Abstract:
Improved apparatus for in-situ forming of polymeric materials. During formation, the polymeric materials can be applied to horizontal or inclined surfaces such as roofs. The improved apparatus is automatically controlled and laser guided.

Description:
FIELD OF THE INVENTION 
     The current invention relates to the field of forming polymeric materials in-place, more particularly the field of simultaneously applying such materials to a roof or a wall. 
     BACKGROUND AND SUMMARY OF THE INVENTION 
     Expired U.S. Pat. No. 4,093,411 (the &#39;411 patent), owned by the same sole inventor as the present sole inventor and incorporated herein by reference, describes an apparatus for in-place formation of foamed polymeric materials and application of those materials to horizontal, vertical, or inclined surfaces including, but not limited to, structural roofs and walls. As the self-propelled &#39;411 patent apparatus moves along a working surface, it dispenses a strip of foamed polymeric material and, if necessary for a particular application, a strip of friction-reducing material and/or a sheet of protective coating. In a series of iterations the apparatus applies a number of strips sufficient to cover the working surface. The beveled, overlapping strip edges join to form a continuous surface that may be, if desired, covered with a protective coating that is dispensed by the apparatus simultaneously with the dispensing of the foamed polymeric material. 
     The &#39;411 patent apparatus requires uneconomical manned guidance during each iteration to assure straight-line movement and accurate stopping. It also requires uneconomical and laborious manned relocation after each iteration. When a strip is laid, for example from a roof eve to the roof peak, the &#39;411 patent apparatus must be manually and precisely stopped at the peak and then manually and precisely moved the full length of the strip back to the eve to be ready for laying of the next strip from eve to peak. 
     The present invention improves upon the &#39;411 patent apparatus by eliminating much of its uneconomical labor requirements. Whereas the &#39;411 patent apparatus has a single frame comprising its transport mechanism, the foam mold, and the dispensing means, the present invention incorporates two frames. A bottom frame comprises the transport mechanism and the foam mold, and a top frame comprises the dispensing means. Because the top frame rotates 180 degrees relative to the bottom frame, the present invention apparatus can apply strips of foamed polymeric material to a working surface while moving forward or backward. 
     The present invention apparatus also improves over the &#39;411 patent apparatus with the additional capability of computer-controlled motion. The new guidance system enables iterations of precise, repeatable distance with minimum human intervention. Another improvement is the addition of an optional means of dispensing adhesive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded partial view of the preferred embodiment of the present invention. 
         FIG. 2  is a side view of the preferred embodiment of the present invention. 
         FIG. 2A  is an enlarged side view of the top frame rotation means of the preferred embodiment of the present invention. 
         FIG. 2B  is an enlarged front view of the laser guidance target face of the preferred embodiment of the present invention. 
         FIG. 3  is a top view of the preferred embodiment of the present invention. 
         FIG. 4  is a front view of the preferred embodiment of the present invention. 
         FIG. 5  is a top view of the traveler assembly of the preferred embodiment of the present invention. 
         FIG. 6  is a front view of the control panel of the preferred embodiment of the present invention. 
         FIG. 7  is a partial side view of the preferred embodiment of the present invention while it is moving right to left. 
         FIG. 8  is a partial top view of the release material assembly of the preferred embodiment of the present invention. 
         FIG. 9  is a partial side view of the preferred embodiment of the present invention while it is moving left to right. 
         FIG. 10  is a partial orthogonal view of the release material assembly of the preferred embodiment of the present invention. 
         FIG. 11  is an exploded partial view of an alternate embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Terms used in the application claims and description are intended to have their broadest meaning consistent with the requirements of law. Where alternative meanings are possible, the broadest meaning is intended. All words and phrases are to be interpreted as they are preferentially defined in commonly accepted English language dictionaries, handbooks, textbooks, and treatises except where defined herein. All words used in the claims are intended to be used in the customary usage of grammar and the English language, except for “a” and “an” which can mean “at least one.” 
     As used herein “friction reducer” can mean a slide, a wheel, a roller, a ball, or any other device capable of reducing the friction between objects moving relative to one another. 
     As used herein “receiver” can mean any device capable of receiving a reflected laser signal and transmitting, broadcasting, or otherwise communicating that signal to another device for manipulation. 
