CA2237865A1 - Method and applicator for field application of anti-skid or decorative aggregate coatings - Google Patents
Method and applicator for field application of anti-skid or decorative aggregate coatings Download PDFInfo
- Publication number
- CA2237865A1 CA2237865A1 CA 2237865 CA2237865A CA2237865A1 CA 2237865 A1 CA2237865 A1 CA 2237865A1 CA 2237865 CA2237865 CA 2237865 CA 2237865 A CA2237865 A CA 2237865A CA 2237865 A1 CA2237865 A1 CA 2237865A1
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- Canada
- Prior art keywords
- particles
- substrate
- hopper
- predetermined path
- liquid binder
- Prior art date
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/14—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
- B05B7/1404—Arrangements for supplying particulate material
- B05B7/1431—Arrangements for supplying particulate material comprising means for supplying an additional liquid
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/34—Applying different liquids or other fluent materials simultaneously
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C19/00—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving
- E01C19/12—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving for distributing granular or liquid materials
- E01C19/21—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving for distributing granular or liquid materials for simultaneously but separately applying liquid material and granular or pulverulent material, e.g. bitumen and grit, with or without spreading ; for filling grooves and gritting the filling
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Nozzles (AREA)
Abstract
An applicator for applying an aggregate coating to a substrate includes an apparatus comprising a first hopper for supplying aggregate particles, the hopper in spaced relation to and above the substrate, first release means for releasing the particles from said first hopper along a first predetermined path that intersects the substrate at a first location, spray means for spraying a liquid binder material along a plurality of paths, including a second predetermined path and a third predetermined path, the second predetermined path intersects the first predetermined path above the substrate, and the third predetermined path intersects the substrate at a second location in spaced relation to the first location, and supply means for supplying the liquid binder material to the spray means;
and, means for moving the apparatus in a first direction relative to the substrate. The method of the present invention includes positioning a particle supply above a portion of said substrate, the supply containing a plurality of particles, releasing the particles from the aggregate supply at a predetermined rate, allowing said particles to free fall towards said substrate, coating said particles with a liquid binder material as the particles free-fall towards the substrate, thereby producing coated particles, coating a portion of the substrate with the liquid binder material, thereby producing a coated portion, and impacting said coated particles onto the portion of substrate.
and, means for moving the apparatus in a first direction relative to the substrate. The method of the present invention includes positioning a particle supply above a portion of said substrate, the supply containing a plurality of particles, releasing the particles from the aggregate supply at a predetermined rate, allowing said particles to free fall towards said substrate, coating said particles with a liquid binder material as the particles free-fall towards the substrate, thereby producing coated particles, coating a portion of the substrate with the liquid binder material, thereby producing a coated portion, and impacting said coated particles onto the portion of substrate.
Description
METHOD AND APPLICATOR FOR FIELD APPLICATION OF
4 The present invention relates to a method and system for coating S a substrate, and spe~ifi~lly relates to a meth~ and system for coating a 6 substrate with an aggregate m~teri~l 8 Currently there are no commercially available spray applicators 9 that can convergently spray thin abrasive anti-skid or decostive co~tin~
on concrete and other surfaces. Co~tin~ a sub~L~te such as concrete with 11 abrasive anti-skid co~ting~ or decorative co~tings typically le~uil~,s mixing 12 the a liquid binder material? with an agglegat~ such as sand or ground 13 quartz and then p~inting or spraying the ~ ul~, onto the concre~. If 14 only a portion of the ~L~Le ~uil~s co~ting~ accuracy and control requirements typically dictate whether the ~ ule iS applied by spraying 16 or by p~inting with some sort of brush. Spray coating processes, 17 however, are limited due to the low sprayability of the liquid binder 18 materials which are typically highly viscous, the limit in ~tt~in~ble coating 19 thickness, and the high amount of waste "laLerial gen~ laLed.
Many liquid binder materials that are utili7~ in applying anti-skid 21 co~tings or decorative co~ g~ (such as the reflective stripes used for lane 22 m~rking~ on roadways) have vi~ositi~s at ambient ~ dlule which 23 preclude the use of conventio~l spray applicators. In order to reduce the24 viscosity to a level which can utilize conventional spray applicators, the liquid binder m~teri~l is often m-ised with a solvent. Unfo-Lullately, such 26 solvents are often environment~lly hazardous, and th~fort waste m~t~ri~l 27 from the spray coating process must be disposed of as hazardous waste.
{ST-90}
The convention~l spray coating processes co~ ise c~lubil ing a 2 liquid binder material (which may incl~lde a curing agent), solvents, and3 ag~cgate in a vat to form a Illi~Ul~,. This l~ e is then ~ul-lped from 4 the vat through con~luit~ to a nozzle where it is atomized and sprayed onto the substrate. Once the ll~uLIule has been applied to the substrate, the 6 solvent is removed the.cIiolll by evaporation of volatile gas or by 7 applying heat to the Illi~LUlc to speed ev~ ;on of the solvent.
8 Unfortunately, Illi~lUles of ag~lcgdle and liquid binder lllatc-ial are 9 very prone to clogging, in both the con~lllit~ and at the nozzle. Since the lllixlule must be pumped thorough the coating system, the liquid binder 11 material can begin to set ~-vithin the system. Furthermore, the abrasive12 effect of the agglcgate on the pump, con~nit~ and nozzle subst~nti~lly 13 reduce the useful life of conventi~n~l spray system collll)ollents, 14 neceS~ ting frequent repair or repl~r~pmpnt of such colll~oncnL~.
What is needed is a method and applicator to con-vcl enlly spray 16 thin abrasive anti-skid or decorative coatings onto SUI~SI~dle such as 17 concrete while avoiding the problems of the prior art.
