WO2013027056A1 - Appareil et procédé de fabrication d'un élément de maçonnerie enduit - Google Patents

Appareil et procédé de fabrication d'un élément de maçonnerie enduit Download PDF

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Publication number
WO2013027056A1
WO2013027056A1 PCT/GB2012/052062 GB2012052062W WO2013027056A1 WO 2013027056 A1 WO2013027056 A1 WO 2013027056A1 GB 2012052062 W GB2012052062 W GB 2012052062W WO 2013027056 A1 WO2013027056 A1 WO 2013027056A1
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WO
WIPO (PCT)
Prior art keywords
body part
coating material
profile
coating
scraping edge
Prior art date
Application number
PCT/GB2012/052062
Other languages
English (en)
Inventor
Norman Nelson
Michael CUSDIN
Anthony EYRE
Simon Baker
Original Assignee
WARING, Stephen Philip
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by WARING, Stephen Philip filed Critical WARING, Stephen Philip
Publication of WO2013027056A1 publication Critical patent/WO2013027056A1/fr

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0046Machines or methods for applying the material to surfaces to form a permanent layer thereon to plastics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05CAPPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C11/00Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
    • B05C11/02Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface
    • B05C11/023Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface
    • B05C11/028Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface with a body having a large flat spreading or distributing surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05CAPPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C11/00Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
    • B05C11/02Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface
    • B05C11/04Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface with blades
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05CAPPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C5/00Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
    • B05C5/02Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work
    • B05C5/0208Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work for applying liquid or other fluent material to separate articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05CAPPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C5/00Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
    • B05C5/02Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work
    • B05C5/0241Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work for applying liquid or other fluent material to elongated work, e.g. wires, cables, tubes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00Processes for applying liquids or other fluent materials
    • B05D1/40Distributing applied liquids or other fluent materials by members moving relatively to surface