     As shown in  FIGS. 1 and 2 , the preferred embodiment of the current invention apparatus  100  has a top frame  10  that is parallel to, and rotatable with respect to, a bottom frame  11 . The axis of rotation of frame  10  is perpendicular to frames  10  and  11 , and is centrally located on frames  10  and  11 . The rotational hinge of apparatus  100  is comprised of concentric cylindrical members, female pivot tube  70 , with pivot tube gear  25  attached, receiving male pivot shaft  71 . In the preferred embodiment pivot tube  70  is attached to top frame  10 , and pivot shaft  71  is attached to bottom frame  11 , but the orientation could be reversed in alternate embodiments. Frames and hinge members are constructed of steel, but could be constructed of any metal or other material with suitable strength and durability. 
     Drive motor  51 , mounted on bottom frame  11 , drives belt  21  that drives conveyor belt  89  that propels apparatus  100  along a working surface  99 . Steering motor  50  is mounted on steering assembly  12  that is attached to bottom frame  11 , and is connected to pulley  13  that drives belt  16 . Belt  16  drives pulley  17  that drives steering belt  30  that provides propulsion complementary to that provided by conveyor belt  89 . Absolute speed of apparatus  100  over working surface  99  can be varied by variation of the power to motors  50  and  51 , both of which are reversible, variable-speed Dayton motors with built-in gear reducers. Motors  50  and  51  are respectively capable of ¾ and 3 hp. 
     Under ideal conditions, the speeds of motors  50  and  51  are controlled so as to drive steering and drive belts  30  and  89 , respectively, at equal speeds in order to produce a straight-line trajectory of apparatus  100 . If working surface friction inconsistencies or topography irregularities cause apparatus  100  to veer from a true course, the laser guidance system senses the misalignment and adjusts the speed of steering motor  50 . The resulting difference in speeds of motors  50  and  51  moves apparatus  100  in the direction necessary to correct the misalignment, at which time the speed of steering motor  50  readjusts to match that of drive motor  51 . 
     The speed of steering motor  50  is automatically controlled by motor controller  5 , the power output from controller  5  to motor  50  being a function of the algorithm programmed into computer  6 . The computer algorithm receives variable voltage inputs from guidance laser  9 , those inputs being a function of how far the beam from laser  9  falls left (L) or right (R) of the center of target face  7  on target  8  ( FIGS. 2 and 2B ). 
     An alternate embodiment of the present invention employs a mechanical means, rather than a laser guidance system, for maintaining apparatus  100  on a desired straight path.  FIG. 11  shows one version of a guidance track, e.g., a channel  28 , attached to working surface  99  with screws, nails, or other fasteners. Guidance rollers or wheels  32 , free to rotate on axles made a part of guidance assembly  33 , are laterally constrained in track  28 , thus constraining apparatus  100  to its desired straight path. Guidance assembly  33  is adjusted vertically with steering assembly adjustors  26 . Locknuts on the adjustors secure guidance assembly  33  in the location necessary for achieving the desired finished foamed layer thickness. As each strip is applied, another track is placed adjacent to it and the process repeated. During the application of each foam strip, track  28  is covered with foam and remains embedded in the ultimate finished foam surface. 
     The present invention is an improvement to the &#39;411 patent apparatus that applies a foamed material to a surface. The application process begins with a continuous strip of wood or rigid foam 3 inches wide that is glued or stapled to the perimeter of working surface  99  so as to form a picture frame around the entire surface. The picture frame thickness matches the desired thickness of the finished foamed layer  98 . 
     Apparatus  100  is positioned with the right edge, as viewed in  FIG. 4 , of drive belt  89  and sheet coating  20  parallel to and approximately at the outside edge of one of the sides (the starting side) of the picture frame (not shown).  FIG. 2  illustrates how sheet coating  20  is pulled from a roll and under drive belt  89  by the rotation of drive assembly  90 . Steering assembly  12  is adjusted vertically with steering assembly adjustors  26  ( FIG. 1 ). Locknuts on the adjustors secure steering assembly  12  so that the bottom plane of sheet coating  20  is level with the top plane of the picture frame, and thus level with the top plane of the desired finished foamed layer  98 . 