18 DISCLOSURE OF THE INVI~TION
19 It is therefore an object of the present invention to provide a method and applicator to conve.E,enlly spray thin abrasive anti-skid or 21 decorative co~ting~ onto ~IlI,slldte such as concrc~e without subjecting the 22 spray no zles of the l"~senl invention to the abrasive effects of ag~ ale 23 particles.
24 Another object of the present invention is to combine the aggregateparticles with a liquid binder material eYtem~l of the spray no771es of the 26 present invention.
27 Accoldillg to the pr~3cnt invention, an applicator is rlic~lose~l for 28 applying an aggr~gate coating to a ~ul,sL~dte, The applicator includes an 29 d~JaldLUS comprising a first hopper for supplying ag~l~gaLe particles, the {ST g0} 2 hopper in spaced relation to and above the substrate, first release means 2 for releasing the particles from said first hopper along a first 3 predele",.ined path that illL~;lS~;L~ the substrate at a first loc~tion, spray 4 means for spraying a liquid binder ",~ 1 along a plurality of paths, including a second predt:Le~ ed path and a third prede~~lll~ned path, 6 wherein the second predetermined path hlL~.secLs the first predel~llllined 7 path above the substrate, and the third ~l~delellllined path inl~ls~ls the 8 s-lb~Lldte at a second location in spaced relation to the first lor~tion, and 9 supply means for supplying the liquid binder material to the spray means;and, means for moving the a~us in a first direction relative to the 1 1 S.-~s~ldle.
12 The method of the present invention includes p~;l;.~n;ng apar~cle 13 supply above a portion of said substrate, the supply con~in;ng a plurality 14 of particles, relç~ing the particles from the ag~legate supply at a predetermined rate, allowing said particles to free-fall towards said 16 su~s~l~te, coating said particles with a liquid binder material as the 17 particles free-fall towards the substrate, thereby pro~ucin~ coated 18 particles, coating a portion of the substrate with the liquid binder material, 19 thereby pro~luçing a coated portion, and imp~cting said coated particles onto the portion of substrate.
21 The foregoing and other featul~s and advantages of the present 22 invention will become more ap~alent from the following description and 23 accoll.pallying drawings.
FIG. 1 is one embo(limPnt of the spray coating applicator of the 26 present invention.
27 FIG. 2 is an end view of the hoppers and ~lhllcU ~I bank of spray 28 nc!771~s taken along line 2-2 of FIG. 1.
{ST-90} 3 -FIG. 3 is a cross-sPction~l sçh~m~fie of the hoppers, spray banks 2 and predelellllined paths of the p~c~lcd embo~limpnt of the present 3 invention.
4 FIG. 4 is a cross-~tio~ schPm~ti~ of the hoppers, spray banks S and prede~lluil1ed paths of the an al~ llale çmbo~imp-nt of the p~senl 6 invention.
8 The present invention, as shown in Figure 1, is dil~;led toward 9 improving spray coating processes for applying anti-skid or decorative co~tings to substrates such as conc,c~ by decreasing hazardous waste and -11 system problems such as elo~in~ and wear. The applicator 10 is 12 preferably mounted on a vehicle 12, such as a truck, to provide a means 13 for moving the applicator in a first direction relative to the ~Ubslldt~. As 14 used herein, the term "liquid binder materiai" means an adhesive .. ~le~
such as epoxy, poly~ ane, or another polymer.
16 The applicator 10 has a supply means that inc!udes at least one 17 (and for binders which must be mixed with a curing agent, at least two) 18 liquid binder storage con~ e.~ 14, 16, a motionless mixer/pump 18 that 19 mixes both liquid binder Illate.;al conchtuçnt~ (if a two part binder liquid binder is used), a first conduit 20 that eysen~s from the collt~iners 14, 16, 21 to the mixer/pump 18, and a second cond~lit 22 that eYten~ls from the22 mixer/pump 18 to one or more sprdy no771~s In the ~l~f~l~d 23 embo limçnt, the storage conl~ine~ ~ 14, 16 are heated and ~ ,s~uli~od to 24 reduce the viscosity of the liquid binder con~ uçnt~ will~oul the use of solvents. The pr~ ed embo~im~nt further includes an air colllplessor 26 24 which may be integral with a ge&e.dtor, or may be driven by some 27 other power source on the truck. The pw~ose of the air colllpressor is 28 described in greater detail below.
{ST-90} 4 As shown in Figure 2, in ~ tion to the supply means, the 2 applicator 10 includ~s at least one, and preferably two hol)pe.a 26, 28 for 3 supplying aggregate particles 30 to the liquid binder ".~ 1 32. Each 4 hopper 26, 28 is located in spaced relation to, and above, the concrete S traveling surface 34. Integ~al with each hopper 26, 28 is a release 6 me~h~ni~m 36 for rele~in~ the particles from the hopper 28 ~c5oci~l~
7 therewith. Preferably, the release "~ ni~m 36 for each hopper 26, 28 8 includes a slot 38 in the hopper 26, 28 for rele~in~ the particles from that 9 hopper 26, 28, and a motorized rotary agitator 40 located in the slot forcontrolling the rate at which the particles are rel~ from that hopper 11 26, 28 through the slot 38.
12 One or more spray no77lps 42 are located on the truck ~ ent the 13 release slots. The no77llos 42 are ~r~f~bly fan spray no77les of the type14 which produce a fan 44 of atollli;c~d liquid binder Illi~f ~ ;~31 32 for broad coverage area. Although the ~r~a~e provided by the cont~in~rs 14, 16 16 and the pump 18 is used to force the liquid binder matelial 32 to spray 17 out of each no~le 42, each nozzle is preferably air-~si~t~. As such, 18 ~lesau-ized air from the air col--~r ssor 24 is introduced around each 19 nozzle 42 and aimed in the same direction as the liquid binder .. late,ial 32 exiting that nozzle 42. This additional air assists in c~lying the atomized 21 droplets along the desired paths. As shown in Pigure 2, when a relatively 22 long release slot 38 is used, several fan spray n- 771Ps 42 may be 23 manifolded to form a primary bank of no771~s which have spray fans 4424 that overlap so as to insure complete coverage of the aggl~ale particles 30 released from the hoppers 26, 28.
