WO2017035231A1 - Systèmes et procédés pour l'automatisation de l'application de revêtements modificateurs de frottement - Google Patents

Systèmes et procédés pour l'automatisation de l'application de revêtements modificateurs de frottement Download PDF

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Publication number
WO2017035231A1
WO2017035231A1 PCT/US2016/048398 US2016048398W WO2017035231A1 WO 2017035231 A1 WO2017035231 A1 WO 2017035231A1 US 2016048398 W US2016048398 W US 2016048398W WO 2017035231 A1 WO2017035231 A1 WO 2017035231A1
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WO
WIPO (PCT)
Prior art keywords
binder
filler
applicator
frame
coupled
Prior art date
Application number
PCT/US2016/048398
Other languages
English (en)
Inventor
Keith Rainwater
Rick Howorko
Matthew Howorko
Jeff Rainwater
Jack D. STONE, Jr.
Original Assignee
Dbi Holding, Llc
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
Priority claimed from US14/835,614 external-priority patent/US9567716B2/en
Application filed by Dbi Holding, Llc filed Critical Dbi Holding, Llc
Priority to MX2018002321A priority Critical patent/MX2018002321A/es
Priority to CA2996411A priority patent/CA2996411C/fr
Publication of WO2017035231A1 publication Critical patent/WO2017035231A1/fr

