Patent Grant
10486182
Painting can be a labor-intensive, costly process. Additionally, traditional painting techniques often result in excessive waste (e.g., in terms of paint consumption, brushes, etc.) or result in the release of potentially hazardous chemicals into the air (e.g., via paint spraying). Accordingly, there is a need for improved systems and methods that address these and other needs.
Various embodiments of a shroud device and overspray capture system are described below. In the course of this description, reference will be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
A shroud device for use in spraying applications, according to various embodiments, has a base portion and a spray release end. In further embodiments, the shroud device defines an open area within the shroud device. In particular embodiments, the shroud device comprises a suction portion and a blowing portion. In some embodiments, the suction portion comprises a suction frame flaring from the base portion to the spray release end. In other embodiments, the suction portion defines a suction access cutaway adjacent the base portion and a spray cutaway disposed adjacent the spray release end. In still other embodiments, the suction frame comprises a recirculation shroud, the recirculation shroud being in communication with the suction access cutaway and defining at least one suction hole. In various embodiments, the spray cutaway is dimensioned to enable spray from a sprayer to pass through the shroud device such that at least a portion of the spray is deposited upon a medium via the spray cutaway.
In particular embodiments, the blowing portion comprises a blowing frame flaring from the base portion to the spray release end. In some embodiments, the blowing portion defines a blower access cutaway adjacent the base portion, and comprises a blowing tube disposed adjacent the spray release end. In some embodiments, the blowing tube is in communication with the blower access cutaway and defines at least one blowing slot. In particular embodiments, the blowing portion and the suction portion are co-facing. In some embodiments, the blowing portion and suction portion are integrally formed. In still other embodiments, the shroud device is configured to recirculate a plurality of overspray droplets from the spray within the shroud device via a combination of a suction force introduced within the shroud via the at least one suction hole and a blowing force introduced within the shroud via the at least one blowing slot.
A paint sprayer shroud for recirculating at least a portion of a plurality of overspray droplets from a sprayer back into a sprayer flow from the sprayer and onto a wall, according to various embodiments, comprises: (1) a suction frame flaring from a base portion to a planar spray release end, defining a suction access cutaway adjacent the base portion and a spray cutaway disposed adjacent the spray release end; and (2) a blowing frame flaring from the base portion to the spray release end, and defining a blower access cutaway adjacent the base portion.
In some embodiments, the suction frame comprises a curved recirculation shroud and a suction tube, the suction tube being in communication with the suction access cutaway and defining a plurality of suction holes. In other embodiments, the spray cutaway is dimensioned to enable spray from a sprayer to pass through the paint sprayer shroud such that at least a portion of the spray is deposited upon a medium via the spray cutaway. In various embodiments, the blowing frame comprises a blowing tube disposed adjacent the spray release end, the blowing tube being in communication with the blower access cutaway and defining at least one blowing slot. In particular embodiments, the recirculation shroud is dimensioned to recirculate at least a portion of the plurality of overspray droplets back into the sprayer flow and onto the medium. In various embodiments, the paint sprayer shroud is configured to direct airflow via the at least one spray cutaway such that the airflow directs the plurality of overspray droplets upward toward the recirculation shroud.
Various embodiments will now be described in greater detail. It should be understood that the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
A shroud device (e.g., a paint sprayer shroud), according to particular embodiments, is configured to capture overspray (e.g., paint or other material that is applied to an unintended location) and/or increase an amount of paint that is delivered to a desired location (e.g., on a wall being painted, etc.). In various embodiments, the shroud device is configured for use in conjunction with a sprayer (e.g., such as any suitable paint spryer or other sprayer). In particular embodiments, the shroud device may comprise the sprayer.
In various embodiments, the shroud device comprises one or more vacuum and/or blower channels configured to cooperate to manipulate a sprayed material (e.g., paint) within the shroud device. In other embodiments, the one or more vacuum channels may comprise one or more suction channels. The shroud device may, for example, comprise one or more blower channels configured to bias a flow of one or more of a plurality of paint droplets that make up overspray from the sprayer back into the shroud device (e.g., as opposed to into the air, onto an unintended location, etc.). The shroud device may, for example, be configured to operate a substantially fixed distance (e.g., a fixed distance) from a surface being painted (e.g., to facilitate the biasing of the plurality of paint droplets back into the shroud device via the directed airflow).
In various embodiments, the one or more blower and/or vacuum channels may facilitate an introduction of one or more blowing or sucking forces within the shroud device. The one or more blowing and/or suction forces may cooperate to produce a turning airflow within the shroud device that is configured to recirculate at least a portion of the overspray (e.g., the plurality of droplets that make up the overspray) back into the sprayer flow (e.g., and, in the case of at least a portion of the overspray, ultimately onto the desired medium).
