ROOF COATING SPRAYER AND METHODS FOR ROOF COATING

Abstract

A roof coating sprayer including a cart assembly and a sprayer assembly. The cart assembly has a frame with a plurality of wheels. The frame has a sprayer support assembly with a boom, and vertical spray nozzle attachment members arranged along the boom. Tbc attachment members each mount a spray nozzle and can be vertically and horizontally shifted relative to the boom. The roof coating sprayer can be pulled or driven over the surface of a roof at a uniform rate, enabling a coating of a uniform thickness to be sprayed on the roof.

Claims

1. A sprayer for applying a liquid coating material to a planar surface, the sprayer comprising: a frame; a plurality of wheels operably coupled to the frame; a variable speed electric motor operably coupled to at least one of the plurality of wheels to propel the sprayer over the planar surface; and a sprayer assembly operably coupled to the frame, the sprayer assembly comprising: a horizontally oriented boom extending laterally outward from each of a pair of opposing sides of the frame; a plurality of vertical spray nozzle attachment members operably coupled to the boom, each one of the plurality of vertical spray nozzle attachment members being selectively separately horizontally and vertically shiftable relative to the boom; a plurality of spray nozzles adapted to spray the liquid coating material onto the planar surface, each of the plurality of spray nozzles operably coupled to a separate one of the vertical spray nozzle attachment members, each of the spray nozzles being selectively rotationally adjustable to cause a spray of the liquid coating material from the nozzle to be directed in a selected direction relative to the nozzle; a plurality of spray nozzle hoses, each of the spray nozzle hoses being fluidly coupled with a separate one of the plurality of spray nozzles; and a supply hose adapted to couple with a pressurized supply of the liquid coating material and fluidly coupled with the plurality of spray nozzle hoses to convey a flow of liquid coating material to the plurality of spray nozzle hoses.

2. The sprayer of claim 1, further comprising a plurality of valves, each one of the plurality of valves arranged between the supply hose and a separate one of the plurality of spray nozzle hoses to control a flow of the liquid coating material to the respective spray nozzle hose.

3. The sprayer of claim 1, wherein the supply hose includes a trigger to start and stop the flow of liquid coating material to the plurality of spray nozzle hoses.

4. The sprayer of claim 1, wherein the variable speed electric motor is a direct current motor.

5. The sprayer of claim 1, further comprising a motor speed controller electrically coupled to the variable speed electric motor.

6. The sprayer of claim 5, wherein the motor speed controller includes a speed control for adjusting the rotational speed of the variable speed electric motor and a switch for controlling the direction of rotation of the variable speed electric motor.

7. The sprayer of claim 1, wherein the plurality of wheels includes a spaced-apart pair of wheels, each of the spaced-apart pair of wheels disposed on one of the opposing sides of the frame, the spaced-apart pair of wheels being operably coupled to the variable speed electric motor.

8. A method of applying a coating to a planar surface, the method comprising: providing a frame, a plurality of wheels operably coupled to the frame, a variable speed electric motor operably coupled to at least one of the plurality of wheels to propel the sprayer over the planar surface, and a sprayer assembly operably coupled to the frame, the sprayer assembly comprising, a horizontally oriented boom extending laterally outward from each of a pair of opposing sides of the frame, a plurality of vertical spray nozzle attachment members operably coupled to the boom, each one of the plurality of vertical spray nozzle attachment members being selectively separately horizontally and vertically shiftable relative to the boom, a plurality of spray nozzles adapted to spray the liquid coating material onto the planar surface, each of the plurality of spray nozzles operably coupled to a separate one of the vertical spray nozzle attachment members, each of the spray nozzles being selectively rotationally adjustable to cause a spray of the liquid coating material from the nozzle to be directed in a selected direction relative to the nozzle, a plurality of spray nozzle hoses, each of the spray nozzle hoses being fluidly coupled with a separate one of the plurality of spray nozzles, and a supply hose adapted to couple with a pressurized supply of the liquid coating material and fluidly coupled with the plurality of spray nozzle hoses to convey a flow of liquid coating material to the plurality of spray nozzle hoses; coupling the supply hose to the pressurized supply of liquid coating material; and actuating the drive assembly to move the sprayer across the planar surface, the plurality of spray nozzles acting to spray the liquid coating material on the planar surface.

9. The method of claim 8, further comprising a manifold including a plurality of operable valves, each of the operable valves coupled to a separate one of the plurality of spray nozzle hoses and arranged so as to control the flow of liquid coating material to the respective one of the plurality of spray nozzle hoses, and wherein the method includes opening at least one of the valves to enable spraying of the liquid coating material.

10. The method of claim 8, further comprising adjusting a relative position of at least one of the plurality of spray nozzles.

