Abstract:
A method for applying a polymer to a substrate having a first surface and a second surface (such as an inside surface and outside surface). One or more apertures are provided through the substrate, with the apertures linking the first and second surfaces. A polymer coating is applied to the first and second surfaces, with some of the polymer coating flowing into and remaining within the aperture(s). The polymer coating within the aperture(s) serves to link the polymer coating covering the first surface and the polymer coating covering the second surface. The invention also encompasses coated objects made using the inventive method.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    This non-provisional patent application is a continuation-in-part of U.S. patent application Ser. No. 12/543,978. The parent application was filed on Aug. 19, 2009 and listed the same inventor. The parent application claimed the benefit of a provisional patent application having Ser. No. 61/090,592. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable. 
       MICROFICHE APPENDIX 
       [0003]    Not Applicable member 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    This invention relates to the field of corrosion protection. More specifically, the invention comprises a method and system for applying a protective coating to a substrate and ensuring that the protective coating remains well-bonded. 
         [0006]    2. Description of the Related Art 
         [0007]    Many objects are used outdoors to serve a variety of functions. Outdoor objects may be made from numerous materials, for example, they may consist of plastics or metals. The outdoor objects are exposed on a day-to-day basis to changing and sometimes harsh weather conditions and/or other external considerations. 
         [0008]    In addition, many objects include both external and internal surfaces. Protective coatings are often applied to the external surface while leaving the internal surface untreated. The internal surface may be subjected to elevated humidity levels because of trapped moisture. It is certainly preferable to provide a method that treats both internal and external surfaces. 
         [0009]    Without some type of protection, outdoor objects can rapidly deteriorate. Therefore, oftentimes these outdoor objects are coated with some type material that tends to protect them from the harsh weather conditions and/or other external anomalies. However, the coating that is placed on the objects oftentimes, over time, tends to crack and peel away from the outdoor object. It is therefore preferable to provide a system and method for adhering the coating to a substrate so that it resists separation. 
       BRIEF SUMMARY OF THE PRESENT INVENTION 
       [0010]    The present invention comprises a method for applying a polymer to a substrate having a first surface and a second surface (such as an inside surface and outside surface). One or more apertures are provided through the substrate, with the apertures linking the first and second surfaces. A polymer coating is applied to the first and second surfaces, with some of the polymer coating flowing into and remaining within the aperture(s). The polymer coating within the aperture(s) serves to link the polymer coating covering the first surface and the polymer coating covering the second surface. The invention also encompasses coated objects made using the inventive method. 
         [0011]    A first embodiment of the invention comprises a substrate having a first and second surface and an aperture formed in the substrate that extends from the first surface to the second surface of the substrate. A polymer-type coating is formed on the first surface and a polymer-type coating is formed on the second surface, the polymer-type coating formed on the first surface extending through the aperture and the polymer-type coating formed on the second surface extending through the aperture thereby connecting the polymer-type coating formed on the first surface with the polymer-type coating formed on the second surface. 
         [0012]    A method in accordance with an embodiment of the present disclosure comprises creating at least one aperture in a substrate and applying a polymer-type coating to a first and second surface of the substrate, and the polymer type coating fills the aperture thereby connecting polymer-type coating on the first surface to the polymer-type coating on the second surface. The method further comprises curing the coating. 
         [0013]    Various methods of attaching the substrate are included, with a preferred embodiment heating the substrate prior to the application of the polymer. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0014]      FIG. 1  is a perspective view of an exemplary substrate having a plurality of apertures in accordance with an embodiment of the present disclosure. 
           [0015]      FIG. 2  is a perspective view of the substrate of  FIG. 1  further having coatings adhered to two surfaces of the substrate. 
           [0016]      FIG. 3  is a top plan view of the coating adhered to the substrate as depicted in  FIG. 2 . 
           [0017]      FIG. 4  is a cross-sectional view of the substrate and the coatings taken along line A-A′ of  FIG. 3 . 
           [0018]      FIG. 5  is a top plan view of an exemplary substrate in accordance with another embodiment of the present disclosure. 
           [0019]      FIG. 6  is a perspective view of an exemplary pole having a plurality of apertures in accordance with an embodiment of the present disclosure. 
           [0020]      FIG. 7  is a perspective view of the pole of  FIG. 5  further having coatings adhered to an inside surface and an outside surface of the pole. 
           [0021]      FIG. 8  is a cross-section view of the pole and the coatings taken along line B-B′ of  FIG. 6 . 
           [0022]      FIG. 9  is a flowchart of an exemplary method in accordance with an embodiment of the present disclosure. 
       
