U.S. patent application number 10/016761 was filed with the patent office on 2003-05-01 for apparatus and method for combining liquids and fillers for spray application.
Invention is credited to Roth, Jay, Wyman, Ransome J..
Application Number | 20030080203 10/016761 |
Document ID | / |
Family ID | 21778825 |
Filed Date | 2003-05-01 |
United States Patent
Application |
20030080203 |
Kind Code |
A1 |
Roth, Jay ; et al. |
May 1, 2003 |
Apparatus and method for combining liquids and fillers for spray
application
Abstract
A method and apparatus for combining a liquid material and a
filler and the composition prepared from the method. A method is
also provided for pre-treating the filler, prior to combining with
the liquid material. A spray gun is provided for mixing and
spraying the liquid material and the filler, the spray gun nozzle
having an inner chamber carrying the liquid material and an outer
chamber carrying the filler material, the outer chamber surrounding
the inner chamber, whereupon leaving the nozzle, the filler and
liquid materials combine.
Inventors: |
Roth, Jay; (La Jolla,
CA) ; Wyman, Ransome J.; (Irvine, CA) |
Correspondence
Address: |
FULBRIGHT & JAWORSKI L.L.P.
29th Floor
865 South Figueroa Street
Los Angeles
CA
90017-2576
US
|
Family ID: |
21778825 |
Appl. No.: |
10/016761 |
Filed: |
October 30, 2001 |
Current U.S.
Class: |
239/101 ;
239/306 |
Current CPC
Class: |
B05D 1/34 20130101; B05B
7/1431 20130101; B05D 1/02 20130101; B29B 7/7447 20130101; B29B
7/905 20130101; B01J 2/006 20130101; B05B 7/1495 20130101; B05D
2601/00 20130101 |
Class at
Publication: |
239/101 ;
239/306 |
International
Class: |
B05B 001/08 |
Claims
1. A method of combining at least one liquid composition with at
least one filler material, comprising: providing the filler into a
pressurized container having a conduit having an orifice whereby
the filler leaves the container through the conduit against
gravity; providing the liquid in a container; metering the filler
by varying the pressure in the container, the diameter of the
orifice of the conduit, or a combination thereof; providing a hose
connected to the liquid container and a hose connected to the
filler container and to a spray gun assembly whereby to pass the
metered filler and liquid; and separately passing the liquid
component and the metered filler component through the spray gun
assembly, wherein the liquid component and the filler component are
sprayed and combine.
2. The method of claim 1 wherein the spray gun assembly comprises a
spray gun nozzle having an outer chamber wherein said filler
component is passed, said outer chamber circumferentially
surrounding an inner chamber wherein said liquid component is
passed.
3. The method of claim 1 wherein the liquid is water, solvent,
plasticizer, paint, glue, polymer, cement slurry, asphalt emulsion,
polymer latex, epoxy, polyester, polyurethane, or methacrylate.
4. The method of claim 1, wherein the filler is sand, glass beads,
garnet, aluminum oxide, tungsten carbide, powdered plastics,
ceramic spheres, or powdered metals.
5. The method of claim 4 wherein the filler is from about 12 to 100
mesh.
6. The method of claim 1 further comprising adding an additive to
the liquid component, said additive is selected from the group
consisting of antistatic agents, blowing agents, delusterants, dye
regulating agents, flame retardants, heat stabilizers, light
stabilizers, lubricants, pigments, plasticizers and combinations
thereof.
7. The method of claim 1 further comprising providing a spacing
device inside and at the bottom of the pressurized filler
container, wherein said device is connected to the hose for
carrying the filler material to the spray gun assembly.
8. An apparatus for combining at least one liquid component with a
filler component, whereby to form a sprayable composition, said
apparatus comprising: (a) a filler component holding system; (b) a
pumping system; (c) a spray gun assembly wherein said liquid and
filler components are sprayed separately and simultaneously,
intersect and combine.
9. The apparatus of claim 7, wherein said spray gun assembly
comprises a spray gun nozzle having an outer chamber whereby said
filler component is pumped, said outer chamber circumferentially
surrounding an inner chamber whereby said liquid component is
pumped.
10. A coating produced according to the method of claim 1.
11. A spray gun nozzle comprising: a cylindrical housing having an
internal cavity through which filler material is blown; a
supporting pipe surrounded by the cylindrical housing; a static
mixer surrounded by the supporting pipe; a retaining nut having an
external male thread and an internal female thread retains both the
supporting pipe and the static mixer, the external thread connected
to the internal thread of the cylindrical housing and the internal
thread connected to a male thread of a manifold of a spray gun.
12. A method of metering a filler material, comprising: providing
the filler into a pressurized container having a conduit having an
orifice whereby the filler leaves the container through the
conduit; metering the filler by varying the pressure in the
container, the diameter of the orifice, or a combination thereof;
providing a hose connected to the filler container and to a hose
assembly whereby to pass the metered filler; and passing the
metered filler component through the hose assembly, wherein the
filler component is poured.
