Patent Grant
10265720
The present invention relates to a device and a method for coating material with resin and subsequently laying the material saturated with the resin onto a surface.
U.S. Pat. No. 3,148,105 discloses an apparatus for applying roofing materials. A sheet of webbing passes downward through a volume of asphalt in a container from a first roller to the bottom of a middle roller. The saturated material exits the container in an open top portion of the container. In a distance from the container, the material passes a space between a front roller and a scraper blade. In total the apparatus of U.S. Pat. No. 3,148,104 seems to be rather complex.
DE 20 2005 000952 U1 shows a similar concept as U.S. Pat. No. 3,148,104. DE 20 2005 000952 U1 discloses a method of laying saturated sheets on a roof or similar surface. The saturated sheets exit a container in an upper open region. After exiting the container, the sheet passes a pivotal rod. Also the structure of DE 20 2005 000952 U1 seems to be rather complex.
Within another technical field, U.S. Pat. No. 1,306,650 A discloses a process and apparatus for impregnating a strip of fragile body fabric with a character converting dope. However, U.S. Pat. No. 1,306,650 A is configured for another purpose and not suitable for “coating material with resin and subsequently laying the material saturated with the resin onto a surface”. In particular, U.S. Pat. No. 1,306,650 A is not particularly relevant for the context of the present invention.
WO 2015/063196 discloses a device and a method for saturating material with resin and subsequently laying the saturated material onto a surface. The device includes a frame and a vessel for retaining the resin attached to the frame. The vessel has a slot sized and configured so that material is passable through the slot after being coated with resin retained in the vessel. A first guide member is positioned adjacent the slot and a second guide member is positioned adjacent the slot and is spaced apart from the first guide member to define a passageway between the first and second guide members. The passageway is sized and configured for the material to be passed through the passageway and out of the device for laying on the surface. In this regard, there seems to be room for further improvement concerning smoothness and reliability of the process.
It is an object of the present invention to propose a device and a method for coating material with resin and subsequently laying the material saturated with the resin onto a surface which allows a reliable and simple regulation of a thickness of the material saturated with the resin.
According to a first aspect of the present invention, a device for coating material with resin and subsequently laying the material saturated with the resin onto a surface comprises a vessel for retaining the resin, the vessel having a slot sized and configured so that material is passable through the slot after being coated with resin retained in the vessel, and a first and a second roller being arranged on either side of the slot or behind the slot (in a moving direction of the unrolled material).
A core idea of the invention is to provide the two (first and second) rollers being arranged on either side of the slot or behind the slot (on an outer side of the vessel). Thereby, the saturated fabric can be simply and reliably guided onto the substrate surface. The (direct) travel path of the reinforcing fabric from the rollers to the substrate surface minimises deformation of the fabric. Moreover, the (minimal) distance from the underside of the first and second rollers (bottom rollers) to the substrate surface minimises air entrapment underneath the membrane and minimises the need for manually finishing. In particular, the first and second rollers (bottom rollers) can be positioned to minimise drag on the reinforcing fabric. The (first and second) rollers may define the slot and/or may be the parts of the device with which the material saturated with resin is last in contact when being laid onto the surface (i.e. in particular the parts of the device from which the material saturated with resin finally leaves the device). According to the invention, a fast, reliable coating of the material with resin and subsequently laying the material saturated with the resin onto a surface is achieved. The thickness of the material laid onto the surface is comparatively consistent. In particular, a drag on the reinforcing material is minimised.
The slot is preferably arranged within a wall, in particular bottom (wall) of the vessel. In embodiments, the slot may be provided in the lowest 80% preferably lowest 50%, further preferably lowest 20% of the vessel (in a configuration where the device can be used). Alternatively or in addition, the slot may be arranged below a liquid surface of the liquid in the vessel (during use).
The device may comprise a distance adjustment mechanism for adjusting a distance between the first and second rollers and/or a slot adjusting mechanism for adjusting the width of the slot, in particular by converging or diverging the rollers with respect to each other. The distance adjustment mechanism and the slot adjustment mechanism may be provided by the same structure or different (at least partially different) structures. In particular, if the two rollers define the slot, the distance adjustment mechanism and the slot adjustment mechanism may be identical (provided by one and the same structure). In such a case, the thickness of the material saturated with the resin can be reliably regulated. A (direct) travel path of the reinforcing fabric from the rollers to the substrate surface may minimise deformation of the fabric. A (minimal) distance from the underside of first and second rollers (bottom rollers) to the substrate surface may minimise air entrapment underneath the material saturated with the resin and may minimise that need for manual finishing. Moreover, uncontrolled resin leakage through the slot may be avoided.
