The present invention is directed to an apparatus and method for applying coatings to various surfaces. The coatings can take many forms including but not limited to a protective coating, a decorative coating, a non-skid coating and a reflective coating. Similarly, the surface to be coated may take many forms including but not limited to offshore heliports, workboat walkways, airport runways, roadways, parking lots and bridge decks.
Coatings have been applied to various different surfaces for various reasons. Concrete and asphalt surfaces have been treated with various coatings to protect these surfaces from the effects of environmental and other exposures (e.g., ultraviolet light, water, aggressive chemical spills, and abrasion). The protective coatings include epoxy type coatings as well as a polymer modified cementitious compounds. One well-known protective coating is E-KRETE® manufactured by Polycon of Madison, Miss. Other coatings are designed to be reflective in nature. For example, directional indicia including arrows are formed on roadways, parking lots and other areas to provide instructions to a vehicle operator and/or a pedestrian. These directional indicia include a reflective material (e.g. glass beads) so that the directional indicia can be readily seen. The reflective material is adhered to the road surface by a suitable binder. Other coatings are designed to form a non-skid surface on various structures including but not limited to offshore heliports, workboat walkways, airport runways, roadways, or bridge decks.
Depending on the coating to be applied as well as the structure or surface to be coated, the application process may vary significantly. For example, in the case of a reflective coating, it is essential that the reflective material be properly bound to a surface without completely covering the reflective material so that the reflective coating can properly function. The reflective coating is typically applied in at least two steps. The binder is initially applied to the surface to be coated and then the reflective material is broadcast over the binder to adhere the reflective material to the surface to be coated without completely covering the reflective material. In the case of non-skid surfaces, the aggregate must be embedded in the binder (e.g., epoxy or cementitious coating) so that the aggregate is not readily dislodged from the binder. Non-skid surfaces of the epoxy type have been applied in several steps. In the first step, the binder or wet material is rolled out on the desired surface. Subsequently, sand is broadcast by hand onto the wet material. The sand is then rolled into the binder or wet material to properly embed the sand to prevent it from being dislodged. Once the first coat of binder or wet material has dried, a second coat of the binder is sprayed over the first coat to encapsulate and lock-in the sand.
It is desirable to provide a single device that can apply different coatings in different environments without significant modification thereof. Further, it is desirable to provide a device that reduces the steps necessary to apply a particular coating to a surface. Moreover, it is desirable to provide a device that is compact in size, portable and operable by a single individual so that a coating can be readily applied to constricted areas including but not limited to workboat walkways. It is further desirable to provide a applicator that applies particular materials to a surface to be coated in a uniform and consistent manner.
An object of a preferred embodiment of the present invention is to provide a novel and unobvious method and/or apparatus for applying a coating to a surface.
Another object of a preferred embodiment of the present invention is to provide an apparatus that is designed to apply different coatings in different manners without significant modification to the apparatus.
A further object of a preferred embodiment of the present invention is to provide a single step method of applying a non-skid coating to a surface.
Yet still another object of a preferred embodiment of the present invention is to provide an apparatus that can simultaneously apply an aggregate and a binder to a surface to be coated such that the aggregate becomes embedded in the binder upon impact with the surface to be coated.
Still a further object of a preferred embodiment of the present invention is to provide an apparatus that can apply two or more materials to a surface to be coated in at least two different manners (e.g., (i) materials simultaneously applied to the surface to be coated; and, (ii) one material applied first followed by application of one or more additional materials).
Another object of a preferred embodiment of the present invention is to provide a compact coating applicator that can be readily carried by an operator to apply various coatings in constricted areas.
A further object of a preferred embodiment of the present invention is to provide a coating applicator that includes a pressurized fluid system for supplying a first pressurized fluid to dispense a first material and a second pressurized fluid to dispense a second material where the first pressurized fluid is at a lower pressure than the second pressurized fluid.
Still a further object of a preferred embodiment of the present invention is to provide a coating applicator that includes a pressurized fluid system for supplying a first pressurized fluid to dispense a first material and a second pressurized fluid to both dispense a second material and agitate the first material where the first pressurized fluid is at a higher pressure than the second pressurized fluid.