26 Referring now to Pigure 3, agglegate particles 30 are released 27 from the first hopper 26 along a first prede~.l-lilled path 46 that int~la~ls 28 the col~crele 34 at a first location 48. Each spray nozzle 42, because of 29 its fan spray characteris~cs, sprays liquid binder .natelial along a plurality of paths, and more spe~ifi~lly each no~le in the l,lilllal~ bank 54 {ST-90} 5 simultaneously sprays atomized liquid binder, ~f ;~l along a second 2 prede~el.. ined path 50 and a third predetf . inçd path 52.
3 The second predetermined path 50 int~L~ the first 4 predeLel-l-ined path 46 above the concrete 34, and th~ ;~ rO~ ~
droplets of liquid binder material sprayed along this path 50 s~bs~ t;~lly 6 coat the aggl~:gate particles as they free fall from the first hopper 26.
7 Atomized droplets of liquid binder ~l.ate~ial :~pl~yed along the third 8 prede~ led path 52 inLel~~l the con~;le~ 34 at a second location 56 in 9 spaced relation to the first loc~hon 48, which, due to the movement of the applicator 10 in the first direction 58 relative to the concrete 34, primes 11 a sele~ted portion of the corcle~ 34 with liquid binder material 12 imme~ tely prior to the ~ubs~n~;~lly coated ag~,legale particles imp~ting 13 thereon.
14 In the plc~lled embodimP-nt of the present invention, a secondary bank 60 of spray no77les is positioned adjacent to the first path 46 16 opposite the first bank 54. The no77l~s of the s~ond~ry bank 60 are of 17 the same type as the no771es of the first bank 54, except that each spray 18 nozzle in the secondary bank 60 ~imlllt~neously sprays a~--,~ed liquid 19 binder material along a fourth predet~,nlined path 62 and a fifth predele,lllined path 64. The fourth predelellllined path 62 intel~ls the 21 first predetellllined path 46 above the concl~te 34, and since the secondary 22 bank of no77lçs 60 is o~oses the primary bank, at~ d droplets of 23 liquid binder material sprayed from the second bank 60 along the fourth 24 path 62 coats one side of each particle as it free-falls, thereby coating the portion of each particle is shiPlded from the spray of the first bank by the 26 particle itself.
27 The fifth prede~ll.. ined path 64 intel~~~ the ~ulJsll~te at a third 28 loc~tion 66 in spaced relation to the first loc~tion 48, and the first loc~tion 29 48 is be~ween the second 56 and third 66 loc~tion~. Atomized droplets of liquid binder material sprayed along the fifth predete,~ ed path 64 {ST-90} 6 intersect the concrete 34 at the third loc~holl 66, which, due to the 2 movement of the applicator 10 in the first direction 58 relative to the 3 concrete 34, lays down a top-coat 68 of liquid binder m~teri~l over the 4 aggregate particles 30 on the sel~ted portion of the concrete 34.
The plcfellcd embo l;.,.. ~nt of the applicator 10 of the present 6 invention incl~ldes a second hopper 28 and a ~efl~tor plate 70 for 7 deflecting particles released from the second hopper 70 into the first 8 predele,."ined path 46 is located im-,~ t~ly below the first 26 and 9 second 28 hoppers. If an ag~legate coating is desired which includes a ~ ure of very fine particles of one type of m~t~ri~l and coarser particles 11 of another type of m~t~ri~l, storing the fine and coarse particles in the 12 same hopper would likely result in the fine particles settling to the bottom 13 thereof. Accordingly, the concentr~tion of fine particles in the aggç~gale 14 released from the hopper would initially be relatively high, and decrease as the hopper was emptied during the coating ~vcess.
16 This problem is avoided by storing the two agg,~gate particle types 17 in sepa,~te hoppers, 26, 28 and using the ~efl~tQr plate 70 to direct the 18 particles released from the second hopper 28 into the path 46 of the 19 particles released from the first hopper 26. By controlling the rate at which the particles are released from each hopper 26, 28, the desired 21 cQI-cçntration of fine particles can be ~ r~ ned throughout the coating 22 l,lucess until one of the hoppers becomes empty. Ad~ition~l hoppers and 23 release mçch~ni~ms may be added as needed to acco~ o~l~te mixing of 24 agglcg~te co~ting~ having three or more different materials of varied particle size.
26 Even if agglcgale particles of only one ~--alelial, such as sand, are 27 used in the co~ting, it may be desirable to use two hoppers 26, 28 to28 obtain a more con~ictent rate of delivery of the sand. For example, if the 29 agit~lol~ tend to release the particles in pulses or "waves", the a~i~lola can be m~h~nically or electrically controlled to insure that when the {ST gO} 7 waves of particles released from the second hopper 28 ihlLfl~L the first 2 predele.,-,ined path 46, the waves of particles released from the second 3 hopper 28 are out of phase with the waves of particles released from the 4 first hopper 26.
An alternate embodiment of the applicator 10 of the present 6 invention is shown in Figure 4. The al~el"ale embo-1inlent is the same as7 the p~relled embo~im~nt, except that the ~llf.. ~e embo~limpnt does not 8 include a ~efl~tor plate 70, and the second bank 60 of no zles in the9 alternate embodiment does not oppose the first bank 54 of no77lPs Absent the dçflector plate 70, agg~aLe particles are released from the 11 second hopper and free-fall along a sL~cth prede~el,llined path 72 that 12 t~l, in~ s at a fourth loc~hon 74.