13. A method of pretreating at least one filler material prior to
combining the filler material to at least one liquid polymer
composition, comprising: providing at least one filler material;
providing at least one liquid polymer composition; and combining
the filler material with a predetermined amount of the polymer
composition, whereby to coat the filler material.
14. The method of claim 13, further comprising: metering the
pretreated filler by varying the pressure in the container, the
diameter of the orifice of the conduit, or a combination thereof;
providing a hose connected to the liquid container and a hose
connected to the filler container and to a spray gun assembly
whereby to pass the metered filler and liquid; and separately
passing the liquid component and the metered filler component
through the spray gun assembly, wherein the liquid component and
the filler component are sprayed and combine.
15. The method of claim 13 wherein the liquid polymer composition
is methylene diphenylene isocyanate.
16. The method of claim 13 wherein the filler material is sand.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates in general to a method for metering a
filler material and combining the filler material with a liquid.
The invention is also directed to the pourable or sprayable
composition prepared by the method, as well as a spray nozzle for
spraying the composition. The invention also relates to methods of
lining or resurfacing the surfaces of a wide range of commercial,
industrial and consumer products with the liquid composition
containing fillers.
[0003] 2. Description of the Related Art
[0004] There is a continuous and increasing need for inexpensive
and durable surfaces made by precise combination of liquid, such as
a polymer, with any number of solids or fillers. U.S. Pat. Nos. to
Hall et al 5,307,992; Mathias et al 5,565,241; and Scarpa
5,979,787, all disclose methods for combining liquids and fillers
for pouring or spraying, including disclosure of separate
containers for holding the components of a two or more component
system. However, these patents disclose conventional means for
holding and feeding the dry filler material/filler into the cavity
of a spray gun, such as holding the filler in a hopper and feeding
it via gravity and sometimes pressure, into tubes connected to a
spray gun.
[0005] U.S. patent to Mobley et al, U.S. Pat. No. 1,849,945;
Thompson, U.S. Pat. No. 2,981,308; Tufts, U.S. Pat. No. 3,606,154;
Medlin, U.S. Pat. No. 4,630,929; Daluise, U.S. Pat. No. 6,159,550;
and Vass U.S. Pat. Nos. 4,590,218 and 5,532,281 also disclose
systems for combining fillers and liquids for spraying and/or
pouring, in which a compressed fluids source is utilized to feed a
particulate material from a tank or hopper to a spray gun. In
particular, Thompson disclosed a compressed air tank which pushes
both the particulate/binding materials through separate conduits to
a discharge gun nozzle. Tufts disclosed a similar system although a
blower and pump are used. Medlin disclosed a liquid (asphalt
emulsion) that exited ports under pressure, mixed in a conduit with
a material (e.g., rock, stone, gravel and baked clay) and was
carried in a conduit by an air stream. Daluise disclosed a liquid
binder stored in a holding tank which was connected to a gun nozzle
and to a hopper which held rubber particulate. Vass disclosed
introducing a gas into a liquid component followed by introduction
of a filler. Upon collapse of the polymer, the resulting product, a
polymer containing a filler, had a density of 95 lbs/ft.sup.3.
However, all of these patents disclosed a liquid component/binder
and a filler particulate mixed within the spray gun prior to
reaching the nozzle head. This mixing of the components often leads
to a blocked spray gun, which greatly increases the time and
expense of the spray application.
[0006] German patent 1,577,773 to Hill also disclosed an apparatus
and method for combining liquids and fillers for spray application.
Hill's apparatus included a tank for holding a particulate material
which was gravity fed to a spray gun assembly via a hose and an air
stream. The particulate spray was disclosed as being expelled from
the gun via a central nozzle while the liquid components were
sprayed via two separate nozzles in a direction toward the
particulate spray, so as to mix with the particles.
[0007] U.S. patents to Uribe, U.S. Pat. No. 5,213,271 and Reimer,
U.S. Pat. No. 5,282,573, both disclosed powder spray coating
systems in which the powder was removed from a tank or hopper via
an air stream. Uribe further disclosed a metering roller for
metering the powder. Reimer disclosed a flame spray coating system
including a powder supply hopper, an eductor to entrain the powder
in a stream of conveying air, and a valve for controlling the flow
of powder from the hopper into the eductor.
[0008] U.S. patents to Moller, U.S. Pat. No. 2,565,696; Lippert et
al., U.S. Pat. No. 3,251,550; Sandell, U.S. Pat. No. 4,263,346;
Shockley, U.S. Pat. No. 3,799,438; Williams, U.S. Pat. No.
5,167,285; and Scarpa et al., U.S. Pat. No. 5,964,418, all
disclosed spray nozzles of having an inner circumferential chamber
for carrying a liquid and an outside chamber for carrying a filler
material.
