Abstract:
An apparatus for applying a coating material such as paints or sealants, to a desired surface area, such as a wall, building or a billboard. The apparatus includes at least two vertical support members that are laterally supported by a horizontally secured beam. In between the vertical support members is a track that is movably secured generally parallel to the horizontal beam and can traverse up and down along the two vertical support members. A paint assembly is movably secured to the track. The paint assembly is used to store and spray the paint onto the desired surface and can traverse along the track. The apparatus is connected to and controlled by a control system. The control system allows the user to input the dimensions of the surface to be painted as well as the desired image to be painted. An image corresponding to the image in the control system can be painted onto the surface whereby the control system controls the manipulation of the painting of the image by the paint assembly, by properly positioning the paint assembly vertically and horizontal.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to a paint application apparatus and method, more specifically but not by way of limitation, to an electrical powered system for painting structures such as walls, buildings, and billboards.  
       BACKGROUND  
       [0002]     Applying paint to large-scale items such as buildings, walls and billboards usually requires the involvement of many skilled workers to accomplish the task. These structures present difficult painting problems and require a significant investment of time. The skilled workers painting these structures usually require assistance from devices such as ladders, scaffolding or automated lifters. Workers also use a variety of paint application devices such as brushes and rollers. Complicated tasks such as murals on building walls usually require specially trained artists and equipment, which can result in a significant investment of time and financial resources.  
         [0003]     While conventional methods of paint application to large-scale structures perform satisfactorily, no current devices eliminate the need for skilled workers and assistance devices. Accordingly, there is a need for a paint application apparatus and a method to apply paint and other suitable coating materials in general or graphical manner to large-scale items without the need for skilled workers, painters, and extensive equipment.  
       SUMMARY OF THE INVENTION  
       [0004]     It is an object of the present invention to provide a portable painting apparatus alternatively configurable to paint a plurality of large-scale items.  
         [0005]     It is another object of the present invention to provide a portable painting apparatus alternatively configurable to paint a plurality of large-scale items that is operated by an automated control system.  
         [0006]     Yet another object of the present invention is to provide a painting apparatus that provides a method to simultaneously utilize multiple sources of paint.  
         [0007]     It is a further object of the present invention to provide a painting apparatus operated by an automated control system that is permanently affixed to a structure such as a paint booth.  
         [0008]     To the accomplishment of the above and related objects the present invention may be embodied in the form illustrated in the accompanying drawings. Attention is called to the fact that the drawings are illustrative only. Variations are contemplated as being a part of the present invention, limited only by the scope of the claims.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]     A more complete understanding of the present invention may be had by reference to the following Detailed Description and appended claims when taken in conjunction with the accompanying Drawings wherein:  
         [0010]      FIG. 1  illustrates a perspective view of an embodiment of the present invention; and  
         [0011]      FIG. 2  illustrates an enlarged detailed view of a partial section of an embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION  
       [0012]     Referring to the embodiments in  FIGS. 1 and 2  and wherein like elements are designated with identical reference numerals throughout the views and figures and wherein various elements depicted are not necessarily drawn to scale, and in particular  FIG. 1 , there is illustrated an automated paint application apparatus  100  constructed according to the principles of the present invention.  
         [0013]     The automated paint application apparatus  100  comprises of two perpendicular vertical support members  50  generally square in shape mounted in parallel each superposed to an attachment mechanism  90 . The attachment mechanism  90  is releasably secured to one end of each of the vertical support members  50 . The attachment mechanism  90  allows the vertical support members  50  to be releasably secured to a horizontal support structure such as but not limited to the ground. The attachment mechanism  90  is a flat, generally square-shaped piece of steel or other suitable material with apertures. The apertures allow for fastening by mechanical methods, such as but not limited to bolts, to a horizontal support structure. Mounted interposed to the vertical support members  50  is a horizontal support beam  75 . The horizontal support beam  75  provides lateral support for the assembled automated paint application apparatus  100 . The horizontal support beam  75  is demountably attached to one end of each the vertical support members  50 . The horizontal support beam  75  is mounted to one end of each of the vertical support members  50  with an attachment bracket  72 . The attachment bracket  72  is a universal coupling constructed of metal or other suitable material. The attachment bracket  72  has two apertures perpendicular to each other and are of shape to be mated with the vertical support members  50  and the horizontal support beam  75 . The attachment bracket  72  allows one end of the vertical support members  50  to be inserted while simultaneously allowing one end of the horizontal support beam  75  to be inserted perpendicular to the adjacent vertical support members  50 .  