Definitions

  • the present invention relates to building materials such as coated products, e.g. masonry products, and particularly though not exclusively to coated masonry products possessing a coating to produce the visual and/or tactile effect of masonry, stone, brick or other building material or masonry material.
  • Masonry-effect products typically comprise a body part coated with a masonry-effect material designed to present the visual appearance of genuine masonry, such as stone or the like. Examples include cladding applied to the external surfaces of houses or other buildings, and the replacement of degraded masonry within a surface of a stone building as part of a renovation work. Such products are desirable when the use of corresponding genuine masonry on the building is not possible or is undesirable. This may be so if the cost of genuine masonry is prohibitive or if the cost or difficulty of applying it to a building (e.g. as cladding) is prohibitive.
  • Existing masonry-effect products may be manufactured by providing a body part of suitably strong yet light material (e.g. plastic) having the desired external shape and profile, then manually applying to a surface of the body part a coating of masonry-effect paint, emulsion or fluid mixture which, when hardened, aims to present the appearance of stone or the like.
  • Other methods of manufacture include moulding the masonry-effect coating material around a surface of the body part using a suitably shaped mould.
  • the present invention aims to provide means and methods which may be employed to address these issues.
  • the invention is to apply a desired external surface profile to a coated product (e.g. masonry-effect) by the scraping action of a correspondingly profiled scraping edge applied to the coating material when fluid.
  • the scraping edge may scrape away excess of the masonry-effect coating thereby to impose the desired profile shape upon the underlying coating revealed by action of the scraping.
  • This permits efficient manufacture and the scraping action has been found, surprisingly, to result in a rough surface texture to the coating material (when hardened) which much better replicated a stone masonry surface both visually and in tactile terms.
  • the invention may provide apparatus for manufacturing a coated product (e.g. masonry product) comprising a body part coated with a coating material (e.g.
  • the apparatus comprising: coating means or apparatus adapted to apply the (e.g. masonry-effect) coating material as a fluid to a surface of the body part; scraper or apparatus defining a scraping edge with a re-entrant profile to engage the coating material to scrape therefrom excess quantities thereof when fluid; drive means or apparatus adapted to impart relative motion between the body part and the scraper apparatus when engaged with the coating material thereby to impose the profile of the scraping edge upon scraped coating material remaining on the body part long the direction of said relative motion.
  • coating means or apparatus adapted to apply the (e.g. masonry-effect) coating material as a fluid to a surface of the body part
  • scraper or apparatus defining a scraping edge with a re-entrant profile to engage the coating material to scrape therefrom excess quantities thereof when fluid
  • drive means or apparatus adapted to impart relative motion between the body part and the scraper apparatus when engaged with the coating material thereby to impose the profile of the scraping edge upon scraped coating material remaining on the body part long
  • the coating appararus may comprise a conduit for guiding said coating material when fluid to an applicator means or apparatus thereof adapted for applying the coating material to a said body part.
  • the applicator apparatus may comprise an inlet opening in a side of the conduit for receiving said body part into the bore of the conduit.
  • the applicator apparatus may comprise an outlet opening in an opposing side of the conduit having a periphery defining the scraping edge.
  • the outlet opening may be arranged for receiving the body part from the inlet opening according to the imparted relative motion together with the coating material applied thereto within the conduit.
  • the conduit may be a hopper having an open top for receiving coating material in fluid form.
  • the hopper may have a front wall defining the inlet opening and a back wall opposing the front wall, and defining the outlet opening.
  • the side walls of the hopper may be slanted to converge towards the inlet/outlet openings.
  • the applicator apparatus may terminate at a closed terminus defined by a (e.g. flat) terminal surface at the terminal end of the conduit (e.g. the floor of the hopper).
  • the terminal surface may define a periphery or boundary (e.g. the floor) of both the inlet opening and outlet opening in common.
  • the terminal surface may extend from the inlet opening to the outlet opening. It may be adapted to provide a sliding support surface across which the body part may slide during its transit through the bore of the conduit from the inlet opening to the outlet opening.
  • surfaces of the body part other than that against the terminal surface are exposed to fluid coating material within the conduit and exit the outlet opening coated therewith.
  • the surface of the body part shielded from coating material by the terminal surface may remain substantially un-coated.
  • the uncoated surface(s) may be desirable for the purposes of attaching the coated product to a surface in use which may preferably be better left uncoated.
  • the body part may comprise a thermally insulating material which should preferably interface directly with the surface to which the product is to be attached (e.g. a house wall, or structure) which can remain thermally decoupled from the coating surrounding other surfaces of the product.
  • the outlet opening is preferably in register with the inlet opening across the bore of the conduit.
  • the imparted relative motion is substantially linear motion.
  • the inlet opening may be smaller than the outlet opening. Consequently, a given portion of the body part which according to said relative motion is opposed initially by a peripheral edge of the inlet opening and subsequently by the scraping edge of the outlet opening, may be spaced further from the scraping edge when opposed thereby.
  • the profile of a peripheral edge of the inlet opening may substantially match the profile of the scraping edge at a reduced scale.
  • a body part having a surface profiling shaped to fill the inlet opening preferably does not fill the outlet opening and may be substantially uniformly spaced from the scraping edge by a spacing adapted to accommodate a desired thickness of the applied coating material.
  • the scraper apparatus may define a further scraping edge of the type defined above, spaced from the applicator apparatus along the path of said relative motion subsequent to the outlet opening.
  • the further scraping edge is aligned in register with the first scraping edge for receiving the coated and scraped body part output from the outlet opening for further scraping as described above.
  • the freshly scraped coating material upon a surface of a coated body part exiting the outlet opening of the coating apparatus often has a tendency to rise slightly as it is relieved of the over-pressure of the overlying coating material within the coating apparatus.
  • This that the thickness of the coating initially achieved by the initial scraping action at the outlet opening may not be the final coating thickness of the coating when hardened.
  • a second scraping action may be applied to the scraped coating on the body part after the scraped coating has had sufficient time to expand to its maximum extent.
  • the second scraping is preferably performed by a further scraping edge located at a distance from the outlet opening which allows sufficient time for this expansion given the speed of the aforesaid relative motion of the coated body part and the further scraping edge.