[0009] One of the problems with the previous patents disclosing the
spraying of a combination of liquids and fillers is that only low
density compositions were sprayed. Another problem with the
traditional methods and equipment for spraying a combination of
liquids and fillers is the use of a high velocity to spray the
combination. It is preferable to use a low pressure during the
application process of the present invention. First, a high
pressure/velocity causes the fillers to bounce away from where the
liquid is being sprayed and thus would not be combined with the
liquid. Second, spraying at low pressures allows for the use of
inexpensive standard hoses, not requiring highly abrasion resistant
hoses.
[0010] Another of the problems with the previous methods of
combining a liquid material, such as polyurethane with a filler,
such as sand, is that the liquids and fillers are difficult to
combine when the liquid content is low and/or the filler content is
high or when the fillers and liquids do not mix uniformly. Previous
methods disclosed introduction of the filler by gravity. Gravity
fed filler materials prove problematic in that they have varying
discharge rates (as the tank empties, the weight above the opening
drops, and the flow rate decreases). Uneven introduction of a
filler material to a liquid composition inhibits complete mixing of
the filler and liquid. Another common means of supplying the filler
material is from a pressurized tank with a bottom opening. By
pressurizing the tank, to over 30 psi, the variation seen in the
discharge rate when the tank is emptying is reduced. However, since
such high pressures are used, the hoses and valves used must be
designed to withstand the wear created by the filler materials.
Furthermore, the valves are commonly kept open and are remotely
closed, adding to the complexity of the equipment. The present
invention also does not require the tank containing the filler
material to be elevated to allow space for a valve and plumbing
under the tank, nor are complex controls needed as is required with
higher pressure systems.
[0011] A further problem with previously used methods of combining
a liquid and filler is the use of compositions made of epoxy and
other catalyzed coatings, including those containing abrasive and
related materials, are generally mixed prior to application and
applied with a pump or compressed air spray apparatus. This
requires a minimum level of viscosity that comprises dry/cure time,
abrasive content, material cost, and the final strength,
durability, and other attributes of the final product. Mixing the
filler and liquid materials at the point of application, as in the
present invention, also minimizes material waste and to simplify
equipment cleanup. Thus, the prior methods do not represent a
reliable or flexible technology; necessitate extra expense and
frequent user intervention and generate maintenance problems.
[0012] The ideal liquid composition for use as a coating or liner
would contain fillers, such as sand and other fillers, that could
be poured or sprayed, would be easy to use, quick to activate,
allow for even mixtures of fillers with the liquids, allow for
varying densities between the fillers and liquids, and have a long
service life. Also of great importance is the cost, performance and
durability of such polymer formulations. Currently, there does not
exist a method of making a liquid composition containing fillers
that satisfies all these criteria.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention discloses a method of combining at
least one liquid composition with at least one filler material,
comprising: providing the filler into a pressurized container
having a conduit having an orifice whereby the filler leaves the
container; providing liquid in a container; metering the filler by
varying the pressure in the container, the diameter of the
conduit's orifice, or a combination thereof; providing a hose
connected on one end to the liquid container and a hose connected
on one end to the filler container and the other ends of the liquid
and filler hoses connected to a spray gun assembly whereby to pass
the metered filler and liquid; and separately passing the liquid
component and the metered filler component through the spray gun
assembly, wherein the liquid component and the filler component are
sprayed and combine. The liquid component is about 15-40% by weight
of the total composition. The filler material makes up about 60-80%
by weight of the total composition. The filler material is chosen
to add predetermined physical and chemical properties to the liquid
component, thus, the total composition varies depending on intended
use of the final product sprayed.
[0014] In another embodiment, prior to the metering of the fillers,
the filler is fluidized by creating a space inside the holding tank
so that when the filler, e.g., sand, is sucked into the orifice of
a conduit, located in the tank, the filler travels against gravity
(FIG. 3 and 4).
[0015] In yet a further embodiment, a spray gun nozzle is disclosed
for spraying at lower pressures and for spraying thinner viscosity
compositions. The spray gun nozzle has a cylindrical housing
through which the filler material is blown and surrounds a
supporting pipe. The supporting pipe in turn surrounds and supports
the static mixer and keeps the static mixer straight. A, retaining
nut (FIG. 13a-b) having an external thread and an internal thread
retains and receives both the supporting pipe and the static mixer.
The external thread of the retaining nut is connected to the
internal thread of the cylindrical housing. The internal female
thread of the retaining nut is connected to the male thread of a
manifold of a commercially available spray gun. The manifold is a
valve system involving ball valves and check valves to allow the
components to come together and includes a handle for on/off
control of the material supply through the manifold.