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Classifications

    • 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

Definitions

  • the present invention relates generally to a system, and associated method, for applying friction-modifying coatings to a surface, and more particularly, for automating the application from a mobile platform of friction-modifying coatings to a surface of a substrate, such as a roadway.
  • the mixed polymer binder is then poured out onto the surface to be coated by tipping the garbage can over or dipping smaller buckets into the garbage can and then pouring the composite polymer binder out of the smaller container onto the surface to be coated.
  • the polymer binder is then spread over the surface, using a squeegee or similar device.
  • laborers manually shovel a friction-modifying filler onto the binder.
  • Manually operated blowers and similar instruments have also been used to distribute the friction-modifying filler.
  • the most common filler is bauxite which, once applied, partially sinks into the polymer binder.
  • the epoxy when it has hardened, acts to bind the filler to the substrate, creating a uniform coating. Because the filler is irregularly shaped, typically jagged and protruding from the polymer binder, it acts to increase the friction coefficient of the surface.
  • the conventionally practiced method of coating preparation utilizes manual mixing of the components. There is the potential for the components not to be mixed adequately, resulting in pockets of polymer binder wherein the ratio of resin to hardener is not optimal. This variability can ultimately affect the quality of the binder, adhesion to filler, the degree of curing and/or the curing time.
  • the mixing time of the binder is too long and the binder starts to cure prior to application on the substrate, it may reduce the spread ability and substrate adhesion as well as filler penetration and adhesion.
  • the binder is spread on the surface using a squeegee or the like which results in significant variability in the thickness of the binder across the surface of the substrate.
  • the binder can be too thick in some places and too thin in others. Thick binder can increase drying times and delay the surface availability. Moreover, it can also diminish the integrity of the coating as well as the performance of the coating if the filler is fully enveloped by the binder and does not stick up from its surface.
  • binder that is too thin can reduce the integrity and performance of the binder by not providing enough material to hold the filler in place or adhere it to the substrate.
  • the way the filler is added to the binder can also influence the quality, performance and integrity of the coating.
  • the filler In the conventional method of application when the filler is shoveled or blown onto the surface of the wet binder, it has the tendency to impact the surface of the binder and displace it away from the impact zone.
  • the filler uniformity and overall coating density can vary significantly. In areas with too much filler, the integrity of the coating can be reduced. In areas with too little filler, the frictional properties of the coating can be reduced.
  • the present invention accordingly, provides a system and method for applying friction-modifying coatings to a surface of a substrate, such as a roadway, using automated equipment mounted on a mobile platform, such as a truck, trailer, cart or the like, to make a simultaneous application of binder and filler to the surface.
  • the mobile platform is preferably driven or pulled across the surface to be coated while the binder and filler are applied to the substrate.
  • the binder applicator which binder may comprise a single component or plural components in nature, is positioned forward of the filler applicator, such that the binder gets applied to the substrate and, as the mobile platform moves forward, the filler is then added to the binder.
  • the time between the application of the binder and the addition of the filler is very short, such as less than a few seconds.
  • the binder applicator preferably comprises a cylindrical tube capable of being attached to a moving platform.
  • the tube preferably defines at least one cavity within the tube, and each end of the tube is closed.
  • the tube further defines at least one upper opening in an upper portion of the tube, and the at least one upper opening is capable of receiving binder into the cavity.
  • One or more lower openings are defined in a lower portion of the tube, wherein the one or more lower openings preferably collectively extend substantially across the length of the tube and are adapted for dispensing binder from the at least one cavity onto the surface of a substrate.
  • the one or more lower openings may assume the shape of a single slot, multiple slots, or multiple circular openings.
  • Multiple slots or openings are preferably arranged in two rows and overlap in an overlap region to facilitate a uniform dispensing of binder to a surface of a substrate.
  • the systems and methods enable the precise and uniform application of the coating by mechanically controlling and metering both the binder and filler. This ensures good control over coating thickness and binder-to-filler ratios, enabling the coating to be optimized to the surface and desired friction performance.
  • the method of this invention preferably utilizes inline mixers located immediately before a novel binder applicator to ensure excellent component mixing.
  • the binder applicator ensures the uniform application of binder to the substrate.
  • the binder applicator of the present invention is designed for ease of manufacture.
  • the systems and methods of this invention have several advantages over conventional means of applying friction-modifying coatings to substrates.
  • the method of this invention has the benefit of decreasing the amount of manual labor required to apply binder and filler to the substrate.
  • the conventional method employs manual labor to mix binder, apply binder to substrate, apply filler, and remove excess filler.
  • the processes of mixing and application of binder and filler are fully automated, thereby reducing the amount of labor required to apply the system to the substrate.
  • a further advantage of this invention is the increased safety benefit to the workers applying the friction-modifying coating.
  • the friction- modifying coating is generally applied after traffic is blocked off in one or more lanes, using barricades and the like. Although signs and markers are used to divert traffic, laborers still are at risk of being hit by vehicular traffic.
  • the mixing and application equipment is preferably mounted on the back of a truck or trailer pulled by a motorized vehicle, reducing the number of people required to openly walk on the roadway, exposed to traffic.
  • a further benefit of this invention is an increase in the application rate of the friction-modifying coating.
  • the conventional method of application results in an application rate of approximately 1,000 square yards per day.
  • the application rate can be increased to over 10,000 square yards per day, although conventional rates of application are possible if desired. This will have the benefit of decreasing the amount of time required to complete a project as well as a reduction in the disruption of the traffic, due to closure of the surface being coated.
  • a further benefit of this invention is a reduction in the time that transpires from the time the binder is applied to the substrate and the time the filler is added to the binder. For the previous methods of application, several minutes can pass before the filler is added to the binder. This is the result of the time required to mix and then manually apply the binder and then the filler to the binder.
  • the method of this invention results in the filler being added almost immediately to the binder in sequence and in virtually a one-step process.
  • the lapsed time between application of the binder and addition of the filler should be short, preferably less than 5 seconds. This results in greater filler penetration and a more durable coating.
  • Another benefit of this invention is the uniformity of the friction- modifying coating and filler within the composition.
  • the filler is added to the binder either by manually shoveling it, or through the use of a manually operated blower. Both of these conventional methods result in variability in the filler density per square foot of substrate surface, and patches containing too much filler and others not containing enough filler.
  • the method of the present invention results in the uniform application of filler across the width and length of the surface being coated.
  • there is high uniformity of filler density per square foot and the filler density can be controlled at an optimal value to ensure a desired friction coefficient with the least amount of filler.
  • the correct filler density also has the added benefit of ensuring the best ratio of filler and binder to produce the greatest coating strength, integrity, and durability.
  • the method of the present invention has the benefit of enabling accurate metering and control over the component ratio, excellent component mixing, and rapid application after the components are mixed.