  • the further scraping edge may be located between 100mm and 200mm from the first scraping edge, e.g. between 140mm and 180mm, or about 160mm. These distances have been found to provide the suitable amount of expansion time without permitting undesirable amounts of drying/hardening in the coating in question, thereby not interfering with the further scraping action.
  • the outlet opening may be formed within an outlet profile member, such as a plate, which is detachably attachable to the conduit of the coating apparatus.
  • the inlet opening may be formed within an inlet profile member, such as a plate, which is detachably attachable to the conduit of the coating apparatus.
  • the conduit apparatus may comprise two opposing side walls defined at least in part by removable plates each defining a respective one of the inlet opening and the outlet opening.
  • the removable plates may be detachably attachable to the other walls of the conduit, or to other wall parts of the conduit, to place the inlet and outlet openings in register. Attachment may be via bolts screws or by a sliding action into suitable slots or grooves formed within the conduit for that purpose, thereby to form a sealing interface with the other wall parts of the conduit which does not permit leakage of the coating material when fluid.
  • the further scraping edge may be formed within an further profile member, such as a plate, which is detachably attachable to the apparatus adjacent (but preferably spaced from) the outlet opening (e.g. outlet profile member) of the coating apparatus along the path of the relative motion.
  • a plurality of further profile members may be provided, each one matching a respective one of the plurality of profiles provided by the plurality of outlet profile members.
  • the apparatus may comprise a plurality of the outlet profile members each defining a scraping edge which presents a different respective said re-entrant profile.
  • the apparatus may comprise a plurality of the inlet profile members each defining a respective peripheral aperture edge for the inlet opening which presents a different respective profile.
  • a scraping edge may be adapted to apply to the body part a coating having a thickness of between 3mm and 10mm, preferably between 3mm and 7mm, e.g. about 5mm.
  • the drive apparatus may comprise a conveyor means or apparatus adapted to convey the body part towards the inlet opening thereby to impart the relative motion.
  • the conveyor apparatus may comprise a plurality of conveying blades or teeth adapted to engage a surface of the body part thereat to impart the relative motion.
  • the conveyor apparatus may comprise a drive wheel or wheels positioned or positionable adjacent the coating apparatus and adapted thereat to engage a surface of the body part to urge the body part, by rotation of the drive wheel, towards the scraping edge.
  • the conveyor apparatus may comprise a continuous drive chain or belt constructed and arranged to outwardly present a belt or chain surface positioned or positionable adjacent the coating apparatus to engage a surface of the body part to urge the body part, by the travelling motion of the drive chain or belt when driven, towards the scraping edge.
  • the drive chain or belt may be driven by suitable drive wheels, gears or cogs. Conveying blades of teeth may project outwardly from the surface of the drive wheel(s), belt or chain to engage with a surface of the body part thereat to impart the relative motion.
  • the drive apparatus may comprise a drive motor, such as an electrical motor, for driving the conveyor apparatus.
  • the drive motor is arranged to drive the conveyor apparatus at one of a plurality of different selectable drive speeds thereby to permit selection of a speed for the relative motion from amongst the plurality of drive speeds.
  • the drive apparatus may comprise an actuator arranged to push a body part towards the inlet opening thereby to impart the relative motion.
  • the actuator may be arranged to extent or contract an actuator rod to perform this pushing.
  • the actuator may be attached to the apparatus such that extension and/or retraction of the actuator rod is in a direction parallel to the direction of the relative motion.
  • the apparatus may include a guide key which extends longitudinally along the direction of relative motion and has a uniform cross-sectional profile comprising a vertically upstanding trunk portion terminated by a horizontal branch portion.
  • a reciprocally shaped guide groove may be formed along the longitudinal length of the body part such that the guide key may be fitted snugly into the guide groove to permit the body part to slide along the guide key as it is moved according to the relative motion.
  • the vertical trunk portion of the guide key restrains/prevents transverse movement of the body part and the horizontal branch portion restrains/prevents vertical movement.
  • the coating material may comprise a cementitious composition, such as a hydraulic lime composition, e.g. a natural hydraulic lime (NHL).
  • the coating may comprise a render, plaster, mortar and/or a cement.
  • the coating comprises any one or more of the following materials: Prependuit; Thermocromex (or Monocromex or Monostastier or equivalent material). Such materials are available for purchase from St. Astier Limes and Mortars, in the United Kingdom.
  • the coating may comprise added fibres as a component of the mixture. Fibres or strands/strips of a malleable or pliant material (e.g. plastics) may be used. The fibres, strands or strips may be elongate and, for example, between 2mm and 10mm in length. These have been found to add strength and some flexibility to the coating when set.
  • the coating may comprise a fluid mixture comprising the following ingredients: 1.5 litres water per 1 kg of Thermocromex.
  • the mixture may be produced by mixing the ingredients for about six minutes. Of these six minutes, preferably the first four minutes of mixing is performed in a bladed mixer, such as a 4-bladed horizontal mixer such as would be known to the skilled person. Preferably the remaining two minutes of mixing is done using a higher speed of mixer/mixing, e.g. using a high-speed hand mixer. This has been found to produce desirable mixture properties in terms of viscosity, texture and response to the scraping action. Similar mixtures of water with Monocromex or Monostastier may be made.
  • the coating may comprise a fluid mixture comprising the following ingredients: 0.14 litres water per 1 kg of Prependuit.
  • the mixture may comprise 1.5 grams of said fibres, strands/strips per 1 kg of Prependuit.
  • the mixture may be produced by mixing the ingredients for about six minutes. The mixing may be performed in a bladed mixer, such as a 4-bladed horizontal mixer such as would be known to the skilled person.
  • the/a coating may comprise a mixture of Prependuit and another natural hydraulic lime, such as Thermocromex, e.g. in the ratio of 25%:75% by weight of the components prior to adding water.
  • the coating may comprise two separate coatings, such as a first coating applied to the body part and a second coating applied to the first coating of the body part.
  • the first coating may comprise a mixture containing Prependuit, such as described above.
  • the second coating may comprise a mixture containing Thermocromex (or Monocromex or Monostastier or equivalent material), such as described above.
  • a flexible mesh is applied to the exposed surface of the body part prior to application of the first coating to the body part, before the second coating is applied.
  • the second coating is preferably then applied to the first coating with mesh once set. It has been found that this assists in bonding or adhering the first coating material to the body part and generally adds to the strength of the coated final product.
  • the mesh may be made from a pliant glass-fibre or plastics material.
  • the mesh may preferably comprise mesh openings of between 5mm and 15mm in size (e.g. diameter or side), such as square mesh openings of about 10mm by 10mm.
  • the apparatus may include the body part, which may comprise polystyrene.