13 Each spray nozzle in the se~ond~ry bank 60 of the alternate 14 embodiment simul~neollsly sprays atomized liquid binder material along a fourth predetell,lhled path 76 and a fifth ~)r~e~l",ined path 78, as in 16 the p,efel,ed embotlimçnt However, in the al~.. "ate embodim~nt, the 17 fourth predetermined path 76 inte.~;Ls the sixth predele.mined path 72 18 above the concrete 34, and therefore atomized droplets of liquid binder 19 material sprayed along this path 76 sul,sl~ lly coat the aggl~:gate particles as they free-fall from the release m~h~ni~m of the second 21 hopper 28. Atomized droplets of liquid binder "~qte~ ;~1 sprayed along the 22 fifth prede~e.l"ined path 78 intelxcl the concrete 34 at a fifth location 80 23 in spaced relation to the fourth location 74 and bel~o~n the first 48 and 24 fourth 74 ~ holls.
Due to the movement of the applic~tor 10 in the first direction 58 26 relative to the concrete 34, liquid binder Ill~t~ 1 sprayed along the fifth 27 predetell"ined path 78 primes the agg~ga~e particles from the first hopper 28 26, which have already been coated onto the s~lect~ por~on of the 29 concrete 34, with liquid binder material, imm~i~tt-ly pAor to subsequent co~ting of the sel~t~d portion with aggregate particles released from the {ST gO} 8 second hopper 28. Since the second bank 60 of no771PS in the all~.l,aLe 2 embo-liment is not positioned so as to produce a top-coat on the aggr~gate3 parhcles released from the second hopper 28, the ~ltprn~te embo~imPnt 4 leaves an aggrcgate top surface 82 which is partially unco~te~. This S parhally unCo~t~ top surface 82 is used to provide a higher coefficiPnt of6 friction for anti-skid co~tin~s, or a higher reflectivity for ~ecol~t;~e 7 co~,tings.
8 The applicator of the present invention sep~ately feeds the mixed 9 liquid binder .. ~te. ,~1 and granular aggregale fillers (sand, filler etc.) into a convergent area and subsequently dyn~mi~lly co.. hines them external 11 to the spray no771es in a cross convelgence. As those skilled in the art 12 will readily apyr~cidte, slot si_es and ~it~ho~ can be varied for dirr~leil~
13 materials or different sel~t~ areas of concleb~. ~ltholug~l the invention 14 has been shown and described as being useful for coating concrete, it is to be understood that the present invention is suitable for use on any 16 siniilar ~ubsLldle such as ~ph~lt, brick, etc. The present invention 17 reyl~se,lts an improvement over prior art spray coating techniques since 18 it improves sprayability, reduces excess material, and improves flowability 19 by re~iucing the viscosity of the liquid binder material without the production of hazardous waste, minimi7~s clogging and elil.. ;n~lf s the 21 wear that a nozzle typically expe~iences as a result of spraying an abrasive 22 material such as aggl~;~ate thelcll~uugb.
23 Although this invention has been shown and described with 24 respect to det~iled embo~im~nt~ thereof, it would be understood by those skilled in the art that various changes in form and detail thereof may be 26 made without depar~ng from the spirit and scope of the c1~ime~
27 invention.
~ST-90} 9
on concrete and other surfaces. Co~tin~ a sub~L~te such as concrete with 11 abrasive anti-skid co~ting~ or decorative co~tings typically le~uil~,s mixing 12 the a liquid binder material? with an agglegat~ such as sand or ground 13 quartz and then p~inting or spraying the ~ ul~, onto the concre~. If 14 only a portion of the ~L~Le ~uil~s co~ting~ accuracy and control requirements typically dictate whether the ~ ule iS applied by spraying 16 or by p~inting with some sort of brush. Spray coating processes, 17 however, are limited due to the low sprayability of the liquid binder 18 materials which are typically highly viscous, the limit in ~tt~in~ble coating 19 thickness, and the high amount of waste "laLerial gen~ laLed.
Many liquid binder materials that are utili7~ in applying anti-skid 21 co~tings or decorative co~ g~ (such as the reflective stripes used for lane 22 m~rking~ on roadways) have vi~ositi~s at ambient ~ dlule which 23 preclude the use of conventio~l spray applicators. In order to reduce the24 viscosity to a level which can utilize conventional spray applicators, the liquid binder m~teri~l is often m-ised with a solvent. Unfo-Lullately, such 26 solvents are often environment~lly hazardous, and th~fort waste m~t~ri~l 27 from the spray coating process must be disposed of as hazardous waste.
{ST-90}
The convention~l spray coating processes co~ ise c~lubil ing a 2 liquid binder material (which may incl~lde a curing agent), solvents, and3 ag~cgate in a vat to form a Illi~Ul~,. This l~ e is then ~ul-lped from 4 the vat through con~luit~ to a nozzle where it is atomized and sprayed onto the substrate. Once the ll~uLIule has been applied to the substrate, the 6 solvent is removed the.cIiolll by evaporation of volatile gas or by 7 applying heat to the Illi~LUlc to speed ev~ ;on of the solvent.
8 Unfortunately, Illi~lUles of ag~lcgdle and liquid binder lllatc-ial are 9 very prone to clogging, in both the con~lllit~ and at the nozzle. Since the lllixlule must be pumped thorough the coating system, the liquid binder 11 material can begin to set ~-vithin the system. Furthermore, the abrasive12 effect of the agglcgate on the pump, con~nit~ and nozzle subst~nti~lly 13 reduce the useful life of conventi~n~l spray system collll)ollents, 14 neceS~ ting frequent repair or repl~r~pmpnt of such colll~oncnL~.