In general, the rollers may be supported on the device (e.g. on the frame and/or the vessel) such that they may roll around their respective centre axis.
At least one of the rollers may be rotatably mounted on a frame of the device and/or on the vessel, wherein converging and/or diverging of the rollers is preferably performed by rotation of the only one or one of the several rotatable rollers. In this context, “rotatably mounted” means that the rollers are mounted such that they may rotate (pivot) around an axis which is offset from a central axis of the rollers. For example, the corresponding roller may be supported by at least one corresponding supporting structure (e.g. at least on supporting arm), wherein the supporting structure may be rotated. In particular, the rotation (pivoting) in this context does not mean a rolling motion of the first and/or second rollers. In an alternative, the rollers may be moveably mounted on the device (e.g. the frame and/or the vessel) so that they can be converged or diverged from each other by an (at least partially) translational movement. In any event, movement (pivoting) of the rollers allows a simple adjustment of the thickness of the material saturated with resin. This further improves the performance of the device.
The distance adjusting mechanism and/or the slot adjustment mechanism may comprise a handle and/or a cable. The cable may be pullable and/or pushable by the handle for adjusting the width of the slot. Moreover, one or more spring member(s) may be provided which may support adjustment of a distance between the first and second rollers and/or the width of the slot, respectively. In this regard, a simple and convenient actuation of the respective adjustment mechanism can be achieved.
Preferably, a first guide member, in particular a first lamella or first vane or first (elongated) plate, adjacent to the first roller for guiding the material saturated with the resin and/or for sealing the first roller with respect to a vessel main body, maybe provided. Alternatively, or in addition a second guide member, in particular second lamella or second vane or second (elongated) plate, adjacent to the second roller, for guiding the material saturated with the resin and/or for sealing the second roller with respect to the vessel main body, may be provided.
The first and/or second guide member may be arranged and mounted so that parts of it are (at least slightly) pressed against the first or second roller, respectively. The first and/or second guide member may extend at least substantially in parallel with the first and/or second roller, respectively. The first and/or second guide member may be formed of a resilient material. The first and/or second guide member may be formed of plastic, in particular polymer material or comprising such material. In any event, resin leakage can be reduced or fully avoided. The first and/or second guide member may be mounted (as separate part, optionally with a different material) onto the main body of the vessel (e.g. by a form-fit optionally comprising a projection and/or recess).
The device may comprise at least one stopping member arranged at least partially between the rollers for stopping a sideward flow of resin located between the rollers. The stopping member may be arranged at or adjacent to at least one end of the rollers. In particular, the stopping member may be arranged within a portion of the rollers which defines less than 20% or less than 10% of an overall (axial) length measured from one of the ends (axial ends) of the rollers. In any event, leakage of resin can be further reduced (or fully avoided) with simple means.
The rollers may comprise a metal, in particular steel, component, preferably as a core member and/or a tubular and/or cylindrical member. Alternatively or in addition, the rollers may comprise a plastic, in particular polymer, component, preferably a plastic, in particular polymer, coating. In this regard, rigid rollers which allow moving the material saturated with resin through the vessel with minimised drag may be achieved.
According to a second aspect of the invention, a device, in particular of the above-described kind, for coating material with resin and subsequently laying the material saturated with the resin onto a surface, may comprise a vessel for retaining the resin attached to the frame, the vessel having a slot sized and configured so that material is possible through the slot after being coated with resin retained in the vessel, a roller from which rolled material is unrolled and a tension adjustment mechanism for adjusting the tension of the unrolled material.
A core idea of the second aspect is the tension adjustment mechanism allowing for a simple and consistent regulation of the tension of the unrolled material such that unwanted folding and/or creasing of the material to be saturated with resin can be reduced or fully avoided.
The tension adjustment mechanism may comprise one, two or more moveable members, in particular spring members, and/or an actuating member, in particular for moving the one or more moveable members towards and/or away from the material to be saturated with resin (in particular towards and/or away from the rolled material to be unrolled). The spring member(s) are preferably leaf-spring member(s). The actuating member may be a rod (in general: elongated member) which may comprise an arresting portion for arresting the elongated member (rod) in different positions. In any event, a simple adjustment of the tension can be obtained.
At least one of the one or more moveable members may be rotationally and/or translationally moveable.
At least one of the one or more moveable members may contact a rolled portion of the material to be saturated with resin. In particular, at least one of the one or more moveable members may be pressed against a rolled portion of the material to be saturated with resin.
An arresting means for arresting the actuating member in at least two different positions may be provided. Thereby, the tension adjustment may be carried out in a well-defined and regulated manner.
