Patent US5057348A successfully refreshed from Google Patents.
US5057348A
Expired / Lapsed
US
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Potted electrical/mechanical devices, and dual cure potting method
Assignee: Henkel Loctite Corp
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Filing: 1990-07-25
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Granted: 1991-10-15
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Expires: 2010-07-25
Abstract
Abstract A device e.g., an electrical or electromechanical assembly (62), comprising a housing (64) with a mechanism (66) disposed therein which is potted by a cured mass of self-leveling liquid composition. The composition comprises an actinic radiation cured first resin component (102) preferably (methacrylate resins, which immobilize the partially cured mass, and a subsequently cured second resin component (100), preferably epoxy resins, which is non-cured under the actinic radiation but curable at ambient or elevated temperature. Depending on the depth of the composition which is to be cured in the housing, it may be desirable to utilize the self-leveling liquid composition as either a single homogeneous mixture of the first and second resin components, or, where the depth of the housing is greater than the depth of UV penetration, as cured mass wherein the first resin component is in a separate and discrete resin layer overlying a lower resin layer containing the second resin component but not the first resin component.
Inventors
- 👤 Kieran F. Drain
- 👤 Larry A. Nativi
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 15:50
CPC Classifications
H; H01; H01G; H01G2/00; H01G2/12; B; B29; B29C; B29C35/00; B29C35/02; B29C39/00; B29C39/02; B29C39/10; B29C70/00; B29C70/68; B29C70/72; C; C08; C08F; C08F283/00; C08F283/10; C08G; C08G59/00; C08G59/18; C08G59/40; C08G59/50; C08G59/56; C08G59/58; C08G59/68; C08L; C08L63/00; G; G01; G01F; G01F15/00; G01F15/006; G03; G03F; G03F7/00; G03F7/004; G03F7/039; H01B; H01B3/00; H01B3/18; H01B3/30; H01B3/302; H01B3/40; H01B3/44; H01C; H01C1/00; H01C1/02; H01C1/028; H01C1/034; H01G9/00; H01G9/004; H01G9/08; H05; H05K; H05K5/00; H05K5/0091; H05K5/0095; B29C35/08; B29C35/0805; B29C2035/0827; B29C2035/0833; B29C2791/00; B29C2791/001; B29K; B29K2033/00; B29K2033/04; B29K2033/08; B29K2063/00; B29K2105/00; B29K2105/0088; B29L; B29L2031/00; B29L2031/34; B29L2031/3406; H05K3/00; H05K3/22; H05K3/28; H05K3/284; H05K3/285; H05K3/287; Y; Y10; Y10S; Y10S428/00; Y10S428/901; Y10S428/913; Y10T; Y10T428/00; Y10T428/23; Y10T428/239; Y10T428/24; Y10T428/24802; Y10T428/24917; Y10T428/31504; Y10T428/31511; Y10T428/31551; Y10T428/31678; Y10T428/31692; Y10T428/31786
Claims Analysis
Total Claims: 42
Claim 1
Independent Claim
197 words
A device comprising a housing containing a mechanism potted therein by a cured mass of a self-leveling liquid composition; the cured mass including a separate and discrete overlying layer comprising an actinic radiation cured first resin component, and an underlying layer comprising a second, ambient temperature curable resin component which is non-cured under actinic radiation conditions effective for curing the first resin component, and with the underlying layer not comprising the first resin component; wherein the layers have been formed by providing in the housing a first portion of the self-leveling liquid components comprising a second resin component but not the first resin component, to form a first self-leveling liquid layer, and a second portion of the self-leveling liquid layer, and a second first component, to form a separate and discrete second self-leveling liquid layer on top of the first self-leveling liquid layer, and prior to curing of the second resin component, exposing the liquid composition to actinic radiation which is curingly effective for the first resin component, to form the overlying layer comprising the cured first resin component, above the uncured underlying layer comprising the second resin component, followed by curing of the second resin component.
Claim 2
Independent Claim
197 words
A device comprising a housing containing a mechanism potted therein by a cured mass of a self-leveling liquid composition; the cured mass including a separate and discrete overlying layer comprising an actinic radiation cured first resin component, and an underlying layer comprising a second, ambient temperature curable resin component which is non-cured under actinic radiation conditions effective for curing the first resin component, and with the underlying layer not comprising the first resin component; wherein the layers have been formed by providing in the housing a first portion of the self-leveling liquid components comprising a second resin component but not the first resin component, to form a first self-leveling liquid layer, and a second portion of the self-leveling liquid layer, and a second first component, to form a separate and discrete second self-leveling liquid layer on top of the first self-leveling liquid layer, and prior to curing of the second resin component, exposing the liquid composition to actinic radiation which is curingly effective for the first resin component, to form the overlying layer comprising the cured first resin component, above the uncured underlying layer comprising the second resin component, followed by curing of the second resin component.