         [0014]     In general axial alignment with the horizontal support beam  75  interposed to the vertical support members  50  is a horizontal support track  70 . Each opposing end of the horizontal support track  70  is releasably secured by suitable mechanical methods to a vertical coupling  55 . The vertical coupling  55  is surroundably mounted to each vertical support member  50 . To each vertical coupling  55  perpendicularly secured by suitable methods such as welding and externally directed from the opposite vertical support members  50  is a mounting plate  57 . The mounting plate  57  is a flat generally square-shaped piece of steel or other suitable material. The mounting plate  57  has apertures to allow fastening by suitable mechanical methods of a vertical movement device  60 . Superposed on each mounting plate  57  is a vertical movement device  60 . The vertical movement device  60  consists of but is not limited to a common electric motor with a shaft and pinion gear. The vertical movement device  60  is fastened to the mounting plate  57  by suitable mechanical methods such as but not limited to steel bolts. The vertical movement device  60  axially moves in a Y-direction, the horizontal support track  70  along the vertical support members  50 . Affixed to one mounting plate  57  adjacent a vertical movement device  60  is a power supply  10 . The power supply  10  is mechanically mounted to the mounting plate  57  by suitable mechanical methods such as but not limited too steel screws. The power supply  10  supplies electrical current to each vertical movement device  60 .  
         [0015]     Demountably attached to the horizontal support track  70  is a paint assembly  95 . The paint assembly  95  traverses along the horizontal support track  70  in an X-axis direction by way of a horizontal movement device  85 . The horizontal movement device  85  is encased in a housing  87  that is surroundably mounted to the horizontal support track  70 . The horizontal movement device  85  consists of but is not limited to a common electric motor configured with a shaft and pinion gear. Secured superposed to the housing  87  and rotatably mounted is the spray nozzle  80 . Beneath the spray nozzle  80  releasably secured to the housing  87  are a plurality of paint storage cells  20 .  
         [0016]     One end of a wiring harness  30  is mated to the horizontal movement device  85  and is releasably secured to the horizontal support track  70 . The opposing end of the wiring harness  30  is secured to the power supply  10 . Juxtaposed to the wiring harness  30  connection on the power supply  10  is a standard 120V junction box  12  to temporarily connect the automated paint application apparatus  100  to an available power source and to allow the automated paint application apparatus  100  to be connected to a control system  40 . Also connected to the power supply  10  is one end of the interface cable  15 . The opposite end of the interface cable  15  is connected to the control system  40 . The interface cable  15  allows the automated paint application apparatus  100  to be controlled by the portable control system  40 . The portable control system  40  uses a plurality of software programs to direct the movement of the spray nozzle  80  and the movement of the paint assembly  95  along the horizontal support track  70 . The portable control system  40  also directs the movement of the horizontal support track  70  along the two vertical support members  50  and controls the flow of paint from the plurality of paint storage cells  20  thus facilitating the application of a paint coating to the desired surface.  
         [0017]     Now referring to  FIG. 1 , the vertical support members  50  consist of a single piece of aluminum tubing or other suitable material of desired length generally square in shape. The vertical support members  50  contain a row of a plurality of apertures on one side designed for meshing with the pinion gear teeth of the vertical movement device  60 . The pinion gear teeth connect with the plurality of apertures as the gear rotates to facilitate the movement of the horizontal support track  70  along the vertical support members  50  in a downward-upward movement. This could be equated as to movement along a Y-axis.  
         [0018]     Although it is not shown, it is contemplated within the scope of the present invention that numerous configurations of the vertical support members  50  are possible. The vertical support members  50  could be a plurality of small segments in length. These segments are then mechanically fastened using suitable methods to configure the vertical support members  50  to a desired length for the particular application needed.  
         [0019]     The vertical support members  50  could also be configured in a manner such as but not limited to common fiberglass tent poles. As with the tent poles, the vertical support members  50  would consist of a plurality of segments each segment having a tapered end to allow insertion into the contiguous segment. The segments of the vertical support members  50  would have an elastic cord positioned internally that would connect the entire plurality of segments. The vertical support members  50  would be manufactured by suitable methods to offer a variety of predetermined lengths.  
