The present invention relates generally to the field of chemical tanks used for component finish processing. More particularly, the present invention relates to covers for finish processing tanks.
In the field of finish processing, tanks are used to contain chemicals for the purpose of submerging components to impart a particular surface finish, or coating, on the component. The components being finished are most commonly made of a base metallic material. A variety of chemicals are used to impart specific finishes to the components and these chemicals are stored in tanks into which the treated parts are submerged. The tanks exist in a variety of rectangular sizes depending on the end use of the components being finished.
An area of concern with firms that operate in the field of finish processing is vapor control of the chemicals used in the processing tanks. When the tanks are not being used for part treatment processing, the uncovered tanks are open to the atmosphere, and evaporative actions take place with the chemicals that are used in the process. There are two main reasons to contain vapors that are released from the processing tanks in which the chemicals are contained. One reason to contain the vapors is the release of volatile organic components. Regulatory agencies have restrictions on the amount of volatile organic compounds that companies can release into the environment. The evaporative nature of chemicals used in finish processing results in elevated volatile organic compounds released and therefore, containment is necessary. A second reason to contain the vapors that are released from the tanks is the cost of adding replacement chemicals and rebalancing the concentration of the chemicals in the tanks.
A common method of covering tanks used in finish processing, is to use sheets of common materials such as metallic plates or wood sheets. There are multiple drawbacks to this method of covering tanks. In the case of wood sheets, although the cost is low, wood is an absorptive material. As such, wood sheets will warp, thus allowing gaps between the tank surface and the sheet, reducing the containment of vapors. Additionally, when fluid vapor is absorbed into wood sheets, they become heavy and more difficult to handle. A third issue with using wood sheets is placing and removing sheets on tanks that are placed side by side in a finishing facility and are long enough to require multiple sheets of wood to properly cover each tank. Finally, wood sheets tend to be heavy and cumbersome for operators to move.
In order to eliminate some of the issues with using wood sheets to cover tanks, large metallic sheets are frequently used in their place. The metallic sheets do not absorb the fluid vapors. The metallic sheets, however, can become heavy due to their size and so they typically have hooks affixed for the purpose of placement and removal. Placement and removal of the metallic sheets is most commonly done by use of an overhead crane system. There are many issues related to this method of tank covering. The metallic sheets can only be placed or removed a single sheet at a time. Finish processing facilities commonly use long tanks and/or have many tanks that require placement and removal of metallic sheets. The process of placing and removal of tank covering plates is unproductive time that must take place at the beginning and end of each workday. Additionally, the metallic sheets require a storage location within the facility when the tanks are not covered adding to unproductive space within the facility.
There are additional tank covering methods that are found within the finish processing industry. One method is to use a metallic rolling cover that is driven out over the tank by use of a motor drive system. One such type of these metallic tank covers typically has a thin sheet of stainless steel and additional support ribs, most commonly aluminum, affixed to the stainless steel. The result of this construction is a thick cross section resulting in a large rolled up size when retracted off of the tank. Another such type of these metallic tank covers uses extruded aluminum slats that are joined in a hinging manner along common edges. These aluminum type tank covers provide a lower profile section height than the previously noted stainless steel and aluminum cover, and thus, a more compact rolled up design, however the low profile limits the operating width of the cover. These metallic cover systems have some beneficial features. They allow for very long lengths to be built as a one-piece cover. These metallic type tank covers can also satisfy the requirement of sealing in the chemical tank vapors and significantly reduces the time required to cover and uncover the tanks due to their one-piece construction and motor-powered actuation. Due to the rolled-up size of these types of covers, the associated storage size is considerable and must be stored at the end of the tank. A second drawback to metallic roll up cover is the cost to produce such a cover. For instance, building a long, single piece, roll up cover from stainless steel sheet with affixed aluminum support ribs, along with a motor drive system, is very costly to produce. One other drawback to a metallic roll up cover is that the metallic components will be affected by the corrosive nature of the vapors that are being contained. Unlike the single metallic sheet covering method, replacing corroded components in a roll up type metallic cover is very costly.