  • the use of automated flow controls ensure the desired component flow ratios, and the use of inline mixers located proximate to application ensure good mixing of components.
  • the short duration of time from mixing until application has the benefit of ensuring that the mixed binder is applied quickly at the ideal curing point and temperature, which in turn will ensure excellent filler penetration, substrate adhesion, and coating uniformity.
  • Still another benefit of this invention is reducing costs of repairs.
  • the non-uniformity of the conventional methods as discussed above resulted in sections of coated substrate with a sub-par coating. Some of these sections lacked sufficient friction- modifying properties due to a lack of filler being applied. Other sections lost their friction- modifying properties sooner than anticipated because not enough binder had been applied. These issues resulted in costly repairs to re-coat the substrate.
  • the present invention provides increased uniformity in the application of binder and filler, thus reducing cost associated with re-coating.
  • the designs of various components used in the systems and methods of the present invention are also optimized for ease of manufacture, thereby further reducing costs associated with practicing the systems and methods of the present invention.
  • the binder applicator described herein employs a novel and cost-effective design that reduces the amount of labor associated with laser-drilling the component.
  • FIGURE 1 is a perspective view of a system for automating the application of friction-modifying coatings from a mobile platform, in accordance with principles of the present invention
  • FIGURE 2 is a schematic top view taken along the line 2-2 of FIG. 1, exemplifying a mobile platform embodying features of the present invention
  • FIGURE 3 is a schematic view exemplifying an alternate embodiment of a mobile platform embodying features of the present invention.
  • FIGURE 4 is a front view of a first embodiment of a binder applicator in accordance with principles of the present invention
  • FIGURE 5 is a bottom view of the binder applicator in FIGURE 4 taken along section line 5-5 of FIG. 4;
  • FIGURE 6 is a cross-sectional view of the binder applicator in FIGURE 4 taken along section line 6-6 of FIG. 4;
  • FIGURE 7 is a front view of a second embodiment of a binder applicator in accordance with principles of the present invention.
  • FIGURE 8 is a bottom view of the binder applicator shown in FIGURE 7 taken along section line 8-8 of FIG. 7;
  • FIGURE 9 is a front view of a third embodiment of a binder applicator in accordance with principles of the present invention.
  • FIGURE 10 is a cross-sectional view of the binder applicator in FIGURE 9 taken along section line 10-10 of FIG. 9;
  • FIGURE 11 is a front view of a fourth embodiment of a binder applicator in accordance with principles of the present invention.
  • FIGURE 12 is a bottom view of the binder applicator in FIGURE 11 taken along section line 12-12 of FIG. 11 ;
  • FIGURE 13 is a partial view of the binder applicator in FIGURE 12 taken within view line 13 of FIG. 12;
  • FIGURE 14 is a front view of a fourth embodiment of a binder applicator in accordance with principles of the present invention.
  • FIGURE 15 is a bottom view of the binder applicator in FIGURE 14 taken along section line 15-15 of FIG. 14;
  • FIGURE 16 is a partial view of the binder applicator in FIGURE 15 taken within view line 16 of FIG. 15;
  • FIGURE 17 is a perspective view of the invention according to an alternative embodiment of the invention.
  • FIGURE 18 is a side view of the invention of FIG. 17 with the dispenser assembly in a raised position;
  • FIGURE 19 is a side view of the invention of FIG. 17 with the dispenser assembly in a lowered position;
  • FIGURE 20 is a top view of the invention of FIG. 17 with the dispenser assembly in a collapsed mode
  • FIGURE 21 is a top view of the invention of FIG. 17 with the dispenser assembly in an expanded mode
  • FIGURE 22 exemplifies a nozzle used for spraying polymer
  • FIGURES 23-25 exemplify the spray bar
  • FIGURE 26 exemplifies the spray bar fully retracted
  • FIGURE 27 exemplifies the spray bar fully extended.
  • the invention relates to the controlled preparation and application of friction-modifying coatings, comprising a binder and filler, to surfaces subject to vehicular, human, and/or animal traffic.
  • Friction-modifying coatings are applied to areas where the friction coefficient of the surface needs to be increased in order to reduce skidding or slipping, making it safer and/or better for its intended purpose. Included in the many substrate surfaces which can benefit from the application of these coatings are pathways, walkways, highways and roadways, bridge decks, parking lots, school zones, road crossings, railway crossings, dangerous intersections, bike lanes, toll lanes, sharp corners, intersections, overpasses, hospital zones, playgrounds, gymnasiums, and the like.
  • the reference numeral 100 generally designates a multi-part coating system embodying features of the present invention.
  • the system 100 includes a mobile platform 102 coupled to a truck tractor 103 (shown only in part) adapted for pulling the mobile platform 102 on the surface of a substrate 202 whose properties are to be modified.
  • the mobile platform 102 coupled to a truck tractor 103 may be replaced with a truck.
  • the truck or truck tractor 103 is preferably adapted for pulling the mobile platform over the substrate 202 at between about 0.1 and 5 miles per hour, although speeds of up to 30 miles per hour or even faster could be used in certain applications.
  • the mobile platform 100 travels over the surface of the substrate 202 to be coated and applies a coating to the substrate as it moves forward.
  • the mobile platform 100 is typically between about 1 and 30 feet wide, and preferably between about 8 and 12 feet wide.
  • One or more storage vessels or containers 104 are positioned on the platform 102 for containing various binder components, discussed in further detail below.
  • the storage containers 104 may be operated at atmospheric or elevated pressure. Further, the storage containers 104 are coupled via lines 106, one or more metering devices 108, and lines 116 to a binder applicator 1 18.
  • the metering devices 108 may include pumps (e.g. , positive displacement pumps, screw pumps, and the like), extruders, valves, control valves, orifices, flow controllers and/or the like, or a combination thereof, well-known to those skilled in the art, for conveying or metering components contained within the containers 104.
  • a hopper 122 is preferably also positioned on the mobile platform 102 for storing filler to be added to the binder, as discussed in further detail below.
  • one or more flow zones and/or zone flow controllers 120 are coupled to the hopper, rearward of the binder applicator 118, for metering filler to be applied onto the binder.
  • a distributor 124 is preferably positioned under the controllers 120 for facilitating an even distribution of filler onto the binder.
  • FIGURE 2 is a schematic top view of the trailer 102, taken along the line 2-2 of FIG. 1.
  • FIG. 2 depicts optional elements, such as an optional mixer 112 coupled to the meters 108 via lines 110.
  • the mixer 112 is adapted for mixing the components stored in containers 104 pumped from the meters 108, although mixing can alternatively occur directly in lines 114 and 116 (e.g., inline mixers) if the mixer 112 is not present.
  • the binder applicator 118 may comprise multiple binder zones (e.g., B- ZONE 1 to B-ZONE x). Each binder zone preferably has at least one line 116 associated with it, which allows binder zones to be individually turned-on or tumed-off
  • the number of hopper flow control zones 120 e.g. , F-ZONE 1 to F-ZONE x
  • the binder applicator 118 consists of a single binder zone, and similarly, there is but a single hopper flow control zone 120.
  • a portion of the surface of the substrate 202 is designated as a heating zone 125 which is heated or dried, prior to application of the binder, using any suitable technique, such as hot air, radiation, ultraviolet (UV) light, infrared (IR) light, microwaves, or the like, to prepare the surface of the substrate and facilitate adhesion of the binder to the surface.
  • a heating zone 125 which is heated or dried, prior to application of the binder, using any suitable technique, such as hot air, radiation, ultraviolet (UV) light, infrared (IR) light, microwaves, or the like, to prepare the surface of the substrate and facilitate adhesion of the binder to the surface.
  • a curing zone 126 optionally identified proximate to the hopper flow control zones 120.
  • equipment or means for expediting or facilitating binder curing including equipment for blowing air onto the binder, or applying to the binder radiation, such as IR light, UV light, heat, microwaves, and/or the like.
  • the systems and methods of the invention comprise the use of a multipart coating system, preferably comprising a binder and a filler embedded in the binder.