  • the body part may comprise a phenolic insulation material, or equivalent.
  • An example is Celotex available from Celotex Insulation Limited, in the United Kingdom.
  • the first coating may be applied directly to a surface of the body part.
  • a first scraping edge is provided for scraping the first coating as described above.
  • a second scraping edge is provided for scraping the second coating as described above.
  • the shape of the first scraping edge preferably matches the shape of the second scraping edge on a reduced scale.
  • the second scraping edge may impose the same profile on the second coating as was imposed on the first coating by the first scraping edge.
  • the body part being coated by the second coating is, of course, larger than the body part before it was coated by the first coating. The increased scale of the profile shape of the second scraping edge accounts for this.
  • the first scraping edge may be adapted to apply to the body part a first coating having a thickness of between 3mm and 10mm, preferably between 3mm and 7mm, e.g. about 5mm. This thickness may be inclusive of the aforesaid mesh if applied.
  • the second scraping edge may be adapted to apply to the body part a second coating having a thickness of between 3mm and 10mm, preferably between 3mm and 7mm, e.g. about 5mm.
  • the second scraping edge may followed by the aforementioned further scraping edge for applying a final "natural" finish (e.g. rough stone effect) to the second coating.
  • the invention may provide a method for manufacturing a coated masonry product comprising a body part coated with a coating material (e.g. masonry-effect), the method comprising: providing a said body part and a quantity of said coating material in liquid form for coating said body part; providing a scraping edge presenting a re-entrant profile; applying the coating material (e.g. in excess) as a fluid to a surface of the body part; imparting relative motion between the coated body part and the scraping edge scraping; engaging the coating material with the scraping edge to scrape therefrom excess quantities thereof, thereby to impose the profile of the scraping edge upon the scraped coating material remaining on the body part along the direction of relative motion.
  • a coating material e.g. masonry-effect
  • the method may include providing a conduit for guiding the coating material when fluid including an inlet opening in a side of the conduit and an outlet opening in an opposing side of the conduit having a periphery defining the scraping edge.
  • the method may comprise applying the relative motion and consequently receiving the body part into the bore of the conduit via the inlet opening and subsequently receiving the body part at the outlet opening with the coating material applied thereto within the conduit.
  • the outlet opening may be provided in register with the inlet opening across the bore of the conduit and said relative motion is substantially linear.
  • the method may include subsequently engaging the scraped coating material with a further scraping edge (such as described above) to scrape therefrom excess quantities thereof, thereby to impose the profile of the further scraping edge upon the scraped coating material remaining on the body part along the direction of relative motion.
  • the body part may be elongate and preferably the relative motion is in a direction along, or parallel to, the elongate axis of the body part.
  • the magnitude of the relative motion is preferably selected according to the dimensions of the profile being imposed by the scraping edge.
  • the relative motion may be expressed in terms of the reciprocal of the speed of relative motion (e.g. seconds of time taken to move one meter of relative movement).
  • the body part may be moved relative to the scraping edge in question, at a speed corresponding to a selected duration of time to move the body part by one meter along the direction of relative motion.
  • the speed of the aforesaid relative motion is most preferably determined according to the value of the length of the portion of the circumference of the profile of the product to be coated (e.g. as view in profile/cross-section across its longitudinal axis). This length value shall be referred to hereafter as the "coated profile parameter".
  • This length value shall be referred to hereafter as the "coated profile parameter”.
  • the speed of relative motion is preferably selected according to the viscosity of the coating material - e.g. lower rates of motion for higher values of viscosity.
  • the relative motion may be selected according to both the value of the coated profile parameter and the coating material being used, concurrently.
  • the speed of the relative motion is preferably inversely proportional to the coated profile parameter and/or the viscosity of the coating material.
  • the following table is a list of suitable measures of such speed (time taken per meter of uniform relative linear movement) for exemplary coating materials and coated profile parameter values.
  • the first coating material may be a Perpenduit composition, or other NHL as discussed above.
  • the second coating material may be a composition comprising Thermocromex (or Monocromex or Monostastier or the like), as discussed above.
  • the invention may provide a coated masonry product comprising a body part coated with a masonry-effect coating according to the method of the invention in its second aspect.
  • the body part of the product may be polystyrene.
  • Figure 1A illustrates a perspective view of an apparatus according to an embodiment of the invention
  • Figure 1 B illustrates a side view of the apparatus of figure 1
  • Figure 1 C illustrates a top view of the apparatus of figure 1 ;
  • Figure 1 D illustrates a front view of the apparatus of figure 1 ;
  • FIG. 1 schematically illustrates aspects of an embodiment of the invention
  • Figure 3 schematically illustrates a cross-sectional view of the aspect illustrated in Figure 2;
  • Figure 4 illustrates a perspective view of an aspect of the invention incorporating the apparatus of figures 1A to 1 D;
  • Figure 5 illustrates a cut-away view of a coated product
  • Figure 6 illustrates the dimensions employed to calculate a Coated Profile Parameter.
  • Figure 7 illustrates a side view of an apparatus according to an embodiment of the invention
  • Figure 8 illustrates a top view of the apparatus of Figure 7
  • Figure 9 illustrates an end view of the apparatus of Figure 7;
  • Figure 10 illustrates a cross-sectional end view of the apparatus of Figure 7 along the direction A-A;
  • Figure 1 1 illustrates a cross-sectional view of the apparatus of Figure 7 along the direction D- D;
  • Figures 12, 13, 14 and 15 show a front, cross-sectional (A-A), side and top view, respectively, of the hopper assembly of the apparatus of Figure 7;
  • Figure 16 schematically shows a guide key of the apparatus of Figure 7, and a reciprocally- grooved profile block for coating.
  • FIG. 1 A to 1 D there is illustrated a sequence of views of an embodiment of the invention comprising apparatus (1 ) for manufacturing a coated masonry product comprising a body part (9) coated with a masonry-effect coating material (100, Figure 3).
  • the apparatus comprises a coating apparatus (2) in the form of a hopper adapted to apply the masonry-effect coating as a fluid to a surface of the body part (9).
  • a scraping edge (16C, Figures 2 & 3) is provided with a re-entrant profile adapted to engage the masonry effect coating to scrape therefrom (see Figure 3) excess quantities thereof when fluid.
  • a drive apparatus (17) is provided which is adapted to impart relative motion (indicated by the bold arrows of figures 1 B, 2 and 3) between the body part (9) and the scraping edge when engaged with the masonry- effect coating.
  • the result is to thereby impose the profile of the scraping edge upon scraped masonry-effect coating (101 ) remaining on the body part long the direction of the relative motion of the body part past the scraping edge (see Figure 3).