     Apparatus  100  then proceeds forward (as indicated by the arrows in  FIGS. 2 and 7 ) powered by drive belt  89  and steering belt  30 . It applies a layer of foamed material abutting the inside, or left edge, as viewed in  FIG. 4 , of the starting side of the picture frame. The foamed layer continues underneath drive belt  89  and sheet coating  20  along their full width and with a consistent height of the desired finished foamed layer  98 . The foamed material is disbursed along the full width of drive belt  89  and to the left, as viewed in  FIG. 4 , of drive belt  89  underneath kickdown assembly  91 . The portion of the foamed material underneath the kickdown assembly becomes a beveled edge that will be foamed over during a later forming of the adjacent strip of foamed material. 
     Apparatus  100  proceeds forward along the starting side of the picture frame until it reaches the end of the starting side. The apparatus may be stopped manually using control panel  24  located on top frame  10  on or near computer  6  or with a predetermined signal generated by the proximity of laser  9  to target  8 , in which case the electronic signal is relayed to computer  6  that responds with a command to motor controller  5  that halts motion of apparatus  100 . Apparatus  100  can also be stopped with a bottom frame safety feature comprising a limit switch (not shown) with a roller that rolls along working surface  99  and senses a sudden predetermined rise or fall. That motion transmits an electrical signal to computer  6  and motor controller  5 , thereby stopping motors  50  and  51  and halting motion of apparatus  100  and the foaming operation. 
     Upon stopping, apparatus  100  has formed a single strip of foamed material along the starting side of the picture frame. The apparatus is then manually turned 90 degrees, a target is positioned the desired distance away, and the operation is duplicated until all sides of the picture frame have been traversed and all sides of working surface  99  have been covered with a strip of foamed material the width of drive belt  89  plus the bevel. The picture frame (the original edge strips of wood or rigid foam) has been covered with foam and/or sheet coating  20  and presents a continuous, substantially smooth surface. 
     After application of a strip of foamed material around the perimeter of working surface  99 , foamed material must be applied to the remainder of the working surface, i.e., the part of the working surface completely surrounded by the newly formed perimeter of foamed material the width of drive belt  89  plus the bevel. To begin this final stage of the process apparatus  100  is positioned adjacent to one of the completed perimeter strips with the right edge, as viewed in  FIG. 4 , of drive belt  89  and sheet coating  20  parallel to the completed strip and approximately three inches to the right, as viewed in  FIG. 4 , of the top of the completed strip bevel. Steering assembly  12  will remain secured with adjustors  26  at the correct height to assure that the bottom plane of sheet coating  20  on drive belt  89  is level with the top plane of the desired finished foamed layer  98  so that all foamed strips have uniform thickness and are parallel to working surface  99 . 
     Apparatus  100  then proceeds forward powered by drive belt  89  and steering belt  30 . It applies a layer of foamed material abutting the inside, or left edge, as viewed in  FIG. 4 , of the previously applied foam strip  98 . As apparatus  100  moves forward applying the new foamed strip, the foam continues underneath drive belt  89  and sheet coating  20  along their full width and with a consistent height of the desired finished foamed layer  98 . The foamed material is disbursed along the full width of drive belt  89  and to the left, as viewed in  FIG. 4 , of drive belt  89  underneath kickdown assembly  91 . The portion of the new foamed strip underneath the kickdown assembly becomes a beveled edge that will be foamed over during the subsequent forming of the immediately adjacent strip of foamed material. 
       FIGS. 1-5  illustrate the foaming procedure. As apparatus  100  proceeds forward, foam supplied by a supply and support truck (the Rig) is disbursed from foam nozzle  19 . The Rig supplies apparatus  100  with foam in liquid or slurry form through hose  1 , compressed air through hose  15 , glue through hose  3 , and electrical power through cable  4 . Reservoir  57  is supplied through hose  15  and provides compressed air to apparatus  100  through gage  58 , valve  59 , and hose  60 . 
     As apparatus  100  moves forward, nozzle  19  dispenses foam as it is moved transversely (side-to-side as viewed in  FIG. 4 ) by the force of compressed air acting against traveler actuator  29  attached to cable  31  inside traveler tube  65  (see traveler assembly  23  in  FIG. 5 ). The preferred embodiment traveler tube  65  is a Parker Origa 120 psi cylinder part number P124-L/28X65-B. 
