Material for filling cracks or gaps and methods of applying same

• US 20040238556A1
• Filed: 03/12/2004
• Published: 12/02/2004
• Est. Priority Date: 09/15/2001
• Status: Abandoned Application

• Current Assignee: Kevin Griff George
• Original Assignee: Kevin Griff George
• Inventors: George, Kevin Griff
• Application Number:
  US10/489,689
• Publication Number:
  US 20040238556A1
• Time in Patent Office: Days
• US Class Current: 221/96
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/24 porous, e.g. foamed glass
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 16/04 Macromolecular compounds C04B16/02 takes precedence
• CPC Class Codes: C04B 2111/00672 Pointing or jointing materials
• CPC Class Codes: C04B 26/06 Acrylates
• CPC Class Codes: C09D 5/34 Filling pastes materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12

Abstract

Flexible filler for filling cracks, gaps or holes in masonry or a rendered finish on masonry, comprising a mixture of an acrylic caulk bulked up with a finely divided particulate material of a size to match the roughness of the surface around the crack gap or hole to be filled. The caulk and particulate material are mixed thoroughly to form a homogeneous mixture which is packed into a cylindrical cartridge having a nozzle through which the mixture can be forced when needed. Apparatus by which the contents of a conventional acrylic caulk filled cartridge can be replaced with the improved filler, comprising a holder for supporting the cartridge, means for forcing out the caulk contents of the cartridge into a container, means for adding particulate material to the caulk in the container, means for mixing the caulk and particulate material to form a homogeneous mixture, means for refilling the cartridge with at least some of the homogeneous mixture and means for reinserting a plunger into the cartridge, for subsequently forcing the filler from the cartridge to fill a crack, gap or hole.

Claims

1-46. -46. (Cancelled).

47. A flexible filler by which cracks, gaps or holes in masonry or a rendered finish can be filled prior to painting so as to hide the existence of the crack, gap or hole, comprising a mixture of an acrylic caulk and finely divided particulate material of a size to match the roughness of the surface around the crack gap or hole to be filled, wherein the caulk and particulate material are mixed thoroughly to form a homogeneous mixture and the mixture is packed into a tube having a nozzle through which the mixture can be forced by pressurising the contents of the tube.

48. A filler as claimed in claim 47 wherein the finely divided particulate material comprises sand.

49. A filler as claimed in claims 47 wherein 300 grams of moist sand is mixed with to 310 ml of Decorators Flexible Caulk.

50. A filler as claimed in claim 47 wherein the particulate material comprises particles of plastics material.

51. A filler as claimed in claim 50 wherein the plastics material is polyethylene or polypropylene.

52. A filler as claimed in claim 47 wherein the particulate material comprises finely chopped glass fibre strands.

53. A filler as claimed in claim 47 wherein the particulate material comprises microspheres of glass.

55. A cartridge when filled with a filler as claimed in claim 47 which further comprises a close fitting piston in the cartridge to the rear of the filler.

56. A cartridge of filler as claimed in claim 55 which further includes means by which air under pressure can be applied to the rear of the piston to pressurise the material ahead of the piston, to force it through the nozzle.

57. A method of filling a crack, gap or hole with filler from a tubular cartridge as claimed in claim 55 wherein the open end of the nozzle is located close to one end of the opening formed by a crack, gap or hole which is to be filled, and after pressurising the tube to cause the mixture of flexible caulk and particles to exit therefrom, the cartridge and nozzle is moved along the opening so that the mixture is forced therein.

58. A method as claimed in claim 57 wherein, prior to the filling step, the opening is prepared, as by brushing and if necessary by gouging or routing, so as to widen the entrance to the opening to assist in filling it with the mixture.

59. A method as claimed in claim 57 wherein the nozzle is positioned substantially perpendicular to the surface surrounding the opening which is to be filled, so that the mixture will tend to be forced deep into the opening.

60. A method as claimed in claim 57 wherein the opening has a significant length such as a crack in rendering or a gap around a window or door frame, and the nozzle is held at an acute angle to the surface containing the opening so as to point away from the direction of movement of the nozzle along the length of the opening.

54. A method of creating a flexible filler by which cracks, gaps or holes in masonry or a rendered finish on masonry can be filled prior to painting so as to hide the existence of the crack, gap or hole, comprising the steps of mixing flexible acrylic caulk and particulate material of a size to match the roughness of the surface around the crack, gap or hole, and in correct proportions, stirring thoroughly to form a homogeneous mixture, and packing the mixture in a tubular cartridge, from which it can be forced through a nozzle as required, just prior to application.

