Apparatus and process for applying liquid to an object

A portable machine and process is described for covering all sides of an elongated object with a liquid without the use of brushes. The machine is particularly useful with manufactured building products such as a fence picket, trim, molding, or any other type of board. The machine generally has four stations, an entry station that drives the object down a track, a liquid application station where the object is covered by liquid that is poured over the object, a blower station where the fluid is spread evenly over the object and excess fluid is blown off, and an exit station that continues to pull the object down the track and directs the object as the object leaves the exit station. Finally, the object may enter a releasably attached drop track.

Not Applicable

Not Applicable

BACKGROUND OF THE INVENTION

The present invention is in the technical field of devices and processes used for applying liquids to objects. More particularly, the present invention is in the technical field of portable apparatuses and processes that are exceptionally useful for staining lumber on-site before the lumber is used to create a structure, such as a deck or a fence.

Elongated objects are regularly covered with a liquid. For example, when a wooden fence is constructed, the wood is almost always treated with a liquid, such as a stain or paint. This treatment may occur at various locations between the source of the lumber and the construction site, or it may occur at the construction site. Current methods of treatment include dipping lumber in pools of liquid, typically in very large quantities, using brushes or brush-rollers to apply and/or distribute the liquid, or applying the liquid using a spray, or atomization method. Each of these described current methods present problems including having a limited selection of colors or types of liquids that are applied, cleaning and maintaining brushes, and creating clouds of atomized liquids that travel to surfaces that are not intended to be treated.

The present invention offers a solution that can be used at various locations along the supply route of the object to be treated, including the actual job site. The solution can be portable, and does not create the nuisances of brushes or atomization processes.

Further, the present invention materially enhances the environment of mankind by offering a solution that does not require brushes. Brushes require cleaning and replacement. Often, the brushes are cleaned with toxic chemicals such as ethyl acetate, toluene, turpentine, and other known pollutants and/or carcinogens. Even more, when the brushes are replaced, the old brushes are typically discarded. Therefore, the use of the present invention eliminates the use of toxic chemicals and eliminates the creation of discarded physical waste, and thus contributes to the restoration and maintenance of the basic life sustaining natural elements including water and soil.

SUMMARY OF THE INVENTION

The present invention is an apparatus and process that applies a liquid to an elongated object. The apparatus can be portable, and generally includes multiple stations. The first station drives the object down a track. The second station is brushless, and applies a liquid using waterfalls and pools. The second station also reclaims and reuses unused liquid. The third station applies a current of gas to evenly apply and remove excess liquid. The apparatus further includes an exit station that adds additional means for driving the object through the machine, and means for directing the object while exiting the apparatus. The process includes feeding an elongated object into one side of an apparatus, driving an object through a station that applies liquid by waterfalls and pools, and driving the object through a station that applies a strong current of air.

DETAILED DESCRIPTION OF THE APPARATUS

Referring now to the apparatus in more detail,FIG. 1is a side view of an apparatus that applies a liquid to an object. The apparatus is useful for applying a fluid to a manufactured building product like manufactured lumber. The machine is configurable to accept objects of varying size, including lumber with a cross section of one inch by two inches and objects with rectangular cross sections of two inches by ten inches.

Still referring toFIG. 1, frame500is shown with optional rolling means520. Attached to frame500is entry drive station100, liquid application station200, blower station300, exit station400, splash guard130, and drop track510. An object is placed into entry drive station100, and driven through the apparatus in direction530, through liquid application station200, blower station300, and exit station400, until the object has completely left exit station400and is on drop track510. Splash guard130surrounds the stations and provides a means of confining the chemicals used during the process inside the machine, and protecting operators of the machine from the chemicals used and the moving parts of the apparatus.

Still referring to the apparatus shown inFIG. 1, the construction details of frame500and drop track510are that they are constructed of a rigid material, such as metal. However, any rigid material will work, including lumber.

Still referring to the invention shown inFIG. 1, rolling means520are shown. Rolling means allow for the apparatus to roll, and include wheels or casters. The invention is not limited by rolling means520.

Still referring to the apparatus shown inFIG. 1, drop track510is shown. In the preferred embodiment, drop track510is inclined slightly so that excess liquid travels back towards exit station400. Further, drop track510may have means of aiding the travel of the object, such as rolling means, including wheels, rollers, or bearings. In addition, the preferred embodiment includes a removable, or releasably attached drop track510.

