end face 14 shown in Figure 1. In this alternative construction, the support ring 30 may be integrally formed adjacent the distal end 14'of the shell member 12, or alternatively may be a separate piece secured to the bags 40 and 42 and/or the end cap 18 and shell member 12. As shown in Figure 7, the support ring 30 may extend slightly axially outwardly from the open distal end 14'of the shell member 12, providing a ledge or shoulder dimensioned for engagement with the annular shoulder 38 of the end cap 18. Preferably, the central rib 32 in the embodiment 10"'is formed integrally with the shell member 12.

With reference to Figures 9,10,11, and 16, an alternative construction of the end cap 18'may include a centrally depending pin 27 disposed on the web 22 and terminating in a frusto-conical portion adapted for snap type engagement with a complementary aperture or socket 29 formed centrally on the central transverse rib 32'of the support ring 30 disposed on, secured to, or integrally formed with the distal end 14 of the shell member 12', as shown in Figures 12,13,14, and 15. In this alternative construction, the end cap 18 may also be fastened to one or more of the ring 30 and shell member 12 by heat welding, radio frequency welding, adhesives, mechanical fasteners, or by other suitable means.

Figure 17 illustrates an example construction of the cartridge 10 in which dotted lines A and B illustrate an example manner of securement of the bags 40 and 42 to the support ring 30 by heat welding, radio frequency welding, adhesives, mechanical fasteners, or by other suitable means. With reference to Figure 17, axial movement of the plunger 52 (not shown in Figure 17) will cause dispensing of the contents of the bags

40 and 42 through respective bag end openings 44 and 46, through support ring openings 34 and 36, and through aligned openings 24 and 26 of the nozzle connection member 20.

Toward this end, the connection member 20 preferably includes a closed end portion 21 (Figures 10 and 11) adapted to be punctured or severed by a user prior to use. With continued reference to Figure 17, abutting alignment of the web 22 with the rib 32' maintains separation of the components from the bags 40 and 42 until the components flow out of the nozzle connection member 20 and into a mixing nozzle (not shown).

Figure 18 illustrates a vacuum fixture 100 for use in an example method of filling the flexible bags 40 and 42 disposed within a cartridge 12. In this method, a vacuum is applied to a temporarily open end portion of the shell member 12 by means of a vacuum port 102 communicating with a port 104. The application of a vacuum to one end of the shell member 12 maintains the bags 40 and 42 (not shown) in a fully inflated condition (thereby eliminating folds, wrinkles, twists, and other volume-diminishing irregularities that are prevalent in thin, flexible membranes) and facilitates filling of the bags with relatively viscous materials such as components of adhesives and sealants through the open opposite ends of the bags. The ends of the bags 40 and 42 disposed closest to the vacuum port 102 are sealed, while flowable material is introduced through the opposite open ends 44 and 46.

The flexible bags may have end portions sealed with a flexible plastic material the same as that used to form the body portions of the bags. Alternatively, one or both ends of the bags may be left open and sealed with a rigid plastic member, such as a circular inner surface 19 of the end cap 18 (Figures 10,11, and 16) and/or an inner surface of the plunger 52. In any event, one aspect of the invention involves a method

of filling one or both of the flexible bags 40 and 42 by applying a vacuum to the shell member 12, while filling open ends or open end portions of the bags with a viscous material such as a component of an epoxy, sealant, or adhesive, and subsequently sealing both ends of the bags using a rigid or flexible plastic material.

Figures 19 and 20 illustrate an alternative plunger 52'for use with a dual component cartridge according to the present invention, in which the plunger 52'includes a central groove 60 which may extend across an end face of the plunger and along opposite sidewall portions thereof, forming semi-circularportions 55 and 57 adapted for abutment with the end faces 48 and 50 of the bags 42 and 44 (Figure 2, for example).

The bag end faces may be disposed in abutment with the respective portions 55 and 57.

