APPLICATOR FOR FLOOR COVERING
FIELD OF THE INVENTION The present invention relates to an applicator system, particularly an application head, configured to apply a coating or film to a substrate surface such as a floor. BACKGROUND OF THE INVENTION Coatings have been applied for a long time to horizontal surfaces to protect surfaces and / or to prolong their finish. The floors, in particular, that are mistreated by pedestrian traffic, vehicles with wheels, and other objects, which are especially difficult to protect. Generally, a coating composition is applied to the floor to protect it from drag marks, scratches, dirt, grease, and other contaminants. The coating is preferably applied as a smooth, even layer on the floor. To facilitate the leveling of the coating composition on the floor, various applicator devices are known, both portable systems and automatic systems (such as scouring machines and casing machines). Various designs and configurations are known for the applicator head used to spread and soften the coating composition. There is always room for improved designs.
Ref. 198840
SUMMARY OF THE INVENTION The present disclosure provides an applicator system, particularly an application head, useful for applying a chemical coating composition on a surface, such as a floor. The application head of the present disclosure is particularly suitable for applying a consistent thin coating, such as less than 127 micrometers (5 thousandths of an inch) in thickness, on the surface, by following the overall contours of the surface. Various modalities of application heads are also provided, as are methods for using the application heads. The application heads of this disclosure are particularly suitable for applying two-component or two-part coating compositions, such as a coating composition that includes a water insoluble polyisocyanate component combined with a cyclic diol hard segment component. For some compositions, cyclohexanedimethanol is the preferred cyclic diol hard segment, and may be 1,4-cyclohexanedimethanol. In addition, some embodiments of the application heads are particularly suitable for applying coating compositions with high solid levels, such as greater than 40% by weight. In addition, some modalities of the heads of
application are, additionally or alternatively, suitable for applying a coating composition with an applicator system including a multi-compartment plastic bag or sack, for separating individual components of the coating composition prior to reacting the individual components together to form the coating composition, the bag that has internal seals that can be broken easily and controllably. These and other modalities and aspects are within the scope of this description. BRIEF DESCRIPTION OF THE FIGURES Figure 1 is a perspective view of a user using an applicator system of the present disclosure; Figure 2 is a perspective view of a portion of the applicator system of Figure 1, particularly, an applicator device; Figure 3 is a perspective view of a portion of the applicator device of Figure 2, particularly, an application head; Figure 4 is an end view of the application head of Figure 3; Figure 5 is a front view of a second embodiment of an application head suitable for use with the system of Figure 1;
Figure 6 is an end view of the application head of Figure 5; Figure 7 is an enlarged view of a portion of the application head of Figure 5; Figure 8 is a perspective view of a third embodiment of an applicator of the present disclosure; Figure 9 is a side view of the applicator of the
Figure 8; Figure 10 is a front view of the applicator of Figure 8; Figure 11 is an enlarged view of a portion of Figure 10; Figure 12 is an enlarged view of an alternative embodiment of Figure 11; Figure 13 is an enlarged view of an alternative embodiment of Figure 11, Figure 14 is an enlarged view of an alternative embodiment of Figure 11; Figures 15A-15E are end views of alternative embodiments of a portion of the applicator; and Figures 16A-16C are diagrammatic views of the applicators in various orientations relative to a horizontal surface. DETAILED DESCRIPTION OF THE INVENTION The present description provides a head of