The device may comprise one or more side wheels, e.g. at least two or at least three or at least four side wheels, preferably being provided on (only) one side of the device or on both sides. These side wheels allow placing the device on its side so that it can be easier to place and/or carry, e.g. in a (cargo) elevator, if necessary. This aspect of the invention is preferable combined with one or more of the other aspects (above or below). However, this aspect may be an independent aspect of the invention. Optionally, the one or more side wheels may be provided without the first and second roller being arranged on either side of the slot or behind the slot. Further optionally, the one or more side wheels may be provided without the tension adjustment mechanism for adjusting the tension of the unrolled material.
Conical centering cones may be provided which may center a roller core of the material roller, even if different material rollers with different roller cores are used. This aspect of the invention is preferable combined with one or more of the other aspects (above or below). However, this aspect may be an independent aspect of the invention. Optionally, the centering cones may be provided without the first and second roller being arranged on either side of the slot or behind the slot. Further optionally, the centering cones may be provided without the tension adjustment mechanism for adjusting the tension of the unrolled material.
According to another aspect of the invention, a method of applying a reinforcing material for waterproofing or roofing of a structure may comprise the steps of coating material with a liquid resin via a device of the above-described kind and of laying the material saturated with the resin on a surface or a subsurface of the structure via the device. The method may further comprise adjusting a width of the slot and/or adjusting a distance between the rollers, in particular by rotation (pivoting) of one or two of the rollers. The method may further comprise adjusting a tension of the unrolled material between a roller on which the material is rolled and a free end of the material.
According to another (independent) aspect of the invention, a use of the device for coating material with resin and subsequently laying the material saturated with the resin onto a surface, in particular a surface of a roof, plaza deck, park deck or other (flat, in particular upper and/or covering) surface, is proposed.
The device for coating material with resin and subsequently laying the material saturated with a resin onto a surface may be moveable and/or transportable. “Moveable” means in particular that the device comprises moving means such as one or more (e.g. at least two or at least three or at least four or more) wheels and/or continuous tracks (caterpillar tracks) and/or (ground-contacting) transportation rollers and/or one or more skids. In particular, the device is moveable during application of the material saturated with resin. Alternatively or in addition, the device may be transportable, meaning that there are one or more means such as one or more (e.g. at least two or at least three or at least four or more) wheels and/or continuous tracks (caterpillar tracks) and/or (ground-contacting) transportation rollers which allow to move the device to another location. Moving means and transportation means may be formed by the same or different structures.
First means (such as wheels etc.) may be provided for moving the device during application. Further, second means (such as wheels etc.) may be provided for moving the device for transportation, whereas an orientation of the device during application is preferably different to an orientation of the device during transportation. In particular, the second means may be provided at another side of the device than the first means, e.g. on a second side which defines, together with a first side, where the first means is provided, an angle of (at least approximately) 90°.
The roofing and/or waterproofing may include applying the material saturated with resin on a roof, plaza deck, park deck, or other (flat, in particular upper and/or covering) surface. Resins such as Sikalastic® 601, 621, 624 or 641 (in its composition at the filing date) may be used. Preferably, a polyurethane based resin may be used. Other polymeric resins may be used. Optionally, epoxy resins or polyester resins or other resins may be used.
The material to be saturated with the resin may be a fabric or a fleece or an (optionally porous) membrane.
The device may comprise a carriage which may be constructed of (e.g. rectangular) metal (in particular aluminium) components (tubes). This allows a low weight of the device. The resin vessel may be constructed of a metal (in particular aluminium or aluminium alloy), in particular polymer-coated. This eases a cleaning step. Optionally, all metal parts may be either aluminium or stainless steel which may eliminate the potential for rust developments. The slot adjustment mechanism and/or the distance adjustment mechanism and/or the tension adjustment mechanism and/or the first and second (bottom) rollers may be constructed so that they can be removed from the device and be replaced (without destroying a connection mechanism with the device, i.e. providing corresponding detaching mechanisms, for example comprising screws or snap-in mechanisms). Front wheels may be able to swivel (to enhance manoeuvrability) and/or may be locked (to facilitate straight-line material application). Rear (roller) wheels (in particular beneath the resin vessel) may provide a (near-) continuous bearing area to reduce concentrated loads on the substrate surface.
The tension adjustment mechanism may be configured to allow for independent variation of pressure applied to each end of the material roll (in order to prevent application of wrinkled material). The front-rear dimension of the device may be less than 48 inch (or less than 121.92 cm) to allow transport in typical commercial pick-up trucks and vans.
