Dispensing Apparatus
This invention relates to fluid dispensing apparatus, and particularly although not necessarily exclusively, to fluid dispensing apparatus for dispensing a fluid lining material onto one or more walls of a conduit, pipe or channel.
Conduits and channels are used in a wide range of industries for transportation of a fluid or solid or storage thereof, such as for example, for use in the transportation of gas, water, sewage and/or the like. Although the following description makes reference to fluid dispensing apparatus for use in dispensing a lining material in generally cylindrical water or gas pipes, it will be appreciated by persons skilled in the art that the present invention has far wider application and can be used in any shaped or dimensioned conduit or channel for use in any industry.
A problem with water pipes is that scale can build up on interior walls thereof, thereby restricting the quantity and flow of water through the pipe. In addition, many water pipes in use today are old and are susceptible to corrosion and leakage. This is particularly problematic with gas or sewage pipes, wherein leakage thereof has both dangerous and environmental implications. In order to overcome this problem, the pipes either have to be replaced regularly or a new smaller pipe inserted in the older pipe. However, this typically requires the digging up of roads or pavements, which is inconvenient and expensive. Alternatively, the pipes can be refurbished by applying a lining material to the interior walls of the pipe to increase the structural properties and strength of the pipe. This lining material can be applied manually by workers entering the conduit and spraying a fluid thereon which cures to form a
substantially rigid liner, or can be applied automatically, typically using remote controlled dispensing apparatus.
An example of a conventional remote controlled dispensing apparatus for dispensing a lining fluid onto interior walls of a conduit is disclosed in EPl 174191. The dispensing apparatus in this patent application includes reservoirs for the containment of fluid which are connected to two dispensing outlets, each outlet for dispensing a different fluid component therefrom. Drive means are provided for driving the movement of the apparatus through a conduit and a cup shaped rotary head is provided opposite the two dispensing outlets onto which the two fluid components are dispensed for mixing. The cup shaped rotary head spins the mixture out of an open end thereof onto the interior walls of the conduit.
A problem associated with the abovementioned apparatus and other conventional dispensing apparatus is that the thickness of the lining material applied to the conduit walls is often too thin, thereby making the lining brittle and requiring passing of the apparatus through the conduit a number of times in order for the required thickness of lining material to be built up by the application of multiple layers (i.e. "a multiple pass system") . This is both expensive and time consuming. To the best of the applicants knowledge, it is not currently possible to apply a number of layers of lining material on an area of a conduit wall at any one time due to the prolonged period of time it takes for conventional lining fluids to cure. Furthermore, application of a thicker single layer of lining fluid is not possible since the lining material begins to sag and provides an uneven distribution of material on the interior conduit walls.
In an attempt to overcome this problem, dispensing apparatus has been provided where the rotary head is capable of
undergoing reciprocal motion relative to the apparatus, thereby allowing a plurality of layers of fluid to be dispensed during linear motion of the apparatus through a conduit, such as the apparatus disclosed in EP145266 and GB2160289.
In EP 145266, a plurality of apertures are provided in the side wall of the rotary head through which the fluid passes for spraying onto the walls of the conduit. A problem with this type of head arrangement is that the apertures are likely to become blocked when used with a rapid curing fluid mixture.
In GB2160289, the rotary head includes three cup members along which the fluid travels prior to being dispensed therefrom. The first cup member is in the form of a cylindrical drum having one end closed by a flat disc, the fluid outlet means terminates adjacent the disc. The wall of the drum includes a plurality of apertures and the fluid impacts the disc and is discharged through the apertures. The fluid then flows along the interior side walls of a truncated cone which diverges outwardly away from the fluid outlet means. The third cup member is connected to the open end of the truncated cone. This third cup member opens out in a direction opposite to the second cup member and the fluid flows from the second cup member along the third cup member inner walls to be dispensed from the free end of the third cup member. A problem with this arrangement is that mixing of the fluids is undertaken in the cup members following dispensing from the fluid outlet means which may lead to inadequate mixing. In addition, there are a number of small apertures that the fluid needs to flow through and these apertures are likely to become blocked when a rapid curing fluid is being dispensed.
It is therefore an aim of the present invention to provide dispensing apparatus which overcomes the abovmentioned
problems and which provides an inexpensive and simpler alternative to conventional dispensing apparatus.
It is a further aim of the present invention to provide a dispensing head member for use with dispensing apparatus.
It is a yet further aim of the present invention to provide dispensing outlet means for use with dispensing apparatus.
