COATING REPAIR KIT

Abstract

A coating repair device for repairing a defect in a paint or coating by forming a repair patch around and over the defect. The repair device comprising a flexible member having an inner section peripherally surrounded by an outer section, each section having top and bottom surfaces with the bottom surface of the inner section being recessed with respect to the bottom surface of the outer section, such that when the flexible member is, in use, placed on the surface of a coating to be repaired it defines a cavity with the surface. An injection through-hole extends between a top and bottom surface of the device for the introduction of repair material into the cavity, in use, and one or more relief through-holes extend between the bottom and top surfaces of the device through which, in use, displaced air or surplus repair material may flow out of the cavity.

Claims

1. A coating repair device comprising a flexible member having an inner section peripherally surrounded by an outer section, the inner and outer sections each having top and bottom surfaces with the bottom surface of the inner section being recessed with respect to the bottom surface of the outer section, such that when the flexible member is, in use, placed on a surface of a coating to be repaired the flexible member defines a cavity with the surface, and an injection through-hole extending between a top surface of the device and the bottom surface of the inner section for the introduction of repair material into the cavity, in use, and one or more relief through-holes extending between the bottom surface of the inner section, at the outer periphery of the inner section, and a top surface of the device through which, in use, displaced air or surplus repair material may flow out of the cavity.

2. A device as claimed in claim 1 wherein a connection between the outer section and inner section is chamfered.

3. A device as claimed in claim 1 wherein a portion of the bottom surface of the inner section surrounding the injection through-hole is recessed with respect to a remaining portion of the bottom surface of the inner section.

4. A device as claimed in claim 1 wherein the injection through-hole is tapered.

5. A device as claimed in claim 1 wherein the injection through-hole narrows as it approaches the bottom surface of the inner section.

6. A device as claimed in claim 1 wherein the bottom surface of the inner section is smooth.

7. A device as claimed in claim 1 wherein at least part of the coating repair device is translucent or transparent.

8. A device as claimed in claim 1 comprising an indicia formed in relief on the bottom surface of the inner section.

9. A device as claimed in claim 1 comprising a tab configured to allow the coating repair device to be removed from a coating after use.

10. A device as claim in claim 9 wherein the tab is angled with respect to the axis of the inner and outer sections.

11. A device as claimed in claim 1 comprising an adhesive disposed on the bottom surface of the outer section configured to provide a seal between the bottom surface of the outer section and a coating to be repaired in use.

12. A device as claimed in claim 11 wherein the adhesive is configured such that, in use, the bond between the adhesive and the coating repair device is stronger than the bond between the adhesive and the coating to be repaired.

13. A device as claimed in claim 11 comprising a release liner provided over the adhesive and configured to cover the bottom surface of the inner section and the outer section.

14. A device as claimed in claim 1 wherein the inner section is circular and the outer section is an annulus.

15. A device as claimed in claim 1 wherein a majority of the bottom surface of the inner section is recessed from the bottom surface of the outer section by a given height, T, wherein T is at least 0.25 mm.

16. A device as claimed in claim 1 comprising two or more relief through-holes equally spaced around a periphery of the inner section.

17. A device as claimed in claim 1 comprising a fitting provided on a top surface of the inner section in communication with the injection through-hole.

18. A device as claimed in claim 17 wherein the fitting is configured to allow an apparatus for delivering repair material to the coating repair device to be received by the coating repair device at various angles with respect to the top surface of the inner section.

19. A coating repair kit comprising: the coating repair device as claimed in claim 1; an abrasion template comprising an aperture corresponding to the shape and size of the inner section; and an abrasion tool.

20. A method of repairing a defect in a coating, the method comprising the steps of: providing either a coating repair device as claimed in claim 1; fixing the coating repair device to the coating to form a cavity comprising the defect; injecting repair material into the cavity through the injection through-hole; curing or setting the repair material in the cavity; and removing the coating repair device from the coating.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0056] In order that the disclosure may be more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:

[0057] FIG. 1 is a top view of a coating repair device for repairing damaged or defective coatings or membranes covering metal pipes, tank linings or structural steel to give a few non-limiting examples;

[0058] FIG. 2 is a cross sectional view of the coating repair device of FIG. 1 taken along the line A-A;

[0059] FIG. 3 is an expanded view of the Detail A in FIG. 2;

[0060] FIG. 4 is a bottom view of an adhesive liner for the coating repair device of FIG. 1;

[0061] FIG. 5 is a cross sectional view of the coating repair device of FIG. 1 along line A-A prior to use with the adhesive liner attached to the coating repair device;

[0062] FIG. 6 is an expanded view of the Detail B in FIG. 5;

[0063] FIG. 7A-D are cross sectional views of a coating defect being repaired using the coating repair device of FIG. 1; and

[0064] FIG. 8 is a perspective, disassembled view of an embodiment of the coating repair device and associated applicator instruments used to repair a coating defect in accordance with the present disclosure.