A resin delivery system may be provided, for example a pump system for pumping the resin from a larger container into the resin vessel. A multi-component resin mixer may be provided (in particular prior to pumping the resin from one container or several containers into the resin vessel). Rollers, squeegees, scrapers (or other apparatus) for spreading out the resin, preventing/reducing air entrapment and/or eliminate/reducing manual finishing may be provided.
The device may comprise a means for securing a roll of the material to be saturated with resin (e.g. fabric) and/or a vessel (in which the liquid resin may be placed) and/or an adjustment mechanism that may vary the width of a slot and may thereby control the thickness of saturated material and/or a resin shut-off mechanism that closes the slot when no material is applied and/or rollers on either side of the slot that may guide the saturated fabric onto the substrate surface and/or a wheeled carriage to which all components may be secured and/or a steering mechanism and/or a material roll tension adjustment mechanism. The device may be configured to be propelled manually but could also be motorised.
Amongst the advantages of the invention are very few moving parts, a low centre of gravity for stability, short and direct travel paths for the material to be saturated with resin, short distances from the rollers to the substrate surface to minimise air entrapment under the reinforcing material, easy cleaning with most surfaces in contact with the resin being made of non-stick materials, a strong and light weight carriage, a good manoeuvring performance to facilitate accurate material placement, the possibility to place the material moving either left-to-right or right-to-left, inset wheels allowing for direct overlap of adjacent membrane sheets, relatively fast material placement when compared to (full) manual application methods, a rather consistent material thickness, in particular when compared to (full) manual application methods.
The method of coating material with resin and subsequently laying the material saturated with the resin onto a surface may comprise the following steps: a (tubular) holder may be passed through the core of a roll of reinforcing material and may then be placed in mounting arms. The material may be pulled down between guide rollers and through the slot at a base of the receiving vessel, may then be passed between the first and second (bottom) rollers and may then be extended onto the substrate surface. The width of the slot opening may be adjusted to the desired material thickness. Liquid resin may be poured into the resin vessel to create a resin bath that surrounds the reinforcement material. The device (e.g. fleece saturator) may be pulled along the substrate surface and the saturated (fabric) material (membrane) may exit the saturator from between the first and second (bottom) rollers and may adhere to the substrate surface. Additional liquid resin and reinforcing fabric may be added as required. At least limited manual finishing of the placed material (membrane) by means of a roller may be performed in order to remove any air bubbles and/or spread out any excess resin. Additional adjustment of the slot width may be performed to achieve desired material (membrane) thickness.
All in all, the simplicity of the device (e.g. fleece saturator) minimises moving parts. Use of the opening adjustment mechanism to regulate the material (membrane) thickness may prevent uncontrolled resin leakage through the slot. A (direct) travel path of the reinforcing material (fabric) from the roll to the substrate surface may minimise deformation of the material (fabric). A rather low (minimal) distance from the underside of the bottom rollers to the substrate surface may minimise air entrapment underneath the material (membrane) and may minimise the need for manual finishing.
In the following, preferred embodiments of the present invention are described with reference to the drawings. These show:
Pointers 13 may be positioned adjacent opposite sides of the frame 10. The pointers 13 may provide a visual indicator that helps the user steer the device to facilitate the laying of saturated material and to help overlay edges of immediately adjacent rows of laid material.
The frame 10 supports a resin vessel 14 that may contain a liquid resin. In addition, the frame 10 supports a material roller 15 (in general material holder) onto which material 16 to be saturated with resin is rolled. In
A tension adjustment mechanism 18 (see
In particular
A distance between the rollers and a width of the slot 38 can be regulated by a distance and/or slot adjusting mechanism 22. In order to adjust a distance between the rollers 23, 24, the first roller 23 can be pivoted (swivelled) around a rotation axis 25 (see
Furthermore,
As seen in
A third 36 and fourth 37 (upper) roller are arranged between the material roller 15 (see
| Number | Date | Country | Kind |
|---|---|---|---|
| 16204177 | Dec 2016 | EP | regional |
| Number | Name | Date | Kind |
|---|---|---|---|
| 1306650 | Weinheim | Jun 1919 | A |
| 2766721 | Paquette | Oct 1956 | A |
| 3148104 | Rapp | Sep 1964 | A |
| 5785270 | Buchko | Jul 1998 | A |
| 6527217 | Lyons | Mar 2003 | B1 |
| Number | Date | Country |
|---|---|---|
| 202005000952 | Jul 2005 | DE |
| 2015-063196 | May 2015 | WO |
| Entry |
|---|
| Mar. 7, 2017 Search Report issued in European Patent Application No. 16204177.6. |
| Number | Date | Country | |
|---|---|---|---|
| 20180161804 A1 | Jun 2018 | US |