[0016] The combining of and uniform mixing of liquid compositions
and filler materials has several beneficial applications, e.g., the
resurfacing of industrial floors, asphalt repair, and lining
surfaces. Since the composition of the present invention can be
applied quickly and seamlessly, it requires less time of the
applicator, as well as less time for any necessary production shut
down. The present invention's ability to minimize the volume of
liquid required, combined with its improved mixing action, helps
improve the mechanical properties of the substances applied with
it, as well as minimizing drying times and the release of volatile
organic compounds and other pollutants. Other applications of the
present invention include the spraying of high strength Portland
cement; the application of roofing compositions that are odorless,
waterproof, and that may be applied at cooler temperatures than
conventional asphalt roofing. The method and compositions of the
present invention can also be used for maintaining asphalt, e.g. by
filling in cracks with the composition, making high traction bridge
decks and floor coatings. The composition of the present invention
also described treatment of the filler material with a polymer. The
treated filler allows a hydrophilic filler to repel water, which is
beneficial to coating applications and allows for easier packaging
of the composition of the present invention into kits.
[0017] These and other features, aspects, and advantages of the
present invention will become better understood with regard to the
following detailed description, appended claims, and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic of the apparatus of the present
invention showing the conduit inside the holding tank of the filler
material, the conduits from the air compressor to the holding
tank;
[0019] FIG. 2 is a broken away cross-sectional view of a
filler/liquid impingement spray gun showing the intersection and
combination of the liquid and filler components;
[0020] FIG. 3 is a schematic of another embodiment of the apparatus
of the present invention showing of the filler material holding
assembly;
[0021] FIG. 4 is a broken away cross-sectional view of the spacing
device and the orifice of FIG. 3, from which the filler material
leaves the filler material holding assembly;
[0022] FIG. 5 is a cross-sectional view of a impingement spray gun
showing the inner and outer chamber of the spray nozzle;
[0023] FIGS. 6a-d are broken away cross-sectional views of the
impingement spray gun of FIG. 5, showing the nozzle tip, (FIG. 6a)
the supporting pipe, the nut (FIG. 6c) and the inlet for liquid
composition (FIG. 6d);
[0024] FIG. 7 is a broken away cross-sectional view of the
impingement spray gun of FIG. 5 showing the passageway of a two
component liquid composition and the passageway of the filler
component material;
[0025] FIG. 8 is a cross-sectional view of the impingement spray
gun of FIG. 5 showing an enlarged view of the spray nozzle and
spray tip;
[0026] FIG. 9 is a cross-sectional view of the outer wall of the
spray impingement gun of FIG. 5;
[0027] FIG.10 is a cross-sectional view of the conduit having a
funnel shaped orifice;
[0028] FIG. 11 is a conduit having an inverted round-shaped
orifice;
[0029] FIG. 12 is a conduit having a round-shaped orifice; and
[0030] FIG. 13a-b is a drawing of the retaining nut (FIG. 13a) and
cross-sectional view of the retaining nut (FIG. 13b).
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention provides a method of metering and
combining a liquid and at least one filler to form a pourable or
sprayable composition. The liquid component and the filler
component are largely mixed at the point of application. The
present invention also provides an apparatus 10 of metering and
combining a liquid and at least one filler 14 to form a pourable or
sprayable composition.
[0032] The liquid component is contained within any suitable
container 16. For reactive liquid mixtures, separate containers 16
are used (FIG. 1). The liquid component that can be used is: water;
solvent; plasticizer; paint; glue; polymer; Portland cement slurry;
asphalt emulsion; polymer latex; epoxy; polyester; polyurethane;
methacrylate; a moisture-cured urethane polymer or a combination
thereof. If polyurethane is used as the liquid, any commercially
available polyurethane may be used. Any of the organic
polyisocyanates used in the art to prepare polyurethanes and
polyurea-containing polyurethanes can be used, for example:
hexamethylene diisocyanate; m-xylylene diisocyanate; toluene
diisocyanate and/or any of its isomers such as 2,4-toluene
diisocyanate or commercially available blends of the 2,4- and
2,6-isomers such as the 80:20 and 65:35 blends; polymethylene
polyphenylisocyanate; 4,4'-diphenylmethane diisocyanate;
m-phenylene diisocyanate; p-phenylene diisocyanate;
3,3'-dimethyl-4,4'-diphenyl diisocyanate; methylenebis
(2-methyl-p-phenylene) diisocyanate;
3,3'-dimethoxy-4,4'-biphenylene diisocyanate;
2,2',4,4'-tetramethyl-4,4'-biphenylene diisocyanate;
3,3'-dimethyl-4,4'-diphenylmethane diisocyanate;
4,4'-diphenylisopropylid- ene diisocyanate; 1,5'-naphthylene
diisocyanate; and polymethylene polyphenylisocyanate.
[0033] A portion of the polyisocyanate, i.e., the polyisocyanate on
the "A" side, can be pre-reacted with a polyol so as to form a
prepolymer or quasi-prepolymer, in which essentially all the
terminal groups are isocyanate groups. Any of the polyols used in
the art to prepare polyurethanes and polyurea-containing
polyurethanes can be used, for example: a polyol chosen from a
variety of OH terminated polyethers such as the polyoxyalkylene
polyols having 2-4 hydroxyl groups and where the alkylene group has
2-6 carbon atoms, obtained by polymerization of an alkylene oxide,
such as ethylene oxide, propylene oxide, or butylene oxide, with a
glycol; polyethers having higher functionality obtained by reaction
with a triol or higher polyol, such as glycerine,
trimethylolpropane, and pentaerythritol, polypropylene-oxide triol,
triethanolamine and diethanolamine.
