ENVIRONMENTALLY FRIENDLY APPARATUS AND METHOD FOR SURFACE PRINTING

Abstract

An apparatus and method for applying an informational patter to a surface is provided. The apparatus includes a system configured to apply fluid on a surface to form the informational pattern, a surface preparation unit for preparing the surface, and a spray head system for applying the informational pattern.

Description

PRIORITY

The present disclosure claims priority to and benefit of U.S. Provisional Patent Application No. 61/258,069, filed Nov. 4, 2009, and titled “APPARATUS AND METHOD FOR SURFACE PRINTING,” which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present disclosure is generally directed to an apparatus and method for applying a fluid to a surface. More particularly, the present disclosure is directed to an apparatus and method for applying an information pattern to a surface.

BACKGROUND OF THE INVENTION

Surfaces, such as pavement, commonly include an information pattern to convey information. Information patterns may be in the form of symbols and/or words. For example, information patterns may include arrows or letters, such as “stop”.

The most common approach to marking a pavement surface is to apply a stencil and to use a paint gun or brush to apply paint to the pattern-defining apertures in the stencil. However, these prior approaches have numerous problems, including, but not limited to protecting workers as the information pattern is applied. Often these processes involve high-solvent paints so that they cure quickly. The high-solvent paints can include dangerous fumes and environmentally unfriendly materials.

Decals can be applied to surfaces to convey information as well. However, the decals can be expensive to manufacture and/or may involve substantial effort by individuals placing the decals. In addition, the decals can deteriorate requiring a completely new decal to be necessary.

An apparatus and method capable of applying a fluid to a surface in quickly, effectively, and/or in an environmentally-friendly manner would be desired in the art.

BRIEF DESCRIPTION OF THE INVENTION

In an exemplary embodiment, a fluid application apparatus includes a system configured to apply fluid on a surface to form an informational pattern, a surface preparation unit for preparing the surface, and a spray head system for applying the informational pattern.

In another exemplary embodiment, a fluid application apparatus includes a fluid application system configured to apply fluid on a surface to form an informational pattern, a spray head system, a spray head system actuator, and a surface preparation unit. The spray head system actuator adjusts the fluid application apparatus between a transport configuration and an application configuration.

In another exemplary embodiment, a method of applying fluid on a surface providing a fluid application apparatus and applying fluid on the surface to form an information pattern. The fluid application apparatus includes a fluid application system configured to apply fluid on a surface to form the informational pattern and one or more of a position indication device and a spray head system actuator. The position indication device gathers data relating to a global position of the fluid application apparatus or a relative position of at least a portion of the fluid application system compared to the surface. The spray head system actuator adjusts the fluid application apparatus between a transport configuration and an application configuration.

One advantage of an exemplary embodiment of the invention includes the ability to apply a fluid to a surface in an informational pattern having resolution capable of being understood by individuals standing close to the informational pattern.

Another advantage of an exemplary embodiment of the invention includes having adhesion to the surface permitting an informational pattern to remain on the surface during use of the surface.

Another advantage of an exemplary embodiment of the invention includes being capable of conveying information about a product or sponsor through an informational pattern on a surface.

Another advantage of an exemplary embodiment of the invention includes fostering safety for individuals applying a fluid to a surface and individuals proximal to the application of the fluid to the surface.

Another advantage of an exemplary embodiment of the invention includes being environmentally friendly in comparison to other methods of applying fluids to surfaces.

Other features and advantages of the present disclosure will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view an exemplary an apparatus according to an embodiment of the disclosure.

FIG. 2 illustrates reverse perspective view of the exemplary apparatus illustrated in FIG. 1.

FIG. 3 shows a side view of an exemplary apparatus positioned in a transport configuration according to an exemplary embodiment of the disclosure.

FIG. 4 shows a side view of an exemplary apparatus positioned in an application configuration according to an exemplary embodiment of the disclosure.

FIG. 5 shows a portion of an exemplary spray head system according to an exemplary embodiment of the disclosure.

FIG. 6 shows a portion of an exemplary spray head system according to an exemplary embodiment of the disclosure.

FIG. 7 shows a bottom view of a portion of an exemplary surface preparation unit according to an exemplary embodiment of the disclosure.

Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.

DETAILED DESCRIPTION OF THE INVENTION

Provided is an apparatus and method for applying a fluid to a surface to form an informational pattern. Embodiments of the apparatus and method permit application of a fluid to any surface suitable for receiving the applied fluid (for example, a road surface), permit application of the fluid in a controlled pattern to form the information pattern (for example, symbols and/or words such as company logos, trademarks, symbols, and lettering), permit application without requiring an operator to be positioned on the printing surface, permit adhesion for a lack of adhesion) to be adjusted, and/or are environmentally friendly in comparison to other methods of applying fluids to surfaces.