DETAILED DESCRIPTION

[0065] Referring to FIGS. 1-3, a coating repair device 10 comprises a generally planar flexible member having an outer section 14 and an inner section 20. In this embodiment, the outer section 14 is an annulus with an outer diameter of 63.0 mm and an inner diameter of 38.5 mm, and the inner section 20 is a circle with diameter 38.5 mm. The outer circumference 18 of the inner section 20 is attached to the inner perimeter of the outer section 14. As such, the axes of both the outer section 14 and inner section 20 are parallel, and in this embodiment, the axes also correspond to the axes of the coating repair device 10.

[0066] The plane defined by a bottom surface of the inner section 20 is offset and recessed with respect to the plane defined by a bottom surface of the outer section 14. In this embodiment, the offset is 0.636 mm, but in other embodiments it may be 0.5-2 mm. Due to this offset, a bottom surface of the coating repair device 10 is defined by the bottom surfaces of the inner section 20 and outer section 14, and has a stepped profile, stepping down from the outer section 14 to the inner section 20, and stepping up from the inner section 20 to the outer section 14. Thus, when the bottom surface of the outer section 14 is placed on a coating to be repaired, the recessed inner section 20 defines a cavity that can be filled with repair material to repair the defect.

[0067] The inner section 20 comprises a chamfered outer periphery 21 connecting the outer section 14 and inner section 20. The outer periphery 21 has a radial extent in the plane of the bottom surface of the inner section 20 of 0.5 mm, and is chamfered at an angle of 45 degrees to the plane of the bottom surface of the outer section 14. In other embodiments, the chamfered outer periphery 21 may have different dimensions.

[0068] The inner section 20 also comprises a circular raised section 22 positioned centrally in the inner section 20. The raised section 22 has a diameter of 12.7 mm. In the raised section 22, the bottom surface of the inner section 20 has a conical shape, with the tip of the cone located on the axes of the inner section 20 and outer section 14. The tip of the cone is recessed from the bottom surface of the inner section 20 by 0.3 mm, and is therefore the point recessed furthest from the bottom surface of the outer section 14. In other embodiments, the dimensions of the raised section 22 may be different to suit the circumstances.

[0069] The coating repair device 10 also comprises an injection through-hole 28 that extends from a top surface of the coating repair device 10 to its opposite bottom surface. The injection through-hole 28 is located at the centre of the inner section 20 of the coating repair device 10 and therefore truncates the cone formed by the bottom surface of the inner section 20. The injection through-hole 28 tapers, such that it narrows, as it approaches the bottom surface of the inner section 20 of the coating repair device 10. The injection through-hole 28 extends along the axis of the inner section 20 from its top surface to its opposite bottom surface. The injection through-hole 28 has a tapered shape and is therefore also a truncated cone with an upper width on the top surface of the coating repair device 10 greater than a lower width on the bottom surface of the coating repair device 10. In this embodiment, the lower width is 0.821 mm but in other embodiments the width of the injection through-hole 28 at the bottom surface of the coating repair device 10 may be any suitable size, such as 0.5-2 mm.

[0070] A fitting 24 is disposed on the top surface of the coating repair device 10 over the injection through-hole 28 in the top surface of the coating repair device 10. The fitting 24 is tubular, having an annular cross-section when viewed parallel to the axis of the injection through-hole 28 and extends away from the top surface of the coating repair device 10. The fitting 24 forms an injection port 26 that communicates with the injection hole 28. The fitting 24 is tapered such that its inner diameter increases as the distance from the injection through-hole 28 increases, and its outer diameter decreases. In this embodiment, the inner diameter increases from 4.2 mm at a proximal end of the fitting 24 adjacent the injection through-hole 28 to 4.3 mm at a distal end opposite the proximal end.