[0034] Also, if a polyurethane liquid is used it is preferred to
also use a catalyst having polyol as well as amine functionality,
for example, amine catalysts with three hydroxyl groups. Such
catalysts are typically derivatives of ammonia and alkylene oxides,
for example, triethanolamine derived from ammonia and ethylene
oxide, or triisopropanolamine derived from ammonia and propylene
oxide. Ethylene diamine and alkylene oxide reaction products can
also be used. For example, Quadrol.RTM. (BASF Wyandotte) is based
on the reaction of ethylene diamine and propylene oxides.
Combinations could also be used. Products of the reaction of other
aliphatic diamines with ethylene or propylene oxide also can be
used. Although triisopropylamine is preferred, other catalysts
which promote the reactive combination of hydroxyl and isocyanate
groups to the exclusion of a water-isocyanate reaction can be used
instead of, or in addition to, triisopropylamine. Such catalysts
include lead (e.g. lead octoate), mercury, bismuth, tin, and ferric
acetylacetonate.
[0035] The filler material 14 used is preferably sand, although the
sand can be substituted with glass beads; garnet; aluminum oxide;
fibers, such as KEVLAR or carbon fullerenes; tungsten carbide;
powdered plastics; ceramic spheres; powdered metals; hollow
spheres; other fillers having from about 12 to 100 mesh, or a
combination thereof. The sand can be either a natural or
manufactured sand, although natural sand is rounded and flows
easily. The problem with some fillers is that they easily wet and
have a high affinity for water, which can be a problem with some
applications. Therefore, a process was developed of treating the
sand with a solution of a low viscosity organic polymer, prior to
its mixture with the liquid component. In particular, an isocyanate
was used. 150 pounds of F-50 sand (manufactured by U.S. Silica Co.,
U.S.A.) having a mesh size of 50 was treated with 140 grams of
Polymeric MDI (RUBINATE.RTM. 9433 manufactured by Huntsman
Corporation, USA) and 50 grams of carbon black.
[0036] It is often desirable to employ minor amounts of certain
other compounds in preparing the liquid composition, such as: one
or more catalysts, surfactants, fire retardants, preservatives,
pigments (including titanium or aluminum dioxide, and high UV
absorbing ultra-fine titanium dioxide), antioxidants,
anti-microbial agents, anti-static agents, and salts, such as
sodium chloride. Amounts used can be up to 5% by volume of the
total weight of the liquid composition.
[0037] The method of metering and combining the liquid and filler
materials of the present invention begins by gravity feeding at
least one filler material 14, such as uniformly graded sand, to a
pressurized tank 12 through a conduit 18 in the tank 12, the
conduit 18 having an orifice 20. Any commercial available tank
capable of being pressurized can be used. The tank 12 includes an
outlet port or hose 26 connected to a spray gun assembly 30. Any
commercially available spray gun assembly can be used. In order to
introduce a second filler material, a second pressurized tank is
used, comprising the same elements and configuration as the first
pressurized tank 12.
[0038] The pressure maintained in the tank 12 was below 35 psi,
preferably in the range of about 10-30 psi. Considering
inconsistent flow, e.g., pulsing, cannot be remedied at low
pressures, it was surprising the present invention was able to
introduce the filler material 14 at low pressure, low velocity, and
at a precise rate to combine effectively with the liquid component.
The filler material 14 is forced with air pressure through a
metering conduit 18 having an orifice 20 and directed up against
gravity. For example, if sand is used as the filler material 14,
the sand particles are pushed by air against gravity and gradually
accelerate to full velocity in turbulent air. The smooth
acceleration of the sand eliminates pulsing and sand agglomeration
at low pressures. The present invention provides high volume sand
with low-volume, low-pressure air, a fluidization of the filler
material 14. The influence of gravity is eliminated and a
consistent flow rate was achieved by a metering conduit 18 having
an orifice 20 shielded from the filler material mass 14 above the
orifice 20. The shield creates a fluidized zone where the particles
of the filler material 14 are separated from each other by a
turbulent airflow. The conduit's orifice 20 preferably has a round
shape (see FIGS. 11 and 12). However, the conduit 18 may be a pipe
having a orifice of a number of shapes and diameters, such as a
funnel shape (FIG. 10). Air moving against gravity through the
filler material mass 114, e.g., sand, creates a vacuum behind each
particle. This vacuum eliminates the friction between the particles
14 to allow high volume fillers flow at low pressurized and low
volume airflow.
