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BR-112021023917-B1 - SYSTEM AND METHOD FOR COATING A SURFACE

BR112021023917B1BR 112021023917 B1BR112021023917 B1BR 112021023917B1BR-112021023917-B1

Abstract

SYSTEM AND METHOD FOR COATING A SURFACE. The present invention relates to a system and a method for coating the surface of an object with a spray coating tool that sprays atomized coating particles. A conditioning layer is applied defining a spray chamber. In operation, the spray coating tool is mounted on one mounting end of the coating tool and an outlet end is positioned in close proximity to the surface of the object to be coated. The spray coating tool is operated to spray atomized coating particles that travel from the coating tool, through the spray chamber and the outlet end to the surface of the object. A carrier gas is injected which, in operation, carries the atomized coating particles to the surface of the object.

Inventors

  • RUBEN GEUTJENS

Assignees

  • QLAYERS HOLDING B.V

Dates

Publication Date
20260310
Application Date
20200527
Priority Date
20190528

Claims (15)

  1. 1. System (1) for coating a surface (3a) of an object (3) with a spray coating tool (2) spraying atomized coating particles (10), comprising a coating material supply (6) communicating with the coating tool (2), comprising a coating material pump defining a coating material flow rate, a conditioning hood (20) defining a spray chamber and having - a coating tool mounting end, - an outlet end opposite the coating tool mounting end, which outlet end is configured to be positioned in close proximity to the surface of the object to be coated, wherein in operation: - the spray coating tool is mounted on the coating tool mounting end, and - the outlet end is positioned in close proximity to the surface of the object to be coated, and - the spray coating tool is operated to spray atomized coating particles traveling from the coating tool, through the spray chamber and the outlet end to the surface of the object, a carrier gas installation (30) communicating with the mounting end of the coating tool of the conditioning hood or with the coating tool (2), configured to provide a carrier gas that in operation transports the atomized coating particles, characterized in that the system further comprises a particle sensor (23; 36) provided in the conditioning hood, detecting the particle size distribution and/or particle density, a central control system (45) communicatively connected to the particle sensor (23, 36) and to the coating material supply (6) and/or to the carrier gas installation (30), to control the coating process based on the particle sensor input data.
  2. 2. System according to claim 1, characterized in that the coating material supply further comprises a heating element for the coating material, and wherein the temperature of the coating material is controlled based on the particle sensor input.
  3. 3. System according to claim 1 or 2, characterized in that a spray chamber adjustment mechanism is provided to adjust the distance between the object surface and the conditioning hood that sets the spray chamber at the outlet end of the conditioning hood, and wherein the distance is controlled based on the particle sensor input.
  4. 4. System, according to any one of claims 1 to 3, characterized in that the carrier gas installation (30) comprises a carrier gas pump defining the gas flow rate at which the carrier gas is injected into the spray chamber, and in that the central control system is communicatively connected to the carrier gas pump to control the gas flow rate based on the particle sensor input data.
  5. 5. System, according to any one of claims 1 to 4, characterized in that the carrier gas installation comprises a humidifier for adjusting the humidity of the carrier gas, and wherein the humidity of the carrier gas is controlled based on the input from the particle sensor.
  6. 6. System, according to any one of claims 1 to 5, characterized in that the carrier gas installation comprises a heating element for adjusting the temperature of the carrier gas, and wherein the temperature of the carrier gas is controlled based on the input from the particle sensor.
  7. 7. System, according to any one of claims 1 to 6, characterized in that the conditioning hood has two concentric walls, defining an annular duct (29) and the spray chamber (5) within the annular duct, wherein a gas extraction installation (35) is in communication with the annular duct, configured to extract gas with residual atomized coating particles adjacent to the outlet end of the conditioning hood, the gas extraction installation comprising a pump (38) defining the extraction rate, wherein the extraction rate is controlled on the basis of the particle sensor input (36), wherein, preferably, the particle sensor (36) is provided in the annular duct (29).