  • the body part in the present example, comprises an elongate polystyrene profiled block intended to be coated with a masonry effect coating (101 ) to be used, when the coating is hardened, as a component for a lintel or window ledge on the external surface of a building.
  • the profile of the elongate block is uniform such that the same transverse profile is presented at all points on the longitudinal axis of the block.
  • the surfaces of the profile of the block intended to be coated are accessible and outwardly presented.
  • One surface of the block which it is not intended to coat is the surface upon which the block rests. This uncoated surface will present, when the coating of the block is otherwise complete, an exposed and accessible polystyrene surface with which to form an interface with elements of the external building surface to which the coated block is to be applied in use. This greatly increases the insulating capabilities of the coated product.
  • the hopper (2) of the coating apparatus comprises an entry wall (5) spaced from, and joined to, an exit wall (4) by two parallel side walls collectively defining a box-shaped hopper. Each of these four walls is joined to a floor surface (8) of the apparatus. The two side walls may be inclined e.g. to converge towards the floor surface to taper the hopper, depending on the size and shape of the profiled block to be coated.
  • the hopper defines a top opening (3) defined by the uppermost edges of the four walls of the hopper into which coating material may be poured in order to fill the hopper with such material in use.
  • the entry wall (5) of the hopper defines a profiled entry through-opening (16) having a profile (16A) shaped to closely match the profile of the polystyrene block (9) so as to permit entry of the profiled block through the entry wall.
  • a correspondingly profiled exit through-opening (16B) is formed in the exit wall (4) of the hopper in register with the entry through-opening such that the profiled block may concurrently pass through both the entry through-opening and the exit through-opening.
  • the shaping of the profile (16C) of the exit through-opening matches the shaping of the profile of the entry through-opening (16A) but on a slightly larger scale. This means that while the edges of the through-opening (16A) in the entry wall of the hopper are intimately close to opposing surface parts of the profiled polystyrene block (9) when received therein, the edges of the exit through-opening (16C) are more spaced from the same profile block surfaces (by about 5mm) when the profiled block is received within the exit through-opening.
  • the edges of the exit through-opening are shaped to closely follow the profiled shape of a received polystyrene block but also to be spaced therefrom consistently by a spacing of about 5mm.
  • an end of the polystyrene block is preferably inserted into the entry through-opening (16) in the entry wall of the hopper (5) so as to effectively close the entry through-opening.
  • the block may then be moved to concurrently enter the exit through-opening (16B) such that the profiled outer surface of the block is in close proximity to the profiled scraping edge (16C) of the exit through-opening.
  • the fluid coating material (100) may then be placed into the hopper to fully immerse the parts of the profiled polystyrene block located within the hopper between the entry and exit through-openings.
  • a subsequent linear movement of the profiled block in a direction along its longitudinal axis as indicated by the bold arrows in Figures 2 and 3, may then be applied to push the profiled block in a direction further out from the exit through-opening (16B) of the hopper.
  • This relative motion is preferably continued at a steady and uniform rate until the desired length of the elongate polystyrene block has passed through the exit through-opening of the hopper and has been coated by the coating material (100) within the hopper to provide a substantially uniform coating (101 ) over the surfaces of the elongate block which were exposed to the coating material within the hopper.
  • a further scraping edge (31 ) is provided by a plate (30) possessing a profiled through-opening substantially identical to the profiled exit through-opening (16C) of the exit wall (4) of the hopper.
  • the plate may be substantially the same as the exit wall (4) of the hopper.
  • the further scraping edge, and the through-opening defining it, are arranged in register with the exit through-opening of the hopper as schematically illustrated in cross- section in Figure 3.
  • the further scraping edge (31 ) is spaced from the scraping edge of the exit through-opening by a separation of about 160mm in a direction along the axis of movement of the profiled polystyrene block.
  • Coated parts of the profiled polystyrene block output from the hopper are received by the through-opening defining the further scraping edge (31 ) which acts upon the coating material, before it has hardened, to remove any remaining excess coating material and to impose once more the profile defined by the scraping edge of the exit through-opening (16C).
  • Figures 1A to 1 D show various views of the coating apparatus schematically represented in Figures 2 and 3.
  • Figure 1A illustrates the apparatus with the profiled polystyrene block (9) in place, whereas Figures 1 B, 1 C and 1 D illustrate the apparatus with the polystyrene block omitted for clarity.
  • the apparatus provides a floor surface (8) along which to slidingly move the polystyrene block.
  • the floor surface is in the form of a table or bench surface mounted upon legs to a convenient height.
  • An elongate rectangular through-opening (24) Figure 1 C is formed in the table surface and extends along a direction parallel to the intended movement of the polystyrene block and in register with both the entry and exit through-openings of the hopper.
  • a toothed belt-drive assembly (17) is mounted underneath the table surface, fixed to the table by suitable beams and struts, such that the toothed belt (18) of the belt-drive is, in part, presented through the through-opening (24) within the table surface.
  • the belt-drive comprises a three-phase electrical motor (20) adapted to power a drive wheel (21 ), and two separate belt wheels (22,23) around and upon which the toothed belt (18) of the belt-drive is mounted.
  • the motor (20) of the belt-drive (21 ) is adapted to drive the belt to travel around and over the two belt wheels (22,23) and the engaging drive wheel of the drive motor concurrently so as to move those parts of the belt exposed through the through-opening (24) of the table in a direction towards the hopper.
  • the speed at which the belt is so movable may be controlled by control of the speed of the drive motor (20).
  • Drive motor control apparatus such as would be readily apparent to the skilled person may be employed to this end.
  • the two separate belt wheels comprise a rear belt wheel (23) located adjacent to the rearmost end of the elongate through-opening (24) in the table top of the apparatus, and a fore-wheel located adjacent to the opposite end of the elongate through-opening nearest to the hopper.
  • the positioning of the two belt wheels (22,23) is such as to cause the teeth of those parts of the toothed belt (18) passing between the two belt wheels, to project beyond the upper periphery of the through-opening (24) at the surface level of the table of the apparatus so as to be able to engage with the opposing surface of the polystyrene block (19) presented to those teeth when the apparatus is in use and the polystyrene block lays over the through-opening.
  • the teeth of the toothed drive belt each comprise a blade which is elongate in a direction transverse to the length of the belt (and the through-opening in the table surface) so as to provide an extended blade edge with which to engage the underside of the polystyrene profiled block (9) as desired.
  • Each blade is shaped to taper to an apex in its mid region, thereby defining a substantially pointed blade which, preferably, has a rounded apex and otherwise straight blade edges either side of the apex.