[0039] Both the inlet end of the spray gun assembly 30 and the
filler tank 12 are connected to a compressed air supply 24 via
conduits or hoses, 26, 27, respectively (FIG. 1). The air pressure
is in the range of about 5-30 psi, preferably between about 10-20
psi. The compressed air supply 24 preferably includes a dryer and
pressure gauge for the tank 12. The sand 14 is suspended in a
turbulent air stream in the conduit 18 for delivery (FIG. 3). The
metering and delivery of the filler 14 is controlled by the orifice
20 size/diameter, the hose 118 size, and the air pressure. The
temperature of the filler 14 can also be increased depending on the
desired outcome. The liquids are metered with a variable speed
metering pump 17. A rheostat controls the speed of a motor that
drives the pump 17. To increase liquid volume, the speed of the
motor is increased and to decrease the volume, the motor speed is
decreased. Standard commercially available hoses and fittings, air
dryer, pump(s), pump drive motor, and control, can be used. In
particular, the hoses 26, 27, and 28 used were low friction,
translucent, low pressure hoses made of polyethylene,
polypropylene, PVC, and TEFLON (manufactured by DuPont, USA).
[0040] If two liquids components 16 are to be combined, two gear
pumps are linked to a single motor. The motor is connected to a
spray gun assembly 30 and thus, the two liquid component streams
are combined in a static mixer 38 to create the reactive liquid
(FIG. 1). Two non-reactive liquids may also be combined, although
they may be mixed in a single container and then pumped to the
spray gun 30. For example, if a two component polymeric composition
is used, such as used for polyurethane, component A and B are
heated to a temperature of about 40.degree. F. to 80.degree. F.,
preferably 70.degree. F.
[0041] Component B contains a polyol. Any additional catalysts,
surfactants, blowing agents, e.g. water or an alcohol/water mixture
may be either added to component B, prior to its reaction with
component A, or may be added to the mixture of component A and
component B. Component A is supplied by pump 17 to a metering unit,
or a metering pump. Component B is also supplied by pump 17 to a
metering unit, or a metering pump. The metering pumps boost the
pressure and control the flow of components A and B to a precise
ratio as determined by the desired chemistry. The ratio of
isocyanates, side A components, to polyols, side B components is
from about 10 to 1 by volume, preferably from about 1 to 1. The
pumps deliver components A and B to the inner chamber 36 of the
spray gun nozzle 32 where they are mixed. Inside the spray nozzle
32, components A and B are statically mixed at high pressure, which
results in intimate mixing of the components. The mixed liquid
composition travels through the center inner chamber 36 of the
spray nozzle 32 to the spray tip (FIGS. 5, 6a-d, 7, 8, and 9).
[0042] The fillers 14 are suspended in turbulent air in a
cylindrical pattern. The filler material 14 is simultaneously
passed through the outer chamber 34, which circumferentially
surrounds the inner chamber 36 (FIG. 5 and 7). Upon leaving the
spray gun's nozzle, the liquid composition stream is atomized (with
or without air) in the center of the suspended fillers 14 in a
conical or fan pattern (FIG. 2). The pot life or working time of
the mixed liquid composition is variable, typically in the range of
about 10-15 minutes, when typically the compositions takes about 10
seconds to react. Upon spraying, the liquids and fillers intersect
and combine. Sand acts as a heat sink to absorb energy from the
cure therefore preventing polymer from decomposing from heat after
it is sprayed. Therefore, low molecular weight components can be
used in the present invention.
[0043] The polymeric composition of the present invention may be
sprayed or poured in any thickness, typically from about {fraction
(1/16)} to 1/4 inch in one application, depending on the project
needs. Typically when surfacing a large area during a spray
application, the composition cures quickly, making it difficult to
pickup spraying again without seeing the seam where one application
pass started and the other began. It was unexpectedly found that
during the application process of the present invention, a
feathered edge could be created during the end of one application
and the beginning of another, thus creating a seamless
surfacing.
[0044] When performing asphalt repair, a liquid rich composition is
used. The liquid content is about 18% of the total composition of
the present invention, which allows the composition to be easily
spread over the cracks in the asphalt. The liquid content is
lowered to about 10% of the total composition when creating a new
surface, i.e., when it is not necessary to spread the composition
thinly.
[0045] Surface Preparation of an Object to be Resurfaced
[0046] The present invention requires that the object to be
surfaced is clean and dry. The composition of the present invention
bonds to painted surfaces, such as truck beds, without a need to
sand the surface or to remove the paint.
EXAMPLE 1
Filler Treatment
[0047] 150 pounds of F-50 sand (manufactured by U.S. Silica Co.,
U.S.A.) having a mesh size of 50 was treated with 140 grams of MDI
(RUBINATE.RTM. 9433 manufactured by Huntsman Corporation, USA) and
50 grams of carbon black.
EXAMPLE 2
Bedliner
[0048] The treated sand of Example 1 was placed in a holding tank
12 that was pressurized with compressed air at about 10-30 psi.