Various embodiments of a shroud device are described in more detail below.
Asymmetrical Shroud
In the embodiment shown in
As further depicted in
In various other embodiments, the suction frame may define one or more side suction cutaways configured to provide suction to recapture any side overspray (e.g., overspray that would tend to the left or right of the shroud during spraying along the medium 90). In various embodiments, the one or more side suction cutaways may be in operable communication with the suction access cutaway 30 to provide suction to the one or more side suction cutaways. In various embodiments, the side suction cutaways may be disposed on either side of the spray cutaway 28.
In particular embodiments, the spray cutaway 28 is substantially planar (e.g., planar). In such embodiments, the spray cutaway 28 is configured such that each portion of the spray cutaway 28 is a substantially fixed distance from a medium 90 (e.g., a flat medium such as a wall) when the shroud device 10 is positioned such that the spray cutaway 28 is substantially parallel (e.g., parallel) to the medium 90. In particular other embodiments, the spray release end 16 of the shroud device 10 is substantially planar (e.g., planar) and comprises a substantially rectangular (e.g., rectangular) area in which the spray cutaway 28 is defined.
In various embodiments, the suction access cutaway 30 is substantially rectangular (e.g., rectangular). In other embodiments, the suction access cutaway 30 may have any other suitable shape (e.g., circular, elliptical, square, polygonal, etc.). In particular embodiments, the suction access cutaway 30 is configured to enable a vacuum or other pressure regulation device to couple with the shroud device 10 such that the vacuum is in operative communication with the shroud device 10.
In various embodiments, the upper suction portion 20 further comprises a recirculation shroud 22 comprising a suction tube 24 defining a plurality of suction holes 26. In the embodiment shown in
As may be understood from
As shown in
The second suction frame sidewall 36 defines a second enclosed suction frame sidewall chamber 38, the second enclosed suction frame sidewall chamber extending at least between a second end 27 of the suction tube 24 and the suction access cutaway 30. As may be understood from this figure, the second enclosed suction frame sidewall chamber 38 facilitates the communication between the suction access cutaway 30 and the suction tube 24.
In various embodiments, the suction tube 24 extends between the first and second suction frame sidewalls, 32, 36 (e.g., between the first and second enclosed suction frame sidewall chambers 34, 38). In various embodiments, the suction tube 25, first enclosed suction frame sidewall chamber 34, and second enclosed suction frame sidewall chamber 38 define a substantially continuous channel configured for the transmission of airflow.
As shown in
In particular embodiments, the shroud device 10 comprises a lower blowing portion 40. In the embodiment shown in
In various embodiments, the blower access cutaway 50 is substantially rectangular (e.g., rectangular). In other embodiments, the suction access cutaway 30 may have any other suitable shape (e.g., circular, elliptical, square, polygonal, etc.). In particular embodiments, the blower access cutaway 50 is configured to enable a blower or other pressure regulation device to couple with the shroud device 10 such that the blower is in operative communication with the shroud device 10.
In various embodiments, the lower blowing portion 40 comprises a substantially circular (e.g., circular) blowing tube 42 adjacent the spray release end 16. In some embodiments, the blowing tube 42 defines at least one blowing slot 44. In particular embodiments, the at least one blowing slot 44 is substantially rectangular (e.g., rectangular). In some embodiments, the at least one blowing slot is at least generally directed toward the spray cutaway 28.
In various embodiments, as may be understood from
The second blowing frame sidewall 56 defines a second enclosed blowing frame sidewall chamber 58, the second enclosed blowing frame sidewall chamber extending at least between a second end 57 of the blowing tube 42 and the blower access cutaway 50. As may be understood from this figure, the second enclosed blowing frame sidewall chamber 58 facilitates the communication between the blower access cutaway 50 and the blowing tube 42.