suitable application for spreading and softening a coating composition on a surface, such as a floor. The application head may be part of an applicator device, which typically includes a handle or other connection that allows proper placement of the application head relative to the surface being coated. The applicator device, with the application head, can be part of a larger applicator system, which includes a source of the coating composition. Referring to the figures, a system for applying the coating composition to a surface, such as a floor, is illustrated. Illustrated in Figure 1 is a user with an illustrative coating applicator system 10 applying a liquid coating composition on the floor 15. The applicator system 10 includes a liquid retainer 20 for storing the liquid coating composition prior to application to the floor 15 and an applicator device 30 that applies the liquid coating to the floor 15. The liquid retainer 20 can have two separate compartments (not seen) to separate the two components of the coating composition until they are ready to be distributed and applied. A hose or other connection passage 25 provides liquid coating composition from the retainer 20 to the applicator device 30. The applicator device 30, also observed in Figure 2, has a
handle 32 connected to an application head 35, which is shown in more detail in Figures 3 and 4. The application head 35, in some embodiments, detachably connects to the handle 32. In this embodiment, the head of application 35 has a body 40 with a first end 40A and a second opposite end 40B, and a width between them. In the illustrated embodiment, the width of the application head 35 is typically at least 22.86 cm (9 inches) and usually is not greater than about 91.44 cm (36 inches). In an alternative embodiment, the width of the application head 35 is approximately 30.48 cm (12 inches) to approximately 60.96 cm (24 inches). It should be appreciated that in other alternative embodiments the size of the application head may vary even outside the dimensions provided above. The body 40, in this embodiment, can be described as formed of a sheet of material that was formed as desired; body 40 can generally be described as having an open construction. The body 40 includes a first portion 43 for connecting to the handle 32 and a second portion 45 which is configured for application of the liquid composition on the floor 15. Present between the first portion 43 and the second portion 45 is a transition portion 44. Depending on the thickness and material of the body
40, the body 40 is deformable or flexible, as will be discussed further below. Referring to Figure 4, the second portion 45 is shown with an outer surface 50 and an inner surface 52, and an arched shape ending in a point 55. The length of the arcuate shape may be defined by a radius or may have a different definition. In a particular embodiment, the second portion 45 has a continuous arcuate shape with a radius of 6.35 cm (2.5 inches). The total length of the second portion 45, from the tip 55 to where the second portion 45 meets the transition portion 44, designated "X", which may also be referred to as the length of the application head 35. In one embodiment X is at least approximately 5.08. cm (2 inches) and is not greater than approximately 30.48 cm (12 inches). In other embodiments, the length X is from about 10.16 cm (4 inches) to about 15.24 cm (6 inches), and in one embodiment, it is 11.30 cm (4.45 inches). It should be appreciated that in other alternative embodiments the size of the device may vary even outside dimensions of the illustrative embodiments provided above. The total height of the application head 35, in this mode the distance between the farthest point in the first portion 43 and the second portion 45, designated as
"Y", is at least approximately 5.08 cm (2 inches) and is not greater than approximately 30.48 cm (12 inches). In some embodiments, the height Y is approximately 7.62 cm (3 inches) to approximately 15.24 cm (6 inches), and in one embodiment, it is 8.28 cm (3.26 inches). The second portion 45 includes a contact area 60 on the outer surface 50. The contact area 60 extends from the first end 40A to the second end 40B in the longitudinal direction of the second portion 45, which is the direction between the tip 55 and wherein the second portion 45 meets the transition portion 44. Stated otherwise, in this embodiment, the longitudinal direction is orthogonal to the width of the application head 35. In some embodiments, including an application head. illustrated, contact area 60 includes the area that is the farthest point from the first portion 43. In some embodiments, the contact area 60 is quite narrow in the longitudinal direction, which is simply a tangential line through the body of the body. first end 40A to second end 40B. In some embodiments, however, the body 40 and particularly the second portion 45, is deformable and / or flexible when a force is applied to the body 40 in the first portion 43. While the second portion 45 flexes and / or deforms, the contact area 60 increases, due to the flattening of the second portion 45