According to a first aspect of the present invention there is provided dispensing apparatus for use in dispensing a fluid lining material onto one or more surfaces, said dispensing apparatus including at least one reservoir for the containment of a least one fluid to be dispensed, dispensing outlet means communicating with said at least one reservoir for dispensing fluid therefrom and a dispensing head member for directing the dispensed fluid from the dispensing outlet means onto said surfaces, said head member having a base wall and side walls, the side walls having an outer edge defining an opening therebetween, and wherein one or more recesses or cut-out portions are defined in the side walls adjacent the outer edge.
The cut-out portions or recess portions are arranged such that the fluid is sprayed, preferably by centrifugal force following rotation of the head member, from the recesses or cut out portions to apply the fluid over a pre-determined band width of the required surface or surfaces. The surface or surfaces are typically interior surfaces of a conduit.
Thus, by allowing the fluid to be sprayed from the head member at different distances along it longitudinal length, rather than an annular 2-dimensional planar edge as is conventionally the case, the need for reciprocation is removed. This greatly reduces the complexity and cost of the apparatus.
Preferably the angle, length and/or dimensions of the cut-out portions or recesses substantially correspond to the pre¬ determined band width of fluid be applied to the surface, such as the interior wall of a conduit. Thus, variation of the angle, length and/or dimensions of the cut out portion results in a corresponding variation in the band width applied to the surface.
The cut out profiles are designed to ensure that the head member remains balanced at the high rotational speeds and are angled in such a way so as to maintain optimum flow and distribution of the material during application.
Preferably the head member has at least one cavity portion defined therein which communicates with the opening through which the fluid travels on being dispensed from the head member.
The opening of the head member typically faces the dispensing apparatus.
Preferably at least one directional member is provided in the at least one cavity portion. The directional member is preferably located substantially opposite said outlet means, such that fluid being dispensed from said outlet means impacts initially with an outer surface of said directional member in use.
The arrangement of the head member and directional member located therein increases the efficiency and speed for which multiple layers of fluid can be dispensed from the apparatus in a "single pass" of the apparatus through the conduit. The application of multiple layers of fluid on the required surface typically occurs during linear movement of the dispensing apparatus through the conduit.
The term conduit can include any type or form of channel, pipe, tubing, sleeve and/or the like of any length and/or shape.
Impact of the fluid in the rotating cavity portion causes the fluid to flow towards the outer free edges of the cut-out portions or recesses, thereby deflecting the fluid therefrom and onto the walls of the conduit.
Preferably the opening defined in the head member faces away from the direction of travel in the longitudinal direction of a pipe or conduit.
Drive means can be provided to drive the linear movement of the apparatus through a conduit. The same or further drive means can be provided to drive rotational movement of the head member.
Preferably damping means are provided in the apparatus to reduce vibrations therein.
In one embodiment the head member can undergo oscillatory movement in order to increase the band width of fluid sprayed from the head.
Preferably the head member is mounted on the apparatus via connection means . The connection means typically includes at least one shaft or arm member. The shaft or arm member can be rotated by drive means provided in the apparatus, thereby resulting in rotation of the head member.
Preferably the rotational head member is rotated at approximately 15,000RPM.
The head member is typically provided at the front of the apparatus in the direction of travel.
At least some of the dispensed fluid impacts initially with the outer walls of the directional member prior to flowing along the interior side walls of the head member and out of the at least one opening, cut out portions and/or recesses of the head member. The directional member has the advantage that it prevents or at least reduces the build up of fluid in the cavity portion of the head in use, directs the flow of fluid along the interior side walls of the head member and aids the even distribution of fluid from the head onto the conduit walls.
In one embodiment the at least one directional member is in the form of a truncated cone. The cone is typically located on the wall of the recessed portion directly opposite the dispensing outlet means, thereby ensuring the dispensed fluid impacts initially with the outer tapered walls of the cone. The base of the truncated cone is typically provided at a point furthest from the dispensing nozzle/outlet means.
The outer side walls of the directional member are planar or straight (i.e. the side walls form a straight line from the top of the directional member to the base of the directional member) .
The directional member can be joined to the base wall of the head member by attachment means or the directional member can be integrally formed with the base wall to provide a substantially continuous surface along which the fluid flows from the outer side walls of the directional member to the inner surface of the side walls of the head member and from the outer free edges of the cut out or recess portions and/or side walls of the head member.
The shaft or arm member which results in rotation of the rotation of the head member can be located through the truncated portion of the cone and typically substantially centrally thereof.