FIGS. 1-2 show an exemplary embodiment of a fluid application apparatus 100. The fluid application apparatus 100 includes a fluid application system 120 configured to apply fluid on a surface 501 as shown in FIGS. 3-4 to form an informational pattern. The fluid application apparatus 100 includes one or more of a position indication device and a spray head system actuator 510. The position indication device gathers data relating to a longitudinal position of the fluid application apparatus 100 or a relative position of at least a portion of the fluid application system 120 compared to the surface 501. The spray head system actuator 510 adjusts the fluid application apparatus 100 between a transport configuration and an application configuration.

The surface 501 may be a suitable surface for receiving the applied fluid. In one embodiment, the surface 501 may be a manufactured surface, such as, but not limited to an asphalt, concrete, artificial turf, or other suitable surface. In another embodiment, the surface 501 may be a natural surface such as a grass surface or field surface. The fluid is any suitable fluid. For example, the fluid may be selected from a group including, but not limited to, a marking fluid, a cleaning, fluid, a chemical solution, a poison, and a fertilizer solution. In one embodiment, the marking fluid may be a paint, dye, ink or other suitable marking liquid. The marking fluid may be a permanent or temporary marking liquid. The fluid may be a liquid, a liquid with dissolved solids, a liquid with dispersed and/or suspended solids, a pressurized gas that sublimes upon contact with the surface 501, or any other suitable fluid capable of being applied to the surface 501.

Referring again to FIGS. 1-2, the apparatus 100 includes a frame 110. The frame 110 provides mobility and support permitting the fluid application apparatus 100 to be used in the transport configuration and the application configuration. The frame 110 is formed of any suitable material. For example, the frame 110 can be metal, composite, polymeric, or any other suitable material capable of supporting the fluid application system 120. The frame 110 supports any suitable combination of a rear bumper 146, a surface preparation unit 140, wheels 210, a cleaning tray 105, a spray head system 114, any combination thereof, or any other suitable portion of the apparatus 100.

For supporting the components of the apparatus 100, the frame 110 includes a main frame section 142 (for example, supporting the surface preparation unit 140) and a spray head frame section 144 (for example, supporting the rear bumper 146). In one embodiment, a housing (not shown) extends from the frame 110 at least partially enclosing the fluid application system 120. In another embodiment, the housing is omitted. In one embodiment, the apparatus 100 is moved by rotation of the wheels 210 by an external force such as a vehicle towing the apparatus 100 (for example, a truck, car, tractor, or other self-propelled vehicle). In an alternate embodiment, the frame 110 is configured for being positioned in a vehicle (not shown) such as in the bed of a truck. Stated another way, in the alternate embodiment, the frame 110 permits the apparatus 100 to be positioned on a pallet or palletized. In this embodiment, the positioning of components within the apparatus 100 may be rearranged or modified for additional protection and/or additional efficacy. For example, the surface preparation system 140 may be provided as a separate unit installed in front of the spray head system 114, for example, in front of the support vehicle.

In one embodiment, prior to applying the fluid to the surface 501, the surface is prepared by the surface preparation system 140. The surface preparation may include cleaning the surface 501, treating the surface 501, smoothening the surface 501, roughening the surface 501, sealing the surface 501, any combination thereof, or other suitable preparation steps. In one embodiment, the apparatus 100 includes additional surface preparation devices, such as brushes that may be directional and/or rotational, for removing debris from the surface 501.

Referring to FIGS. 3-4, in one embodiment, the surface preparation system 140 includes an air dryer 641. The air dryer 641 is in fluid communication to receive pressurized air from a pneumatic system 111 (for example, by a pressurized air distribution system controlling the release of pressurized air to the air dryer 641). The air dryer 641 distributes and directs the pressurized air towards the surface 501. The air dryer 641 includes a dryer body 642 and casters 643. The dryer body 642 can he raised and lowered by linkages, supports and actuators operating in conjunction with the castors. Additionally or alternatively, the surface preparation unit 140 may include additional gaskets and/or other fluid directing devices to generally direct the pressurized air towards the surface 501.