     An electrical solenoid valve or fluidics control valve  27  is located between feed air hose  67  (emanating from tee  56  fed by reservoir  57  through hose  60  in  FIG. 1 ) and traveler air hoses  61  and  62  ( FIGS. 1 and 5 ). The valve causes air flow from hose  67  to be shunted into hose  61  or  62  in response to signals received from traveler reversal switches  72  ( FIG. 5 ). When foam nozzle traveler  18 , sliding along traveler shaft  68 , impacts either reversal switch  72 , the control valve switches air flow from hose  61  to  62  or vice versa, thus reversing the direction of actuator  29  and traveler  18 . Adjustable traveler accelerators  69  alternately apply spring force that accelerates traveler turn-around to eliminate the lag time inherent in the air flow switching system. Such lag time tends to cause unwanted buildup of excess foam at the edges of the foam strips where traveler motion reverses. Foam is supplied from the Rig through hose  1 . Compressed air is supplied from reservoir  57  through hose  60 , tee  56 , and hose  67 . 
     As apparatus  100  proceeds forward, sheet coating material is laid on top of the newly applied foam. Sheet coating  20 , pulled off of a roll and under drive belt  89  by the rotation of drive assembly  90 , adheres to the top of the foam as it cures. The coating can be any material chosen for desired characteristics including, but not limited to, insulating capability, impermeability, wear-resistance, paintability, and reflectivity. One coating material candidate is butyl rubber, and others are discussed in the &#39;411 patent. 
     As apparatus  100  proceeds forward, and as sheet coating  20  is pulled from its roller on top frame  10 , a flexible release sheet material is pulled from a separate roller on bottom frame  11 . The release material is chosen for its ability to release from curing foam. One release material candidate is polyethylene, and others are discussed in the &#39;411 patent. As shown in  FIGS. 2 and 7 , release material  14  is pulled off of a roll onto the top of drive belt  89  by the rotation of steering belt  30  further explained below. Release material  14  is pulled forward and between drive belt  89  and sheet coating  20  and ultimately laid on top of a part of sheet coating  20  as the new strip is applied.  FIG. 3  shows that release material assembly  22 , holding the roll of release material  14 , is situated on the side of apparatus  100  containing steering assembly  12 . Thus, release material  14  is wide enough to cover only a small part of sheet coating  20  (approximately 1 ft.), extend under kickdown assembly  91 , and extend approximately 1 inch under steering belt  30 . The release material prevents uncured foam from adhering to kickdown assembly  91  and steering belt  30  during the foam application process. After a foam strip is applied to the working surface, release material  14  is pulled off of the strip of sheet coating and the cured foam bevel and discarded. 
     Completion of the first strip within the initially-formed perimeter of foamed material is accomplished when an electronic signal generated by a predetermined proximity of laser  9  to target  8  is relayed to computer  6  and motor controller  5  stopping motors  50  and  51  thereby halting motion of apparatus  100  and the foaming operation. After severing sheet coating  20  and release material  14  at the front edge of drive belt  89 , apparatus  100  is ready to be moved into place for the process of forming the next adjacent foamed strip. 
     With two hand cranks  92  and two hand cranks  93  shown in  FIG. 1 , apparatus  100  is raised just enough to provide clearance between drive belt  89  and the just completed foam layer. With the wheels of hand cranks  92  rolling on working surface  99  and the wheels of hand cranks  93  rolling on the just completed foam layer, apparatus  100  is rolled into place for the process of forming the next adjacent strip. All four hand cranks are then raised until apparatus  100  is supported on one side by steering belt  30  bearing on working surface  99 , and on the opposite side by drive belt  89 , the edge of which bears on the just completed foam layer close to its beveled edge as shown in  FIG. 4 . Release material  14  is pulled off of the just completed strip of sheet coating and the cured foam bevel and discarded. 
     If during the just completed foam application, apparatus  100  was configured as in  FIG. 7  and moving as indicated by the arrow from right to left, apparatus  100  will be configured as in  FIG. 9  and moving as indicated by the arrow from left to right during the subsequent foaming application. This is made possible by the improvement that enables the top frame  10  to rotate 180 degrees relative to the bottom frame  11 . Top frame  10  rotates about the hinge comprised of pivot shaft  71  and pivot tube  70 . Pivot tube gear  25  is turned by a mating bevel gear attached to the drive shaft of pivot motor  2  ( FIG. 2A ). Thus the present improved invention apparatus  100  can apply strips of foamed polymeric material to a working surface while moving in either direction. 