In various embodiments, the blowing tube 42 extends between the first and second blowing frame sidewalls, 52, 56 (e.g., between the first and second enclosed blowing frame sidewall chambers 54, 58). In various embodiments, the blowing tube 42, first enclosed blowing frame sidewall chamber 54, and second enclosed blowing frame sidewall chamber 58 define a substantially continuous channel configured for the transmission of airflow. As shown in
In various embodiment, such as the embodiment shown in
In particular embodiments, the upper suction portion 20 is integrally formed with the lower blowing portion (e.g., the suction frame 21 is integrally formed with the blowing frame 41). In particular embodiment, the upper blowing portion 20 and the lower suction portion 40 are substantially co-facing (e.g., co-facing), for example, along the line 18 shown in
In various embodiments, such as the embodiment shown in
Operation of Asymmetrical Shroud
In particular embodiments, only a portion of the spray 62 from the sprayer 60 may impact the wall and stick (e.g., only about 65%, only about 60%, up to about 75%, up to about 80%, up to about 95%, etc.). A remainder of the spray 62 may result in overspray as discussed above. In particular embodiments, the shroud device 10 is configured to utilize one or more air flows to manipulate the overspray such that at least a portion of the overspray is deposited on the wall (e.g., resulting in up to 100% application of the medium 90, up to about 90% application to the medium 90, up to about 95% application to the medium 90, etc.). In other embodiments, the shroud device 10 is configured to utilize one or more air flows to recapture (e.g., for recycling or later reuse) at least a portion of the overspray (e.g., via suction).
As may be understood from
Additionally, overspray (e.g., at least some of the overspray) that would have turned in an upward direction may flow back into the shroud device 10 based on a relative position of the shroud device 10 to the medium and a curved shape of the recirculation shroud 22. In various embodiments, the shroud device 10 is configured to be positioned between about zero and about one half inches from the medium 90. In a particular embodiment, the shroud device 10 is configured to be positioned about one quarter inch from the medium 90 during spraying.
As may be understood from
As may be further understood from
In particular embodiments, the suction force 83 may remove at least some paint droplets from the recirculation channel 23 (e.g., particularly smaller droplets). In such embodiments, the plurality of suction holes may be coated with a hydrophobic coating to reduce potential blockage and sticking within the plurality of suction holes 26. In various embodiments, the droplets removed via the suction force 83 may constitute less than about 5% of the overspray (e.g., by mass). In particular embodiments, the system may comprise a cyclone separator for removing paint droplets from the suctioned air. In various embodiments, the cyclone separator may include any suitable cyclone separator or series of cyclone separators.
In a particular embodiment, a volumetric airflow approaching the medium 90 may be about 0.18 m3/s. In some embodiments, the estimated blower flow required for the shroud device to operate may be about 80 cubic feet/minute. In various embodiments, a total flow to the shroud (e.g., the recirculation shroud 22) may be about 460 cubic feet/minute. In other embodiments, a suction into the suction tube 24 via the plurality of holes 26 may be about 300 cubic feet/minute. In some embodiments, the bypass flow back to the sprayer flow (e.g., via the recirculation channel 23), which may include a plurality of the overspray droplets, may be about 110 cubic feet/minute. In some embodiments, up to about 50 cubic feet per minute of air may be suctioned off using one or more side suction devices.
Alternative Embodiments
Shroud Device with Roller or Simulated Rolling
In particular embodiments, such as the embodiment shown in
In a particular embodiment that comprises a roller, a volumetric airflow approaching the medium 90 may be about 0.18 m3/s (e.g., about 380 cubic feet/minute). In other embodiments, a suction into the suction tube 24 via the plurality of holes 26 may be about 260 cubic feet/minute. In some embodiments, the bypass flow back to the sprayer flow (e.g., via the recirculation channel 23), which may include a plurality of the overspray droplets, may be about 80 cubic feet/minute. In some embodiments, up to about 40 cubic feet per minute of air may be suctioned off using one or more side suction devices.
In particular other embodiments, the shroud device may be configured to simulate a rolled texture of the sprayed paint on the medium 90 using one or more forced air sources. For example, the shroud device (e.g., any suitable shroud device described herein) may comprise a plurality of blowing openings that are each configured to blow air in a particular location at the medium 90. In particular embodiments, this blown air may smear the wet paint as it impacts the medium 90 in order to create a desired wall texture. In some embodiments, the system may be configured to adjust a pressure of air blown from any particular one of the one or more openings (e.g., in any suitable manner). In other embodiments, the system is configured to apply a substantially consistent pressure to produce a consistent smearing effect on the wall.
Shroud Device with Flow Reverse Half Cylinder
In particular embodiments, the shroud device 810 (e.g., such as the embodiments shown in
In still further embodiments, the suction force 883 may remove at least some paint droplets from the flow reversal portion 823 (e.g., particularly smaller droplets). In various embodiments, the droplets removed via the suction force 883 may constitute less than about 5% of the overspray (e.g., by mass). In particular embodiments, the system may comprise a cyclone separator for removing paint droplets from the suctioned air. In various embodiments, the cyclone separator may include any suitable cyclone separator or series of cyclone separators. IN other embodiment, the system may include a suitable filter for removing one or more paint droplets from the suctioned air.