  • the binder acts as a matrix to suspend and hold the filler in place and causes it to adhere to the surface of the substrate.
  • the filler acts to change the friction coefficient of the surface by protruding from the binder or otherwise increasing the overall coefficient of friction.
  • the systems and methods of the invention apply binder and filler to surfaces of a substrate (e.g. , roads, highways, and the like) subject to traffic, thereby modifying the frictional properties of the surfaces.
  • the filler and binder are metered and applied to the substrate 202 in an automated, continuous, virtually one-step process that results in better coating integrity, uniformity, durability, and reduced application time.
  • the binder is preferably a single or plural component binder that is preferably stored in one or more storage vessels or containers 104 on the mobile platform 102. In the case of a single component binder that is solid at ambient conditions, heat may optionally be added to storage containers 104 and/or lines 106 to liquefy the binder and enable it to be more readily transferred through lines, piping, or the like.
  • the flow of the binder is precisely metered using metering devices 108, such as positive pumps, displacement pumps, screw pumps, extruders, valves, control valves, orifices, or the like, or a combination thereof.
  • multi-component binders the various components are preferably mixed by way of a mixer 112, and are then passed via lines 114 and 116 to the binder applicator 118.
  • multi-component binders may be mixed in lines 114 and 1 16, for example, using an inline mixer (not shown).
  • the mixer 112 is not needed, and the binder preferably flows directly to the binder applicator 118.
  • the binder applicator 1 18 spreads out the binder across the width of the surface to be coated and deposits a uniform layer of binder across the desired width.
  • the binder applicator 1 18 may have one or more binder zones (B-ZONE 1 to B-ZONE X). Each binder zone preferably has at least one line 116 associated with it. This allows an operator to individually turn-on or turn-off a particular binder zone.
  • the width of the substrate being coated can be controlled by the number of binder zones (B-ZONE 1 to B-ZONE X) that are activated.
  • the filler contained in hopper 122 is metered through zone flow controllers 120 (F-ZONE 1 to F-ZONE x) and applied onto the binder.
  • the number of hopper flow control zones is preferably the same as the number of binder zones.
  • the width of application is controlled by controlling the number of binder zones (B- ZONE 1 to B-ZONE x) and filler zones (F-ZONES) used. Additional conveyers (not shown) may be used to more uniformly distribute the filler across the width of the binder.
  • accelerators such as UV or IR radiation, heat, microwaves, and/or the like, may be used to facilitate or accelerate the curing of the binder.
  • the binder first flows through lines 110 to one or more mixers 1 12, through the lines 1 14 and 116, and then through the binder applicator 118.
  • the one or more mixers 112 preferably comprise contained motorized mixers, mixing screws, paddles, impellers, propellers, in-line mixers, static mixers, and/or the like, effective for uniformly mixing a plurality of components.
  • the binder then flows to the binder applicator 118 proximate to B-ZONE 1 to B-ZONE x.
  • the filler is preferably applied as discussed above after the binder has been applied to the substrate 202.
  • the filler and binder are mixed prior to application and then applied at the same time.
  • the filler and binder are metered into a mixing zone comprising a section, such as a vessel, tank, channel, pipe, box, or other suitable means effective for creating contact between a plurality of components prior to application on the substrate.
  • a mixing device such as a paddle, blade, impeller, propeller, screw, conveyor, tumbler or the like, effective for mixing a plurality of components, may be used to mix the filler and binder.
  • the binder can be a one or multiple part system, comprising one or more of polymers, elastomers, thermoplastics, thermosets, or the like, including vulcanized rubbers, Bakelites, urea-formaldehydes, melamine resins, epoxy resins, polyamides, plastics, peroxides, silanes, cross-linked metallic compounds, isocyanates, resins, polyethylenes, polypropylenes, polystyrene, polymethylmethacrylate, vinyls, Polybutylene terephthalates, polyureas, polycarbonates, Polyethylene terephthalates, Acrylonitrile butadiene styrene (ABS) acrylics, celluloids, cellulose acetates, ethylene-vinyl acetates, ethylene vinyl alcohols, fluoroplastics, ionomers, Kydex, liquid crystal polymers, polyacetals, polyacrylates, Polyacrylonitriles, polyamides, Polyamide-
  • additives such as viscosity modifiers, catalysts, accelerators, UV protectors, inhibitors, antioxidants, repellants, oils, and the like, can be added to the binder to change its physical or chemical properties to enhance characteristics such as pumpability, spreadability, curing rate, cured binder properties, ductility, motility, hardness, adhesion cohesion sprayability, extrudability, durability, wear rate, applyability, oxidative stability, thermal stability, UV stability, and the like.
  • the binder once applied and cured, be solid or semisolid at the normal, or ambient, operating conditions of the substrate.
  • the binder is preferably applied as a liquid which then solidifies once it is applied to the substrate; however, it is possible to apply solids such as powders, pellets, or the like, directly to the substrate and subsequently melt, react, or dissolve them to form a uniform coating.
  • the binder is applied as a liquid which cures and hardens after application to the substrate through chemical or physical changes, such as cross-linking, curing or solidification, and/or the like.
  • thermo-plastic if a thermo-plastic is used as the binder, the thermoplastic may be heated above its melting point, prior to its application to the substrate, until it becomes a fluid. Thereafter, the fluid cools to a uniform solid. If a multi-component liquid binder is used, then the liquid parts are preferably combined prior to application and cured into a solid. Heating may be used depending on the binder to change the physical properties of the binder to enhance pumping and/or ease of application.
  • a liquid binder may be applied to the substrate, and radiation, heat, microwaves, light, and/or the like, may be used to cure the binder.
  • the binder applicator 1 18 preferably applies the binder to the substrate by pouring, dripping, spraying, rolling, brushing, extruding, wiping, squeegeeing, ribboning, baring, and/or the like.
  • the filler is preferably added to the binder prior to hardening or curing in a metered fashion at a rate calculated to attain a desired density and respective coating frictional properties.
  • the filler preferably comprises one or more minerals, rocks, metals, metal oxides, hydrates, hydroxides, salts, silicates, plastics, polymers, glasses, halides, sulfides, phosphates, carbonates, carbon, oxides, ores, and/or the like.
  • the filler is preferably applied to the binder through a hopper or similar device which temporarily stores the filler. Application of the filler to the binder preferably occurs through a drop or rotary spreader, blower, conveyor, screw, or similar material transfer device.
  • fillers, catalysts, or performance-enhancing materials can also be added to the binder to enhance the properties of the friction-modifying coating.
  • fillers, catalysts, or performance-enhancing materials may include catalysts, compatabilizers, ultra-violet stabilizers, thermal stabilizers, oxidative stabilizers, chemical stabilizers, wear resistance modifiers, reflectivity enhancers, water repellants, oil repellants, ice repellants, co-polymers, rubbers, pigments, and/or the like, effective for changing the properties or performance of the coating.
  • the application of the binder and filler are preferably mechanically linked in close proximity to each other on a mobile platform 202, such as a truck or trailer, which passes over the substrate to be coated.
  • the binder can be applied from one mobile platform and the filler can be applied from another mobile platform.
  • the binder As the mobile platform(s) moves forward, the binder is precisely metered and applied to the substrate 202.
  • the filler is metered and precisely added on top of the binder. Both the binder and filler are added in proportion to the speed of the mobile platform(s) to ensure the proper application thickness and proportions of filler and binder. Once the binder has hardened, the excess filler is collected and reused.
  • the preferred binder is a two part epoxy comprising a catalyst (hardener) and a resin.
  • the hardener and resin are stored in storage vessels or containers 104 on the mobile platform 100.
  • Each part of the epoxy individually, is preferably filtered and then conveyed using positive displacement pumps on meters 108, or similar means of material transfer and control, to one large static mixer, or preferably a series of smaller static mixers, located in close proximity to a binder applicator 1 18.
  • inline mixers may be located in lines 116.