Referring now to the apparatus shown inFIG. 2, entry drive station100is shown. Entry drive station100, or infeed station100, includes Entry pressure wheel110and entry drive wheel120. Said wheels are also referred to as rollers. An elongated object, such as lumber, is placed between these two wheels in an upright position (SeeFIG. 4Afor upright position) and driven through the machine by drive wheel120. Entry pressure wheel110can include an axle, and is attached to entry adjustment means115and entry tension means117. In the preferred mode, entry pressure wheel110includes an axle installed within a slot so that it is tree to move longitudinally so that the relative position between the pressure roller and drive roller can change. Said slot is entry adjustment means115. Entry tension means117constantly apply force to entry pressure wheel110in the direction towards entry drive wheel120. In the preferred embodiment, tension means117is a spring fixedly attached to frame500and the axle of drive wheel110. Further, in the preferred embodiment, there exits two entry adjustment means115and two entry tension means117, one set at the top and one set at the bottom of entry pressure wheel110. This configuration allows for entry pressure wheel110to move away from entry drive wheel120so that objects may be placed between the two wheels, including objects of different widths. In other words, entry adjustment means115and entry tension means117is a mechanism for allowing for the distance between entry drive roller120and entry pressure roller110to change. Pressure is applied by entry pressure wheel110to the object and thus pressuring the object against entry drive wheel120, allowing entry drive wheel120to drive the object through the machine.

Still referring to the apparatus shown inFIG. 2, entry drive motor125is shown. Entry drive motor125provides power to entry drive wheel120. In the preferred embodiment, entry drive motor125is an electric motor that provides power to entry drive wheel120via entry drive means127. In the preferred embodiment, entry drive means127is a chain and sprocket configuration. Other embodiments include gas-powered engines, belt drives, and configurations that do not require entry drive means127because entry drive wheel120is directly attached to entry drive motor125.

Still referring to the apparatus shown inFIG. 2, splash guard130is shown. While the present apparatus is in use, chemicals may splash or spray the operators of the machine. Thus, splash guard130is installed to prevent this occurrence. Similarly, entry splash guard flap135provides protection from the liquid within the machine, and also allows for the object to pass through it. In the preferred embodiment, entry splash guard flap135is a series of thin strips attached above track150.

Still referring to the apparatus shown inFIG. 2, track150is shown. Track150runs through all four stations, including station100. Track150is wide enough to accommodate an object being treated by the apparatus when the object is placed on its shortest side, assuming that the object has a rectangular cross section. The liquid used by the apparatus is preferably an oil-based, low viscosity liquid because the liquid provides a means of lubrication between the object being treated and track150. In the preferred embodiment, the apparatus does not have rolling aids on the track between the entry and exit stations. Track150may be made of a permeable material, or may have drain holes at any point as needed.

Referring now to the apparatus shown inFIG. 3, liquid application station200, also referred to as the waterfall-pool system, is shown. Liquid application station200is the primary means for applying liquid to the object traveling through the apparatus. Liquid jet210directs the flow of liquid over the object as the object passes below it on track150. The liquid application apparatus includes a waterfall system that is essentially a closed system where liquid pump220draws liquid through liquid feed tube243out of liquid reservoir230. In the preferred embodiment, liquid feed tube243has filtering means so that the liquid being drawn from liquid reservoir230is filtered before the liquid enters liquid pump220. Liquid pump220powers liquid through liquid delivery tube245and subsequently to liquid jet210. Liquid flows out of liquid jet210and onto the object traveling though the machine. Generally, gravity causes the excess liquid to flow through liquid drain holes250and into drip pan240where it is directed into liquid reclamation tube247that delivers the excess liquid back into liquid reservoir230. In the preferred embodiment, drip pan240is under all stations. This can be seen inFIG. 1. Liquid drain holes250are holes in track150that allow for liquid to flow through track150. Liquid dram holes250may be holes that are drilled out of track150, or they may exist because track150is made of a material or structure that allows for liquid to flow though track150.

Liquid pump220is capable of pumping enough liquid so that the object is completely covered with liquid when the object passes under the liquid jet210. This requirement of a certain flow rate is a function of the power exerted by drive wheels120and420, as the object will have more or less time under the jets depending on the power exerted by the drive wheels onto the object. The faster the object is moving, the greater the flow rate required from liquid pump220. In the preferred embodiment, the object is traveling a little faster than a foot every two seconds, and the pump system moves a little less than six gallons per minute.

Jets210are configured with a simple slot for fluid to flow through. With respect to location of jests210, the preferred embodiment is the one shown inFIG. 3. In the preferred embodiment, jets210do not atomize the liquid. Rather, the liquid pours from the jets. In other words, the object passes under a stream, or a waterfall of liquid. Thus, liquid pours over the top and both sides of the object.

Referring now toFIG. 4A, pool260is shown on a flat track150. Pool260fills with liquid so that the part of the object that is touching the track is covered with liquid when the object passes over liquid pool260.