  8. 8. A system according to any one of claims 1 to 7, characterized in that the conditioning hood has a concentric outer wall, an intermediate wall and an inner wall, the inner wall defining the spray chamber, the outer wall and the intermediate wall defining an outer annular duct and the intermediate wall and the inner wall defining an inner annular duct; a gas extraction installation in communication with the inner annular duct, configured to extract gas with residual atomized coating particles adjacent to the outlet end of the conditioning hood; a protective fluid injection installation in communication with the outer annular duct, configured to inject protective fluid into the outer annular duct which exits the annular duct at the outlet end thereof, thus protecting the spray chamber from the environment; wherein the gas extraction rate is controlled based on the particle sensor input and/or wherein the protective fluid pressure is controlled based on the particle sensor input.
  9. 9. A method for coating the surface of an object with a spray coating tool by spraying atomized coating particles, wherein a system as defined in any one of claims 1 to 8 is used, characterized in that it comprises the steps of: - mounting the spray coating tool on the mounting end of the coating tool, and - positioning the outlet end in close proximity to the surface of the object to be coated, and - operating the spray coating tool to spray atomized coating particles that travel from the coating tool, through the spray chamber and the outlet end to the surface of the object, and during the operation of the spray coating tool detecting the particle size and/or particle density, - controlling the flow rate of the coating material and/or the flow rate of the carrier gas based on the particle sensor data.
  10. 10. System (1) for coating a surface (3a) of an object (3) with a spray coating tool (2) spraying atomized coating particles (10), comprising a conditioning hood (20) defining a spray chamber (5) and having: - a coating tool mounting end (21), - an outlet end (22) opposite the coating tool mounting end, which outlet end is configured to be positioned in close proximity to the surface of the object to be coated, wherein in operation: - the spray coating tool is mounted on the coating tool mounting end, and - the outlet end is positioned in close proximity to the surface of the object to be coated, and - the spray coating tool is operated to spray atomized coating particles that travel from the coating tool, through the spray chamber and the outlet end to the surface of the object, a carrier gas installation (30) communicating with the coating tool mounting end (21) of the conditioning hood or with the coating tool, configured to provide a The carrier gas that, in operation, transports the atomized coating, the conditioning cap having three concentric walls, namely, outer wall (25), intermediate wall (26) and inner wall (27), the inner wall defining the spray chamber (5), the outer wall and the intermediate wall defining an outer annular duct (28) and the intermediate wall and the inner wall defining an inner annular duct (29), wherein the system further comprises: a gas extraction installation (35) in communication with the inner annular duct (29), configured to extract gas with residual atomized coating particles adjacent to the outlet end of the conditioning cap, a protective fluid injection installation (40) in communication with the outer annular duct (28), configured to inject protective fluid into the outer annular duct which exits the annular duct at the outlet end thereof, thus protecting the spray chamber from the environment, the system characterized in that: the conditioning cap has a conical shape with the coating tool mounting end of the cap The conditioning vent is located on one side of the cover with a relatively small opening, and the outlet end of the conditioning vent is located on the other side of the cover with a relatively large opening.
  11. 11. System according to claim 10, characterized in that the inner annular duct is separated from the spray chamber.
  12. 12. System, according to claim 10 or 11, characterized in that a spray chamber adjustment mechanism is provided to adjust the distance di between the object surface and the inner wall defining the spray chamber at the outlet end of the conditioning hood.
  13. 13. System, according to any one of claims 10 to 12, characterized in that an external wall adjustment mechanism is provided for adjusting the distance between the object surface and at least the external concentric wall at the outlet end of the conditioning hood.
  14. 14. System, according to any one of claims 10 to 13, characterized in that it further comprises a particle sensor provided in the spray chamber detecting the particle size and/or particle density and a central control system communicatively connected to the particle sensor and to the coating material supply and/or carrier gas injection installation, to control the coating process based on the particle sensor input data.
  15. 15. Method for coating the surface of an object with a spray coating tool by spraying atomized coating particles, wherein use is made of a system as defined in any one of claims 10 to 14, characterized in that it comprises the steps of: - mounting the spray coating tool on the mounting end of the coating tool, and - positioning the output end in close proximity to the surface of the object to be coated, and - operating the spray coating tool to spray atomized coating particles that travel from the coating tool, through the spray chamber and the output end to the surface of the object.