    
    
       [0023]      
         [0000]    
       
         
               
             
               
               
               
             
           
               
                   
               
               
                 REFERENCE NUMERALS IN THE DRAWINGS 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 100 substrate 
                 101 aperture 
               
               
                   
                 102 coating 
                 103 coating 
               
               
                   
                 105 coating portion 
                 200 first surface 
               
               
                   
                 201 second surface 
                 500 substrate 
               
               
                   
                 600 pole 
                 601 inside surface 
               
               
                   
                 602 outside surface 
                 603 aperture 
               
               
                   
                 700 coating 
                 701 coating 
               
               
                   
                 900 aperture forming step 
                 901 polymer application step 
               
               
                   
                 902 curing step 
               
               
                   
                   
               
             
          
         
       
     
       DETAILED DESCRIPTION OF THE INVENTION 
       [0024]    The present disclosure generally relates to coating reinforcement systems and methods. In particular, the present disclosure relates to a system whereby a structure is protected from environmental conditions, such as, for example harsh weather conditions, by applying a coating, such as, for example, a polymer-type material, to two or more surfaces of the structure. 
         [0025]    The polymer coating is selected to be thick and strong, so that it may be applied in a single thick sheet. It is preferably non-porous, non-fibrous, inert, and non-chemically bonding. The polymer selected should have a shear-strength sufficient to avoid cracking, flaking, or tearing. Instead, it should delaminate as a unified sheet. It preferably does not need to be applied in layers. The single-ply thickness is preferably greater than 0.250 inches and may be as much as 0.750 inches. Delamination is avoided by mechanically linking two or more coated surfaces together using aperture(s) passing between the surfaces. The apertures are at least partially filled with the polymer, so that a polymer coating on a first surface is mechanically joined to a polymer coating on a second surface by polymer flowing through the aperture(s). 
         [0026]    In accordance with the present disclosure, the coating is reinforced by the perforation of the structure, i.e., one creates apertures in the structure that extend from one surface of the structure to the other. The coating adheres to both surfaces of the structure, and also fills the apertures (at least partially) thereby reinforcing the polymer coating after it hardens and adheres to the surface of the structure and hardens and adheres within the apertures. The coating that fills the apertures reinforces the coating on the surfaces so that the coating will not flake or peel away from the surface of the structure as a result of wear or harsh weather conditions. 
         [0027]      FIG. 1  depicts an exemplary substrate  100  in accordance with an embodiment of the present disclosure. The substrate  100  may comprise any type of material, including metallic, plastic, or fiberglass material. Notably, the substrate  100  may comprise other types of materials known in the art or future-developed. Within the substrate  100  are a plurality of apertures  101  that extend completely through the substrate  100 . 
         [0028]    The number, size, and shape of the apertures may vary depending upon the application. Thus, while three circular apertures  101  are shown in  FIG. 1 , this is for exemplary purposes only. 
         [0029]    In one embodiment, the aperture  101  has a diameter that is substantially equal to the thickness of the substrate  100 . In such an embodiment, there is a direct relationship between the thickness of the substrate  100  and the desired diameter of the aperture  101 . 
         [0030]    Note that the apertures may be formed in the structure using any type of process known or future-developed, including, but not limited to drilling, punching, stamping, or any other method for generating the apertures  101 . Further note that the apertures  101  may be in a random or ordered pattern in the substrate, which is described further herein. The pattern shown in  FIG. 1  is a random pattern of three apertures. 
         [0031]      FIG. 2  depicts the substrate  100  having a coating  102  on a first surface  200  of the substrate  100 , and a coating  103  on a second surface  201  of the substrate  100 . In one embodiment, the coatings  102 ,  103  consist of a polymer-type material, however, other types of materials may be used in other embodiments for protecting the substrate  100  from, for example, weather elements. 