The side walls of the truncated cone typically diverge outwardly in a direction away from the dispensing outlet means . The inner surface of the side walls of the head member and/or edges of the cut-out portions or recessed portions diverge outwardly in a direction towards the dispensing outlet means and in an opposite direction to the diverging side walls of the truncated cone.
Preferably at least one edge of the cut-out or recessed portions are inclined at an acute angle with respect to the longitudinal axis of the head member, thereby aiding the deflection or flow of the fluid from the recessed portion and onto the walls of the conduit. At least one edge of the cut-out or recess portions is substantially parallel to the longitudinal axis of the head member.
In one embodiment the dispensing outlet means is in the form of a housing having at least two inlets, an outlet and at least one mixing compartment located between said inlets and outlets. The mixing compartment acts as an impingement mixing chamber allowing at least two different fluids to be separately delivered to the compartment via the two inlets prior to being mixed and dispensed from said outlet. The mixing typically takes place under high pressure. The ability to mix the fluids in the compartment just prior to dispensing from said outlet is advantageous, particularly if the fluids, when mixed, have a rapid curing or reaction time.
Preferably ail" flow means are provide and are arranged so as to direct a flow of air adjacent the outlet of said dispensing outlet means.
The air flow means can be arranged so as to direct at least one flow of air, a plurality of flows of air and/or a continuous or shroud of air flow adjacent the outlet.
Preferably shroud means are provided for allowing a supply of substantially evenly distributed air flow, preferably 360 degrees surrounding the outlet, to be provided adjacent the outlet, thereby preventing fluid from building up at or adjacent the outlet which would otherwise result in a blockage.
The air flow can be passed through a stepped and/or tapered passageway prior to exiting adjacent the outlet of the dispensing outlet means.
In one embodiment the head member is capable of undergoing reciprocal motion. Preferably the fluid dispensed from the apparatus has a curing time which is only slightly greater than the time taken for the component fluid or fluids to be mixed, dispensed onto the head member and deflected therefrom, but which is less than the time taken for the head member to complete a single reciprocating motion. This allows a first fluid lining to be located on the conduit and cured prior to a second fluid lining to be located thereon.
For example, in a preferred embodiment of the present invention the fluid being dispensed includes an amine and an aromatic isocyanate which, on mixing results in a mixture having a curing time of less than 60 seconds. Thus, it is essential that the mixing compartment is adjacent the dispensing outlet to prevent curing of the mixture and thus blockage of the outlet.
Preferably the fluid being dispensed from the apparatus has a curing time of less than 10 seconds. Further preferably the fluid has a curing time of approximately 3 seconds.
Preferably the dimensions of the mixing compartment and/or outlet are less than the dimensions of the two inlets, thereby ensuring increased pressure in the compartment relative to the inlet passages to allow rapid flow of mixed fluid therethrough. This prevents or at least reduces curing of the mixed fluid in the compartment.
Preferably the dispensing outlet means is a spaced distance apart from said head member such that the fluid has to move through free space prior to impacting with a portion of the directional means.
Control means are typically provided with the dispensing apparatus, either directly thereon or remotely therefrom, for controlling any or any combination of the rotational speed of the head member, the temperature of the one or more fluids and/or the pressure of fluid delivery of the one or more of fluids in the apparatus.
According to a second aspect of the present invention there is provided a dispensing head member for use with dispensing apparatus, said head member having a base wall and side walls, the side walls having an outer edge defining an opening therebetween, and wherein one or more recesses or cut-out portions are defined in the side walls adjacent the outer edge.
According to a further aspect of the present invention there is provided a method of applying a fluid onto a surface using dispensing apparatus, said method including the steps of
dispensing a fluid contained in a reservoir in the apparatus onto a dispensing head member via dispensing outlet means communicating with the reservoir, and directing the dispensed fluid from the dispensing head onto said surface, and wherein the head member has a base wall and side walls, the side walls having an outer edge defining an opening therebetween, and wherein one or more recesses or cut-out portions are defined in the side walls adjacent the outer edge.
According to a yet further aspect of the present invention there is provided dispensing outlet means for use with dispensing apparatus.
The advantage of the present invention is that the fluid dispensing apparatus allows a multilayered lining to be applied to the interior walls of conduits in a single pass of the apparatus through the conduit. This allows any required thickness of lining to be produced. The lining fluid rapidly cures on application to the walls of the conduits, thereby protecting the conduit from deterioration/corrosion and increasing the structural properties thereof. The lining fluid applied in accordance with the present invention provides a smooth, even and glossy finish to the interior wall surfaces of the conduit, thereby reducing the build up of scale or other debris/contaminants thereon.