What is needed is a method and applicator to con-vcl enlly spray 16 thin abrasive anti-skid or decorative coatings onto SUI~SI~dle such as 17 concrete while avoiding the problems of the prior art.
18 DISCLOSURE OF THE INVI~TION
19 It is therefore an object of the present invention to provide a method and applicator to conve.E,enlly spray thin abrasive anti-skid or 21 decorative co~ting~ onto ~IlI,slldte such as concrc~e without subjecting the 22 spray no zles of the l"~senl invention to the abrasive effects of ag~ ale 23 particles.
24 Another object of the present invention is to combine the aggregateparticles with a liquid binder material eYtem~l of the spray no771es of the 26 present invention.
27 Accoldillg to the pr~3cnt invention, an applicator is rlic~lose~l for 28 applying an aggr~gate coating to a ~ul,sL~dte, The applicator includes an 29 d~JaldLUS comprising a first hopper for supplying ag~l~gaLe particles, the {ST g0} 2 hopper in spaced relation to and above the substrate, first release means 2 for releasing the particles from said first hopper along a first 3 predele",.ined path that illL~;lS~;L~ the substrate at a first loc~tion, spray 4 means for spraying a liquid binder ",~ 1 along a plurality of paths, including a second predt:Le~ ed path and a third prede~~lll~ned path, 6 wherein the second predetermined path hlL~.secLs the first predel~llllined 7 path above the substrate, and the third ~l~delellllined path inl~ls~ls the 8 s-lb~Lldte at a second location in spaced relation to the first lor~tion, and 9 supply means for supplying the liquid binder material to the spray means;and, means for moving the a~us in a first direction relative to the 1 1 S.-~s~ldle.
12 The method of the present invention includes p~;l;.~n;ng apar~cle 13 supply above a portion of said substrate, the supply con~in;ng a plurality 14 of particles, relç~ing the particles from the ag~legate supply at a predetermined rate, allowing said particles to free-fall towards said 16 su~s~l~te, coating said particles with a liquid binder material as the 17 particles free-fall towards the substrate, thereby pro~ucin~ coated 18 particles, coating a portion of the substrate with the liquid binder material, 19 thereby pro~luçing a coated portion, and imp~cting said coated particles onto the portion of substrate.
21 The foregoing and other featul~s and advantages of the present 22 invention will become more ap~alent from the following description and 23 accoll.pallying drawings.
FIG. 1 is one embo(limPnt of the spray coating applicator of the 26 present invention.
27 FIG. 2 is an end view of the hoppers and ~lhllcU ~I bank of spray 28 nc!771~s taken along line 2-2 of FIG. 1.
{ST-90} 3 -FIG. 3 is a cross-sPction~l sçh~m~fie of the hoppers, spray banks 2 and predelellllined paths of the p~c~lcd embo~limpnt of the present 3 invention.
4 FIG. 4 is a cross-~tio~ schPm~ti~ of the hoppers, spray banks S and prede~lluil1ed paths of the an al~ llale çmbo~imp-nt of the p~senl 6 invention.
8 The present invention, as shown in Figure 1, is dil~;led toward 9 improving spray coating processes for applying anti-skid or decorative co~tings to substrates such as conc,c~ by decreasing hazardous waste and -11 system problems such as elo~in~ and wear. The applicator 10 is 12 preferably mounted on a vehicle 12, such as a truck, to provide a means 13 for moving the applicator in a first direction relative to the ~Ubslldt~. As 14 used herein, the term "liquid binder materiai" means an adhesive .. ~le~
such as epoxy, poly~ ane, or another polymer.
16 The applicator 10 has a supply means that inc!udes at least one 17 (and for binders which must be mixed with a curing agent, at least two) 18 liquid binder storage con~ e.~ 14, 16, a motionless mixer/pump 18 that 19 mixes both liquid binder Illate.;al conchtuçnt~ (if a two part binder liquid binder is used), a first conduit 20 that eysen~s from the collt~iners 14, 16, 21 to the mixer/pump 18, and a second cond~lit 22 that eYten~ls from the22 mixer/pump 18 to one or more sprdy no771~s In the ~l~f~l~d 23 embo limçnt, the storage conl~ine~ ~ 14, 16 are heated and ~ ,s~uli~od to 24 reduce the viscosity of the liquid binder con~ uçnt~ will~oul the use of solvents. The pr~ ed embo~im~nt further includes an air colllplessor 26 24 which may be integral with a ge&e.dtor, or may be driven by some 27 other power source on the truck. The pw~ose of the air colllpressor is 28 described in greater detail below.
{ST-90} 4 As shown in Figure 2, in ~ tion to the supply means, the 2 applicator 10 includ~s at least one, and preferably two hol)pe.a 26, 28 for 3 supplying aggregate particles 30 to the liquid binder ".~ 1 32. Each 4 hopper 26, 28 is located in spaced relation to, and above, the concrete S traveling surface 34. Integ~al with each hopper 26, 28 is a release 6 me~h~ni~m 36 for rele~in~ the particles from the hopper 28 ~c5oci~l~
7 therewith. Preferably, the release "~ ni~m 36 for each hopper 26, 28 8 includes a slot 38 in the hopper 26, 28 for rele~in~ the particles from that 9 hopper 26, 28, and a motorized rotary agitator 40 located in the slot forcontrolling the rate at which the particles are rel~ from that hopper 11 26, 28 through the slot 38.