         [0020]     It is also contemplated that sensors utilizing such things as magnetism or lasers could be integrated into the vertical support members  50 . The sensors would allow the automated paint application apparatus  100  to detect the area desired for coating and assist in the control of the paint assembly  95  all being generally operated by the control system  40 .  
         [0021]     Yet another possible configuration of the vertical support members  50  is that in place of the apertures to mesh with a pinion gear configured to the vertical movement device  60 , a groove would exist to mate with a frictionally annular device that would facilitate the movement of the horizontal support track  70  in a downward-upward movement along the vertical support members  50 . Those skilled in the art will recognize that many alternatives exist which could be used in place of and/or in conjunction with the methods and materials suggested herein to achieve the functionality of the vertical support members  50 .  
         [0022]     Still referring to  FIG. 1 , the horizontal support track  70  consists of a single piece of aluminum tubing or other suitable material of a desired length generally square in shape. The horizontal support track  70  contains a row of apertures on one side adapted to mesh with the pinion gear teeth of the horizontal movement device  85 . The horizontal movement device  85  traverses the horizontal support track  70 . This could be equated to an X-axis direction. Each opposing end of the horizontal support track  70  is releasably secured to the vertical coupling  55  by suitable mechanical fasteners such as but not limited to steel screws.  
         [0023]     Alternate arrangements of the embodiment of the horizontal support track  70  while not shown are contemplated within the scope of the present invention. More specifically, but not limited to, an additional member mounted perpendicular to the horizontal support track  70  could be releasably secured in order to provide a third, Z-axis, movement for the paint assembly  95  to assist in coating applications of three dimensional objects such as but not limited too automobiles, buses, aircraft and motorcycle gas tanks. Although not shown it is contemplated within the scope of this invention that the horizontal support track  70  could be manufactured in at least all but not limited to the configurations and principles of the vertical support members  50  as suggested herein.  
         [0024]     Now referring to  FIG. 2 , the paint assembly  95  is common paint sprayer such as but not limited to an airless paint sprayer or aerosol paint sprayer. The spray nozzle  80  is constructed according to well-known manufacturing techniques in the field of manufacturing paint spray nozzles. The spray nozzle  80  is rotatably mounted superposed on the housing  87 . The spray nozzle  80  has a predetermined orifice sized for spraying paint at a desired volume and rate. Although it is not shown, it is contemplated within the scope of this invention that alternate spray nozzles  80  could be attached with a different orifice to vary the degrees of spray pattern and volume for painting the desired item. Those skilled in the art will recognize that a variety of different paint spray nozzles and configurations could be used in place of and/or in conjunction with the spray nozzle  80  to achieve the function suggested herein.  
         [0025]     The paint assembly  95  also consists of a horizontal movement device  85 . The horizontal movement device  85  is encased in a housing  87  that surroundably mounts the horizontal support track  70 . The housing  87  is manufactured of metal or other suitable material. The housing  87  encases the horizontal movement device  85 , which is but not limited to a common electric motor with a shaft and pinion gear designed to mesh with the apertures of the horizontal support track  70 . As the pinion gear rotates, the teeth mesh with the apertures of the horizontal support track which moves the paint assembly  95  in a generally X-axis direction.  
         [0026]     Sealably mounted to one side of the housing  87  is a plurality of paint storage cells  20 . The paint storage cells  20  consist of bottles constructed of plastic or other suitable material. Although it is not shown it is contemplated within the scope of this invention that the paint storage cells  20  could comprise of a variety of sizes suitable for desired applications. Those skilled in the art will recognize that many different types of readily available paint sprayers could be used in place of and/or in conjunction with the paint assembly  95  to achieve the functions suggested herein of the paint assembly  95 .  