[0071] As described above, the fitting 24 and injection through-hole 28 thereby allow an apparatus for delivering repair material to be connected to the coating repair device 10, and for liquid repair material be passed through the coating repair device 10 from its top surface to its bottom surface. The repair material will also be introduced by the injection through-hole 28 at the centre of the recessed bottom surface of the inner section 20 of the coating repair device 10. Thus, where the defect is aligned with the centre of the inner section 20, repair material may pass directly from the injection through-hole 28 into the defect.

[0072] In other embodiments, the fitting 24 and injection through-hole 28 may allow the apparatus for delivering repair material to be connected to the coating repair device 10 at various different angles with respect to the top surface of the coating repair device 10 and at various different locations on the top surface of the coating repair device 10 to suit the circumstances.

[0073] Around the outer circumference 18 of the inner section 20 are disposed four relief through-holes 16 that extend parallel to the axis of the inner section 20 from the top surface of the coating repair device 10 to its opposite bottom surface. The relief through-holes 16 are each spaced at equal points around the outer circumference 18 of the inner section 20. In other embodiments, more or fewer relief through-holes 16 may be used and at positions not necessarily on the outer circumference 18 of the inner section 20, as required. In this embodiment, each relief through-hole 16 has a constant diameter of 1 mm along its axis, in other embodiments this may be different. The relief through-holes 16 thereby allow air or repair material to pass between the top and bottom surfaces of the coating repair device 10. Specifically, in use, they allow air to be displaced from the cavity formed by the inner section 20, outer section 14, and coating to be repaired while repair material is injected into the cavity through the injection through-hole 28.

[0074] In this embodiment, the coating repair device 10 also comprises a tab in the form of a thumb grab 12 attached to one side of the outer circumference of the outer section 14. The thumb grab 12 is annular with an outer circumference that is smaller than the outer circumference 18 of the inner section 20. The axis of the thumb grab 12 is angled with respect to the axis of the inner section 20 such that their axes converge at a point above the top surface of the coating repair device 10.

[0075] In this embodiment, the entire coating repair device 10 is formed in a single step by curing a plastics material in a mould corresponding to the shape of the coating repair device 10. However, in other embodiments, the different parts may be formed separately and then joined together to form the coating repair device 10.

[0076] In this embodiment, the inner section 20, outer section 14 and thumb grab 12 all have the same thickness of 1.3 mm. As such, the top surface of the coating repair kit 10 has the same profile as the bottom surface of the coating repair kit 10. In alternative embodiments, the thickness of each section may vary such that the profile of the top surface does not correspond to that of the bottom surface of the coating repair kit 10. For example, the thickness may depend on the overall size of the coating repair device 10, for example it may be between 0.8-3 mm.

[0077] In this embodiment, the coating repair device 10 additionally comprises an indicia 23 formed in relief on the bottom surface of the inner section 20.

[0078] Advantageously, this allows a corresponding indicia to be formed on the surface of the repair patch once formed in use. In this embodiment the indicia 23 is the letter “D”, to signify that the repair patch is covering a defect. In alternative embodiments many other types of indicia may be used alone or in combination such as: the date or time of repair, the materials used in the repair, branding or trade marks, serial numbers, etc.

[0079] Referring to FIGS. 4-6, prior to use, an adhesive 60 is attached to the bottom surface of the coating repair device 10. The adhesive 60 comprises a circular impermeable release liner 61 with an outer diameter that matches that of the outer section 14, and an annular adhesive film 63 with the same inner and outer diameter as the outer section 14. The adhesive 60 also comprises a rectangular release flap 62 that extends from one side of the release liner 61. The release flap 62 is configured to allow the release liner 61 to be separated from the adhesive film 63.

[0080] In this embodiment, the adhesive film 63 is a double-sided adhesive and comprises two layers: a device adhesive 64; and a coating adhesive 66. The device adhesive 64 is configured to adhere the adhesive film 63 to the bottom surface of the coating repair device 10. The coating adhesive 66 is configured to be releasably adhere to the release liner 61 and a surface of a coating to be repaired. Preferably, the bonding strength between the device adhesive 64 and the coating repair device 10 is stronger than between the coating adhesive 66 and the surface of the coating to be repaired.

[0081] Advantageously, this allows the coating repair device 10 to be removed from the coating while retaining the adhesive 60 on the coating repair device 10 and without leaving adhesive residue on the coating.