against the 15th floor or another surface. In some embodiments, the body 40 is sufficiently flexible so that the length of contact area 60, in the longitudinal direction, is at least about 0.63 cm (0.25 inches) and not more than about 5.08 cm (2 inches). In some application head designs 35, the contact area 60 has a length in the longitudinal direction of about 1.90 cm (0.75 inches) to about 3.17 cm (1.25 inches), with a contact area length 60 of about 2.54 cm (1 inch) which is particularly preferred for some embodiments. Preferably, the second portion 45 has a smooth radius in the longitudinal direction on the outer surface 50. To facilitate use of the application head 35, it is preferred that the surface 50 along the length be uniform. Along its width, the outer surface 50 of the second portion 45, in this embodiment, has a smooth surface, without angles, channels, grooves, or other surface aspects. It should be appreciated that other modalities may include angles, channels, grooves, planes, or other features. In some embodiments, the body 40 is additionally or alternatively flexible sufficiently along its width, from the end 40A to the end 40B, to
allowing the application head 35 to follow the total contours of the surface that is coated. For example, head 35 is flexible enough along its width to allow undulations, depressions, grooves, or other features on the surface that remove the surface from being flat. As a particular example, the application head 35 can be used on a surface having a large depression, for example, a depression that is 1.27 cm (0.5 inches) deep and 2.54 cm (10 inches) wide. A 30.48 cm (12 inch) wide head can be sufficiently flexible so that the second portion 45 maintains contact with this surface along the width of the head 35. Of course, the amount of flexibility and head deformation of application 35 it depends on the body material 40, the body configuration 40, and the shape and size of the surface feature. The application head 35 can be used in conjunction with an applicator pad placed on the second portion 45. Examples of suitable pads, which are generally well known for applicator systems, include microfiber, wool, and foam pads. Preferably, the application head 35, with or without a pad, provides a smooth surface appearance and avoids an orange peel appearance on the applied coating.
In the illustrated embodiment, the specific configuration of the first portion 43 and portion of 'transition
44, different from its ability to deform the second portion
45, generally does not affect the operation of the second portion 45. The specific configuration of the transition regions between the various portions, i.e., the first portion 43 to the transition portion 44, transition portion 44 to the second portion 45, neither does it affect the operation of the application head 45. The first portion 43 and the transition portion 44 are configured so that when in use, the contact area 60 comes into contact with the surface to be coated. In a particular example, the first portion 43 has a length of approximately 1.85 cm (0.73 inches), and the transition regions are arched with a radius of approximately 0.6 cm (0.25 inches). A second embodiment of an application head for use with an applicator device and optionally an applicator system is illustrated in Figures 5 to 7 as application head 75. In this embodiment, the application head 75 has a body 80 with a first end 80A and a second opposite end 80B, and a width between them. In this embodiment the width of the application head 75 is typically similar to the width of the application head 35, described above.
The body 80 includes a first portion 83, for example, for connecting to the handle 32, and a second portion 85 that is configured for application of the liquid composition on the floor 15. In this application head embodiment 75, the first portion 83 finds the second portion 85 without a transition portion between them. The body 80, at least from the end view of Figure 6, is a solid construction. The body 80, in some cases, may be sufficiently flexible in the longitudinal direction to follow contours of the floor 15. In some embodiments, the body 80 is solid completely from the end 80A to the end 80B. The second portion 85 has an arcuate shape ending at both ends in the first portion 83. In this embodiment, the second portion 85 is 180 degrees and is defined by an individual radius. In a particular embodiment, the second portion 85 has a diameter of approximately 1.27 cm (0.5 inches), which is also the total height of the application head 75. The second portion 85, in the longitudinal direction, is smooth, without angles or flat portions. Along its width, however, the second portion 85, in this embodiment, is serrated or serrated in a regular pattern by a plurality of spaced protuberances 90, to provide a row of spaced spaces between them.