It must be understood that no one embodiment of the present invention need include all of the aforementioned objects of the present invention. Rather, a given embodiment may include one or none of the aforementioned objects. Accordingly, these objects are not to be used to limit the scope of the claims of the present invention.
In summary, one embodiment of the present invention is directed to an apparatus for applying a coating to a surface. The apparatus includes a hopper assembly having a first compartment and a second compartment operably associated with the first compartment. The first compartment is configured to receive and store an aggregate. The second compartment is configured to receive and store a coating substance. The hopper assembly is further configured such that the aggregate does not mix with the coating substance when the aggregate and the coating substance are stored in the first compartment and the second compartment, respectively. The apparatus further includes means for simultaneously dispensing the aggregate and the coating substance from the first compartment and the second compartment so that at least a portion of the aggregate stored in the first compartment mixes with the coating substance after the aggregate and the coating substance are dispensed from the first compartment and the second compartment, respectively.
Another embodiment of the present invention is directed to an apparatus for applying a coating to a surface. The apparatus includes a hopper assembly having a first compartment and a second compartment operably associated with the first compartment. The first compartment is configured to receive and store a first material. The second compartment is configured to receive and store a second material. The first material is different from the second material. A first applicator gun operably associated with the first compartment for dispensing the first material from the first compartment and onto a surface to be coated. A second applicator gun is operably associated with the second compartment for dispensing the second material from the second compartment and onto a surface to be coated. The apparatus further includes a support member for supporting the hopper assembly, the first applicator gun and the second applicator gun about an individual's body to allow the individual to carry the hopper assembly, the first applicator gun and the second applicator gun while material is being dispensed from the hopper assembly.
A further embodiment of the present invention is directed to an apparatus for applying a coating to a surface. The apparatus includes a hopper assembly having a first compartment and a second compartment operably associated with the first compartment. The first compartment is configured to receive and store a first material. The second compartment is configured to receive and store a second material. The first material has at least one property different from the second material. A first dispenser operably associated with the first compartment for dispensing the first material from the first compartment and onto a surface to be coated. A second dispenser operably associated with the second compartment for dispensing the second material from the second compartment and onto a surface to be coated. The second dispenser is disposed relative to the first dispenser such that the second material mixes with the first material upon contacting a surface to be coated.
Still another embodiment of the present invention is directed to a method for applying a coating to a surface. The method comprises the steps of: (a) providing a hopper assembly having a first compartment and a second compartment connected to the first compartment, the first compartment is configured to receive and store an aggregate, the second compartment is configured to receive and store a coating substance, the hopper assembly is further configured such that the aggregate does not mix with the coating substance when the aggregate and the coating substance are stored in the first compartment and the second compartment, respectively; (b) providing at least a first dispenser for dispensing the aggregate and the coating substance from the first compartment and said the compartment; and, (c) simultaneously dispensing the aggregate and the coating material from the hopper assembly such that the coating material encapsulates at least a portion of the aggregate.
Yet another embodiment of the present invention is directed to an apparatus for applying a coating to a surface. The apparatus comprises a hopper assembly having a first compartment and a second compartment operably associated with the first compartment. The first compartment is configured to receive and store a first material. The second compartment is configured to receive and store a second material. The first material is different from the second material. A first applicator gun is operably associated with the first compartment for dispensing the first material from the first compartment and onto a surface to be coated. A second applicator gun is operably associated with the second compartment for dispensing the second material from the second compartment and onto a surface to be coated. The apparatus further includes a pressurized air system for providing pressurized air to the first applicator gun and pressurized air to the second applicator gun wherein pressurized air directed to the first applicator gun is at a different air pressure than pressurized air directed to the second applicator gun.
Yet still a further embodiment of the present invention is directed to a method of applying a non-skid coating to a surface. The method comprises the steps of: (a) providing a hopper assembly having a first compartment and a second compartment connected to the first compartment, the first compartment is configured to receive and store an aggregate, the second compartment is configured to receive and store a coating substance, the hopper assembly further includes at least a first dispenser for dispensing the aggregate and the coating substance from the first compartment and the second compartment; and, (c) dispensing the aggregate from the first compartment; and, (d) during step (c) dispensing the coating substance from the second compartment.