         [0027]     The control system  40  operates the automated paint application apparatus  100 . The control system  40  consists of but is not limited to a portable laptop computer. The control system  40  contains a software program that allows the user to input the dimensions of the surface that is desired for coating application. The control system  40  allows for the user to include areas, which are not to be coated during the application such as but not limited to doors and windows of an interior or exterior wall. Alternatively, the control system  40  could receive feedback from the sensors or lasers mounted to the vertical support members  50  and the horizontal support track  70  to control the area that is to be applied with the coating. The control system  40  has a plurality software programs to allow the user to program the automated paint application apparatus  100  for simple applications such as but not limited to the application of a single coat of paint to a desired surface or complex applications such as the reproduction or image transfer of a photograph or complicated design that has been inputted into the software program of the control system  40 . The control system  40  is linked to the automated paint application apparatus  100  via the interface cable  15 , which consists of but is not limited to a standard RS-232 or LAN cable. Those skilled in the art will recognize that many alternatives of control systems and interface methods could be used in order to achieve the functions suggested herein of the control system  40 .  
         [0028]     Referring in particular to the drawings submitted herewith, a description of the operation of the automated paint application apparatus  100  is as follows. In use, a user would assemble the vertical support members  50  to the desired length. A vertical coupling  55  with mounting plates  57  is then mounted to each vertical support member  50 . An attachment bracket  72  is secured by a suitable mechanical method to one end of each of the vertical support members  50 . A horizontal support beam  75  is assembled to the desired length. The user, into each attachment bracket  72  perpendicular to each adjacent vertical support member  50 , inserts the horizontal support beam  75 . Opposite the attachment bracket  72 , an attachment mechanism  90  is mounted by suitable mechanical methods to each end of the vertical support members  90 . The entire automated paint application apparatus  100  is then secured to the ground or other structure. Next, the horizontal support track  70  is assembled to the desired length. The horizontal support track  70  is then fastened by suitable mechanical methods to each of the vertical couplings  55  that are mounted to the vertical support members  50 .  
         [0029]     Subsequently, the paint storage cells  20  are filled with the desired paint or coating material. The paint storage cells  20  are then mounted to the housing of the paint assembly  95 . The user then mounts the paint assembly  95  to the horizontal support track  70 . The user then connects one end of the wiring harness  30  to the paint assembly  95  and the other end of the wiring harness  30  to the power supply  10 . Next, the user connects one end of a 120V power cord to the junction box  12  and the other end to an available power source. The user then connects one end the interface cable  15  to the junction box  12  and the opposite end to the control system  40 . The control system  40  is programmed with the desired dimensions of the area to be painted or programmed with a specific image to be painted. The user then initiates the program of the control system  40  to start the application of the paint coating or the painting of the image in the program.  
         [0030]     Upon initiation of the control system  40 , the control system will position the paint assembly  95  to the desired starting position which could be but is not limited to the top of the inputted dimension furthermost to one side. The control system  40  maneuvers the paint assembly  95  laterally, or X-axially, across the horizontal track  70  via instructions sent to the horizontal movement device  85 .  
         [0031]     Vertical or Y-axial movement is controlled by the control system  40  sending instructions to the vertical movement devices  60 . When a detailed or high-resolution image has been programmed into the control system  40  for reproduction on a desired surface, the control system  40  will move the paint assembly  95  axially in the X and Y direction as needed to reproduce the image.  
         [0032]     The control system  40  also controls the flow of paint through the spray nozzle  80  to correspond to the amount needed depending on the type of image being reproduced. For example, the control system  40  would send instructions to the spray nozzle  80  to use a different amount of paint if the desired application is a single coat of paint as opposed to a complex graphic image. During the replication of a complex image, the control system  40  will send instructions to the paint assembly  95  not only to control the flow of the paint through the spray nozzle  80  but the control system  40  will also direct the type of coating needed from each different paint storage cell  20  needed to reproduce the inputted image.  
         [0033]     The control system  40  will also monitor the amount of coating material in the paint storage cells  20  and halt the process when at least one paint storage cell  20  becomes substantially depleted. The control system  40  will then alert the user to refill a particular paint storage cell  20  and upon filling the user can resume the coating application at the point that the process had been halted. Once the desired coating or image has been applied to the chosen surface, the automated paint application apparatus  100  can be used to apply at least one coating of a sealant such as but not limited to a weatherproof polyurethane.  
         [0034]     In the preceding detailed description, reference has been made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments, and certain variants thereof, have been described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that other suitable embodiments may be utilized and that logical changes may be made without departing from the spirit or scope of the invention. The description may omit certain information known to those skilled in the art. The preceding detailed description is, therefore, not intended to be limited to the specific forms set forth herein, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents, as can be reasonably included within the spirit and scope of the appended claims.