         [0032]    Note that in one embodiment, the substrate  100  is treated before the coatings  102 ,  103  are applied to the substrate  100 . If the substrate  100  comprises, for example, a metallic material, then it may be desirable to galvanize the surfaces  200 ,  201  of the substrate  100  or cover the surfaces  200 ,  201  of the substrate  100  with a primer (not shown), for example, before applying the coatings  102 ,  103 . Galvanization or priming ensures that the coatings  102 ,  103  stick to the surfaces  200 ,  201  of the substrate  100 . 
         [0033]    If the substrate  100  comprises, for example, plastic or fiberglass, it may be desirable to prime or etch the surfaces  200 ,  201  of the substrate  100 . Priming or etching the surfaces  200 ,  201  of the substrate  100  ensures that the coatings  102 ,  103  stick to the surfaces  200 ,  201  of the substrate  100 . 
         [0034]    In one embodiment, the coatings  102 ,  103  can be applied through a heating process. In this regard, the substrate  100  is preferably heated to a temperature above 200 degrees Fahrenheit, even more preferably above 250 degrees Fahrenheit, and even more preferably above 300 degrees Fahrenheit. In one embodiment, a temperature of 315 degrees Fahrenheit (F) is used. Note that 315 degrees F. is provided as an exemplary desired temperature, and other temperatures may be used in other embodiments. 
         [0035]    The polymer-type material is then applied to a specified thickness. Notably, the thickness to which the polymer-type material is applied varies depending upon the application of the coatings  102 ,  103 . The polymer-type material is applied by immersing the substrate  100  in the polymer-type material, by wrapping a layer of raw polymer-type material about the heated substrate  100 , by spraying the polymer material onto the heated substrate, or any other suitable method. 
         [0036]    When the polymer-type material contacts the heated substrate  100 , it melts and adheres to the substrate  100 . As it melts to the substrate  100 , portions of the polymer-type material form the coatings  102 ,  103  and portions pass through the apertures  101  thereby linking the coatings  102 ,  103  one to the other. In one embodiment, the temperature of the substrate  100  is maintained for twenty minutes to cure the coatings  102 ,  103 . 
         [0037]    The temperature of the substrate  100  may be maintained in a number of ways. As an example, in one embodiment, the temperature of the substrate  100  may be maintained by convection. In this regard, hot air may be blown over the substrate  100  to bring the substrate  100  to the desired temperature and maintain the temperature prior to coating and during coating of the substrate  100  until the substrate  100  is cured. 
         [0038]    In another embodiment, the substrate  100  may be placed in an oven to reach the desired temperature. Once the substrate reaches the desired temperature, the substrate  100  may then be removed from the oven, immersed in the polymer-type material, then placed back into the oven until the coatings  102 , 103  of the polymer-type material cure. 
         [0039]    In another embodiment, a positive charge may be applied to the substrate  100 . The positive charge induces a current in the substrate  100  that causes the substrate  100  to heat to the desired temperature. The polymer-type material is then applied to the substrate  100  when it reaches the desired temperature, and the current continues to flow through the substrate  100  until curing occurs forming the coatings  102 ,  103 . 
         [0040]    In another embodiment, raw polymer-type material may be applied to the substrate within a vacuum chamber. The vacuum causes the raw polymer-type material to conform to the substrate and a portion of the raw polymer-type material to pass through the apertures  101 . Thus, the coatings  102 ,  103  are formed. To cure, heat is applied within the vacuum chamber at the desired temperature in order to cure the coatings  102 ,  103 . 
         [0041]      FIG. 3  is a top plan view of  FIG. 2  showing the coating  102  in relation to the apertures  101 .  FIG. 4  is a cross-sectional view of  FIG. 3  taken along line A-A′ of  FIG. 3 . Notably, when the coating  102  is applied to the surface  200  of the substrate  100 , and the coating  103  is applied to the surface  201  of the substrate  100 , a portion of the coating  105  fills the aperture  101 , thereby supporting and reinforcing the coating  102 ,  103  that adheres to the substrate  100 . In this regard, the coating  105  connects the coating  102  to the coating  103 , thereby supporting and reinforcing the coatings  102 ,  103 . Such support reduces cracking, chipping, and peeling that may result from harsh weather, for example. 
