Device for capturing an overspray, system and robot

Abstract

Disclosed is a device for capturing an overspray resultant from a spray of coating material being directed towards a surface Also disclosed is system and a robot including the system. The device includes an extractor for extracting coating material accumulated on the device, and a capturing section for surrounding the spray of coating material and being, at least partially, coated by the overspray. The capturing section is configured to guide a run of coating material formed on the capturing section towards the extractor. The extractor is configured to extract an accumulation of coating material from at least one portion of the extractor, each of the at least one portion of the extractor being the lowest portion of the extractor in a respective orientation of use of the device.

Description

[0001] DEVICE FOR CAPTURING AN OVERSPRAY, SYSTEM AND ROBOT

[0002] The present invention relates to a device for capturing an overspray resultant from a spray of coating material being directed towards a surface. The present invention also relates to a system. Also, the present invention relates to a robot for treating a hull of a ship.

[0003] Background

[0004] Nowadays, there are known approaches for spraying coating materials onto surfaces like a ship's hull, a wall of a storage tank, a mast of a wind turbine, and similar surfaces. Due its size and shape, this type of surface can be physically challenging and take a long time to be sprayed directly by a human being. One approach is to provide a robot for moving a spray tool and controlling the spraying of coating materials onto the surface.

[0005] There are known robots for carrying out these operations, such as robots including systems for magnetically adhering to the surface and for moving the robot relative to the surface. There are numerous benefits to providing a robot in alternative to having a human being directly maneuvering a spray tool.

[0006] In this context, it can be challenging to spray a coating material onto a surface in an efficient and environmentally friendly manner. One of the challenges relates to the occurrence of a, so-called, overspray, which is formed by sprayed particles that do not adhere to the surface and instead are transferred to the surroundings of the surface. The overspray particles that get transferred somewhere other than the surface and cannot be recovered are considered a loss of coating material. It is relevant to note that the types of surfaces mentioned above are typically coated outdoors, where the presence of natural phenomena, such as wind, can affect the overspray. Transfer efficiency in spray applications is a metric for the percentage of sprayed material that does adhere to the target surface. Typically, there is a 50% transfer efficiency expectation in standard applications like airless spray painting for a ship's hull. This expectation permits that 50% of the coating material (e.g. paint) transfers to the surroundings of the surface being treated, such as the atmosphere or ocean. Some known coating materials contain volatile organic compounds, such as toluene, xylene, and methyl ethyl ketone, which are considered to be hazardous air pollutants by environmental authorities.

[0007] WO 2020 / 239798 Al discloses an approach for coating a surface with a spray coating tool spraying atomized coating particles onto the surface. A conditioning hood is used, the conditioning hood defining a spray chamber. In operation, the spray coating tool is mounted at a coating tool mounting end, and an output end of the spray chamber is positioned in proximity of the surface to be coated. Atomized coating particles travel from the spray coating tool, through the spray chamber and the output end to the surface. A carrier gas is injected that in operation carries the atomized coating particles to the surface.

[0008] However, this known solution has practical drawbacks. It relies on a complex system of ducts formed by concentric walls (visible with reference numerals 28 and 29 in the publication figure in WO 2020 / 239798 Al), which define two concentrical suction and injection channels surrounding the spray chamber. The duct system also imposes requirements of providing suction and injection supply tubes that, due to contrary pressurization, must be separate. The increased number of supply tubes required for this solution can have a negative impact on the maneuverability and weight of the conditioning hood. Moreover, the simultaneous suction and injection effects entail that both a suction pump and an injection pump must be provided in connection with the conditioning hood, which means that a high-power consumption is required for operating the conditioning hood. Also, in practice this solution can be bulky due to the duct system, as is observable from the figures in WO 2020 / 239798 Al, which is not ideal for use onboard of a robot. The bulkiness drawback appears to be overcomeable by configuring a small distance between the spray nozzle and the surface being coated, which is disclosed as being in the range of from 10 to 30 cm (see page 14, lines 25-26 in WO 2020 / 239798 Al). Although this range of distances allows reducing the overall size of the conditioning hood, it disadvantageously results in a severe reduction of the maximum width that may be set for a sprayed trace. This severe reduction makes spraying operations in large surfaces, such as ship's hull, take a long time, which in turns results in high costs for performing the spraying operation.