61. Apparatus to enable the contents of a conventional acrylic caulk filled cartridge to be replaced by a filler mixture by which cracks, gaps or holes in masonry or a rendered finish on masonry can be filled prior to painting and comprising a mixture of an acrylic caulk and finely divided particulate material of a size to match the roughness of the surface around the crack, gap or hole, comprising a holder for supporting the cartridge, ejector means for forcing out the caulk contents of the cartridge into a container, means for adding particulate material to the caulk in the container, mixing means for mixing the caulk and particulate material to form a homogeneous mixture, withdraw means for removing the plunger from the cartridge, filling means for refilling the cartridge with at least some of the homogeneous mixture and insertion means for reinserting the plunger into the cartridge.

62. Apparatus as claimed in claim 61 comprising a cartridge holder into which an acrylic caulk filled cartridge can be fitted, a cutting device for cutting off the sealed end of the nozzle, a push rod plunger and drive therefor adapted to act on a movable closure at the far end of the acrylic caulk filled cartridge to force the contents thereof through the nozzle, a first reservoir adapted to receive the ejected acrylic caulk, an elongate pin and drive therefor adapted to enter the nozzle after the cartridge has been emptied, to push the closure back along the cartridge and out of the said far end thereof, a second reservoir containing particulate material, mixing means for mixing the particulate material with the caulk in the first reservoir, a mixing aid such as a paddle or helical screw and a drive therefor to rotate the mixing aid in the first reservoir to thoroughly mix the acrylic caulk and the particulate material, and a feed by which the mixture is conveyed from the first reservoir to be forced into the open far end of the empty cartridge until it is full, insertion means for inserting the closure into the open end of the cartridge after it has been re-filled, and drive means to push the closure therealong until the contents are compacted and are ready for discharge through the nozzle.

63. A method of mixing ingredients to form a flexible filler by which cracks, gaps or holes in masonry or a rendered finish can be filled prior to painting, and storing same ready for use, comprising the steps of removing acrylic caulk from a pre-filled cartridge thereof, mixing water with particulate material, mixing the caulk, water and particulate material to form a homogeneous mixture and refilling the cartridge therewith, for subsequent dispensing through a nozzle attached to the end of the cartridge.

64. Apparatus for mixing ingredients in accordance with claim the method of 63 comprising a first reservoir for the caulk, a second reservoir of particulate material, a passage through which particulate material passes to be mixed with the caulk, a supply of water, a valve to control the flow of water into the second reservoir or into the passage and a region in which the caulk and particulate material are to be mixed, so that the particulate material is moistened before it is mixed with the caulk from the first reservoir, and a mixing aid to create a homogeneous mixture of the caulk and the particulate material.

65. A method of mixing ingredients to form a flexible filler by which cracks, gaps or holes in masonry or a rendered finish on masonry can be filled prior to painting, and which comprises a mixture of an acrylic caulk and finely divided particulate material of a size to match the roughness of the surface around the crack, gap or hole, wherein water is supplied to a mixing region before, during or after the supply of particulate material thereto, a mixing aid therein is operated to mix the water and particulate material, whereafter acrylic caulk is introduced into the mixing region for mixing therewith, to form a homogeneous mixture prior to being loaded into an empty cartridge.

66. A container filled with flexible filler by which cracks, gaps or holes in masonry or a rendered finish on masonry an be filled prior to painting, and comprising a mixture of an acrylic caulk and finely divided particulate material of a size to match the roughness of the surface around the crack, gap or hole, from which air is evacuated when it is sealed after filling (and resealed after use) to prevent the acrylic material from curing, as it will do if exposed to air.

67. A container filled with flexible filler by which cracks, gaps or holes in masonry or a rendered finish on masonry can be filled prior to painting, and comprising a mixture of an acrylic caulk and finely divided particulate material of a size to match the roughness of the surface around the crack, gap or hole, comprising a squeezable tube which can be systematically squeezed to move the mixture from one end to the other, to mix the caulk and particulate material to a smooth paste prior to discharging the mixture for filling an opening.

68. A flexible filler by which cracks, gaps or holes in masonry or a rendered finish on masonry can be filled prior to painting, which comprises a mixture of an acrylic caulk and finely divided particulate material of a size to match the roughness of the surface around the crack, gap or hole, wherein mixing the particulate material with the acrylic caulk bulks up the latter and results in a mixture having more body to it than does the basic acrylic caulk, so that the resulting mixture is thicker in consistency and will tend to remain where it is located in a crack, gap or hole.