  • the ratio of the two parts of the epoxy is precisely controlled by adjusting the ratio of the flow or hardener to the flow of resin using a hardener pump and/or resin pump.
  • the ratio of resin to hardener differs with the epoxy system, but conventionally varies from approximately 5 parts resin and 1 part hardener to 1 part resin and 5 parts hardener. In one preferred embodiment, an approximate ratio of 1 part resin to 1 part hardener is used.
  • the application rate of the binder is adjusted to produce a thickness of between about 1 mil and 500 mils, and preferably between 40 and 80 mils.
  • the desired application thickness is determined by the substrate 202 properties, surface, climate, filler properties, desired frictional properties, and/or the like. Using the method of this invention, the thickness can be precisely controlled by varying the speed of the mobile platform 100 and the total flow rate of the binder.
  • a series of between 1 and 20 inline mixers are used to combine and uniformly mix the two parts of the epoxy, although other mixer types can also be used.
  • the number of inline mixers corresponds to the number of binder zones (B-ZONES); however, it is possible to use one mixer and then feed each of the binder zones from the one mixer.
  • the inline mixers are designed to ensure thorough mixing of the hardener and resin prior to application through the binder applicator 118.
  • the binder applicator 118 preferably comprises a cylindrical tube, such as a pipe, within which is defined a hollow cavity 405.
  • the binder applicator 1 18 has one or more zone partitions 410 that define two or more binder zones, as also exemplified by FIG. 2.
  • Lines 116 connect the binder applicator 118 to the upstream components (e.g. , storage vessels or containers, metering devices, and mixers).
  • the upstream components e.g. , storage vessels or containers, metering devices, and mixers.
  • an applicator bar 404 comprising a plate shown most clearly in FIG. 6, is attached to the binder applicator 118 to further regulate the uniformity and thickness of binder deposited onto the substrate 202.
  • the plate constituting the applicator bar 404 is preferably flat, as shown, but may also be curved.
  • FIGURE 5 shows a bottom view of the binder applicator 1 18 shown in FIG. 4.
  • One or more elongated co-linear openings or slots 402 are formed in the bottom of the binder applicator 1 18.
  • Each slot 402 corresponds to a separate binder zone.
  • the binder applicator 118 is preferably 8 to 12 feet long, although it may be shorter or longer.
  • the length of the openings or slots 402, collectively, is preferably at least 90% of the length of the binder applicator 1 18.
  • the width of the slots 402 is suitably sized for facilitating a desired or optimal binder flow rate.
  • the slots 402 may be formed in any suitable manner, such as by way of laser in a single pass while still permitting an optimal binder flow rate.
  • FIGURE 6 shows a cross-sectional view of the binder applicator 118 taken along section line 5-5 in FIG. 4.
  • the binder applicator 118 is roughly cylindrical with a diameter between one and six inches.
  • the binder applicator 118 can be of another shape (e.g., hexagonal, square, or rectangular when viewed from the side).
  • Line 116 is connected to the upper portion of binder applicator 118.
  • Opening or slot 402 is formed in the lower portion of the binder applicator 118.
  • the applicator bar 404 is preferably attached (e.g. , by welding) as shown to the binder applicator 118 behind the slot 402.
  • binder enters the binder applicator 118 via lines 116.
  • Binder fills the cavities 405 and is then dispensed through slot 402 preferably onto the applicator bar 404.
  • the applicator bar 404 further regulates the uniformity and thickness of binder, which is then dispensed onto the surface of the substrate 202.
  • the binder applicator 118 has three binder zones corresponding to the three cavities 405 fed by corresponding lines 116.
  • Each line 116, and hence each binder zone may be individually controlled, e.g. , by a switch or valve (not shown). Thus, the width of the surface of the substrate coated may be controlled.
  • FIG. 7-8 A second preferred embodiment of the binder applicator 118 is shown in FIGURES 7-8.
  • the zone partitions 410 (see FIG. 4) are omitted.
  • a single hollow cavity 405 is formed inside the binder applicator 118.
  • a single slot 402 is formed extending substantially along the length of the binder applicator 118.
  • the slot 402 corresponds to a single binder zone, as exemplified by FIG. 3.
  • the applicator bar 404 is preferably attached to the binder applicator 118 as in the embodiment of FIGS. 4-6.
  • binder enters the binder applicator 118 via lines 116. Binder fills the cavity 405 and is then dispensed through slot 402 preferably onto the applicator bar 404. The applicator bar 404 further regulates the uniformity and thickness of binder, which is then dispensed onto the surface of the substrate 202.
  • flanges 602 are attached to the binder applicator 118.
  • the flanges 602 provide additional structural support to the walls of the binder applicator 118 against the forces applied by the binder, which in some embodiments is pumped into the cavity (or cavities) 405 at high pressure. Such forces over time may distort the shape of the slots 402 and cavity (or cavities) 405, particularly when zone partitions 410 are omitted.
  • the flanges 602 prevent such distortion and allow the binder applicator 118 to perform optimally for years.
  • the applicator bar 404 is preferably attached to the binder applicator 118 as in the embodiments of FIGS. 4-8.
  • binder enters the binder applicator 118 via lines 116. Binder fills the cavity 405 and is then dispensed through slot 402 preferably onto the applicator bar 404. The applicator bar 404 further regulates the uniformity and thickness of binder, which is then dispensed onto the surface of the substrate 202.
  • lines 116 are coupled to binder applicator 118.
  • a plurality of openings 802 and 804 are formed in the lower portion of binder applicator 118.
  • zone partitions 410 e.g. , FIG. 4 may be utilized, and the applicator bar 404 is preferably attached to the binder applicator 118 as in the embodiments of FIGS. 4-10. .
  • FIGURE 12 A bottom view of binder applicator 118 of FIGURE 11 is shown in FIGURE 12.
  • the opening or slot 402 e.g. , FIGS. 5 and 8
  • openings 802 and 804 which are preferably generally circular in shape, having a diameter suitable for a desired or optimal binder flow rate and ease of manufacture and maintenance.
  • the openings 802 and 804 are linearly arranged into two rows along the length of the binder applicator 118 as shown in FIG. 12.
  • each opening 802 is offset from a corresponding opening 804, thus forming an overlap region 806.
  • the overlap region 806 is sized to provide increased uniformity when binder is dispensed.
  • the width of each overlap region 806 is approximately 10-40% of the diameter of each opening.
  • the number of rows used may vary, from a single row of openings to three or more rows of openings.
  • the size and number of the openings 802 and 804 may vary to obtain the desired binder flow-rate properties.
  • the openings 802 and 804 permit binder to be dispensed on the surface of the substrate in a substantially uniform manner similar to the slot 402 (FIGS. 5 and 8). But, because more structural material 808 of the binder applicator 118 remains along the bottom of the applicator after forming the openings 802 and 804 than remains with slot 402 of the embodiments of FIGS. 5 and 8, there is more structural integrity to the binder applicator 118. As such, flanges 602 are preferably not used. [0087] According to a preferred method and operation of binder applicator 118 of FIGS. 11-13, binder enters the binder applicator 118 via lines 116.
  • Binder fills the cavity 405 and is then dispensed through slot 402 preferably onto the applicator bar 404.
  • the applicator bar 404 further regulates the uniformity and thickness of binder, which is then dispensed onto the surface of the substrate 202.
  • the binder applicator is similar to the binder applicator of FIGS. 11-13, but for using slots 1402 and 1404 in place of circular openings 802 and 804.
  • zone partitions 410 e.g., FIG. 4
  • the applicator bar 404 is preferably attached to the binder applicator 118 as in the embodiments of FIGS. 4-13.
  • FIG. 16 A bottom view of binder applicator 118 of FIGURE 14 is shown in FIGURE 15, and a partial view taken along section line 16 is shown in FIG. 16.
  • the slots 1402 and 1404 are linearly arranged into two rows along the length of the binder applicator 118. Each slot 1402 is offset from a corresponding slot 1404, thus forming an overlap region 1406.
  • the size and number of slots 1402 and 1404 are suitable for dispensing binder at a desired or optimal flow rate, and the overlap regions 806 are suitably sized to provide increased uniformity when binder is dispensed.
  • the number of rows of slots may vary, from a single row of slots to three or more rows of slots.