FIG. 7 shows a bottom view of a portion of the air dryer 641 according to an embodiment. In this embodiment, the air dryer 641 includes dryer body 642, an air knife 644, and a gasket 646. The air knife 644 includes a plurality of apertures or air nozzles 648 for directing pressurized air towards the surface 501. The pressurized air may dry the surface 501 and/or remove debris from the surface 501. The gasket 646 assists in directing fluid from the surface away from the spray area. In one embodiment, there is a gap between the air knife 644 and the floor of the dryer body 642. This gap exposes the surface 501 to the high velocity air. There is a lip on the floor of the dryer body 642. This lip creates a channel through which water is collected during this process (for example, water removed from the surface 501). One end of the dryer body 642 is closed, the other open. Water flows in the channel and out the open end of the dryer body 642. The dryer body 642 is set at a predetermined angle substantially perpendicular to the movement of the air dryer 641.

Referring again to FIGS. 3-4, in embodiments having the surface 501 prepared by the surface preparation system 140, the fluid is applied by the fluid application system 120 thereafter. For example, the apparatus 100 may move along a road substantially continuously preparing the road with the surface preparation system 140 and substantially continuously applying the fluid with the fluid application system 120 after the road is prepared. In embodiments without the surface 501 being prepared, the fluid is applied by the fluid application system 120 at any suitable time.

The fluid application system 120 includes any suitable components. Referring to FIGS. 1-2, in one embodiment, the fluid application system 120 of the apparatus 100 includes a power unit 101, a fluid supply 104, a fluid pumping system 106, a control system 108, a pneumatic system 111, and a spray head system 114. The power unit 101 includes an internal combustion engine 202, an oil pump 203, an oil reservoir 204, an oil accumulator 205 (see FIG. 2), a dump valve 206 (see FIG. 2), and a fuel supply 207 (see FIG. 2). The apparatus 100 includes an electrical power system (not shown). The electrical power system may be a gas or diesel driven generator or a generator powered by the power unit 101.

The fluid supply 104 includes one or more fluid supplies, for example, a marking fluid supply 212 and a cleaning fluid supply 222 (see FIG. 2). The marking fluid supply 212 includes one or more supply containers, for example, a first marking fluid supply container 212a and a second marking fluid supply container 212b. The cleaning fluid supply 222 includes one or more supply containers, for example, a first cleaning fluid supply container 222a and a second cleaning fluid supply container 222h. In one embodiment, the marking fluid containers 212a, 212b and the cleaning fluid containers 222a, 222b are reusable and/or resealable. For example, the containers 212a, 212b, 222a, 222b may include openings that are opened and/or closed upon attachment to the apparatus 100.

Fluid is pumped from the fluid supply 104 by the fluid pumping system 106. The fluid pumping system 106 may include one or more pumps. For example, in one embodiment, the pumping system 106 includes a pump 106a. The pumping system 106 includes a fluid distribution system including any suitable fluid distribution components such as, but not limited to piping, valves, and manifolds for providing fluid to the spray head system 114 from the fluid supply 104.

The spray head system 114 includes any suitable spray application device. For example, in one embodiment, the spray head system 114 includes a print head. The spray head system 114 includes banks of multiple automatic airless spray guns arranged in a substantially linear array. Each automatic spray gun is actuated via the pneumatic system 111 (having one or more pneumatic and/or hydraulic cylinders an electric solenoid. The pneumatic system 111 includes an air accumulator and an air compressor and an air valve system. The pneumatic and/or hydraulic cylinders are pressurized by solenoid driven valves. FIG. 5 shows an exemplary embodiment a portion of the spray head system 114 (see region A of FIG. 4). In this embodiment, the spray head system 114 includes a nozzle manifold 710, a nozzle plate 720, a nozzle plate clamp 730, a nozzle plate catch plate 740, and a solenoid connector 750. FIG. 6 shows another exemplary embodiment a portion of the spray head system 114, In this embodiment, the components the spray head system 114 are enclosed by a spray head system housing 814.

Referring again to FIGS. 1-2, in one embodiment, the spray head system 111 is positioned on a spray head system position assembly 122. The spray head system position assembly 122 includes a plurality of bar linkages and an actuator 510 configured to raise and lower the spray head system 114. The actuator 510 may be a motor, hydraulic device, pneumatic device or other positioning component that can be actuated to lower and raise the spray head system 114 to and from the application configuration. In another embodiment, the spray head system position assembly 112 may include an electrical, pneumatic, or other device to lower and raise the print head. system 114. In yet another embodiment, the spray head system position assembly 112 may be manually lowered and raised.

The spray head system 114 and the surface preparation system are configured to be lowered to a position proximate a surface 501. The spray head system 114 is lowered by actuating the actuator 510 and moving the first, second and third bar linkages 502, 503, 504 (see FIGS. 3-4) to a lowered position. The surface preparation system 140 is lowered to a position proximate the surface 501.