12 One or more spray no77lps 42 are located on the truck ~ ent the 13 release slots. The no77llos 42 are ~r~f~bly fan spray no77les of the type14 which produce a fan 44 of atollli;c~d liquid binder Illi~f ~ ;~31 32 for broad coverage area. Although the ~r~a~e provided by the cont~in~rs 14, 16 16 and the pump 18 is used to force the liquid binder matelial 32 to spray 17 out of each no~le 42, each nozzle is preferably air-~si~t~. As such, 18 ~lesau-ized air from the air col--~r ssor 24 is introduced around each 19 nozzle 42 and aimed in the same direction as the liquid binder .. late,ial 32 exiting that nozzle 42. This additional air assists in c~lying the atomized 21 droplets along the desired paths. As shown in Pigure 2, when a relatively 22 long release slot 38 is used, several fan spray n- 771Ps 42 may be 23 manifolded to form a primary bank of no771~s which have spray fans 4424 that overlap so as to insure complete coverage of the aggl~ale particles 30 released from the hoppers 26, 28.
26 Referring now to Pigure 3, agglegate particles 30 are released 27 from the first hopper 26 along a first prede~.l-lilled path 46 that int~la~ls 28 the col~crele 34 at a first location 48. Each spray nozzle 42, because of 29 its fan spray characteris~cs, sprays liquid binder .natelial along a plurality of paths, and more spe~ifi~lly each no~le in the l,lilllal~ bank 54 {ST-90} 5 simultaneously sprays atomized liquid binder, ~f ;~l along a second 2 prede~el.. ined path 50 and a third predetf . inçd path 52.
3 The second predetermined path 50 int~L~ the first 4 predeLel-l-ined path 46 above the concrete 34, and th~ ;~ rO~ ~
droplets of liquid binder material sprayed along this path 50 s~bs~ t;~lly 6 coat the aggl~:gate particles as they free fall from the first hopper 26.
7 Atomized droplets of liquid binder ~l.ate~ial :~pl~yed along the third 8 prede~ led path 52 inLel~~l the con~;le~ 34 at a second location 56 in 9 spaced relation to the first loc~hon 48, which, due to the movement of the applicator 10 in the first direction 58 relative to the concrete 34, primes 11 a sele~ted portion of the corcle~ 34 with liquid binder material 12 imme~ tely prior to the ~ubs~n~;~lly coated ag~,legale particles imp~ting 13 thereon.
14 In the plc~lled embodimP-nt of the present invention, a secondary bank 60 of spray no77les is positioned adjacent to the first path 46 16 opposite the first bank 54. The no77l~s of the s~ond~ry bank 60 are of 17 the same type as the no771es of the first bank 54, except that each spray 18 nozzle in the secondary bank 60 ~imlllt~neously sprays a~--,~ed liquid 19 binder material along a fourth predet~,nlined path 62 and a fifth predele,lllined path 64. The fourth predelellllined path 62 intel~ls the 21 first predetellllined path 46 above the concl~te 34, and since the secondary 22 bank of no77lçs 60 is o~oses the primary bank, at~ d droplets of 23 liquid binder material sprayed from the second bank 60 along the fourth 24 path 62 coats one side of each particle as it free-falls, thereby coating the portion of each particle is shiPlded from the spray of the first bank by the 26 particle itself.
27 The fifth prede~ll.. ined path 64 intel~~~ the ~ulJsll~te at a third 28 loc~tion 66 in spaced relation to the first loc~tion 48, and the first loc~tion 29 48 is be~ween the second 56 and third 66 loc~tion~. Atomized droplets of liquid binder material sprayed along the fifth predete,~ ed path 64 {ST-90} 6 intersect the concrete 34 at the third loc~holl 66, which, due to the 2 movement of the applicator 10 in the first direction 58 relative to the 3 concrete 34, lays down a top-coat 68 of liquid binder m~teri~l over the 4 aggregate particles 30 on the sel~ted portion of the concrete 34.
The plcfellcd embo l;.,.. ~nt of the applicator 10 of the present 6 invention incl~ldes a second hopper 28 and a ~efl~tor plate 70 for 7 deflecting particles released from the second hopper 70 into the first 8 predele,."ined path 46 is located im-,~ t~ly below the first 26 and 9 second 28 hoppers. If an ag~legate coating is desired which includes a ~ ure of very fine particles of one type of m~t~ri~l and coarser particles 11 of another type of m~t~ri~l, storing the fine and coarse particles in the 12 same hopper would likely result in the fine particles settling to the bottom 13 thereof. Accordingly, the concentr~tion of fine particles in the aggç~gale 14 released from the hopper would initially be relatively high, and decrease as the hopper was emptied during the coating ~vcess.
16 This problem is avoided by storing the two agg,~gate particle types 17 in sepa,~te hoppers, 26, 28 and using the ~efl~tQr plate 70 to direct the 18 particles released from the second hopper 28 into the path 46 of the 19 particles released from the first hopper 26. By controlling the rate at which the particles are released from each hopper 26, 28, the desired 21 cQI-cçntration of fine particles can be ~ r~ ned throughout the coating 22 l,lucess until one of the hoppers becomes empty. Ad~ition~l hoppers and 23 release mçch~ni~ms may be added as needed to acco~ o~l~te mixing of 24 agglcg~te co~ting~ having three or more different materials of varied particle size.
26 Even if agglcgale particles of only one ~--alelial, such as sand, are 27 used in the co~ting, it may be desirable to use two hoppers 26, 28 to28 obtain a more con~ictent rate of delivery of the sand. For example, if the 29 agit~lol~ tend to release the particles in pulses or "waves", the a~i~lola can be m~h~nically or electrically controlled to insure that when the {ST gO} 7 waves of particles released from the second hopper 28 ihlLfl~L the first 2 predele.,-,ined path 46, the waves of particles released from the second 3 hopper 28 are out of phase with the waves of particles released from the 4 first hopper 26.