  • the separation between successive blade edges is about 1 cm, or thereabouts.
  • Successive teeth are preferably arrayed in a regular array with a regular such spacing between them.
  • each blade is preferably between 2mm and 4mm, most preferably about 3mm in thickness (thickness prior to the thinner blade edge at the top of the blade element). This thickness has been found to provide the requisite tooth strength when employed as follows.
  • Operation of the belt drive to turn the toothed belt in the direction indicated by the bold arrows in Figure 1 B causes the array of teeth upon the belt to move towards the hopper and to push the polystyrene block in the same direction by action of the belt teeth engaging (i.e. "biting") the exposed polystyrene underside of the polystyrene block.
  • a pair of adjustable guide roller units (15) are suspended above the table surface of the apparatus in line with and over the through-opening (24) formed in the table surface.
  • Each roller guide unit comprises a plurality of rollers (15) adapted to touch the uppermost surface of the polystyrene block when located underneath them, so as to restrain any vertical movement of the polystyrene block such as might otherwise be produced by an upward pushing thereupon from the teeth of the toothed belt drive (18) underneath the polystyrene block.
  • each of the roller units (15) provide a back-stop to generate a reactive force against the polystyrene block when pushed from the opposite side by teeth of the belt drive wishing to engage the underside of the polystyrene block. This assists in the teeth engaging with that underside surface.
  • the vertical position of each of the roller units (15) may be adjusted to accommodate polystyrene blocks of different thicknesses and profiles by using dedicated height-adjusters (13, 14) via which the roller units are suspended over the table top surface.
  • Each guide roller unit is suspended from a transverse suspension frame mounted to and passing over the table surface in a direction transverse to the longitudinal axis of the through-opening (24) formed in the table surface.
  • a given roller unit (15) is suspended from a suspension frame via height adjusters (13,14) thereof.
  • a height adjuster preferably comprises a threaded screw element (14) mounted upon the suspension frame which concurrently engages a reciprocally threaded element (13) mounted upon the respective roller unit (15). Consequently, the turning of the screw element causes the reciprocally threaded element (13) and roller unit (15) to move axially along the threaded element (14).
  • the threaded element depends vertically from a transverse suspension frame.
  • a pair of opposed parallel guide walls (10) flank either side of the elongate through-opening (24) in order to restrain lateral movement of the polystyrene block (19) as it is driven therealong towards the hopper by action of the turning of the toothed belt drive (18) underneath it.
  • An adjustable guide platform (23A) is located between the rear belt wheel (23) and the fore belt wheel (22) of the belt drive in line therewith and is adapted to engage the (toothless) underside of the toothed belt (18) so as to support and maintain the vertical position of the toothed belt engaged with it.
  • the guide platform is adapted such that the belt is able to slide over the uppermost surface of the guide platform without being impeded.
  • the position of the guide platform is adjustable relative to the table surface (8) so as to adjust its spacing from the through-opening (24) formed in the table top of the apparatus. In this way, the guide platform may be used to adjust the extent to which teeth (19) of the tooth belt drive project or extend beyond the uppermost surface of the table through its through-opening in use.
  • the guide platform (23A) is also adjustable in inclination such that the inclination of those parts of the belt (18) passing over it may also be adjusted. It has been found that a slight inclination which causes the toothed belt to fall slightly in a direction away towards the hopper assists in providing a desirable degree of engagement between the teeth of the belt and the exposed polystyrene underside of the polystyrene block. It also enables a disengagement of teeth from the polystyrene of the block which causes far less damage to the polystyrene than at other inclinations.
  • Figure 4 shows a view of the apparatus illustrated in Figures 1 A to 1 D in which additional table units (25,26) are arranged either side of the hopper in order to support polystyrene blocks which are of considerable elongate length.
  • the polystyrene blocks in question made be one or several meters in length and much longer than they are wide.
  • the polystyrene employed in the polystyrene block may be Expanded Polystyrene (EPS). Such polystyrene of "Grade 200" is preferable.
  • EPS Expanded Polystyrene
  • Figure 5 illustrates schematically, in a cut-away view, a coated product according to a preferred embodiment of the present invention.
  • the coated product comprises the polystyrene block (9) illustrated in Figures 1A, 2 and 3.
  • a first coating comprises a base coating formed from a composition including a natural hydraulic lime, such as Prependuit (100A) into which is embedded a flexible glass-fibre mesh (102).
  • a second coating, applied over the first coating comprises Thermocromex (100B).
  • the thickness of the first coating is substantially 5mm and so is the thickness of the second coating.
  • the second coating is applied after the first coating has hardened.
  • Different scraping profiles are employed when applying the second coating as compared to the first coating. The profiles in question are of the same re-entrant shape, whereas the scale of the second scraping profile is slightly larger than that of the first scraping profile so as to permit the second coating material to be applied.
  • the speed of motion of the profiled block (9) relative to the hopper containing the material for coating the block is related to the circumference of the profile being coated.
  • a "coated profile parameter" may be defined as the value of the length of that portion of the circumference of the profile, viewed in cross-section across the longitudinal axis of the profiled block to be coated, excluding those portions of the circumference which are not intended to be coated.
  • the greater the value of the coated profile parameter the slower should be the relative motion of the profiled block as it is moved through the hopper.
  • the greater the viscosity of the coating material then the lower should be the rate of motion of the profiled block through the hopper.
  • Figure 6 schematically illustrates the method of calculating the coated profile parameter with reference to the cross-sectional profile (103 to 108) of the profiled block (9).
  • the circumference of the profile in question comprises contiguous lengths 103, 104, 105, 106, 107 and 108 of portions of the profile which collectively define the entire circumference of the profile.
  • all but the back profile portion (103) of the profiled block are intended to be coated. That is to say, the portions of the profile comprising the top (104), shoulder (105, 106), side (107) and base (108) of the profiled block are intended to be coated in this illustrative example with the result that the coated profile parameter would be calculated as the sum of the lengths of those profile portions.
  • the length of the top profiled portion (104) is 50mm.
  • the depth of the step (105) portion of the profile is 15mm.
  • the subsequent sloping shoulder (106) of the profile has a length of 131 mm which leads to a side profile portion (107) having a length of 85mm.
  • the base portion of the profile (108) has a length of 175mm. The sum of these lengths defines the value of the coated profile parameter, which is 456mm.