Claim 3
Dependent Claim
40 words
A device according to claim 1, wherein the actinic radiation cured first resin component comprises a material selected from the group consisting of: (a) (meth)acrylic resins, (b) vinyl monomers, (c) unsaturated polyesters, solubilized in vinyl monomers, and (d) epoxy resins.
Claim 4
Dependent Claim
19 words
A device according to claim 1, wherein the actinic radiation cured first resin component comprises a (meth)acrylic acid ester.
Claim 5
Dependent Claim
19 words
A device according to claim 1, wherein the actinic radiation cured first resin component comprises a (meth)acrylic acid ester.
Claim 6
Dependent Claim
66 words
A device according to claim 1, wherein the cured second resin component is cured under ambient temperature curing conditions selected from one or more compatible conditions of the group consisting of: (a) moisture exposure, (b) reaction with curative species, (c) in situ formation of curative species, and (d) actinic radiation exposure differing from the actinic radiation exposure which is curingly effective for the first resin component.
Claim 7
Dependent Claim
25 words
A device according to claim 1, wherein the second resin component comprises a material selected from the group consisting of epoxy resins, silicones, and urethanes.
Claim 8
Dependent Claim
9 words
An electronic liquid flow sensor according to claim 1.
Claim 9
Dependent Claim
9 words
A printed circuit board element according to claim 1.
Claim 10
Dependent Claim
11 words
A printed circuit board comprising an element according to claim 1.
Claim 11
Dependent Claim
6 words
A potentiometer according to claim 1.
Claim 12
Dependent Claim
20 words
A device according to claim 1, wherein the thickness of the cured composition mass is greater than about 40 mils.
Claim 13
Dependent Claim
20 words
A device according to claim 1, wherein the thickness of the cured composition mass is greater than about 60 mils.
Claim 14
Dependent Claim
34 words
A device according to claim 1, wherein the second resin component comprises an epoxy resin, and the housing is formed of a material selected from the group consisting of polybutylene teraphthalate and polyphenylene sulfide.
Claim 15
Dependent Claim
29 words
A device according to claim 1, wherein the housing has an opening therein through which a structural element is extended and joined to the potted mechanism in the housing.
Claim 16
Dependent Claim
42 words
A device according to claim 1, wherein the concentration of the first resin component in the composition is from about 1 to about 50 percent by weight, based on the total weight of the first and second resin components in the composition.
Claim 17
Dependent Claim
42 words
A device according to claim 1, wherein the concentration of the first resin component in the composition is from about 1 to about 30 percent by weight, based on the total weight of the first and second resin components in the composition.
Claim 18
Dependent Claim
42 words
A device according to claim 1, wherein the concentration of the first resin component in the composition is from about 5 to about 20 percent by weight, based on the total weight of the first and second resin component in the composition.
Claim 19
Dependent Claim
42 words
A device according to claim 1, wherein the concentration of the first resin component in the composition is from about 5 to about 10 percent by weight, based on the total weight of the first and second resin components in the composition.
Claim 20
Dependent Claim
43 words
A device according to claim 1, wherein the specific gravity of said layer comprising said first resin component prior to its curing is from about 5 to about 95 percent of the specific gravity of the underlying layer comprising said second resin component.
Claim 21
Dependent Claim
18 words
A device according to claim 3, wherein said second resin component comprises an ambient temperature cure epoxy resin.
Claim 22
Dependent Claim
14 words
A device according to claim 1, wherein the underlying layer comprises an inert filler.
Claim 23
Dependent Claim
23 words
A device according to claim 1, wherein the thickness of the layer comprising the first resin component does not exceed about 120 mils.
Claim 24
Independent Claim
69 words
A device comprising a housing containing a mechanism potted therein by a dual layer cured mass of a self-leveling liquid composition comprising an actinic radiation cured first resin component in an upper layer which is initially cured, and a non-actinic radiation curable second resin component in a lower layer which is subsequently cured at ambient temperature conditions, wherein the thickness of the cured mass is at least 40 mils.