  • the slots 1402 and 1404 permit binder to be dispensed on the surface of the substrate in a substantially uniform manner similar to the slot 402 (FIGS. 5 and 8). But, because more structural material 1408 of the binder applicator 118 remains along the bottom of the applicator after forming the slots 1402 and 1404 than remains with slot 402 of the embodiments of FIGS. 5 and 8, there is more structural integrity to the binder applicator 118. As such, flanges 602 are preferably not used.
  • binder enters the binder applicator 118 via lines 116. Binder fills the cavity 405 and is then dispensed through slot 402 preferably onto the applicator bar 404. The applicator bar 404 further regulates the uniformity and thickness of binder, which is then dispensed onto the surface of the substrate 202.
  • binder is applied to the surface of the substrate 202 by the binder applicator 118.
  • the binder applicator 118 preferably extends over the width of the mobile platform 100 in such a way as to produce a uniform coating across that width on the substrate 202.
  • Flow to each of one or more binder zones (B-ZONE) of the binder applicator 1 18 may be adjusted or turned off, thereby enabling the overall width of the binder to be adjusted to the desired application width.
  • filler is added to the binder.
  • the time lapse between the application of the filler and the application of the binder should be sufficiently short to ensure that the filler adequately penetrates the binder and good adhesion occurs.
  • the filler is applied from hopper 122 through one to twenty zone flow controllers 120 (preferably four to twelve zone flow controllers are used) onto the binder at a rate of between about 0.5 and 45 kilograms per square meter (preferably between about 3.5 and 9 kilograms per square meter).
  • the zone flow controllers 120 may comprise broadcast spreaders, drop spreaders, blowers, pumps, screws, conveyors, or other similar device.
  • the filler is contained in a hopper 122 positioned on the mobile platform 100.
  • the preferred filler is bauxite with a particle size in the range of between about 10 microns and 100,000 microns, and preferably between about 800 microns and 2,000 microns.
  • the bauxite filler preferably flows by gravity, although mechanical conveyance can be used, through one or more flow control zone gates (not shown) on the bottom of the hopper 122, which meters the flow rate, onto a distributor 124 and finally onto the surface of the binder. Because the density of the bauxite is greater than that of the epoxy, it will tend to sink down into the epoxy. A sufficient quantity of filler is added to ensure that a portion of the filler is left protruding from the binder. As the epoxy hardens, it will bind to both the filler and the substrate, creating a strong, uniform coating.
  • thermoplastic binder is used instead of an epoxy binder.
  • thermoplastic melting units are positioned on the mobile platform 100 which act to liquefy the plastic, making it pumpable.
  • a pressurization and material metering device 108 is used as described herein to provide a means of material transfer and control.
  • static mixers are not used and the thermoplastic flows directly to the nozzles, where it is applied to the substrate.
  • reflective material is mixed with the filler or added through a separate hopper, in close sequence with the addition of the filler, to the binder.
  • the reflective material preferably comprises glass beads or other suitable material, which would help to increase the light reflectivity of the coating. This provides the additional benefit of making potentially hazardous areas more visible at night.
  • pigments or other colored fillers could be added to change the appearance of the coating.
  • the filler is added to the binder by blowing it onto the surface, using air conveyance.
  • the filler is aspirated into an air stream and blown through one or more nozzles onto the binder surface. This process may have the added benefit of providing a greater downward force for the filler, resulting in greater binder penetration and adhesion.
  • the filler is applied to the binder by means of a conveyor or other such flow control devices used to move and meter solids.
  • the speed of the conveyor can be used to control the flow of filler and adjust the ratio of filler to binder.
  • more than one mobile platform 102 can be used to store, heat, meter, mix, and apply the binder and store, meter, and apply the filler.
  • the binder storage, metering, mixing, and application could be performed from one mobile platform, and the storage, metering, and application of the filler from another mobile platform.
  • a first mobile platform comprising the binder system would apply the binder to the substrate, and a second mobile platform comprising the filler would follow the first platform and would add the filler to the binder.
  • the applicator bar 404 may be supplemented by or replaced with a squeegee, and/or the like to further regulate binder uniformity and thickness.
  • FIGS. 17-27 Further embodiments 1700 of the invention are depicted by FIGS. 17-27, wherein an assembly 1702 is attached via a linkage assembly 1704 to a vehicle 1706, such as a truck.
  • Vehicle 1706 preferably includes a flatbed having mounted thereon a bin 1708 for holding aggregate, at least one tote 1720 having a capacity of several hundred gallons of resin, a container 1722 for holding catalyst, a container 1724 for holding accelerant, and an air compressor 1726.
  • Assembly 1702 includes a vertical structural member 1824, horizontal structural member 1816, and sidewall 1818.
  • Assembly 1702 further includes polymer sprayers 1810 coupled for fluid communication to tote(s) 1720 and containers 1722 and 1724, air knives 1812 coupled for fluid communication to air compressor 1726, and aggregate dispensers 1820 and 1822 coupled for fluid communication to bin 1708.
  • Linkage assembly 1704 is a parallelogram linkage assembly having vertical vehicle member 1804 secured to vehicle 1706. Two preferably parallel structural members 1802 couple ends of structural members 1804 and 1824 together. A hydraulic cylinder 1806 is coupled to opposing ends of structural members 1802 so that when the hydraulic cylinder is extended, the assembly 1702 is raised (FIG. 18, e.g., for travel), and when the hydraulic cylinder is retracted, the assembly 1702 is lowered (FIG. 19, e.g., for application). Two linkage assemblies 1704 are preferably provided for lowering and raising the assembly 1702. A feedback control system is preferably positioned for movement, preferably using a string potentiometer suitably positioned for measuring movement.
  • the assembly 1702 and more specifically, spray bar 1811, air knives bar 1813, and aggregate dispensers 1820 and 1822, may be laterally contracted and expanded, respectively, as single unit for accommodating various road widths. Expansion and contraction are preferably achieved using a hydraulic actuator and a carriage and rail linear bearing system.
  • the spray bar 1811 is depicted in FIGS. 23-25, showing push arm 2302, clevis pin 2304, and wiring 2306, and in FIGS. 26 and 27 as retracted and extended, respectively.
  • a feedback control system is preferably utilized to monitor lateral movement preferably using a string potentiometer such as depicted by reference numeral 2308.
  • the spray bar 1811 and air knives bar 1813 can preferably be manually extended using a spring pull pin and slots.
  • the extension wings preferably slide on linear rail and carriage systems.
  • the air knives bar 1813 preferably defines a slit in a tube that extends across the length of the tube through which compressed air (from an air compressor mounted on the vehicle 1706) is ejected to create an air curtain for smoothing the polymer resin to prepare it for receiving aggregate from dispensers 1820 and 1822.
  • FIGURE 22 exemplifies a spray nozzle 1810.
  • the nozzle 1810 is a KML1000 paint spray gun with a port 2204 added to it.
  • resin preferably a polyester polymer, or alternatively an epoxy polymer
  • catalyst 2206 and preferably an accelerant 2208 enter through the port 2204.
  • the catalyst flows through the atomizing air ports of the gun and mixed at the tip.
  • Each spray gun preferably has individual vertical adjustment with an electric actuator. Such actuators preferably have built-in feedback control.
  • Each gun can also be individually laterally adjusted by loosening its mount bolt and sliding it in the slots on the main spray bar body.
  • the air knife 1812 can be controlled by turning five sections on and off.
  • the middle section is theoretically always on, and the outer sections can be turned on and off depending on the "target path width"; which in turn determines how many spray nozzles are active.
  • Each section is preferably turned on or off using a valve.
  • the pressure of the whole air knife system can be varied.
  • the aggregate bars 1820 and 1822 are configured to slide laterally on a rail and carriage system and are actuated using hydraulic actuators. There is preferably a feedback control system in place for this movement that preferably uses string potentiometers.
  • the aggregate bars 1820 and 1822 preferably include gates which are opened and closed using individually controlled electric actuators. These actuators have built-in feedback control. The speed at which the aggregate is allowed out of the gates is controlled by the bottom screw.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