The fluid dispensing apparatus can be used for the refurbishment of existing conduits or channels and/or can be used to provide a lining on new conduits or channels.
An embodiment of the present invention will now be described with reference to the accompanying figures, wherein:
Figure 1 is a cross sectional view of dispensing apparatus according to an embodiment of the present invention;
Figure 2 is a side view of directional means according to one embodiment of the present invention;
Figures 3a and 3b illustrate a cross sectional view and an end view respectively of dispensing outlet means in one embodiment;
Figures 4a and 4b illustrate a cross sectional view and an end view respectively of dispensing outlet means according to a further embodiment of the present invention; and
Figure 5 illustrates a cross sectional view of air shroud means for use with dispensing outlet means according to an embodiment of the present invention.
Referring to the figures, the.re is illustrated dispensing apparatus 2 for the dispensing of a fluid lining mixture for lining the interior walls of a conduit 4.
The fluid lining mixture for use with the apparatus of the present invention in one example, when cured, provides a lining which is sufficiently strong and resistance to wear and corrosion and which is capable of standing alone (i.e. forms a conduit within a conduit), even after the original outer conduit has eroded away.
The mixture includes an amine and an aromatic isocyanate, together with a filler or cleaning component which typically has a cleaning function in the apparatus of the present invention, and an optional colouring pigment, which can be used to identify the function of the pipe, such as gas or water pipe. Conventionally, filler components have been used in lining mixtures but only to provide bulk thereto and not to provide a cleaning function as in the present invention.
The fluid lining, when mixed, cures rapidly and typically within approximately 3 seconds, especially formulated to avoid the problem of shrinking associated with conventional lining mixtures. Due to the rapid curing of the mixture, this allows multiple layers of lining material to be applied to the interior walls of a conduit in rapid succession, thereby allowing the thickness of the lining to be built up quickly, typically up to thicknesses of 6-8mm, or possible greater in some cases . However, the rapid curing rate creates the potential problem of curing of the fluid in the apparatus prior to application on the conduit walls. Thus, the present invention has been designed to utilise the advantages provided by the rapid curing liner mixture whilst overcoming conventional problems associated therewith.
In accordance with the present invention, the dispensing apparatus 2, includes dispensing outlet means in the form of a spray nozzle 6 for dispensing fluid pumped from a reservoir (not shown) therefrom, a rotational head 8 for directing the dispensed fluid onto the conduit walls 4 and drive means (not shown) for driving the movement of apparatus 2 through the conduit.
The rotational head 8 is connected to apparatus 2 via a drive shaft 10. Rotation of drive shaft 10 and thus rotation of the rotational head 8 is driven by a pneumatic air motor 12.
Each component of the two component lining fluid (amine and aromatic isocyanate) is separately pumped into the spray nozzle 6 via inlet channels 14, 16, as shown in figures 3a and 3b. The inlet channels 14, 16 are connected to pipes through which the fluid components are pumped from reservoirs typically located remotely from the applicator part of the dispensing apparatus . The fluids then enter and become mixed in a compartment 18
prior to being dispensed through open end 20 of outlet passage
22.
The diameter of compartment 18 is less than the diameter of inlet channels 14, 16, thereby ensuring rapid flow of the mixture through compartment 18 to prevent curing of the mixture therein.
The open end 20 of spray nozzle 6 oppositely faces rotational head 8, thereby allowing fluid dispensed from open end 20 to impact a surface of head 8 in a cavity portion 24 thereof. The rotational head 8 is generally cup shaped including a closed end or base wall 26, side walls 28 and an open end 30. At least the interior surface of side walls 28, which define the cavity portion 24, together with end 26, taper outwardly relative to a longitudinal axis of the head indicated by reference 32. The closed end of the head is typically located at the front of the apparatus and faces the direction of travel of the apparatus in use.
A truncated cone 34 is provided substantially centrally of the recessed portion 24 of the rotational head, as shown in figure 2. A channel 36 is provided through the truncated cone for location of drive shaft 10 therein. The side walls 38 of truncated cone 34 diverge outwardly in an opposite direction to the outermost interior side walls of head 8 (i.e. towards end 26) and are at an angle of less than 90 degrees to the longitudinal axis 32. The angle of the interior side walls 28 relative to the longitudinal axis is greater than 0 degrees and less than 90 degrees. For example, preferred angles can be any of 45, 50, 55, 60, or 65 degrees.