[0082] The adhesive film 63 is aligned in register with the release liner 61, with the release liner 61 attached to the coating adhesive 66. As such, the adhesive 60 may be attached to the bottom surface of the coating repair device 10 using the device adhesive 64.

[0083] Referring to FIG. 8, this embodiment of the disclosure is configured to be used as part of a coating repair kit comprising a static mixer. As such, the entrance of the injection port 24 is configured to receive a tip 54 located at the end of the static mixer. The static mixer also comprises a mixing tube 42 in communication with, and attached at one end to, the tip 54. The mixing tube 42 is attached at its other end to a dispenser 52 which is used to dispense repair material through the mixing tube 42 and out of the tip 54 into the injection port 24. The injection port 24 is a similar shape of the tip 54 of the static mixer and may have an O-ring in the end to prevent repair material escaping between the tip 54 and injection port 24, and prevent air from entering the cavity during injection of repair material. The static mixer further comprises an optional heater 44 configured to heat the repair material prior to use. This can help to reduce the viscosity of the repair material to ensure it completely fills the cavity and speed up the repair process. Depending on the type of repair material used, the heater 44 may also be required to ensure the repair material is at the correct operational temperature prior to use.

[0084] The coating repair kit also includes an abrasion tool 30 and corresponding abrasion template 32. The abrasion tool 30 comprises a handle at one end and an abrasive surface at the other, such as sandpaper. The abrasion template 32 is annular with a shape that corresponds to the outer section 14. The abrasion tool 30 may be manual, battery or electrically operated.

[0085] A bottom surface of the abrasion template 32 may be formed from a flexible non-slip rubber. Furthermore, the abrasion template 32 is magnetic, made of magnetic materials, or contains magnets so as to temporarily attract the abrasion template 32 to metallic surfaces. Thus, the abrasion template 32 is less likely to slip or slide around when placed on the coating 71.

[0086] Referring to FIGS. 1-8, a coating 71 for a surface 70 comprises a defect 72. In this example, the surface 70 may be a metal pipe, and the coating 71 may be a protective layer of paint. The coating repair device 10 may be used to repair the defect 72 as described below.

[0087] The abrasion template 32 is placed over the defect 72, exposing the defect 72 and the coating 71 immediately surrounding the defect 72 through the aperture in the centre of the abrasion template 32. The abrasion tool 30 is used to abrade the exposed coating 71 in a patch that corresponds to the final shape and size of the repair patch 73. The shape/size of the abraded area is indicated by disk 38 in FIG. 8. This abrasion simultaneously removes dirt from the coating 71 and reduces the risk of premature delamination of the repair patch 73 from the coating 71, as the coating 71 is primed with a rough surface that the repair material can securely adhere to. Following abrasion, the abraded area may be cleaned to remove any debris caused by the abrasion process, for example using a stream of air or wiping across the surface.

[0088] The coating 71 is now ready for the coating repair device 10 to be attached to it. Prior to use, the adhesive 60 is attached to the bottom surface of the coating repair device 10. In this configuration, the entire bottom surface of coating repair device 10 is covered by the release liner 61 and as such, is not able to adhere to the coating 71. Advantageously, in this state the release liner 61 prevents dirt or other objects from touching the bottom surface of the inner section 20, which may interact with the repair processes and detrimentally affect the performance of the coating repair device 10. It also prevents the adhesive film 63 from touching objects prematurely and thereby reducing its capacity to adhere to the coating 71.

[0089] The release flap 62 may be used to separate the release liner 61 from the adhesive film 63 and the coating repair device 10. Referring to FIG. 7B, the coating repair device 10 may now be adhered to the coating 71 by placing the injection through-hole 28 in register with the defect and lowering the bottom surface of the coating repair device 10 onto the coating 71. In doing so, the coating adhesive 66 will contact with the coating 71 and adhere the coating repair device 10 to the coating 71.

[0090] Once the coating repair device 10 is adhered to the coating 71 as described above, the recessed bottom surface of the inner section 20 will form a cavity with the coating 71 and the defect 72, the cavity being sealed about its periphery by the adhesive film 63. Referring to FIG. 7C, repair material may now be introduced to the cavity through the injection through-hole 28, which introduces the repair material in the centre of the inner section 20. The cavity therefore defines the repair area 40 (see FIG. 8) that is covered by the repair material, and this area corresponds to the area of the coating 71 that has been abraded.