L'invention concerne un système et un procédé pour l'application de revêtements modificateurs de frottement sur des chaussées, des trottoirs, des chemins et d'autres zones soumises à un trafic de véhicules, d'êtres humains ou d'animaux, le système et le procédé comprenant l'application simultanée et régulée d'un liant et d'une charge sur une surface d'un substrat, grâce à un dispositif mobile qui passe sur le substrat pendant que le liant et la charge sont en cours d'application. Le système comprend un châssis accouplé à un véhicule. Une barre de pulvérisation est montée sur le châssis et comprend un réseau de buses de pulvérisation accouplées à un récipient de résine. Un couteau à air est monté sur le châssis et est accouplé à un compresseur d'air permettant de produire un rideau d'air. Une barre de distribution d'agrégat comprenant au moins un distributeur d'agrégat est accouplée à une trémie d'agrégat et est montée sur le châssis pour distribuer de l'agrégat.
PCT/US2016/048398 2015-08-25 2016-08-24 Systèmes et procédés pour l'automatisation de l'application de revêtements modificateurs de frottement WO2017035231A1 (fr)

Priority Applications (2)

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MX2018002321A MX2018002321A (es) 2015-08-25 2016-08-24 Sistemas y metodos para automatizar la aplicacion de revestimientos que modifican la friccion.
CA2996411A CA2996411C (fr) 2015-08-25 2016-08-24 Systemes et procedes pour l'automatisation de l'application de revetements modificateurs de frottement