In accordance with the present invention the head member 8 has a plurality of cut out portions 27 defined in side walls 28 thereof.
These cut out portions typically have a first edge 29 located substantially parallel with the longitudinal axis of head 8 and a second edge 31 located at an acute angle to the first edge. A plurality of cut out portions can be provided in the head and these cut out portions allow fluid to be sprayed from the head via centrifugal force at different distances along the longitudinal length of the head. This allows the fluid to be sprayed onto the walls of the conduit at different bandwidths, thereby allowing multiple layers of fast curing fluid to be dispensed without using reciprocating means in a single pass of the equipment through the conduit.
During dispensing, a bead of fluid is directed onto side wall 38 of truncated cone 34, which directs the flow of the fluid in the direction of dispensing/impact, thereby preventing fluid flow back towards the dispensing nozzle which would typically result in a build up of cured material on the head. As such, the fluid flows towards closed end 26 via side walls 38 and then towards open end 30 via outermost interior side walls 28 as a result of rotation of head 8. When the fluid reaches free edges 27, 29 of the head it is spun outwardly onto the walls of the conduit via centrifugal force. This process occurs rapidly due at least in part to the rapid rotation of the head, thereby preventing or at least reducing the likelihood of fluid curing on the head.
The width of the side walls of the head member is greater adjacent the closed end 26 compared to the free edge adjacent the open end 30.
Motor 12 is connected to the rotational head and dispensing nozzle for driving rotation thereof.
Other components can be provided in the apparatus, such as heating means (i.e. heat exchanger) for heating the lining
components to keep them fluid in the apparatus (i.e., up to 75°C) , micro-processing means or metering system for controlling the temperature, speed and/or pressure of the fluid in the apparatus, purge means (i.e. nitrogen purge system) for purging the isocyanate component, fluid reservoirs, pumps, filter means, control means for controlling the speed of linear movement of the apparatus through the conduit (i.e. hose or winch speed) and/or any of the abovementioned components.
The conduit can be any size or shape, such as for example square, rectangular or circular in cross section.
In the embodiment shown in figures 4a and 4b, dispensing outlet means are provided in the form of spray nozzle 100. The nozzle 100 has inlet channels 102, 104 with openings 106, 108 respectively which communicate with fluid reservoirs and openings 110, 112 respectively communicating with a mixing compartment 114. An outlet channel 1 16 communicates with the mixing compartment 114 at a first end and has an outlet aperture 118 at an opposite end. In addition, a further channel 120 is provided in nozzle 100 which has an end in communication with mixing compartment 114 and a second open end 122 in which closure means, in the form of a locking screw in this example can be detachably provided. This screw can be removed and a drill can be inserted therethrough to allow drilling and thus release of any fluid which has built up and/or cured in the mixing chamber 114. Side channels 124, 126 can also be provided in the housing to allow drill bits to be located therein to aid cleaning of the nozzle. These side channels are also provided with detachable closure means. This is required since solvent which may be used for cleaning in some applications of the nozzle may not be used when the nozzle is used in drinking water applications and where the presence of any solvent is not allowed.
Thus, any number of further channels can be provided to allow the dispensing outlet means to be cleaned.
Referring to figure 5, there is illustrated air flow means in the form of an air shroud 200 for use with outlet dispensing means 6. The air shroud 200 can be integrally formed with the outlet dispensing means, fixed or detachably attached thereto.
The shroud provides an annular aperture 202 defined in front plate 204 of the shroud. The outlet nozzle 206 typically protrudes a small distance through the annular aperture. A flow of air is directed through the aperture and prevents fluid being dispensed through outlet 206 from building up adjacent the same.
A channel 208 is defined in the shroud 200 which communicates with an air supply to allow air to be directed through the shroud to aperture 202. Channel 208 is tapered and typically includes a number of sections 208a, 208b of increasingly narrowing cross section. A series of cross drilled holes allow the air to circulate around the channel or void between the shroud and outlet nozzle. The inner profile of the shroud directs the air over the nozzle without disturbing the material flow from the outlet.
Thus, the present invention provides dispensing apparatus, typically remote controlled, and method of use thereof, which allows any required thickness of lining to be applied to a surrounding following a single pass.
In one embodiment the directional member extends beyond the opening of the recessed portion of the head member. In an alternative embodiment the directional member is recessed within said recessed portion of the head member.
Any or any combination of the abovementioned features can be provided with the present invention.