Referring again to FIG. 6, in one embodiment, the spray head system 114 includes a plurality of print head nozzles 810 and a plurality of pressure wash nozzles 820. The pressure wash nozzles 820 (and valves) are in fluid communication with the same fluid supply 104 as the printing valves. To clean the surface 501, and in particular to clean the surface 501 of markings or information patterns applied by the spray head system 114, the fluid application system 120 is pressurized with a cleaning solution (for example, a solvent or an environmentally friendly solution having an abrasive composition) contained in the cleaning fluid supply 222. The cleaning solution is sprayed onto the surface 501 through the pressure wash nozzles 820. In one embodiment, the pressure wash nozzles are only actuated when the supply line is pressurized with clean water or cleaning fluid to flush the fluid application system 120.

During cleaning, the cleaning tray 105 slides under the spray head system 114. In one embodiment, the cleaning tray 105 is only able to he used during the transport configuration when the spray head system 114 is retracted or stored within the frame 110. In a method of cleaning the spray head system 114, marking fluid is purged from the supply lines and valves by directing a cleaning fluid contained in a spray head cleaning fluid supply (not shown) through the spray head system 114. The used cleaning fluid is collected, by the cleaning tray 105 by a suitable fluid collection system (not shown). For example, a suction hose connected to a disposal tank.

Referring to FIGS. 3-4, the apparatus 100 further includes a position indication device 170. The position indication device 170 includes an encoder caster wheel 172 and an encoder 174. The position indication device 170 provides position data to the control system 108. The position data may include, but is not limited to, the distance of travel of the apparatus 100 and speed of travel of the apparatus 100. The apparatus 100 further includes a caster wheel 176 to assist in providing uniform contact with the surface 501 (see FIG. 6).

Referring to FIG. 6, in one embodiment, as the apparatus 100 moves, the encoder caster wheel 172 informs the control system 108 of the relative position of the spray head system 114 to the surface 501, if the surface 501 is wet, the surface preparation unit 140, including the air dryer 641, is deployed and activated. In one embodiment, air is only supplied to the air dryer 641 while the air dryer 641 moves over the areas of the surface 501 to be printed on. A dump valve is automatically actuated, which pressures the hydraulic system, which in turn pressurizes the fluid system via the pumping system 106. As the apparatus 100 continues to move, the control system 108 actuates the pneumatic system 111 in a computed pattern. Each valve (not shown) is tied to a spray gun in the spray head system 114. As each spray gun is pneumatically pressurized, a pneumatic cylinder in the gun opens a zero-flow valve, which releases pressurized fluid to be applied to the surface 105. By turning the nozzles 810 on and off in a computed pattern while the apparatus 100 is moving, text or images are applied on the ground.

In the application configuration, the encoder caster wheel 172 is in contact with the surface 501 to provide position data to the control system 108. The encoder wheel 172 and castor wheel 811 assist in maintaining the spray head system 114 at a substantially constant fixed distance from the surface 501. Similarly, the caster wheels 643 maintaining the air dryer 641 at a substantially constant fixed distance from the surface 501.

Referring to FIGS. 3-4, in an exemplary method of operating the apparatus 100, the apparatus 100 is converted between the transport configuration and the application configuration by lowering/deploying or raising/retracting the spray head system 114 and/or the surface preparation unit 140. A data input is provided to the control system 108. In one embodiment, the spray head system 114 and the surface preparation unit 140 may be lowered in response to a command in the data input. In one embodiment, an outside computer supplies a message for the system to print, or a command is input directly into the microprocessor. As will be appreciated by those skilled in the art, any suitable aspect of operation of the apparatus 100 may be adjusted and/or maintained by the control system 108. For example, in one embodiment, the containers 212a, 212b, 222a, 222b include microcontrollers and/or sensors that record and/or sense the amount of fluid per container. The microcontrollers provide data to the control system 108. In yet another embodiment, the microcontrollers include pump data obtained from the control system 108 as to the amount of fluid pumped per container.

In one embodiment, the control system 108 includes a machine control interface that communicates with the microprocessor and various encoders that drive the various components of the fluid application system 120, including the power unit 101, the fluid supply 104, the pumping system 106, the pneumatic system 111, and the spray head system 114. For example, the control system 108 provides control inputs to the valve drive electronics to control hydraulic and pneumatic valves in the power system (not shown) and pneumatic system 111, respectively. The control system 108 includes data or accepts data as to the information pattern applied or sprayed by the spray head system 114. The control system 108 includes command functions for controlling the operation of the spray head system 114 to spray or print the information pattern.