Description

[0001] The present invention relates to a system and method for coating the surface of an object with a spray coating tool that sprays atomized coating particles, for example paint. [0002] It is known that the surfaces of such objects are covered with one or more layers of coatings, contributing to the protection of the object. These layers are applied by a robot or a person operating a spray coating tool, such as a spray gun, with which atomized coating particles are applied to the object at a relatively short distance. [0003] However, due to wind and other environmental factors, a substantial portion of the atomized coating particles escapes and is deposited in areas where it is not desired. This phenomenon is also known as overspray. As a result, on the one hand, the efficiency of the coating material application is relatively low and, on the other hand, problems arise for the environment. [0004] For example, from US5688323, an enclosure is known which is placed at a very short distance from the object to be treated, and in which a person is located with the upper part of the body inside the enclosure and the lower part outside it. A vacuum is created in the enclosure with a fan, in which air is drawn from the gap between the enclosure and the surface to be processed. [0005] Starting with EP2859960, a conditioning layer is known, to be positioned between a coating tool and the object to be treated. [0006] The objective of the present invention is to provide an alternative solution to reduce the problems associated with overspray. [0007] According to the invention, the system for coating the surface of an object with a spray coating tool by spraying atomized coating particles, for example paint, comprises a conditioning cap defining a spray chamber and having: - a mounting end of the coating tool, - an outlet end opposite the mounting end of the coating tool, which outlet end is adapted to be positioned in close proximity to the surface of the object to be coated, wherein in operation: - the spray coating tool is mounted on the mounting end of the coating tool, and - the outlet end is positioned in close proximity to the surface of the object to be coated, and - the spray coating tool is operated to spray atomized coating particles that travel from the coating tool, through the spray chamber and the outlet end to the surface of the object, a carrier gas installation in communication with the mounting end of the coating tool of the conditioning cap or with the coating tool, adapted to provide a carrier gas that in operation carries the atomized coating. [0008] Possible objects that are suitable for coating according to the invention are ships, aircraft such as airplanes, helicopters, rockets, satellites, buildings and infrastructure components such as parts of bridges, locks and water barriers. [0009] A coating layer is applied by moving the spray coating tool over the surface. The movement can be performed manually or automatically, at a coating speed. In embodiments, a drive with an adjustable coating speed is provided to move the spray coating tool. [00010] One or more layers of coatings are commonly applied, contributing to the protection of the object. For example, anti-corrosion layers, color layers, and/or protective varnish layers are applied. Generally, the term 'coating' is used for the deposited layer. [00011] 'Coating material' is used to identify the composition being deposited, i.e., before spraying. Typically, water-based or solvent-based coating material compositions are applied, especially water-based or solvent-based paints. The amount of water or solvent can be varied to alter the viscosity of the coating material. [00012] In embodiments, a coating material supply is provided with a heating element for the coating material supply, to be able to change the temperature and therefore the viscosity of the coating material. The heating element can be used both to heat and to cool the coating material. [00013] The spray coating tool atomizes coating particles. The spray coating tool generally comprises a spray nozzle to facilitate the dispersion of a coating material, for example, breaking a coating fluid into droplets, also known as atomization, and discharging them in a spray of atomized coating particles. Preferably, a spray nozzle with a single outlet is used. [00014] The coating material can be solid or liquid. A solid coating material is, for example, a powder, so that the atomized coating particles are solid powder particles. A liquid coating material may have a relatively high viscosity, but the system of the invention is also suitable for liquid coating material with a low viscosity. The atomized coating particles are droplets. It is also conceivable that the liquid coating material comprises dispersed particles. [00015] A conditioning cap is provided defining a spray chamber. The geometry and dimensions of the conditioning cap are advantageously tailored to the spray coating tool and