In various embodiments, the shroud device 810 shown in these figures may further comprise one or more side suction openings 811, such as any suitable side suction opening described above. In various embodiments, each side suction opening 811 (e.g., side slot) may be about one inch in length, or any other suitable length. Any suitable surface of the shroud device 810 shown in these figures may be coated with a hydrophobic material (e.g., a super-hydrophobic material). These may include, for example, any surface which may come in contact with paint.
Symmetrical Shroud Device
As may be understood in light of this disclosure, the first and second enclosed chambers 934, 938 are configured to redirect overspray (e.g., a plurality of overspray droplets) back into the shroud device 910. The air flow may then direct the overspray droplets via one or more of the recirculation channels 923a, 923b back into the sprayer flow 980. In other embodiments, a shroud device may comprise any suitable number of suction tubes, recirculation shrouds, and corresponding recirculation channels for redirecting overspray back to a sprayer flow (e.g. three, four, five, six, seven, up to ten, etc.).
Ceiling Painting Shroud Device
In various embodiments, the ceiling painting shroud device 1010 further comprises a passive collector 1020. As may be understood from this figure, the passive collector may comprise any suitably shaped reservoir for collecting and maintaining overspray droplets for later re-use or recycling.
In various embodiments, the ceiling painting shroud device 1110 further comprises an active collector 1120. As may be understood from this figure, the active collector may comprise any suitably shaped reservoir for collecting and maintaining overspray droplets for later re-use or recycling. In the embodiment shown in this figure, the active collector 1120 further defines a suction inlet 1030 via which a suction force 1081 may remove at least a portion of the droplets collected by the active collector 1120. The suction force 1081 utilized may be similar to any suction force described herein, or any other suitable suction force for sufficiently removing the overspray droplets.
In particular embodiments, a ceiling painting shroud device may be substantially asymmetrical. In such embodiments, a substantially asymmetrical shaped shroud device may be configured to accommodate a plurality of overspray droplets falling in an irregular pattern due to movement of the shroud during painting (e.g., along a ceiling surface). In various embodiments, the shroud may be designed to paint a ceiling of a rate of between about 1 foot per second and about two feet per second. In some embodiments, the shroud is configured to be removed from a sprayer for the purpose of collecting any paint that is collected in a collector. In particular embodiments, the shroud may comprise two halves and be configured to remove at a first half of the two halves while painting a portion of the ceiling where the ceiling abuts a wall.
Application of Non-Paint Materials
Although various embodiments of a shroud device are described above in the context of applying paint or other liquid to a surface, it should be understood that other embodiments may utilize any suitable technique described herein to apply any other suitable material (e.g., either singularly or additively). These other materials may include, for example, stucco, cement, gunite, one or more plastics, insulation, foam, or other suitable materials. In various other embodiments, one or more techniques described herein may be utilized for the application of any other suitable material such as, for example, a solid material (e.g., a powder, sand, glitter, pellets such as BBs etc.), semi-solid material, a molten material, gaseous material, plasma, textured material, solid suspended in a liquid, etc. The system may, for example be utilized to apply any material in any suitable location regardless of a density, consistency, or other property of the material.
In various embodiments, the system is configured to utilize any suitable technique herein to apply any suitable material under pressure (e.g., through an orifice, via a suitable mold, etc.). In particular embodiments, the system is configured to atomize a material for application. In other embodiments, the system is configured to apply the material in its substantially natural state. In still other embodiments, the system is configured to apply one or more materials in a suitable matrix. In some embodiments, the system is configured to utilize one or more techniques described herein in a suitable 3-D printing application (e.g., portable and/or largescale 3-D printing).
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. For example, while the above shroud is discussed in particular in regard to paint, it should be understood that various other embodiments may be configured to apply any other liquid to any other suitable surface using any of the techniques described herein. Furthermore, any combination of any features described may be utilized in the context of any specific embodiment. Additionally, certain embodiments may comprise a portion of features attributed to any particular embodiment described herein. For example, although one or more features may not be discussed in relation to one another, various embodiments of a paint robot may utilize any feature of component described herein in any combination. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for the purposes of limitation.
| Number | Name | Date | Kind |
|---|---|---|---|
| 5360165 | Singhal | Nov 1994 | A |
| 6171656 | Settles | Jan 2001 | B1 |
| Number | Date | Country | |
|---|---|---|---|
| 20180021799 A1 | Jan 2018 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62365893 | Jul 2016 | US | |
| 62365897 | Jul 2016 | US |