[0009] Summary

[0010] The invention will now be disclosed and has for its object to remedy or to reduce at least one of the drawbacks of the known prior art, or at least provide a useful alternative to the known prior art. The object is achieved through features, which are specified in the description below and in the claims that follow. The invention is defined by the independent patent claims, and the dependent claims define advantageous embodiments of the invention.

[0011] According to a first aspect of the invention, there is provided a device for capturing an overspray resultant from a spray of coating material being directed towards a surface. The device comprises:

[0012] - an extractor for extracting coating material accumulated on the device; and

[0013] - a capturing section for surrounding the spray of coating material and being, at least partially, coated by the overspray, the capturing section being configured to guide a run of coating material formed on the capturing section towards the extractor.

[0014] The extractor is configured to extract an accumulation of coating material from at least one portion of the extractor, each of the at least one portion of the extractor being the lowest portion of the extractor in a respective orientation of use of the device.

[0015] Thus, the device can effectively capture the overspray, providing the capturing section that can physically intercept and be coated by the overspray and then extracting runs of coating material from the capturing section with the extractor. It will be appreciated that this approach is not focused on avoiding accumulations of coating material on the device. It has been found that it is possible to guide runs of coating material and effectively capture a substantial amount of the overspray while avoiding drips of accumulated coating material from running off of the device. Also, the device can be made both with a reduced number of components and with a low weight, which make the device suitable to be used as part of a spraying system maneuvered by a robot and without requiring extensive adaptation and specialization of the robot in order to be able to maneuver the device.

[0016] The simplicity and light weight of the device permit dimensioning the device for use onboard of a robot and having longer distances between the surface being coated and the source of the spray, such as an airbrush or a spray gun. Thus, wider sprayed traces can be achieved and higher proportions can be set for the size of the device relative to the robot. For example, the spray source may be provided at a distance of up to 2 meters, for example 50 to 70 cm, from the surface being coated. This greater distance is advantageous in achieving a bigger coated area over an amount of time, and thus reducing the costs associated with a spraying operation.

[0017] Optionally, each of the at least one portion of the extractor comprises an outlet for draining the accumulation of coating material from the portion of the extractor, the outlet being positioned, in the respective orientation of use of the device, at the bottom of the portion of the extractor.

[0018] Thus, the positioning of the at least one outlet at the bottom of the portion of the extractor increases the efficacy of extraction, the accumulation of coating material being removable as soon as it forms on the lower portion of the extractor in an orientation of use of the device.

[0019] Optionally, the extractor is configured to extract an accumulation of coating material from two portions of the extractor, each of the two portions of the extractor being the lowest portion of the extractor in a respective one of two orientations of use of the device, wherein the two orientations of use are substantially perpendicular to each other.

[0020] Thus, the device can be provided with a design suitable to be used mainly in two orientations of use, the orientations being substantially perpendicular to each other.

[0021] Optionally, the extractor further comprises at least one suction outlet for providing a pressure differential so that a part of the overspray is directly captured by the extractor. In one embodiment, the extractor is configured so that the at least one suction outlet is arranged uniformly around the spray.

[0022] Thus, the device is further complemented with the ability to extract the overspray, in addition to the extraction of coating material accumulations at a lowest portion of the extractor in an orientation of use.

[0023] Optionally, the extractor comprises at least one inlet for deviating the run of coating material into the extractor. The at least one inlet may be arranged in a mesh pattern. Thus, the effect of deviating the run of coating material can be increased. Optionally, each of the at least one inlet is a slit provided on the extractor.

[0024] Optionally, the extractor comprises a detachable lid.

[0025] Optionally, the capturing section comprises an end overlapping on the detachable lid.

[0026] Thus, the device achieves an improved maintainability as the end overlapping on the detachable lid provides a mechanical bridge for transferring coating material runs to the lid.