Moisture affects the sand flow, therefore the sand and compressed
air were kept dry. The compressed air supply 24 included a suitable
air dryer. The sand flow and sand velocity was controlled by air
pressure, the length and size of the conduits 18, 27, e.g. hoses,
carrying the compressed air to and from the holding tank 12, and
the diameter and shape of the orifice 20 of the conduit 18 carrying
the filler 14 from the tank 12 to a spray gun or other dispenser
30. The sand quantity was controlled by air pressure, sand size,
and the diameter and shape of the orifice 20 carrying the filler
14.
[0049] The side A reaction component, an isocyanate, was comprised
of 75.00% MDI (RUBINATE.RTM. 9433 manufactured by Huntsman
Corporation, USA); 20.00% Poly G 55-37 (manufactured by Arch
Chemical Co., U.S.A.); and 5.00% diisononyl phthalate (DINP). The
side B reaction component, a polyol, comprised 58.56% of Poly G
85-36 (manufactured by Arch Chemical Co., U.S.A.); 26.12% of a
premix of diethylene glycol (DEG) and phenyldiethanolamine (PDEA)
(the premix comprised 50.0% of DEG and 50.0% of PDEA); 10.00% of
Quadrol.RTM.; 4.00% of black carbon paste; 1.00% of a desiccant (3A
molecular sieves); 0.10% of C-231 (ferric acetylacetonate); and
0.22% of C-232 (bismuth). The side A and B components were at
ambient temperature. The isocyanate and the polyol were in an about
1:1 ratio by volume. During the spraying of the composition, the
pressure remained constant, at about 10-30 psi. The resulting
bedliner produced from this process comprised of 50% of the treated
sand from Example 1 and 50% of the polymer described above.
EXAMPLE 3-4
[0050] The procedure of example 2 was followed by substituting the
following filler materials 14 for the treated natural 50 mesh sand:
natural 30 mesh sand and natural 60 mesh sand. The resulting
product produced from this process and made with manufactured 30
mesh sand had a density of about 1.5.
EXAMPLE 5
[0051] The procedure of example 2 can be followed by substituting
the following filler materials 14 for the treated natural 50 mesh
sand: glass beads, or a combination of glass beads, natural 30
mesh, 50 mesh, or 60 mesh sand.
EXAMPLE 6
Industrial Floors
[0052] The procedure for example 2 was followed with the addition
of second filler material 14, a natural 12 mesh sand. A second
container holding the 12 mesh sand was used. The smaller mesh sand
fell to the bottom of the lining or coating, leaving the larger
mesh sand toward the top surface of the lining or coating, allowing
for the coated surface to have better traction. The resulting
coating produced from this process comprised about 18% polymer
composition and about 82% of the treated sand from Example 1 and
had a density of about 2.0.
EXAMPLE 7
[0053] The procedure of example 6 can be followed by substituting
the following filler materials 14 for the treated natural 12 and 50
mesh sand: glass beads, or a combination of glass beads, natural 30
mesh, 50 mesh, or 60 mesh sand.
EXAMPLE 8
Asphalt Repair
[0054] The treated sand of Example 1 was placed in a holding tank
12 that was pressurized with compressed air at about 10-30 psi.
Moisture affects the sand flow, therefore the sand and compressed
air were kept dry. The compressed air supply 24 included a suitable
air dryer. The sand flow and sand velocity was controlled by air
pressure, the length and size of the conduits 18, 27, e.g. hoses,
carrying the compressed air to and from the holding tank 12, and
the diameter and shape of the orifice 20 of the conduit 18 carrying
the filler 14 from the tank 12 to a spray gun or other dispenser
30. The sand quantity was controlled by air pressure, sand size,
and the diameter and shape of the orifice 20 carrying the filler
14.
[0055] The side A reaction component comprised 71.50% Polymeric MDI
(RUBINATE.RTM. 9258 manufactured by Huntsman Corporation, USA) and
28.50% of a plasticizer, such as 2,2,4-trimethyl-1,3-pentanediol
diisobutyrate (TXIB). The side B reaction component, a polyol,
comprised 75.42% of a primary diol, such as Poly G 55-173
(manufactured by Arch Chemical Co., U.S.A.); 17.43% of a premix of
diethyleneglycol (DEG) and triisopropylene butanediol (TIPA) (the
premix was made up of about 45.4% DEG and 54.6% TIPIA); 5.00% black
carbon paste; 1.00% of a desiccant, such as 3A molecular sieves;
1.00% A-450 (Epoxysilane); 0.10% C-231 (Ferricacetylacetonate); and
0.05% bismuth (C-232). The A and B components were at ambient
temperature. The isocyanate and the polyol were in an about 1:1
ratio by volume.
EXAMPLE 9
[0056] The procedure of example 8 was followed by substituting the
following filler materials 14 for the treated natural 50 mesh sand:
12 mesh sand or a combination of 12 mesh and 50 mesh sand.
EXAMPLE 10
[0057] The procedure of example 8 can be followed by substituting
the following filler materials 14 for the treated natural 50 mesh
sand: 30 mesh sand, 60 mesh sand, glass beads, or a combination
thereof.