         [0042]      FIG. 5  depicts a top plan view of a substrate  500  in accordance with another embodiment of the present disclosure. Substrate  500  differs from the substrate  100  ( FIG. 1 ) in that a plurality of apertures  501  are created in the substrate  500  in an ordered pattern, i.e., in rows and columns. In contrast, the apertures  101  ( FIG. 1 ) are randomly created in the substrate  101 . 
         [0043]      FIGS. 6-8  as described illustrate one application of the present disclosure. In this regard,  FIG. 6  depicts a pole  600 , such as, for example, an outdoor lighting pole. The pole  600  comprises a hollow cylinder. The two surfaces of the lighting pole are inside surface  601  and outside surface  602 . In addition, the pole  600  comprises a plurality of apertures  603  that extend from the outside surface  602  to the inside surface  601 . 
         [0044]      FIG. 7  depicts the pole  600  having a coating  700  on its outside surface  602  ( FIG. 6 ) and a coating  701  on its inside surface  601  ( FIG. 6 ). In one embodiment, the coatings  700 ,  701  comprise a polymer-type material; however, other types of materials may be used in other embodiments for protecting the pole  600  from weather elements, for example. 
         [0045]      FIG. 8  is a cross-sectional view of  FIG. 7  taken along line B-B′. When the coating  701  is applied to the inside surface  601  of the pole  600  and the coating  700  is applied to the outside surface  602  of the pole  600 , coating  803  fills the aperture  603  (at least partially), thereby supporting and reinforcing the coating  700 ,  701  that adheres to the pole  600 . In this regard, the coating  803  connects the coating  700  to the coating  701 . Such support reduces cracking, chipping, and peeling that may result from harsh weather, for example. 
         [0046]    It is possible to provide a moving assembly that provides the necessary heating, coating application, and curing to only a portion of a pole. Those skilled in the art will know that utility poles are tall vertical objects that are not easily laid flat for operations such as corrosion protection. Accordingly, in one embodiment of the present invention, a ring structure may be provided around a short section of the pole. This ring structure may be supported using cables attached to the top of the pole or by some other means. The ring structure could then be advanced along the height of the pole. 
         [0047]    The ring structure would carry heating elements and polymer applying elements. It might even carry aperture-creating elements (though in many cases the apertures would have been created beforehand). The ring structure would heat a small portion of the pole and apply the polymer when the pole&#39;s surfaces reached the proper temperature. 
         [0048]      FIG. 9  is a flowchart depicting an exemplary method in accordance with an embodiment of the present disclosure. In step  900 , at least one aperture  101  ( FIG. 1 ) is formed in a substrate  100  ( FIG. 1 ). As described hereinabove, the substrate  100  may be a metal-like or plastic-like material. In addition, one aperture  101  or a plurality of apertures  101  may be formed randomly or in a pattern within the substrate  100  by drilling, punching, stamping or by another other method known in the art or future-developed. 
         [0049]    In step  901 , a polymer-type material is applied to a first and a second surface of the substrate  100  such that the polymer-type material forms coatings  102 ,  103  ( FIG. 2 ) and fills the at least one aperture  101 . In step  902 , the coatings  102 ,  103  are cured. Such curing and application of the polymer-type material may be accomplished in any manner known in the art or future-developed. 
         [0050]    As described hereinabove, the substrate  100  may be heated by convection and the substrate  100  coated with the polymer-type material. In addition, the substrate  100  may be placed in an oven, heated, the polymer-type material placed on the substrate  100 , and the substrate  100  placed back in the oven. Further, electrical current may be used to heat the substrate  100  before the polymer-type material is applied or the polymer-type material may be cured in a pressurized vacuum, as described hereinabove. 
         [0051]    The first surface of the substrate has a total original surface area. When apertures are added, this original surface area is reduced to a “net surface area.” In the present invention, it is significant that the number and size of the apertures be such that the net surface area is at least 50% of the total original surface area. Even more preferably, the net surface area is at least 75% of the total original surface area. 
         [0052]    Although the preceding description contains significant detail, it should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the scope of the present invention should be fixed by the claims rather than the specific examples given.