The protrusion 90 may be integral with the second portion 85, or may be attached to it. For example, the protrusion 90 may be molded simultaneously with the second portion 85. In an alternate illustrative protrusion 90 may be a cable or other filament that is applied (e.g., entangled) in the second portion 85. Each protrusion 90 has a tip 95. which is the furthest portion of the surface of the second portion 85. See Figure 7, which is an enlargement of a portion of Figure 5. Tip 95 may be a rounded tip, may be a point, or have a flat surface . The protrusion 90 may be tapered from the tip 95 to the surface of the second portion 85. The protrusions 90 are preferably spaced through the second portion 85 from the end 80A to the end 80B, preferably have a uniform size, and are preferably spaced apart uniform. In the illustrated embodiment, the protrusion 90 is typically at least 0.01 mm (0.0004 inches) high and not more than 10 mm (0.4 inches) high. In some embodiments, the protrusion 90 is at least 0.1 mm (0.004 inches) high and no more than about 5 mm (0.2 inches) high, and in other embodiments, the protrusion 90 is approximately 0.2 mm (0.008 inches) high to approximately 2 mm (0.08 inches) high. It should be noted that in other alternative modalities the size of the
bump may vary even outside dimensions provided above. In a particular example, the tip 95 extends from the surface of the second portion 85 approximately 0.1 mm (0.004 inches) and has a radius of approximately 0.02 mm (0.001 inches). Adjacent protrusions 90 are spaced approximately 10 mm (0.4 inches) apart. In another particular example, the tip 95 extends from the surface of the second portion 85 approximately 0.63 mm (0.025 inches) and adjacent protrusions 90 are spaced approximately 1.27 mm (0.05 inches) apart. The protuberances 90 facilitate controlling the depth or thickness of the coating that is applied to a surface. In use, the protrusions 90 come into contact with the surface that is coated, which thereby preferably allows a coating thickness no greater than the distance between the tip 95 and the surface of the second portion 85. In most embodiments, the composition that is coated may flow sufficiently to spread and absorb any of the uncoated areas left by the protuberances 90. The resulting coating has a smooth surface, typically without the appearance of orange. In some embodiments, the body 80 is flexible enough along its width, from the
end 80A towards the end 80B, to allow the application head 75 to follow and mold the overall contours of the surface that is coated and provide a coating of constant thickness. For example, the head 75 is sufficiently flexible along its width to allow undulations, depressions, grooves, or other features on the surface that removes the surface from being flat. In some embodiments, the application head 75 is flexible enough within its width to accommodate non-uniform surfaces, in some embodiments as much as 2-3 mm of the level, such as, for example, adjacent non-uniform tiles. Otherwise, the body 80 is sufficiently flexible along its width to incline at least 1 cm, from the end 80A to the end 80B, often at least 2 cm, and provide a coating of constant thickness. As a particular example, the application head 75 can be used on a surface having a large depression, for example, 2.5 mm (0.1 inches) deep and 25.4 cm (10 inches) wide. A head 75 in width of 30.48 cm (12 inches) can be sufficiently flexible so that the protuberances 90 maintain contact with that surface along the width of the head 75. Of course, the amount of flexibility and deformation of the head of application 75 depends on the material of the body 80, the configuration of the body 80, the height of protuberances 90, and
the shape and size of the surface feature. Examples of suitable materials for application head 35, 75, especially body 40, 80 include plastics, metals, and composite materials. Plastic is typically thermoplastic, although thermosetting materials can also be used. Examples of suitable plastic materials include polyethylene (both HDPE and LDPE), polyethylene terephthalate (PET), polypropylene, and polystyrene. Materials such as polyvinyl chloride (PVC) and polyurethane can also be used. Referring to Figures 8-10, an alternative mode of an applicator device is shown. The applicator device 100 includes an application head 102 connected to a handle 104. In the illustrated embodiment, the application head 102 and the handle 104 comprise a one-piece construction. However, it should be appreciated that in alternative embodiments of the device the head 102 may be removable from the handle 104. The application head 102 of the device 100 includes an applicator 106 having a curved end profile and a support member 108. The support member 108 connects the application head 102 to the handle 104. In the illustrated embodiment, the support member 108 is
