System for applying a masking material to a substrate

Abstract

Systems for applying a masking material to a substrate, the system comprising: a source feed for delivering a quantity of masking material to a substrate, a waste deposit for receiving masking material when removed from the substrate, a spray nozzle moveable relative to the substrate and a controller for controlling movement of the nozzle relative to the substrate and the speed of delivery of the masking material from the source feed, wherein the speed of movement of the spray nozzle relative to the substrate is substantially equal to the speed of delivery of the masking material from the source feed.

Claims

1. A system for applying a paint medium to a substrate using a masking material, the system comprising: a source feed for delivering a quantity of masking material close to the substrate, a waste deposit for receiving the masking material when removed from the substrate, a spray nozzle moveable relative to the substrate for applying the paint medium to the substrate, a cleaner arranged to clean excess paint medium from the masking material, and a controller configured to control movement of the spray nozzle relative to the substrate and the speed of delivery of the masking material close to the substrate from the source feed such that the speed of movement of the spray nozzle relative to the substrate is substantially equal to the speed of delivery of the masking material from the source feed.

2. The system according to claim 1, further comprising a spray unit defined at least in part by the source feed, waste deposit and spray nozzle, wherein the spray unit is controlled by the controller to be moveable relative to the substrate as a single unit.

3. The system according to claim 1, wherein the source feed comprises two rollers, each roller driving a respective continuous loop of masking material, wherein each continuous loop of masking material is configured to be applied to the substrate, one on each of opposite sides of the nozzle.

4. The system according to claims 3, wherein the source feed is configured to deliver the continuous loop of masking material such that the continuous loop of masking material is spaced apart from the substrate by a distance y.

5. The system according to claim 1, wherein the source feed comprises a roller.

6. The system according to claim 1, wherein the waste deposit comprises a roller.

7. The system according to claim 1, further comprising a guide for facilitating transfer of the masking material from the source feed to the waste deposit.

8. The system according to claim 7, wherein the guide comprises a pair of rollers spaced apart to contact either side of the masking material.

9. The system according to claim 8, wherein the pair of rollers is biased in an engaged position to contact the masking material and is moveable out of the engaged position to facilitate loading of the masking material.

10. The system according to claim 7, wherein the guide comprises at least two pairs of rollers, wherein a first pair of rollers is arranged between the source feed and the spray nozzle and a second pair of rollers is arranged between the spray nozzle and the waste deposit.

11. The system according to claim 1, further comprising angular adjustment means for modifying the angle of the source feed relative to the substrate.

12. The system according to claim 1, wherein the cleaner comprises a reservoir and at least one or more wiping blades.

13. The system according to claim 12, wherein the cleaner further comprises a drain for removal of paint material from the reservoir, wherein the drain comprises a valve having a closed position in which paint material cannot exit the reservoir and an open position in which paint material can exit the reservoir through the drain.

14. The system according to claim 12, wherein the cleaner comprises a level sensor for detecting the level of paint medium within the reservoir and the valve is controllable by the controller such that when the level of the paint medium within the reservoir is detected to have reached a pre-determined level by the level sensor the valve is moved to the open position to permit paint medium within the reservoir to drain therefrom.

15. The system according to claim 1, wherein the source feed comprises a roller configured to accommodate two respective continuous loops of masking material space apart to define a gap therebetween within which the nozzle is positioned, in use.

16. The system according to claim 15, wherein the source feed is configured to deliver the continuous loop of masking material such that the continuous loop of masking material is spaced apart from the substrate by a distance y.

Description

FIGURES

(1) The invention will now be described by way of reference to the following figures.

(2) FIG. 1 illustrates a prior art method of spray painting a substrate;

(3) FIG. 2 illustrates a system for applying a masking material to a substrate according to a first aspect of the invention;

(4) FIG. 3 illustrates a system for applying a masking material to a substrate according to a second embodiment of the invention;

(5) FIG. 4 illustrates a variation of the system of FIG. 3 that comprises an angle setting motor to enable the system to be used with curved surfaces;

(6) FIG. 5 illustrates another variation of the system of FIG. 3 that does not bring the masking material into contact with the substrate;

(7) FIG. 6 illustrates another variation of the system of FIG. 3 that is arranged either side of the nozzle.