Referring now toFIG. 4B, pool260is shown on a curved, or U-shaped, track150. A U-shaped track offers the benefit of having a pool as part of the track without having to remove material, and also allows for the object to only touch the track with its corners. Further, bothFIG. 4AandFIG. 4Bshow an object with a rectangular cross section that is being driven down track150in an upright position. Here, an upright position means that the object's shortest side is touching track150. The preferred method includes driving the object down the track in the upright position for several reasons, including but not limited to applying fluid to the longest sides of the object with the waterfall, applying fluid to the shortest side with the pool, and having the least amount of friction when a flat track is used.

Referring now toFIG. 5, blower station300is shown. Blowers310apply a stream of gas, preferably air, onto the object being treated. InFIG. 5, two blowers are positioned on opposite sides of track150and generally angled towards each other. This stream of air provides multiple functions including removing excess liquid, and moving the wet liquid around the surface of the object so that the liquid is applied evenly. In the preferred embodiment, track150has additional drain holes located at blower station300. Blowers310can be commercially available leaf blowers that are capable of producing an air velocity over 100 miles per hour and move over 350 cubic feet of air per minute. Further, in the preferred embodiment, the position of blowers310is configurable. The configurability may be achieved by frame500having multiple locations to releasably attach blowers310to frame500.

Referring now to the apparatus shown inFIG. 6, exit station400is shown. Exit station400has many of the same features as entry drive station100, but has an additional feature defined as knock over means440. Instead of allowing the objects to randomly fall out of the apparatus, knock over means440ensure that the object exiting the station falls in a certain direction, and can be almost any physical object that can be used for creating a predictable falling direction for objects that exit the apparatus. Knock over means440can be a compressed spring, or can be exit pressure wheel410when the axis of exit pressure wheel410is positioned just downstream of exit drive wheel400.

Still referring to the apparatus shown inFIG. 6, exit drive motor425is shown. In this embodiment, exit drive wheel420has an independent drive motor, exit drive motor425that powers exit drive wheel420via exit drive means427. But the preferred embodiment uses one drive motor to drive both exit drive wheel420and entry drive wheel120. Thus, in the preferred embodiment, exit drive motor425and entry drive motor125are one motor that is attached to entry drive means127and exit drive means427. In the preferred embodiment, the motor used provides three hundred and thirty inch-pounds of torque at forty rotations per minute.

Still referring to the apparatus shown inFIG. 6, exit pressure wheel410, exit adjustment means415, exit tension means417, and exit drive wheel420are shown. These apparatuses work in the same manner as entry pressure wheel110, entry adjustment means115, entry tensioning means117, and entry drive wheel120. Similarly, the preferred embodiment includes two exit tension means417and two exit adjustment means415installed on the top and bottom of exit pressure wheel410.

Still referring to the apparatus shown inFIG. 6, exit splash guard flap435is shown. Exit splash guard flap435is similar to entry splash guard flap in that it provides additional protection from the chemicals used within the machine, and provides means for allowing the object to pass through it while protecting the operators of the machine.

Referring now to bothFIG. 6andFIG. 2, tension means417and117may be accomplished with compression. The term tension is used because the preferred embodiment uses tension to press the object against the drive wheels420and120, but compression would also work, and the apparatus is not limited by the use of tension.

Still referring toFIG. 6andFIG. 2, exit drive wheel420and entry drive wheel120are configured to operate to ensure that the objects travelling through the machine travel at the same speed throughout the process so that all objects receive the same coverage, and that all points on each object receive the same coverage. When an object is not being driven by entry drive wheel120, the object will be driven by exit drive wheel420, and vice versa. Thus, the object travelling through the liquid application station200and blower station300will, be travelling at the same speed regardless of whether the object is driven by entry wheel120, exit wheel420, or both.

The advantages of the apparatus include, without, limitation, the ability to treat an object with liquid in a small space without brushes. Further, the apparatus allows for an object to be treated with a liquid in small batches, limiting the effect on the environment where the object is treated. In addition, the object may be treated with a liquid without atomizing the liquid, further limiting the impact on the environment at the location where the object is treated. Moreover, with respect to lumber, the current business practice of staining lumber involves shipping the lumber from the lumber yard to a location where lumber is stained in large batches, and then shipping the stained lumber back to the lumber yard. With the apparatus, a lumber yard can stain its own lumber, thereby eliminating the need to ship large amounts of lumber, and saving the energy that is expended when shipping the lumber.

In broad embodiment, the apparatus is a machine that is used to apply liquid to all sides of an object without brushes and without atomizing the liquid.