Another method of covering finish processing tanks is to use powered, rigid plastic sheets to cover the tanks. The rigid plastic sheets have a benefit of providing corrosion resistance to the vapors. The sheets however are typically hinged along a tank edge and then cover and uncover the tank by powered rotation of the sheet upward and downward. One drawback to this tank covering method is that the sheets stand vertically upward when rotated open so parts that are being submerged in the tanks must clear the rotated cover during transport to prevent collisions. An additional drawback to this type of rotating cover is that it is limited in the length of tank that can be covered with a single system. As the cover gets longer, it requires much more torque to rotate the cover open and closed, thus requiring a larger motor to drive the system. At some length, the system will not operate, or will be too costly due to the size of the powering components required for proper operation.
As such, there is a need for a product that can cover finish processing tanks in a variety of widths and lengths, contain vapors produced by the chemicals in the tanks, resist the corrosive nature of the vapors, be stored in a small area, be able to cover and uncover the tanks in a minimal amount of time, and be cost effective to produce.
A movable cover for selectively covering a fluid containment tank including a rotatable storage drum and a flexible cover attached at a first end to the storage drum such that when the storage drum rotates in a first direction, the flexible cover rolls onto the storage drum to uncover the fluid containment tank and wherein the storage drum rotates in a second direction when the flexible cover is rolled off of the storage drum to cover the fluid containment tank. A plurality of cover retaining devices is attached to the flexible cover and disposed on either side of the cover. A plurality of guide rails are disposed on either side of the fluid containment tank. The flexible cover extends into a cavity in each of the guide rails, each of which includes a guiding surface that selectively engages the cover retaining devices to suspend the flexible cover over the fluid tank. At least one drive cable extending along the length of the guide rails is attached to a lead bar that is attached to a second end of the flexible cover such that when the drive cable is driven, the lead bar and flexible cover move along the guide rails to selectively cover the fluid containment tank.
It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can lead to certain other objectives. Other objects, features, benefits and advantages of the present invention will be apparent in this summary and descriptions of the disclosed embodiment, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above as taken in conjunction with the accompanying figures and all reasonable inferences to be drawn therefrom.
This invention is a roll away cover system that includes a thin flexible cover made in some embodiments from a thin sheet of flexible plastic type material, that can roll onto a drum or spool in a small space. The roll away cover system may be powered manually or by commonly available, inexpensive, motor powered, rotating devices, and is restrained by a plurality of guide rails.
The cover is preferably a flexible plastic type material that is resistant to the corrosive effects of the vapors which are being contained by the cover. Some non-limiting examples of plastic materials that are resistant to corrosive chemicals are polyvinyl chloride (PVC), polyethylene, polypropylene, and polyvinylidene fluoride (PVDF). These plastic materials can come in the form of a film, a fabric that is woven from strands of the plastic, or a fabric that is coated with a film of the plastic. These materials are all common to the finish processing industry either as materials that the tanks are constructed from, as tanks liners that prevent contact between the chemicals and metallic tanks, or as tank covers. Of course, the cover may be made of any other suitable materials without departing from the invention.