11. The method of claim 8, further comprising a motor controller electrically coupled with the variable speed electric motor and having a speed selection control enabling a user to adjust a rotation speed of the variable speed electric motor, and wherein the method includes adjusting a rate of progress of the sprayer using the speed selection control.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Subject matter hereof may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying figures, in which:

[0024] FIG. 1 is a right-side elevation view of a roof coating sprayer according to an embodiment of the invention;

[0025] FIG. 2 is a front elevation view of the roof coating sprayer of FIG. 1, with an optional wind skirt depicted in phantom for clarity;

[0026] FIG. 3 is a top plan view of the roof coating sprayer of FIG. 1;

[0027] FIG. 4 is a perspective view of a roof coating sprayer according to an embodiment of the invention that does not incorporate a drive system;

[0028] FIG. 5 is an isometric view of the valve manifold of the sprayer of FIG. 4;

[0029] FIG. 6 is an isometric view of the body plates of the sprayer of FIG. 4;

[0030] FIG. 7 is an isometric view of the control handle of the sprayer of FIG. 4;

[0031] FIG. 8 is an isometric view of the sprayer of FIG. 4 in use;

[0032] FIG. 9 is an isometric view of a drive assembly of a roof coating sprayer according to an embodiment of the invention;

[0033] FIG. 10 is another isometric view of the drive assembly of FIG. 9;

[0034] FIG. 11 is an isometric view of the motor speed controller of the embodiment of FIG. 9; and

[0035] FIG. 12 is a high-level schematic of electrical details of the embodiment of FIG. 9.

[0036] While various embodiments are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the claimed inventions to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

DETAILED DESCRIPTION

[0037] There is depicted in FIGS. 1-12 roof coating sprayer 20 according to embodiments of the invention. Sprayer 20 generally includes cart assembly 22 and sprayer assembly 24. Cart assembly 22 generally includes body plates 26, 28, side wheel struts 30, 32, strut brace 34, rear wheel strut 36, handle member 38, sprayer support assembly 40, and lateral member 42. Cart assembly 22 rolls on side wheels 44, 46, which are coupled by axle 48, and rear wheel 50, which is rotatably coupled to rear wheel strut 36. It will be appreciated that side wheels 44, 46, can be spaced apart at a distance corresponding to the common spacing of ridges in metal roof material so that side wheels 44, 46, can ride along the ridges in use to provide a guide for straight-line application. Although three wheels are depicted, it will be appreciated that four or more wheels could also be provided in some embodiments while remaining within the scope of the invention. For a non-limiting example, rear wheel 50 could be replaced by a pair of wheels spaced apart by the same distance as between side wheels 44, 46. In some embodiments, drive assembly 52 can be coupled to axle 48 to make cart assembly 22 self-propelled.

[0038] Rear wheel strut 36 is coupled to body plates 26, 28, with removable pins 58, 60, and handle member 38 is coupled to body plates 26, 28, with removable pins 62, 64, enabling rear wheel strut 36 and handle member 38 to be easily removed and reattached for transporting sprayer 20, and to enable sprayer 20 to be hoisted to a roof for use. Rear wheel strut 36 further includes detachable counterweight 66 to counterbalance the weight of sprayer support assembly 40.

[0039] Sprayer support assembly 40 generally includes axial member 68, lateral member 70, and vertical spray nozzle attachment members 72, 74, 76, 78. Attachment members 72, 74, 76, 78, are coupled to lateral member or boom 70 with clamps 80, which enable attachment members 72, 74, 76, 78, to be selectively vertically shifted relative to boom 70 and horizontally shifted along boom 70 as depicted by the arrows in FIG. 2, providing for width and height adjustability. Moreover, it will be appreciated that boom 70 could be made telescoping to provide width adjustability. Sprayer support assembly 40 is coupled to body plates 26, 28, with removable pins 82, 84, enabling sprayer support assembly 40 to be easily removed and reattached.

[0040] Sprayer support assembly 40 can include optional wind skirts 86, 88, to shield the sprayed area from wind, and control drift of spray. Each wind skirt 86, 88, can include a lightweight metal frame 90 coupled to axial member 68, and a cloth, rubber, or plastic shield 92 stretched over frame 90.

[0041] Sprayer assembly 24 generally includes control handle 94, supply hose 96, feed hose 98, valve manifold 100, spray nozzle hoses 102, 104, 106, and 108, and spray nozzles 110, 112, 114, and 116. Each spray nozzle hose 102, 104, 106, and 108, is controlled by a separate valve 118, 120, 122, 124. Spray nozzles 110, 112, 114, 116, are rotatably attached to attachment members 72, 74, 76, 78, and can be rotated through 360 to direct spray in any desired direction. In addition, as described above, attachment members 72, 74, 76, 78, can be shifted vertically and horizontally to provide any desired spray pattern. Although depicted as manual valves, valves 118, 120, 122, 124, could be electric or pneumatic valves if desired. In addition, although four spray nozzles are depicted, any other number of spray nozzles can be provided while remaining within the scope of the invention.

[0042] Control handle 94 generally include grip portion 126 and trigger 128. Supply hose 96 connects with a pressurized source of spray fluid (not depicted) such as is commonly known to those skilled in the art, and feed hose 98 connects with valve manifold 100. Trigger 128 can be operated to enable liquid coating fluid to pass from supply hose 96 through feed hose 98 to valve manifold 100. Valves 118, 120, 122, 124, can be opened or closed to enable or prevent coating fluid from reaching nozzles 110, 112, 114, 116.