narrow from the application head 102 to the handle 104 and includes a generally triangular woven support structure. The total length Li of the device is approximately 45.72 cm (18 inches) and the total width Wi of the head 102 is approximately 5.08-15.24 cm (2-6 inches). It should be appreciated that many other sizes and geometric configurations are also possible. Referring to Figures 10-14, the surface features of the application head 102 are shown and described in greater detail. In the illustrated embodiment the curved end profile of the applicator 106 is convex relative to a surface to be coated. The applicator includes a grooved contact surface 110 that is configured to contact the surface to be coated. The slots in the illustrated embodiment are parallel to each other and perpendicular to the width Wi of the applicator head 102. It should be appreciated that other slot distributions are also possible. Referring to Figure 11, a groove profile with triangular grooves is shown. The grooves have a height hi of between approximately 0.01 to 10 millimeters (0.004 to 0.4 inches) and the groove has a Si width of approximately 0.05-0.17 cm (0.2-0.07 inches). Figure 12 illustrates an alternative slot layout where the slots have a rectangular profile
and includes plans. It should be appreciated that the raised portions between the grooves also include planes and / or may be discontinuous. The rectangular grooves have a height h2 of between ° approximately 0.2-0.12 cm (0.01-0.05 inches) and the groove has a width of t2 of between approximately 0.05-0.07 cm (0.02-0.03 inches). The width ti of the raised portion is between approximately 0.05-0.07 cm (0.02-0.03 inches) and the distance S2 from the center of a raised portion to the next is approximately 0.02-0.2 cm (0.01-0.1 inches). When referring to Figure 13, another mode of the resumed contact surface is shown. In the illustrated embodiment the slots are U-shaped and the raised portions are dome-shaped. The U-shaped grooves have a height h3 of between about 0.02-0.12 cm (0.01-0.05 inches) and the groove has a width t6 of between about 0.05-0.07 cm (0.02-0.03 inches). The width t5 of the raised portion is between approximately 0.05-0.07 centimeters (0.02-0.03 inches) and the distance S3 from the center of a raised portion to the next is between approximately 0.02-0.2 cm (0.01-0.1 inches). Figure 14 shows an embodiment of the grooved contact surface that is similar to the embodiment shown in Figure 12 and Figure 13. The grooves have a height h of between about 0.02-0.12 cm (0.01-0.05 inches) and the groove has a width of t4 between approximately 0.05-0.07 cm
(0.02-0.03 inches). The width t3 of the raised portion is between approximately 0.05-0.07 cm (0.02-0.03 inches) and the distance S4 from the center of a raised portion to the next is between approximately 0.02-0.2 cm (0.01-0.02 inches). It should be appreciated that many other alternatives of the grooved contact surface are possible and include combinations of the groove distributions illustrated above as well as contact surface distributions not illustrated. Referring to Figures 15A-15E, a number of end profiles are shown. Each of the illustrated end profiles is curved and convex when viewed from below. The embodiment shown in Figure 15A includes a generally consistent curve wherein the curve can be described as having a radius of curvature Ri of approximately 0.4762 cm (0.1875 inches). The embodiment shown in Figure 15B includes end portions that have similar curvatures, but a middle portion that is less curved than any end portion. The embodiment shown in Figure 15C includes end portions and a middle portion each having different curvatures. In the illustrated embodiment the portion of one of the ends and the middle is almost straight, but the total shape of the end profile is convex. Referring to Figure 15D, the middle portion and one of the end potions have a curvature
similar R2 that is smaller than the curvature R3 of the other end portion. When referring to Figure 15E, the full-end profile has a similar curvature R4 that is relatively large. In the illustrated embodiment the curvature R4 is approximately 7.62-12.7 cm (3-5 inches). It should be appreciated that many other end profiles are possible in alternative modes. Referring to Figures 16A-16C, the schematic views of the device are shown to illustrate that the applicator head 102 is configured so that the tool can be used effectively, even when the handle 104 is at a variety of different angles relative to the horizontal . Figure 16A describes the handle that is at an angle ?? about 45 degrees from the horizontal. Figure 16B depicts the handle 104 that is at an angle 22 of approximately 80 degrees from the horizontal. Figure 16C describes the handle 104 that is at an angle 33 of approximately -5 degrees from the horizontal. The device in the illustrated embodiment is configured so that approximately the same portion of the grooved surface of the applicator head is in contact with the horizontal surface, even when the angle of the handle rotates through more than 90 degrees. In alternative embodiments the mode can be configured so that approximately the same portion of the grooved surface of the applicator head