Applications Claiming Priority (2)

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US14/835,614 US9567716B2 (en) 2014-02-25 2015-08-25 Systems and methods for automating the application of friction-modifying coatings
US14/835,614 2015-08-25

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020252106A1 (fr) * 2019-06-11 2020-12-17 Dbi Holding, Llc Systèmes et procédés pour l'automatisation de l'application de revêtements modificateurs de la friction

Citations (4)

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Publication number Priority date Publication date Assignee Title
DE1534429A1 (de) * 1966-09-15 1969-09-04 Zindel Jakob Gmbh Markiervorrichtung zum Herstellen von Verkehrsleitlinien
FR2661929A1 (fr) * 1990-05-14 1991-11-15 Screg Routes & Travaux Dispositif de fabrication d'une couche intermediaire dans une membrane routiere sur le sol.
US20060034653A1 (en) * 2004-08-02 2006-02-16 Jerome Laury Modular device for simultaneously spreading cut fibers and binders and a spreading machine
US9109332B1 (en) * 2014-02-25 2015-08-18 Dbi Holding, Llc Systems and methods for automating the application of friction-modifying coatings

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1534429A1 (de) * 1966-09-15 1969-09-04 Zindel Jakob Gmbh Markiervorrichtung zum Herstellen von Verkehrsleitlinien
FR2661929A1 (fr) * 1990-05-14 1991-11-15 Screg Routes & Travaux Dispositif de fabrication d'une couche intermediaire dans une membrane routiere sur le sol.
US20060034653A1 (en) * 2004-08-02 2006-02-16 Jerome Laury Modular device for simultaneously spreading cut fibers and binders and a spreading machine
US9109332B1 (en) * 2014-02-25 2015-08-18 Dbi Holding, Llc Systems and methods for automating the application of friction-modifying coatings

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020252106A1 (fr) * 2019-06-11 2020-12-17 Dbi Holding, Llc Systèmes et procédés pour l'automatisation de l'application de revêtements modificateurs de la friction

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CA2996411A1 (fr) 2017-03-02
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