The modified plunger 52'shown in Figure 19 is preferably employed in combinationwith a modified shell member 12"'shown in Figure 20. The shell member 12"'includes a pair of diametrically opposed longitudinally extending guide rails 62 and 64 each dimensioned and disposed for engagement with the groove 60 (Figure 19) extending along opposite sidewall portions of the plunger 52'. By virtue of engagement of the guide rails 62 and 64 with the groove 60 upon insertion of the plunger 52'through the open end 13 of the shell member 12"', the plunger 52'is prevented from becoming canted, cocked or otherwise misaligned with the shell 12.

Figure 21 illustrates another alternative plunger 52"disposed within a shell member 12, in which the plunger 52"comprises a centrally disposed, transversely extending circular floor portion 70 including a pair of axially, oppositely directed cup- shaped skirt portions 72 and 74. The axially proximal skirt 72 is initially disposed adjacent the open end 13 of the shell member 12 and is adapted for engagement with a

ram end portion of a conventional caulking or other type dispensing gun. The axially distal skirt 74 is adapted to receive and substantially surround end portions of the flexible bags 40 and 42 (not shown) disposed within the shell member 12. The axial extent of the skirt 74 forms a cup or well adapted to receive at least a portion of the collapsed bags 40 and 42 upon use, so as to permit the plunger 52"to be advanced substantially the entire length of the shell member 12 so as to permit substantiallythe entire contents of the bags 40 and 42 to be dispensed. In the absence of provision of a receptacle or well for receipt of at least a portion of the collapsed bags 40 and 42, the collapsing bags may jam or otherwise inhibit advancement of the plunger along substantially the entire axial extent of the shell member 12, thus leaving a portion of the contents of the bags 40 and 42 unavailable for use.

Figure 22 illustrates another alternative plunger 52"'having an axially forward or distal end face provided with a plurality of intersecting angular facets 82 and 84 forming a plurality of axially advanced, generally radially extending valley lines 86 and peak crests 88, and also including a central circular well or receptacle 80. The plunger 52"' also provides clearance space adapted to receive at least a portion of the collapsing bags 40 and 42 as the plunger 52"'is advanced axially within the shell member 12 to dispense the contents of the tubes 40 and 42. The plunger 52"'also provides axially leading protrusions or ridges that serve to compress and dispense the last remaining contents from the flexible bags 40 and 42, while at the same time affording clearance space to receive at least a portion of the collapsing bags.

Various other alternative plunger constructions are contemplated within the scope of the present invention. For example, the plunger 52"of Figure 21 may be constructed

with one or more of the skirts 72 and 74 detachable when a predetermined force is exceeded. For example, the floor 70 may break away at its outer peripheral edge from the skirt 74, to provide an indication of an advanced axial position of the plunger to a user, and to permit continued advancement of the plunger 52"to dispensing the last remaining contents. Toward this end, the peripheral edge of the floor 70 may be scored, perforated, or formed with a reduced thickness at its juncture with the skirt 74.

The various plunger constructions according to the present invention solve, or at least substantially mitigate potential problems with convention cylindrical disk shaped plungers. First, conventional plungers do not afford clearance space for collapsing flexible bags, thus preventing complete dispensing of the bag contents. Second, conventional plungers can tilt or rotate, which, in the case of dual component systems, can result in the uneven dispensing of the two separate components, spoiling the designed mixing ratios and deterioratingthe physical and chemical characteristics of the resulting applied product. Third, extreme tilting or canting of the plunger may jam the cartridge entirely, leaving the remaining contents unusable.

As shown in Figure 23, an alternative dual component cartridge according to the present invention employs an integral construction of the flexible bags 40"and 42"in which a central membrane or dividing wall 45 separates the interior portions of the bags 40"and 42". An upper end of the wall 45 forms an enlarged sealing flange 45'disposed between the open upper ends 44 and 46 of the bags 40"and 42". In an assembled condition, the upper face of the flange 45'is preferably affixed to the transverse rib 32 of the shell member 12.

It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts or types of material within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.