is in contact with the horizontal surface, even when the angle of the handle rotates between approximately 30-60 degrees. It should be understood that although only several specific embodiments are illustrated in the figures, variations of each of these embodiments are within the scope of this description. Additionally, it is understood that the elements or features described with respect to a modality may be incorporated within or with other modalities and variations thereof. The application head of some embodiments is suitable for applying a composition, such as a reactive composition, to a surface, such as floor 15 of Figure 1. Some embodiments of the application head are suitable for application of compositions having high levels solids, such as at least 40% by weight solids. Some embodiments of the application head are suitable for application of compositions having a dynamic viscosity less than or equal to about 25,000 centipoise. The application head 35, 75, 106 can be used in the system 10, which includes composition retainer 20 and applicator device 30. It should be appreciated that in other alternative embodiments, the application heads can be configured to suit compositions having less solids in weight and / or higher viscosity
dynamic A preferred coating applicator system 10 for use with heads 35, 75, 106 includes a multi-compartment plastic bag or sack, for separating individual components, having internal seals that can be broken easily and controllably. To mix the individual components, the internal divider between the bags is broken and the individual components are mixed, for example, by kneading. The mixed components are distributed from the bag as a reactive composition. A preferred retainer 20, which also functions as a distribution unit, is described in PCT publication WO 2004/108404, the full disclosure which is incorporated herein by reference. This publication describes several types of plastic bags or bags with multiple compartments. When dispensing from the retainer 20, the composition is easy to apply to a surface, such as a floor. The surface may generally be of any material, such as vinyl, linoleum, ceramic, wood, marble, and the like. The application head 35, 75, 106 provides suitable coatings on soft as well as porous surfaces or other surfaces having a texture. With application heads 35, 75, 106, the reactive coating is easy to apply and forms a
Slim coating, easily handled with minimal scratches, grooves, or other surface imperfections. In some situations only one step with application head 35, 75, 106 is needed to obtain a smooth and uniform coating. The application head 35, 75, 106 is especially suitable for applying a coating in a thickness usually not greater than about 5 mils (about 127 microns). In some embodiments, depending on the composition and the surface that is coated, the applied coating is approximately 2 mils (approximately 51 microns), or even approximately 1 mil (approximately 25 microns) in thickness. Compositions having high solid levels, such as greater than 40% by weight, or even greater than 50% by weight, can be easily applied with the application head 35, 75, 106. The application head 35, 75, 106 is able to provide a thin, consistent coating, with high solid levels, on non-uniform surfaces. In some cases the surface to be coated should be prepared, for example, clean, scrape or remove previous coatings, and / or priming. Although the discussion was directed to using application head 35, 75, 106 on a floor, a variety of other surfaces such as, for example, walls, covers and shelves, furniture, and bath surfaces, can be coated.
An example of a reactive coating composition for spreading and / or coating with application head 35, 75, 106 is a two-part water-based polyurethane finishing composition formed of a two part or two component system. Such a reactive composition may include a water-dispersible polyisocyanate component combined with a hard segment component of the cyclic diol, such as cyclohexanedimethanol. A preferred cyclohexanedimethanol, for some compositions, is 1,4-cyclohexanedimethanol. Further details with respect to such a composition formed of a water dispersible polyisocyanate component and a cyclic diol hard segment are disclosed in the co-pending patent application having record no. 62026US002 (application number 11/423061) the full description that is incorporated by reference. It is to be understood that the two-part water-based polyurethane finishing composition and the various features thereof described herein and in the co-pending patent application having the record of record no. 62026US002 (application number 11/423061) are only examples of compositions suitable for application by the application head, applicator devices and applicator system of the present disclosure. Other compositions may also be applied. The invention was described with reference to several
modalities and techniques. However, it will be apparent to one skilled in the art that many variations and modifications may be made while remaining within the spirit and scope of the invention. It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.