[0043] In use, as depicted in FIG. 8, roof coating sprayer 20 can be positioned on roof 130. Supply hose 96 is attached to the pressurized source of coating liquid (not depicted). Valves 118, 120, 122, 124, are opened. Trigger 128 is operated to start the flow of coating liquid to nozzles 110, 112, 114, 116, and sprayer 20 is pulled at a steady rate in the direction of the arrow as depicted. Alternatively, in embodiments with drive assembly 52, the motorized drive can be engaged to drive sprayer 20 as indicated.

[0044] As depicted in FIGS. 9-12, drive assembly 52 generally includes housing 54, drive assembly 55, control circuitry 56, and transmission assembly 57. Drive assembly 55 generally includes gear motor 150 and motor mount 152. In a preferred embodiment, gear motor 150 is a 24 VDC variable speed gear motor such as is commonly known in the art, but it will be appreciated that any suitable electrically driven gear motor could be used while remaining within the scope of the invention. Motor mount 152 is secured to housing 54, and may be adjustable so that gear motor 150 can be selectively shifted relative to housing 54 to locate and position gear motor 150. Gear motor 150 is fixed to motor mount 152 with bolts 154.

[0045] Transmission assembly 57 generally includes first stage drive assembly 156 and second stage drive assembly 158. First stage drive assembly 156 generally includes drive sprocket 160 and driven sprocket 162 which are coupled by chain 164. Drive sprocket 160 is coupled with the output of gear motor 150, and driven sprocket 162 is fixed to intermediate shaft 166. Intermediate shaft 166 is rotatable in bearings 168, 170, which are coupled to housing 54. Second stage drive assembly 158 generally includes drive sprocket 172 and driven sprocket 174, which are coupled by chain 176. Drive sprocket 172 is fixed to intermediate shaft 166, and driven sprocket 174 is fixed to axle 48. Axle 48 rotates in pillow block bearings 178, 180.

[0046] FIG. 12 is a high-level schematic showing electrical details of drive assembly 52. In the depicted embodiment, 110 VAC mains power is supplied to power supply/rectifier 182, which provides an output of 24 VDC, which is then supplied to control circuitry 56, in the form of motor speed controller 184, and gear motor 150. Motor speed controller 184 can be any suitable gear motor speed control such as are commonly known in the art. As depicted in FIG. 11, motor speed controller 184 can include three-position switch 185, rotary speed control 186, and relative speed display 187. Three-position switch 185 can have an off position, a forward position, and a reverse position. Relative speed display 187 can be a numeric display having a suitable scale such as, for example, 0-100 to indicate the rotational speed of gear motor 150. Using rotary control 186, the rotational speed of gear motor 150, and the resultant moving speed of cart assembly 22, can be adjusted by an operator as desired. It will be appreciated that safety features such as circuit breakers (not depicted) may be incorporated into the circuit to prevent damage and failures due to overloading. Also, it will be appreciated that an operator safety tether (not depicted) can be connected to a switch (not depicted) to interrupt power to gear motor 150 if the operator loses control of roof coating sprayer 20 while being operated in self-propelled mode.

[0047] Again, with roof coating sprayer 20 positioned on roof 130, power cord 188 can be connected to a suitable source of 110 VAC power, and supply hose 96 attached to a pressurized source of coating liquid (not depicted). Three-position switch 185 can be moved from the off position to either the forward position, or the reverse position to start rotation of gear motor 150 and thereby initiate movement of sprayer 20 in the desired direction. The rotation of gear motor 150 is transmitted to axle 48 through transmission assembly 57, thereby causing wheels 44, 46, to rotate and roof coating sprayer 20 to move. The velocity of movement of roof coating sprayer 20 can be controlled by adjusting rotary control 186 to achieve the desired rate of progress. Valves 118, 120, 122, 124, can be opened, and trigger 128 operated to start the flow of coating liquid to nozzles 110, 112, 114, 116.

[0048] It will be appreciated by those skilled in the art that the drive can also be in a separate enclosure from the cart assembly or may be a separate unit towing the sprayer. Further, in any of the embodiments, power may be provided with a battery instead of a power cord connected to AC power.

[0049] In embodiments, advantages of the present invention can include providing up to a 60 spray width using four spray nozzles. Valves 118, 120, 122, 124, can be selectively closed to selectively decrease spray width, which may be useful for example, to avoid fixtures or projections on the roof. The adjustability of attachment members 72, 74, 76, 78, and nozzles 110, 112, 114, 116, enable tailoring of the spray pattern and thickness of coating as needed to accommodate different spray coating materials and roof configurations. Roof coating sprayer 20 can provide a uniform consistent coating thickness over the entire roof surface, especially with the uniform rate of advance provided by drive assembly 52, and can enable the coating to be applied up to ten times faster than using a manual spray wand or roller.

[0050] It will be appreciated that roof coating sprayer 20 can also be used to apply coatings to large areas of concrete, for example parking lots, garages, and the like. Moreover, roof coating sprayer 20 may be used with water or other solvents for power washing surfaces.

[0051] Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.

[0052] Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

[0053] Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.

[0054] Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

[0055] For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. 112(f) are not to be invoked unless the specific terms means for or step for are recited in a claim.