In one embodiment, the control system 108 includes control components (not shown), including, but not limited to a microprocessor, valve drive electronics and a power supply. In one embodiment, the microprocessor is a computer, central processing unit (CPU), or electronic circuit board capable of executing command functions. The computer may be a portable computer, such as, but not limited to a laptop computer. The microprocessor may include input devices, such as such as, but not limited to USB ports, ethernet ports, and disk drives. In another embodiment, the input device may include a wireless system for receiving data input for the control system 108. The microprocessor may also include a keyboard or other manual data entry device to manually receive a data input or commands. The microprocessor may further include a monitor for monitoring the input data and/or operational data of the apparatus 100. The power supply may be a battery. The microprocessor may include a memory module. The memory module may include an internal and/or external memory module. For example, the memory module may be RAM, ROM or other memory for receiving and storing coded programs for executing the method of the present disclosure.

While the disclosure has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment disclosed as the best mode contemplated. for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.

Claims

1. A fluid application apparatus (100), comprising:

a system (120) configured to apply fluid on a surface (501) to form an informational pattern;

a surface preparation unit (140) for preparing the surface (501); and

a spray head system (114) for applying the informational pattern.

2. The apparatus (100) of claim 1, further comprising a spray head system actuator (510).

3. The apparatus (100) of claim 2, wherein the spray head system actuator (510) is configured to adjust the fluid application apparatus (100) between a transport configuration and an application configuration.

4. The apparatus (100) of claim 3, further comprising a cleaning tray (105) configured to be slid under the spray head system (114) in the transport configuration.

5. The apparatus 00) of claim 1, further comprising a position indication device.

6. The apparatus (100) of claim 2, wherein the position indication device gathers data relating to a longitudinal position of the fluid application apparatus (100).

7. The apparatus (100) of claim 2, wherein the position indication device gathers data relating to a relative position of at least a portion of the fluid application system (120) compared to the surface (501).

8. The apparatus (100) of claim 7, wherein the surface preparation unit (140) is configured for the relative position in comparison to the surface (501) to be adjusted in response to the data gathered by the position indication device.

9. The apparatus (100) of claim 7, wherein the spray head system (114) is configured for the relative position in comparison to the surface (501) to be adjusted in response to the data gathered by the position indication device.

10. The apparatus (100) of claim 1, wherein the surface preparation unit (140) comprises an air dryer (641) positioned to direct air onto the surface (501).

11. The apparatus (100) of claim 10, wherein the surface preparation unit (140) is configured to smoothen the surface 501.

12. The apparatus (100) of claim 10, wherein the surface preparation unit (140) is configured to roughen the surface 501.

13. The apparatus (100) of claim 10, wherein the surface preparation unit (140) is configured to remove debris from the surface 501.

14. The apparatus (100) of claim 10, wherein the surface preparation unit (140) further comprises brushes.

15. The apparatus (100) of claim 1, further comprising:

a spray head system actuator (510), the spray head system actuator (510) configured to adjust the fluid application apparatus (100) between a transport configuration and an application configuration;

a position indication device configured to gather data relating to a longitudinal position of the fluid application apparatus (100) or a relative position of at least a portion of the fluid application system (120) compared to the surface (501); and

an air dryer (641) positioned to direct air onto the surface (501).

16. A fluid application apparatus (100), comprising:

a fluid application system (120) configured to apply fluid on a surface (501) to form an informational pattern;

a spray head system (114);

a spray head system actuator (510);

a surface preparation unit (140);

wherein the spray head system actuator (510) adjusts the fluid application apparatus (100) between a transport configuration and an application configuration.

17. The apparatus (100) of claim 16, further comprising a position indication device configured to gather data relating to a longitudinal position of the fluid application apparatus (100) or a relative position of at least a portion of the fluid application system (120) compared to the surface (501).

18. A method of applying fluid on a surface, the method comprising:

providing a fluid application apparatus, the fluid application apparatus (100) comprising: a fluid application system (120) configured to apply fluid on a surface (501) to form an informational pattern; and one or more of a position indication device and a spray head system actuator (510); wherein the position indication device gathers data relating to a global position of the fluid application apparatus (100) or a relative position of at least a portion of the fluid application system (120) compared to the surface; wherein the spray head system actuator (510) adjusts the fluid application apparatus (100) between a transport configuration and an application configuration; and

applying fluid on the surface (501) to form the information pattern.

19. The method of claim 18, further comprising preparing the surface prior to applying the fluid.

20. The method of claim 18, further comprising adjusting the relative distance the at least portion of the fluid application system (120) in response to the data gathered, wherein the position indication device gathers data relating to the relative position of the at least portion of the fluid application system (120) compared to the surface (501).