  • a profile having this profile parameter should preferably be coated with a Prependuit composition at a rate of motion corresponding to 30 seconds per metre of uniform linear motion of the profile through the hopper. Furthermore, experiments have shown that a profile having this coated profile parameter when coated with a Thermocromex composition should be subject to a relative movement corresponding to 95 seconds per metre of uniform linear movement of the profile through the hopper. It is to be noted that profiles of a widely varying variety of shapes may each result in the same or similar coated profile parameter (e.g. within a range) to which the same relative motions should be applied, for a given coating material, for optimal results. Furthermore, if different (e.g. fewer, more or other) profile portions of the profile (9) illustrated in Figure 6 are intended to be coated, this may also result in a different coated profile parameter and, therefore, a different optimal relative motion to be imposed during the coating process, depending on the coating material in question.
  • Figures 7 to 16 illustrate another embodiment of apparatus for manufacturing a coated masonry product according to the invention.
  • this embodiment and alternative drive assembly and hopper structure are employed as explained in more detail below.
  • the apparatus comprises an elongate table (1 10) centred upon the upper surface of which is a hopper assembly (60) for containing coating material (100) and comprises an entry wall (5) and an exit wall (4) within which profiled through-openings are formed to admit the cross-sectional profile shape of a profiled block (9) to be coated, in the manner described above.
  • a drive assembly comprises an actuator (1 13) including an actuator rod (1 13A) retractably extendable from within a double-acting hydraulic cylinder (1 13B) attached to the underside of the top surface of the table (1 10) at a distal end of the table via a mounting bracket (1 14).
  • the hydraulic cylinder and actuator rod each extent along the underside of the table top surface in parallel with the central axis of the table from one side of the hopper assembly to the other side where the actuator rod is coupled to the underside of the top surface of the table via an upstanding drive plate assembly (1 12) to which the distal end of the actuator rod is attached.
  • a control panel (1 15) comprises controls via which the actuator is controllable to extend or retract the actuator rod from/to the hydraulic cylinder at a controlled rate to control the speed and direction in which the drive plate assembly moves relative to the table surface to which it is coupled.
  • Hydraulic fluid drive apparatus (120) is arranged in fluid communication with the hydraulic cylinder to supply drive power thereto.
  • FIG. 10 shows the apparatus in cross-section A-A illustrating the roller bearings provided at the outer sides of the drive plate assembly to rollingly bear against, and be supported by, a roller guide-way assembly (1 17) comprising two separate but parallel roller tracks depending from the underside of the table top surface and extending along that underside in parallel with the longitudinal axis of the actuator rod.
  • a roller guide-way assembly (1 17) comprising two separate but parallel roller tracks depending from the underside of the table top surface and extending along that underside in parallel with the longitudinal axis of the actuator rod.
  • extension and contraction of the actuator rod imparts a sliding linear movement of the drive plate assembly along the longitudinal axis of the table towards or away from the hopper, as appropriate.
  • the sliding movement is supported by the roller bearings within the roller guide- way assembly underneath the table upper surface.
  • the drive plate assembly comprises two parallel plates which project upwardly from the upwardly from the uppermost surface of the table through a respective one of two parallel, elongate drive slots formed in the table surface.
  • the drive slots extend from a distal and of the table reachable by the drive plate assembly when the actuator rod is extended, to the nearmost side surface of the hopper where the inlet wall (5) of the hopper is located.
  • a drive bar (1 16) extends from one upwardly projecting drive plate to the other transversely across the longitudinal axis of the table on the side of the drive plate assembly facing the hopper.
  • the drive bar is mounted within recesses formed within upstanding edges of each of the two drive plates thereby to hold the drive bar to the drive plates.
  • a guide key (1 18), shown in detail in Figure 16, is also formed upon the uppermost surface (1 10) of the table top to be vertically upstanding therefrom and to extend longitudinally along the table top with uniform cross-sectional profile from the distal and of the table (where the drive plate assembly resides at maximum actuator extension) to the opposite end of the table passing centrally through the hopper.
  • the guide key comprises a vertically upstanding trunk portion (130) terminated by a horizontal branch portion (131 ) forming an inverted "L" profile.
  • a reciprocally shaped guide groove (1 18B) is formed along the longitudinal length of the profile block (9) parallel to its long edges such that the guide key may be fitted snugly into the guide groove to permit the profiled block to slide along the guide key as it is driven along the surface of the table by the advancing drive plate assembly.
  • the vertical trunk portion (130) of the guide key restrains/prevents transverse movement of the profiled block and the horizontal branch portion (131 ) restrains/prevents vertical movement.
  • Figures 12 to 15 show views of an alternative structure for the hopper (60) which is made easily adjustable in its lateral width to accommodate wider range of entry and exit wall (4, 5) widths containing wider/narrower profiled re-entrant edges, as desired for coating a variety of profiled block widths (9).
  • a frame (123) is releasibly mounted to the top surface of the table (1 10) via releasable clamps (121 ) at opposite sides of the hopper (60) and extends over the top surface transversely at a height above that surface corresponding to the height/dept of the hopper.
  • the hopper comprises four separate corner legs which each firmly attached (adjustably) to the transverse frame depend downwardly from the transverse frame to, and firmly against, the upper surface of the table.
  • the transverse frame includes two parallel, separated transverse beams from which a respective two of the four corner legs are attached collectively defining the rectangle corners of the hopper volume.
  • Two hopper side walls (124) each connect two nearmost corner legs across to bridge the two parallel transverse beams and define a pair of parallel opposing hopper side walls.
  • Each hopper side wall is firmly attached to each one of the two transverse beams via a respective clamp (122) which is releasable to release the hopper side wall from the transverse beam, and fixable to firmly reattach the side wall to the transverse beam again at a different location along the beam. In this way, the separation between the parallel opposing side walls of the hopper may be adjusted as desired.
  • Each clamp (122) is fitted to a flat top plate (125) extending transversely from the top end of the vertical portion of a respective side wall. The top plate abuts the top surface of the parallel beams of the frame (123) so as to be slidable along them when adjusting the vertical side wall position and maintaining its vertical orientation.
  • Opposing pairs of plate slots (127) are arranged in register at the opposing surfaces of the hopper side walls and are dimensioned to snugly receive, slidingly from above the hopper, a plate defining a profiled entry or exit wall (4,5).
  • the range of lateral adjustment of the hopper side walls mey be, for example, from 100mm to 1000mm in hopper width, or more if desired. While a few exemplary embodiments of the invention have been described both, it is to be understood that modifications, variants and equivalents thereto, such as would be readily apparent to the skilled person are encompassed within the scope of this invention, such as is defined by the claims.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Coating Apparatus (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