DESCRIPTION

(8) A prior art paint spray system 10 is illustrated in FIG. 1. A nozzle 12 is arranged such that it is spaced apart from a substrate 14 to be painted. Masking material 16 is applied to the substrate 14 such that when paint is applied a sharp edge finish is possible. The masking material 16 is removed from the substrate following completion of the painting process. The masking material 16 is disposed of into general landfill due to being contaminated with paint thus preventing recycling.

(9) A first aspect of the invention 100 is illustrated in FIG. 2. A spray unit 102 is arranged such that it is spaced apart from a substrate 104 to be painted. The spray unit comprises a nozzle 106, a source feed 108 for dispensing a masking material 110, a waste deposit 112 for receiving used masking material 110 and a guide 114 for guiding the masking material 110 between the source feed and the waste deposit 112.

(10) The source feed 108 and the waste deposit 112 are shown as rollers in the embodiment illustrated in FIG. 2. The masking material 110 is fed from the source feed 108 and applied to the substrate immediately before painting. Following painting, the masking material 110 is removed from the substrate 104 and stored in or on the waste disposal 112. One, or both, of the source feed 108 and waste deposit 112 rollers are driven by motors.

(11) The spray unit 102 is controlled by a controller 116 which is operable to control the linear movement of the spray unit 102 and transfer of the masking material 110 from the source feed 108 to the waste deposit 112. To facilitate effective operation of the spray unit 102, the controller 116 is configured such that the speed of transfer V.sub.1 of the masking material 110 from the source feed 108 to the waste deposit 112 is equal to the speed of movement V.sub.2 of the spray unit 102 relative to the substrate 104. As one or both of the source feed 108 and waste deposit 112 rollers are controllable by motor, the speed of the motors can be controlled as appropriate

(12) A second aspect of the invention 200 is illustrated in FIG. 3. A spray unit 202 comprises a nozzle 203, a roller 204 around which a continuous loop of masking material 206 is positioned. The masking material 206 is tensioned by one or more guides 208. A cleaning box 210 is provided in contact with the masking material 206. The cleaning box 210 comprises a wiper 212 for wiping paint medium from the masking material 206. The paint medium is collected in a reservoir 214 that is either part of the cleaning box 210 or external to the cleaning box 210. The reservoir 216 comprises a drain 220 to enable paint material within the reservoir 214 to be drained. The drain 220 comprises a valve 222 that has an open position in which paint material cannot be removed drained from the reservoir 214 and an open position in which paint material can be drained from the reservoir 214 through the drain 220.

(13) To tension the continuous loop of masking material, a second roller (not shown) can be provided in-line with the first roller 204. Both the first roller 204 and second roller, if present, are offset from the nozzle 206.

(14) The spray unit 202 is controlled by a controller 216 which is operable to control the movement of the spray unit 202 relative to the substrate 218 and movement of the continuous loop of masking material 206 around a looped path. To facilitate effective operation of the spray unit 202, the controller is configured such that the speed of movement V.sub.1 of the masking material 206 around the path is equal to the linear movement V.sub.2 of the spray unit 202.

(15) In use, the continuous loop of masking material 206 is positioned against or close to a substrate 218 to be painted. As the spray unit 202 moves relative to the substrate 218, the masking material 206 moves around a pre-determined path. The masking material prevents paint medium from being applied to certain areas of the substrate 218.

(16) FIG. 4 illustrates a spray unit 202 that further comprises an angle setting motor 224. The angle setting motor 224 enables axial rotation around a y-axis such that the angle of the first roller 204 can be adjusted. In one embodiment, the angle of the first roller 204 is controlled by the controller 216 such that angle setting motor 224 is instructed to adjust the angle of the first roller 204 in accordance with a change of direction of travel of the nozzle 203.

(17) FIG. 5 illustrates a spray unit 202 that is configured such that the masking material 206 is not in contact with the substrate 218 during use. In this example, the masking material 206 is offset a distance x from the substrate 218. The first roller 204 is adjustable such that the distance of the first roller 204 relative to the substrate 218 is adjustable in height.

(18) FIG. 6 illustrates a spray unit 202 that enables two continuous loops of masking material 206 to be applied against or close to the substrate 218. This can be achieved either through a roller design that can accommodate two loops of masking material 206. or through provision of two sets of rollers with each set of rollers accommodating respective loops of masking material 206. Each continuous loop of masking material 206 is delivered to the substrate 218 such that the nozzle 203 is positioned between the two continuous loops of masking material 206 on opposite sides of the nozzle 203.

(19) The aforementioned description is intended to describe an embodiment of the invention and is given as an example only.