An alternate embodiment of the applicator 10 of the present 6 invention is shown in Figure 4. The al~el"ale embo-1inlent is the same as7 the p~relled embo~im~nt, except that the ~llf.. ~e embo~limpnt does not 8 include a ~efl~tor plate 70, and the second bank 60 of no zles in the9 alternate embodiment does not oppose the first bank 54 of no77lPs Absent the dçflector plate 70, agg~aLe particles are released from the 11 second hopper and free-fall along a sL~cth prede~el,llined path 72 that 12 t~l, in~ s at a fourth loc~hon 74.
13 Each spray nozzle in the se~ond~ry bank 60 of the alternate 14 embodiment simul~neollsly sprays atomized liquid binder material along a fourth predetell,lhled path 76 and a fifth ~)r~e~l",ined path 78, as in 16 the p,efel,ed embotlimçnt However, in the al~.. "ate embodim~nt, the 17 fourth predetermined path 76 inte.~;Ls the sixth predele.mined path 72 18 above the concrete 34, and therefore atomized droplets of liquid binder 19 material sprayed along this path 76 sul,sl~ lly coat the aggl~:gate particles as they free-fall from the release m~h~ni~m of the second 21 hopper 28. Atomized droplets of liquid binder "~qte~ ;~1 sprayed along the 22 fifth prede~e.l"ined path 78 intelxcl the concrete 34 at a fifth location 80 23 in spaced relation to the fourth location 74 and bel~o~n the first 48 and 24 fourth 74 ~ holls.
Due to the movement of the applic~tor 10 in the first direction 58 26 relative to the concrete 34, liquid binder Ill~t~ 1 sprayed along the fifth 27 predetell"ined path 78 primes the agg~ga~e particles from the first hopper 28 26, which have already been coated onto the s~lect~ por~on of the 29 concrete 34, with liquid binder material, imm~i~tt-ly pAor to subsequent co~ting of the sel~t~d portion with aggregate particles released from the {ST gO} 8 second hopper 28. Since the second bank 60 of no771PS in the all~.l,aLe 2 embo-liment is not positioned so as to produce a top-coat on the aggr~gate3 parhcles released from the second hopper 28, the ~ltprn~te embo~imPnt 4 leaves an aggrcgate top surface 82 which is partially unco~te~. This S parhally unCo~t~ top surface 82 is used to provide a higher coefficiPnt of6 friction for anti-skid co~tin~s, or a higher reflectivity for ~ecol~t;~e 7 co~,tings.
8 The applicator of the present invention sep~ately feeds the mixed 9 liquid binder .. ~te. ,~1 and granular aggregale fillers (sand, filler etc.) into a convergent area and subsequently dyn~mi~lly co.. hines them external 11 to the spray no771es in a cross convelgence. As those skilled in the art 12 will readily apyr~cidte, slot si_es and ~it~ho~ can be varied for dirr~leil~
13 materials or different sel~t~ areas of concleb~. ~ltholug~l the invention 14 has been shown and described as being useful for coating concrete, it is to be understood that the present invention is suitable for use on any 16 siniilar ~ubsLldle such as ~ph~lt, brick, etc. The present invention 17 reyl~se,lts an improvement over prior art spray coating techniques since 18 it improves sprayability, reduces excess material, and improves flowability 19 by re~iucing the viscosity of the liquid binder material without the production of hazardous waste, minimi7~s clogging and elil.. ;n~lf s the 21 wear that a nozzle typically expe~iences as a result of spraying an abrasive 22 material such as aggl~;~ate thelcll~uugb.
23 Although this invention has been shown and described with 24 respect to det~iled embo~im~nt~ thereof, it would be understood by those skilled in the art that various changes in form and detail thereof may be 26 made without depar~ng from the spirit and scope of the c1~ime~
27 invention.
~ST-90} 9
Claims (19)
1. A method for applying an aggregate coating to a substrate, said method comprising:
positioning a particle supply above a portion of said substrate, said supply containing a plurality of particles;
moving said particle supply relative to said substrate;
releasing said particles from said particle supply at a predetermined rate;
allowing said particles to free-fall towards said substrate;
coating said particles with a liquid binder material as said particles free-fall towards said substrate, thereby producing coated particles;
coating a portion of said substrate with said liquid binder material, thereby producing a coated portion; and, impacting said coated particles onto said portion.
positioning a particle supply above a portion of said substrate, said supply containing a plurality of particles;
moving said particle supply relative to said substrate;
releasing said particles from said particle supply at a predetermined rate;
allowing said particles to free-fall towards said substrate;
coating said particles with a liquid binder material as said particles free-fall towards said substrate, thereby producing coated particles;
coating a portion of said substrate with said liquid binder material, thereby producing a coated portion; and, impacting said coated particles onto said portion.
2. The method of claim 1 wherein the step of impacting said coated particles onto said portion is followed by the step of spraying a top coat of liquid binder material onto the coated particles imparted onto said portion.
3. The method of claim 2 wherein the step of positioning a particle supply above a portion of said substrate includes positioning a first particle supply above a portion of said substrate, said supply containing a plurality of first particles; and, positioning a second particle supply above a portion of said substrate, said supply containing a plurality of second particles.
4. The method of claim 3 wherein the step of releasing said particles from said aggregate supply at a predetermined rate includes releasing said first particles from said first particle supply at a first predetermined rate and releasing said second particles from said second particle supply at a second predetermined rate.
5. The method of claim 4 wherein the step of releasing said first particles from said first particle supply at a first predetermined rate and releasing said second particles from said second particle supply at a second predetermined rate is followed by the step of mixing said first particles with said second particles external of said hoppers.
6. The method of claim 4 wherein the step of impacting said coated particles onto said portion includes impacting said first particles onto said portion.
7. The method of claim 6 wherein the step of spraying a top coat of liquid binder material onto the coated particles impacted onto said portion is followed by the step of impacting said second particles onto said portion.