Cette invention concerne un appareil (1) pour fabriquer un élément de maçonnerie enduit comprenant une partie corps (9) revêtue d'un matériau d'enduit (101). Ledit appareil comprend un appareil applicateur d'enduit (2) conçu pour appliquer le matériau d'enduit (101) à l'état fluide sur une surface de la partie corps. Un ou plusieurs éléments de raclage (4, 30) définissent un bord de raclage présentant un profil rentrant pour entrer en contact avec le matériau d'enduit afin d'en racler les quantités excédentaires pendant qu'il est à l'état fluide. Un appareil d'entraînement (17, 113) est conçu pour appliquer un mouvement relatif entre la partie corps et le ou les élément(s) de raclage lors du contact avec le matériau d'enduit, de façon à appliquer le profil du bord de raclage sur le matériau d'enduit raclé restant sur la partie corps dans le sens dudit mouvement relatif.
PCT/GB2012/052062 2011-08-24 2012-08-22 Appareil et procédé de fabrication d'un élément de maçonnerie enduit WO2013027056A1 (fr)

Applications Claiming Priority (2)

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GB1114665.1 2011-08-24
GB201114665A GB2493952A (en) 2011-08-24 2011-08-24 Method and apparatus for coating building materials

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WO2013027056A1 true WO2013027056A1 (fr) 2013-02-28

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107262328A (zh) * 2017-08-16 2017-10-20 河北惠驰装饰材料有限公司 一种型材涂装装置
WO2018073776A1 (fr) * 2016-10-20 2018-04-26 Prometec S.R.L. Station pour l'application de substances fluides sur des matériaux en pierre
CN114589058A (zh) * 2022-01-11 2022-06-07 美述家智能家居有限公司 一种复合木板自动化涂胶设备

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US5672391A (en) * 1995-08-28 1997-09-30 888804 Ontario Limited Method of manufacturing foam core moldings
US20050229846A1 (en) * 2004-04-16 2005-10-20 David Schmidt Coating chamber and templates to produce decorative mouldings
US20050242463A1 (en) * 2004-04-29 2005-11-03 David Schmidt Method and apparatus to produce starter strips and decorative mouldings
US20090277380A1 (en) * 2008-05-09 2009-11-12 Schmidt David A Method and apparatus to coat eps foam cored mouldings

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Publication number Priority date Publication date Assignee Title
US5951805A (en) * 1997-10-02 1999-09-14 Nonis; Vittorino Method and apparatus for coating a decorative workpiece
WO1999017913A1 (fr) * 1997-10-02 1999-04-15 Angelo Rao Procede et appareil pour revetir une piece decorative

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5672391A (en) * 1995-08-28 1997-09-30 888804 Ontario Limited Method of manufacturing foam core moldings
US20050229846A1 (en) * 2004-04-16 2005-10-20 David Schmidt Coating chamber and templates to produce decorative mouldings
US20050242463A1 (en) * 2004-04-29 2005-11-03 David Schmidt Method and apparatus to produce starter strips and decorative mouldings
US20090277380A1 (en) * 2008-05-09 2009-11-12 Schmidt David A Method and apparatus to coat eps foam cored mouldings

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2018073776A1 (fr) * 2016-10-20 2018-04-26 Prometec S.R.L. Station pour l'application de substances fluides sur des matériaux en pierre
CN107262328A (zh) * 2017-08-16 2017-10-20 河北惠驰装饰材料有限公司 一种型材涂装装置
CN107262328B (zh) * 2017-08-16 2022-12-09 河北惠驰装饰材料有限公司 一种型材涂装装置
CN114589058A (zh) * 2022-01-11 2022-06-07 美述家智能家居有限公司 一种复合木板自动化涂胶设备

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GB201114665D0 (en) 2011-10-12

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