A further embodiment of the present invention is directed to an apparatus for applying a coating to a surface including a hopper assembly having a first compartment and a second compartment operably associated with the first compartment. The first compartment is configured to receive and store a first material. The second compartment is configured to receive and store a second material. The hopper assembly is further configured such that the first material does not mix with the second material while the first material and the second material are stored in the first compartment and the second compartment, respectively. The apparatus further includes a dispenser system for dispensing the first material and the second material from the first compartment and the second compartment, respectively. The dispenser system is configured to simultaneously dispense the first material and the second material from the first compartment and said second compartment. The dispenser system further is configured to dispense one of the first material and the second material from a corresponding compartment without dispensing the other of the first material and the second material from a corresponding compartment.
The most preferred form of the invention will now be described with reference to
Referring to
Referring to
Mixing assembly C preferably includes a pneumatic motor 10 and an agitator 12 operably connected thereto. In the embodiment depicted in
Pneumatic spray guns 14 and 16 are connected to compartments 2 and 4, respectively by rubber hoses 18 and 20. Rubber hose 18 is removably connected at one end to outlet 22 of compartment 2 and removably connected at the other end to feeding chamber 24 (shown in
The inner workings of guns 14 and 16 are the same and, therefore, only one will be described in detail. Referring to
As seen in
A single fluid source (e.g., a single air compressor) maybe used to supply a pressurized fluid to guns 14 and 16 and motor 10. A manifold 44 and valves 46,48 and 50 may be used to vary the pressure of the fluid provided to guns 14 and 16 and motor 10. Valve 46 controls the flow of pressurized fluid (e.g., air) to gun 14. Valve 48 controls the flow of pressurized fluid (e.g., air) to motor 10. Valve 50 controls the flow of pressurized fluid (e.g., air) to motor 10. It should be noted that the applicator A may include pressure gauges to indicate the particular pressure of the fluid being supplied to guns 14 and 16 and motor 10. Alternatively, separate fluid sources (e.g., multiple air compressors) may be provided to accommodate any variance in pressure needed to operate guns 14 and 16 and motor 10.
Applicator A can be operated in different manners to apply different coatings. For example, where applicator A is used to apply a non-skid coating, compartment 2 is filled with a suitable coating material (e.g., E-KRETE®) manufactured by Polycon of Madison, Miss. while compartment 4 is filled with aggregate (e.g., sand). Valves 46, 48 and 50 are adjusted such that air is supplied to motor 10 and gun 16 at approximately 60 psi while air at approximately 80 psi is supplied to gun 14. The operator simultaneously pulls the triggers of guns 14 and 16 to simultaneously dispense the aggregate and coating materials from compartments 4 and 2, respectively. The orientation of the nozzles of guns 14 and 16 in the manner depicted in
For other coatings it may not be necessary or desirable to encapsulate or completely embed one material in another material. For example, applicator A can be used to form a reflective coating on a surface. In this instance, gun 16 is reoriented such that it points straight down (i.e., not titled toward gun 14). Compartment 2 can contain the same coating material (e.g., E-KRETE®) while compartment 4 would contain glass beads or other reflective material. The coating material include a color pigment to provide a colored reflective surface (for example, red or yellow directional arrows on a roadway). In this instance, the operator would first engage only gun 14 to apply the coating material from compartment 2 onto the surface to be coated. After the coating is applied to the surface, the operator would engage only gun 16 to dispense the glass beads over the coating so that the glass beads are adhered to the surface by the coating while a portion thereof is still exposed to provide the necessary reflection when illuminated. As is readily apparent from the above discussion, applicator A can simultaneously dispense two materials or one material at a time. It will be readily appreciated that the applicator of the present invention is not limited to non-skid or reflective coatings. Rather, the present invention could be used to protective coatings, decorative coatings, etc.
While this invention has been described as having a preferred design, it is understood that the preferred design can be further modified or adapted following in general the principles of the invention and including but not limited to such departures from the present invention as come within the known or customary practice in the art to which the invention pertains. The claims are not limited to the preferred embodiment and have been written to preclude such a narrow construction using the principles of claim differentiation.