Claim 25
Independent Claim
69 words
A device comprising a housing containing a mechanism potted therein by a dual layer cured mass of a self-leveling liquid composition comprising an actinic radiation cured first resin component in an upper layer which is initially cured, and a non-actinic radiation curable second resin component in a lower layer which is subsequently cured at ambient temperature conditions, wherein the thickness of the cured mass is at least 40 mils.
Claim 26
Dependent Claim
58 words
A device according to claim 23, wherein the self-leveling liquid component contains the first and second resin components in sufficient amounts, viscosities, and specific gravities relative to one another as to cause said composition prior to curing thereof to separate into an overlying layer comprising the first resin component and an underlying layer comprising the second resin component.
Claim 27
Independent Claim
63 words
A device comprising a housing containing a mechanism therein in a partially cured potting mass formed from a self-leveling composition, and comprising a cured overlying solid layer comprising an actinic radiation cured first resin component, and an underlying uncured liquid layer comprising an ambient temperature curable second resin component which is non-curable under actinic radiation conditions effective for curing the first resin component.
Claim 28
Independent Claim
63 words
A device comprising a housing containing a mechanism therein in a partially cured potting mass formed from a self-leveling composition, and comprising a cured overlying solid layer comprising an actinic radiation cured first resin component, and an underlying uncured liquid layer comprising an ambient temperature curable second resin component which is non-curable under actinic radiation conditions effective for curing the first resin component.
Claim 29
Dependent Claim
40 words
A device according to claim 25, wherein the actinic radiation cured first resin component comprises a material selected from the group consisting of: (a) (meth)acrylic resins, (b) vinyl monomers, (c) unsaturated polyesters, solubilized in vinyl monomers, and (d) epoxy resins.
Claim 30
Dependent Claim
19 words
A device according to claim 25, wherein the actinic radiation cured first resin component comprises a (meth)acrylic acid ester.
Claim 31
Dependent Claim
64 words
A device according to claim 25, wherein the second resin component is curable under ambient temperature conditions selected from one or more compatible conditions of the group consisting of: (a) moisture exposure, (b) reaction with curative species, (c) in situ formation of curative species, and (d) actinic radiation exposure differing from the actinic radiation exposure which is curingly effective for the first resin component.
Claim 32
Dependent Claim
25 words
A device according to claim 25, wherein the second resin component comprises a material selected from the group consisting of epoxy resins, silicones, and urethanes.
Claim 33
Dependent Claim
18 words
A device according to claim 25, wherein said second resin component comprises an ambient temperature cure epoxy resin.
Claim 34
Dependent Claim
28 words
A device according to claim 25, wherein the thickness of the cured overlying layer comprising the actinic radiation cured first resin component does not exceed about 120 mils.
Claim 35
Dependent Claim
12 words
A device according to claim 25, comprising an electronic liquid flow sensor.
Claim 36
Dependent Claim
11 words
A device according to claim 25, comprising a printed circuit board.
Claim 37
Dependent Claim
11 words
A printed circuit board comprising a device according to claim 25.
Claim 38
Dependent Claim
9 words
A device according to claim 25, comprising a potentiometer.
Claim 39
Dependent Claim
21 words
A device according to claim 25, wherein the thickness of the partially cured potting mass is greater than about 40 mils.
Claim 40
Dependent Claim
21 words
A device according to claim 25, wherein the thickness of the partially cured potting mass is greater than about 60 mils.
Claim 41
Independent Claim
84 words
A device comprising a housing containing a mechanism potted therein by a cured mass of a self-leveling liquid composition comprising upper and lower layers, wherein the upper layer comprises a UV-curable acrylic resin and a room temperature curing epoxy resin, with the upper layer having a specific gravity in the range of from about 1.0 to 1.2, and a separate and discrete lower layer containing a room temperature curing epoxy and having a specific gravity in the range of from about 1.4 to 1.7.
Claim 42
Independent Claim
84 words
A device comprising a housing containing a mechanism potted therein by a cured mass of a self-leveling liquid composition comprising upper and lower layers, wherein the upper layer comprises a UV-curable acrylic resin and a room temperature curing epoxy resin, with the upper layer having a specific gravity in the range of from about 1.0 to 1.2, and a separate and discrete lower layer containing a room temperature curing epoxy and having a specific gravity in the range of from about 1.4 to 1.7.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1994-10-14 | 1995-04-15 | 1995-10-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-10-14 | 1999-04-15 | 1999-10-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-10-14 | 2003-04-15 | 2003-10-15 | $7700.00 | Window Closed / Lapsed |