Turning now to
As shown in
Turning now to
As previously described, retaining devices 114 are secured on either side of flexible cover 102. During assembly or installation, retaining devices 114 are inserted into channels 120 which are temporarily open at the ends of guide rails 116. Retaining devices 114 travel through channels 120 and restrain flexible cover 102 as it travels along the length of guide rails 116 during extension and retraction operations that cover and uncover the fluid tank 106. In the embodiment shown, retaining devices 114 are made of chemical resistant plastic similar to those plastics that can be used for flexible cover 102, however alternate materials including, but not limited to stainless steel may be used without departing from the invention. In order to reduce the combined friction of the plurality of retaining devices 114 in contact with guiding surfaces 122, a low friction plastic, a rolling element design, or a combination of these may be used. Any other suitable material or element may be used for retaining devices 114 without departing from the invention. As shown in
As previously described, flexible cover 102 is made of thin material and thus, allows the cover to be rolled up in a compact manner. As shown in
As shown in
As further shown in
Due to the lightweight construction of flexible cover 102, the amount of force necessary to drive the cover out during the tank covering operation does not require high powered, high torque drive device. The amount of force required to rotate the drive pulley 136 or to rotate the storage drum 128 will vary depending on the length and width of flexible cover 102. As the total mass of flexible cover 102 increases, or as the number of cover retaining devices 114 increases, the force necessary to extend and retract the flexible cover will also increase. The embodiment shown uses two methods to provide rotational power to the drive pulley 136 and storage drum 128. One method of providing rotational power is through use of a manual crank handle 144. As noted previously, flexible cover 102 extends over the tank through movement of cable 132 and retracts through rotational movement of storage drum 128. In the present embodiment, a separate manual crank handle 144 is used for each operation. Alternately, as the force required to extend and retract cover becomes too much for an operator to use manual crank handle 144, a handheld, commercially available drill, driver, or any other suitable motor may be used to rotationally move powering gears 142, 146 thus transferring the necessary movement and power to cable gear 143 or drum gear 145. An alternate powering method in this invention would be to eliminate the powering gears 142, 146 and then directly drive cable gear 143 or drum gear 145 through a crank handle or motor adaptation on the respective gears.
Roll away cover system 100 includes a canister 150 to contain the gears (142, 143, 145, 146), drum 128, and rolled up flexible cover 102 and serves as a first end close out to contain vapors from the tank. A second end close out is provided through provision of an opposite end wall 152 to which the lead bar 134 can be moved when flexible cover 102 is extended over the tank 106. Opposite end wall 152 serves to additionally contain vapors in tank 106.
An additional feature of this invention is the use of an optional guide rail rising element 154 to which the guide rail 116 can mount. The purpose of rising element 154 is to allow evaporative reclamation pipes, or fluid fill pipes 250 (see
Turning now to
The tank uncovering operation in this embodiment is carried out by rotating the storage drum 128 in a direction that is opposite the drum rotation direction of the covering operation. In the embodiment shown, storage drum 128 is driven directly using cover powering gear 146, which engages drum gear 145 to rotate the storage drum in the desired direction to facilitate rolling up of flexible cover 102 onto the drum. Any suitable alternative means of driving storage drum 128 may be used without departing from the invention. During the tank uncovering operation, the drive pulley 204 is free to rotate allowing flexible cover 102 to be retracted from its position covering the tank.
As in the previously described embodiment, due to the lightweight construction of flexible cover 102, the means to drive the cover out during the tank covering operation does not require high powered, high torque drive device. The amount of force required to rotate drive pulley 204 or to rotate storage drum 128 will vary depending on the length and width of flexible cover 102. As the total mass of the flexible cover 102 increases, or as the number of cover retaining devices 114 increases, the force to extend and retract flexible cover 102 increases. This invention uses two methods to provide rotational power to drive pulley 204 and storage drum 128. One suitable method of providing rotational power to belt drive pulley 204 and storage drum 128 is through manual crank handle 144. As described previously, in the present embodiment flexible cover 102 extends over tank 106 through movement of drive belt 202 and retracts through rotational movement of storage drum 128. In the embodiment shown, a separate manual crank handle 144 is used for each operation. As previously described, any alternative means for providing the force required to extend and retract cover 102 may be used without departing from the invention.
As shown in
As in the previous embodiment, this embodiment also shows the use of optional guide rail rising element 154 to which guide rail 116 is mounted, which allows evaporative reclamation pipes (not shown), or fluid fill pipes (not shown), to be located under flexible cover 102 when it extends and retracts in order to prevent interference between these pipes and the flexible cover 102.
Although the invention has been herein described in what is perceived to be the most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims and the description of the invention herein.
This application is based on and claims priority to U.S. Provisional Patent Application No. 62/901,017 filed on Sep. 16, 2019, which is incorporated herein by reference in its entirety for all purposes.
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