     The present invention improvement includes a target  8  that is positioned directly in the sight line of guidance laser  9  each time apparatus  100  applies a foamed strip. When the target is in position and the previously cut leading edges of sheet coating  20  and release material  14  are inserted under the new leading edge of drive belt  89 , apparatus  100  is ready to proceed with the next application of foam. 
     Improvements to the &#39;411 Patent 
     The present invention provides and claims improvements over the &#39;411 patent: (1) an automated glue option, (2) automated speed control, (3) automated precision guidance, and (4) dual-directional operation. 
     (1) Automated Glue Option. The present invention provides an improvement over the &#39;411 patent in the form of means for application of glue to the area along the beveled seam of adjacent foam strips. This might be necessary where sheet coating  20 , applied during the foaming of a strip, fails to adhere tightly to the top surface of the beveled area of the cured adjacent foam strip. A fan spray of glue from nozzle  64  ( FIGS. 1-4 ) can apply an approximately 3 in. wide strip of glue along the top of the foam joint as it is created, providing a means for good adherence between sheet material  20  and the top of the joint. Glue is supplied from the Rig through hose  3 . Air is supplied from reservoir  57  through hose  60 , tee  56 , and hose  63 . 
     (2) Automated Speed Control. The present invention provides an improvement over the &#39;411 patent in the form of a speed control means for automatically maintaining a desired relationship between the speed of apparatus  100  and the rate of foam application. Different foaming materials cure at different rates depending on composition, driving air pressure, and environmental factors such as sunlight, ambient air density, temperature, and humidity. The best finished foamed surface is produced when apparatus  100  moves at a speed conducive to the optimum curing of the foam. As apparatus  100  proceeds forward, laser range finder assembly  66  monitors the distance between it and the leading edge of the foamed layer as it is being formed ( FIGS. 1 ,  2 , and  4 ). That data is relayed to computer  6  that responds with a command to motor controller  5  that adjusts the speeds of motors  50  and  51  according to an algorithm programmed into computer  6 . The forward speed of apparatus  100  is thus automatically controlled to accommodate the foam cure rate produced by on-site prevailing environmental conditions. 
     (3) Automated Precision Guidance. The present invention provides an improvement over the &#39;411 patent in the form of means for automated precision guidance. Guidance and cessation of motion of apparatus  100  and the foaming operation is controlled with a laser attached to apparatus  100  operating in conjunction with a target fixed to the working surface. 
     (4) Dual-directional Operation. The present invention provides an improvement over the &#39;411 patent in the form of means for dual-direction operation. When an interior strip (a strip inside the initial perimeter strips) was completed using the &#39;411 patent apparatus, the apparatus had to be manually moved back along the last-formed strip in order to begin applying the next adjacent strip. No foaming was accomplished while the apparatus was being moved the entire length of a foamed strip to its next starting position. All strips were laid with the apparatus moving in the same direction. The present improvement invention eliminates that time-consuming, labor-intensive requirement. Because the top frame  10  of the present invention apparatus  100  rotates 180 degrees relative to the bottom frame  11 , the present invention apparatus can apply strips of foamed polymeric material to a working surface while moving forward or backward, cutting a job&#39;s required time almost in half. 
     It will be apparent to those with ordinary skill in the relevant art having the benefit of this disclosure that the present invention provides improvements to an apparatus for in-situ forming of polymeric materials. It is understood that the forms of the invention shown and described in the detailed description and the drawings are to be taken merely as the currently preferred embodiment, and that the invention is limited only by the language of the claims. The drawings and detailed description presented herein are not intended to limit the invention to the particular embodiment disclosed. While the present invention has been described in terms of one preferred and one alternate embodiment, it will be apparent to those skilled in the art that form and detail modifications can be made to the described embodiment without departing from the spirit or scope of the invention. For example, chains and sprockets can be used in place of pulleys and belts; the rotational hinge of apparatus  100  and guidance track  28  can take many forms; foam nozzle traveler lateral motion can be accomplished with a reversible lead screw.