[0091] In this embodiment, repair material is introduced through the injection though-hole 28 by connecting a source of repair material to the injection port 24. Repair material is introduced into the cavity until the cavity is filled with repair material. As repair material enters the cavity it may spread radially from the centre of the inner section 20 due to the geometry of the injection through-hole 28 and the cavity, in particular the shape of the bottom surface of the inner section 20. The relief through-holes 16 disposed on the outer circumference 18 of the inner section 20 allow air to escape the cavity, preventing a pressure increase in the cavity and permitting additional repair material to enter the cavity. Once the cavity is filled, the relief through-holes 16 are the final part of the cavity to be filled with repair material. As such, repair material can be introduced into the cavity until it is observed emerging from one or more of the relief through-holes 16, signifying that the cavity is full of repair material.

[0092] Where the inner section 20 and/or coating repair device 10 is made of a translucent or transparent material, the process of filling the cavity with repair material may also be followed by observing the repair material through the inner section 20 of the coating repair device 10. Advantageously, this may allow for errors or abnormalities, such as air bubbles in the cavity to be identified

[0093] In this embodiment, repair material is introduced by connecting the tip 54 of the static mixed to the injection port 26. The tip 54 is connected by pushing the tip 54 into the injection port 26 to form an interference fit. The dispenser 52 is then used to urge repair material out of the tip, through the injection through-hole 28 and into the cavity. This process continues until repair material is visible emerging from all four relief through-holes 16, or where the inner section 20 is translucent/transparent, until the cavity is observed through the inner section 20 to be full of repair material.

[0094] Once the cavity is full of repair material, the coating repair device 10 remains adhered to the coating 71 until the liquid repair material has set or cured solid into a repair patch 73. Referring to FIGS. 7C and 7D, once the repair patch 73 has set/cured, the coating repair device 10 may be removed from the coating 71 by grasping the thumb grab 12 that is projecting away from the coating 71, and pulling the coating repair device 10 away from the coating 71. Advantageously, the flexible nature of the coating repair device 10 allows it to be progressively peeled back from the coating 71. This reduces the risk of damage to the repair patch 73. Furthermore, the chamfered edge of the inner section 20, conical shape of the inner section 20 close to its axis, and the tapered narrowing width of the injection through-hole 28 ensure that that the coating repair device 10 may be removed from the coating 71 leaving the repair patch 73 undamaged and attached to the coating 71 and defect 72.

[0095] In particular, the tapered shape of the injection through-hole 28 ensures that a local point of weakness in the set repair material is on, or adjacent to, the bottom surface of the inner section 20. This ensures the repair material breaks at this point during removal of the coating repair device 10 leaving the outer edge of the repair patch 73 smooth at this point. The tapered shape also ensures that no additional set/cured repair material falls out of the injection through-hole 28 during removal.

[0096] As mentioned above, the bond created between the device adhesive 64 and the coating repair device 10 is preferably stronger than a bond created between the coating adhesive 66 and a surface of a coating to be repaired. This allows the coating repair device 10 to be removed from the coating 71 without leaving behind any layers from the adhesive film 63.

[0097] Referring to FIG. 7D, the repair patch 73 is retained on the coating 71 and fills the defect 72 reducing the risk that the surface 70 will be damaged in future.

[0098] Advantageously, the chamfered edge of the inner section 20 creates a chamfered edge to the repair patch 73 that reduces the likelihood that soil and liquid stresses will damage the repair patch 73 or coating 71.

[0099] The conical shape of the inner section 20 close to its centre also results in a thicker section of the repair patch 73 at its centre, and in register with the centre of the defect 72. This improves the performance of the repair patch 73 as it is stronger in this region and is less likely to be pulled out of the defect during removal of the coating repair device 10 from the coating.

[0100] The repair material may be made of any one or combination of epoxies, urethanes, ultra-violet curing compounds or other resinous materials.

[0101] The specific embodiments described above have been shown by way of example, and it should be understood that these embodiments may be susceptible to various modifications and alternative forms. It should be further understood that the claims are not intended to be limited to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the spirit and scope of this disclosure.

[0102] The one or more embodiments are described above by way of example only.

[0103] Many variations are possible without departing from the scope of protection afforded by the appended claims.