8. A system for applying an aggregate coating to a substrate, said system comprising:
an apparatus comprising a first hopper for supplying aggregate particles, said hopper in spaced relation to and above said substrate, first release means for releasing the particles from said first hopper along a first predetermined path that intersects the substrate at a first location, spray means for spraying a liquid binder material along a plurality of paths, including a second predetermined path and a third predetermined path, wherein the second predetermined path intersects the first predetermined path above the substrate, and the third predetermined path intersects the substrate at a second location in spaced relation to the first location, and supply means for supplying the liquid binder material to the spray means; and, means for moving the apparatus in a first direction relative to the substrate.
an apparatus comprising a first hopper for supplying aggregate particles, said hopper in spaced relation to and above said substrate, first release means for releasing the particles from said first hopper along a first predetermined path that intersects the substrate at a first location, spray means for spraying a liquid binder material along a plurality of paths, including a second predetermined path and a third predetermined path, wherein the second predetermined path intersects the first predetermined path above the substrate, and the third predetermined path intersects the substrate at a second location in spaced relation to the first location, and supply means for supplying the liquid binder material to the spray means; and, means for moving the apparatus in a first direction relative to the substrate.
9. The system of claim 8 wherein the supply means comprise at least one liquid binder storage container, a pump, a first conduit that extends from the container to the pump, and a second conduit that extends from the pump to the spray means.
10. The system of claim 9 wherein the first release means comprise a first slot in the first hopper for releasing the particles from the first hopper, and a first agitator for controlling the rate at which the particles are released from the first hopper through the first slot.
11. The system of claim 10 wherein the spray means comprise at least one primary fan spray nozzle which simultaneously sprays atomized liquid binder material along the second and third predetermined paths.
12. The system of claim 10 wherein the plurality of paths further include a fourth predetermined path and a fifth predetermined path, wherein the fourth predetermined path intersects the first predetermined path above the substrate, and the fifth predetermined path intersects the substrate at a third location in spaced relation to the first location, and the first location is between the second and third locations.
13. The system of claim 12 wherein the spray means comprise at least one primary fan spray nozzle which simultaneously sprays atomized liquid binder material along the second and third predetermined paths, and at least one secondary nozzle which simultaneously sprays atomized liquid binder material along the fourth and fifth predetermined paths.
14. The system of claim 10 wherein the apparatus further comprises a second hopper for supplying aggregate particles, said second hopper in spaced relation to and above said substrate, and second means for releasing the particles from said second hopper along a sixth predetermined path that intersects the first predetermined path above the substrate.
15. The system of claim 14 wherein the second release means comprise a second slot in the second hopper for releasing the particles from the second hopper, a second agitator for controlling the rate at which the particles are released from the second hopper through the second slot, and a deflector plate for deflecting particles released from the second hopper into the first predetermined path.
16. The system of claim 10 wherein the apparatus further comprises a second hopper for supplying aggregate particles, said second hopper in spaced relation to and above said substrate, and second means for releasing the particles from said second hopper along a sixth predetermined path that intersects the substrate at a fourth location.
17. The system of claim 16 wherein the second release means comprise a second slot in the second hopper for releasing the particles from the second hopper, and a second agitator for controlling the rate at which the particles are released from the second hopper through the second slot.
18. The system of claim 17 wherein the plurality of paths further include a fourth predetermined path and a fifth predetermined path, wherein the fourth predetermined path intersects the sixth predetermined path above the substrate, and the fifth predetermined path intersects the substrate at a third location in spaced relation to the first location, and the third location is between the first location and the fourth location.
19. The system of claim 18 wherein the spray means comprise at least one primary fan spray nozzle which simultaneously sprays atomized liquid binder material along the second and third predetermined paths, and at least one secondary nozzle which simultaneously sprays atomized liquid binder material along the fourth and fifth predetermined paths.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US85923897A | 1997-05-20 | 1997-05-20 | |
| US08/859,238 | 1997-05-20 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2237865A1 true CA2237865A1 (en) | 1998-11-20 |
Family
ID=25330413
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2237865 Abandoned CA2237865A1 (en) | 1997-05-20 | 1998-05-19 | Method and applicator for field application of anti-skid or decorative aggregate coatings |
Country Status (2)
| Country | Link |
|---|---|
| EP (1) | EP0879648A3 (en) |
| CA (1) | CA2237865A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2800757B1 (en) * | 1999-11-09 | 2002-06-21 | Cmtp Sarl | GRAVILLONNEER AND BINDER SPREADER ASSEMBLY WITH BINDER DIFFUSER RAMP FOR PREPREGNATION OF GRAVILLONS |
| US7798744B2 (en) | 2007-10-15 | 2010-09-21 | Road Science, L.L.C. | Seal coat process utilizing multiple applications of asphalt binder and aggregate |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR745592A (en) * | 1932-01-25 | 1933-05-12 | Alphonse-Josephe Schars | Coating or coating process for all applications, in particular for coating roads and means for implementing this process |
| FR2626593B1 (en) * | 1988-01-29 | 1992-02-28 | Screg Routes & Travaux | METHOD AND DEVICE FOR THE PRODUCTION OF A ROAD COVERING |
| FR2626907B1 (en) * | 1988-02-09 | 1992-03-27 | Secmair Sa | ROAD VEHICLE FOR THE SIMULTANEOUS APPLICATION OF BINDER AND GRAVILLAS ON A PAVEMENT |
-
1998
- 1998-05-19 CA CA 2237865 patent/CA2237865A1/en not_active Abandoned
- 1998-05-20 EP EP98304017A patent/EP0879648A3/en not_active Withdrawn
Also Published As
| Publication number | Publication date |
|---|---|
| EP0879648A3 (en) | 1999-04-14 |
| EP0879648A2 (en) | 1998-11-25 |
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