EXAMPLE 11
Polymer Flooring
[0058] The filler pre-treatment procedure of example 1 was followed
to obtain the filler material. A premix was then made comprising
58.59% TIPA and 44.41% Butanediol. The side A reaction component
comprised 71.50% MDI (RUBINATE.RTM. 9433 manufactured by Huntsman
Co., U.S.A); 14.25% Poly G 55-56 (manufactured by Arch Chemical
Co., U.S.A.); and 14.25% TXIB (S-142). The side B reaction
component comprised 18.24% of the TlPA/Butanediol premix; 5.00%
Quadrol.RTM.; 30.00% Poly G 55-173 (manufactured by Arch Chemical
Co., U.S.A.); 25.90% TXIB (S-142); 14.25% Poly G 55-56
(manufactured by Arch Chemical Co., U.S.A.); 4.00% White paste;
0.50% black carbon paste; 1.00% 3A Mol sieves; 0.50% A-450
(Epoxysilane); 0.50% A-500 (defoamer); 0.10% C-231 (Ferric
acetylacetonate); and 0.01% C-232 (Bismuth).
EXAMPLE 12
[0059] The procedure of example 12 was followed by substituting
glass beads for the treated natural 50 mesh sand.
EXAMPLE 13
Concrete Flooring Repair
[0060] The filler pre-treatment procedure of example 1 was followed
to obtain the filler material, substituting a 50:50 mixture of 12
and 50 mesh sand for the 50 mesh sand. A premix was then made
comprising 58.59% TIPA and 44.41% Butanediol. The side A reaction
component comprised 71.50% MDI (RUBINATE.RTM. 9433 manufactured by
Huntsman Co., U.S.A); 10.7% Poly G 55-56 (manufactured by Arch
Chemical Co., U.S.A.); and 18.43% TXIB (S-142). The side B reaction
component comprised 18.24% of the TlPA/Butanediol premix; 5.00%
Quadrol.RTM.; 30.00% Poly G 55-173 (manufactured by Arch Chemical
Co., U.S.A.); 25.90% TXIB (S-142); 14.25% Poly G 55-56
(manufactured by Arch Chemical Co., U.S.A.); 10.00% White paste;
1.00% black carbon paste; 2.00% 3A Mol sieves; 0.50% A-450
(Epoxysilane); 0.50% A-500 (defoamer); 0.05% C-231 (Ferric
acetylac,etonate); and 0.005% C-232 (Bismuth).
[0061] The filler materials were treated prior to preparing the
composition of the present invention. 100 pounds of F-50 sand
(manufactured by U.S. Silica Co., U.S.A.) having a mesh size of 50
and natural 12 mesh sand was treated with 140 grams of pure MDI
(RUBINATE.RTM. 9433 manufactured by Huntsman Corporation, USA). A
50:50 mixture of the treated 12 and 50 mesh sand was combined. The
50:50 ratio of the two fillers 14 provided the best flow. A 50
pound kit comprising the composition of the present invention was
prepared, the kit comprising about 9 pounds of the polymer
composition and about 41 pounds of the treated sand mixture.
EXAMPLES 14-22
[0062] Example 2 can be followed by substituting the following
filler materials 14 for treated natural 50 mesh sand: garnet;
aluminum oxide; fibers, such as KEVLAR or carbon fullerenes;
tungsten carbide; powdered plastics; ceramic spheres; powdered
metals; or hollow spheres.
[0063] The following references are incorporated herein by
reference: U.S. patents to Hall et al, U.S. Pat. No. 5,307,992; to
Mathias et al., U.S. Pat. No. 5,565,241; to Scarpa, U.S. Pat. No.
5,979,787; to Mobley et al., U.S. Pat. No. 1,849,945; to Thompson,
U.S. Pat. No. 2,981,308; to Tufts, U.S. Pat. No. 3,606,154; to
Medlin, U.S. Pat. No. 4,630,929; to Daluise, U.S. Pat. No.
6,159,550; to Uribe, U.S. Pat. No. 5,213,271; to Reimer, U.S. Pat.
No. 5,282,573; to Moller, No. U.S. Pat. 2,565,696; to Lippert et
al., U.S. Pat. No. 3,251,550; to Sandell, U.S. Pat No. 4,263,346;
to Shockley, U.S. Pat. No. 3,799,438; to Williams, U.S. Pat. No.
5,167,285; to Scarpa et al., U.S. Pat. No. 5,964,418; to Larsen et
al., U.S. Pat. No. 6,105,8,22; German patent 1,577,773 to Hill; and
U.S. Patent to Vass, U.S. Pat. No. 5,532,281.
[0064] Although the foregoing invention has been described in some
detail by way of illustration and example for purposes of clarity
and understanding, it will be obvious that various modifications
and changes which are within the knowledge of those skilled in the
art are considered to fall within the scope of the appended
claims.
* * * * *