[0027] Optionally, the capturing section is shaped so that, in a cross-section perpendicular to the direction of the spray, gravity causes the run of coating material to flow towards an accumulating portion of the capturing section, the accumulating portion being the lowest portion of the cross section in an orientation of use of the device.

[0028] Optionally, the device comprises a first opening for outputting the spray of coating material onto the surface, the first opening being enclosed by the extractor.

[0029] Optionally, the device comprises a second opening opposite to the first opening, the second opening being configured to receive air into a volume surrounded by the capturing section.

[0030] According to a second aspect of the present invention, there is provided a system comprising: - a spray tool for directing a spray of a coating material towards a surface; and

[0031] - a device for capturing an overspray resultant from directing the spray towards the surface, the device being as described in the first aspect of invention.

[0032] According to a third aspect of the present invention, there is provided a robot for treating a hull of a ship, the robot comprising a system as described in the second aspect of the invention.

[0033] Benefits and advantages of the present invention will also become apparent after a reading of the detailed description with appropriate reference to the accompanying drawings.

[0034] Brief description of the drawings

[0035] In the drawings:

[0036] Fig. 1 shows a perspective view of a device embodiment while being maneuvered in an orientation of use;

[0037] Fig. 2 shows an elevation view of the device embodiment as seen from A to A' in Fig. 1; and

[0038] Fig. 3 shows, in a larger scale, a cross-sectional view of an extractor.

[0039] Detailed description

[0040] The drawings are shown in a schematic and simplified manner, and a person skilled in the art will understand that the figures are just principal drawings. The relative proportions of individual elements may also be distorted. Any positional indications refer to the position shown in the figures. In the figures, same or corresponding elements are indicated by same reference numerals. For clarity reasons, some elements may in some of the figures be without reference numerals.

[0041] Figures 1 and 2 show a device embodiment 100 for capturing an overspray resultant from a spray of coating material being directed towards a surface. For the purpose of simplifying the figures, the surface being coated, the spray and a source emitting the spray are not shown in the figures. Figure 1 shows a perspective view of the device while being maneuvered in one of its orientations of use, and Figure 2 shows an elevation view of the device as seen on a plane perpendicular to the A-A' axis shown in Fig. 1, in the direction from A to A'.

[0042] The device 100 includes a capturing section 110 for surrounding the spray and be, at least partially, coated by the overspray. The capturing section 110 can be observed occupying the central region of Figure 1. The reference numeral identifying the capturing section 110 can be found close to the top-right region of Figure 1. The capturing section 110 includes an inner surface 111 configured to surround the spray and be coated, at least partially, with the overspray resulting from the spray. The capturing section 110 is illustrated surrounding an axis A-A' in Figure 1, which is generally aligned with the path of the spray towards the surface being coated. The overspray resultant from spraying more and more coating material onto the surface being coated causes an accumulation of coating material on the inner surface 111 of the capturing section 110. Over time, the accumulation will cause runs of coating material to form on the inner surface of the capturing section 110.

[0043] The device also includes an extractor 120 for receiving a run of coating material formed on the capturing section 110. The extractor 120 can be observed closer to the left-hand side in Figure 1. In the elevation view in Figure 2, it can be observed that the extractor 120 encloses an open end of the capturing section 110 in a diamond shape. The runs of coating material formed on the capturing section 110 flow towards and are received by the extractor 120, which includes slits 124 to deviate the runs of coating material into the extractor 120. Within the extractor 120, the accumulated coating material will, due to the orientation of use of the device 100, flow downwards and run towards the lowest portion 122 of the extractor 120 because of gravity. By "lowest portion" 122 it is meant the lowest portion of the extractor 120 in the orientation of use of the device 100. It is possible to see that, for the orientation of use of the device 100 shown in Figure 1, the lowest portion of the extractor 120 generally corresponds to the portion 122 of the extractor shown in the bottom regions in Figures 1 and 2. In the lowest portion 122, the extractor 120 includes an outlet 121 configured to extract the coating material that has run to and accumulated within that portion 122. The outlet 121 can be connected to means suitable for extracting the accumulated coating material from the lowest portion 122. For example, a suction hose may be connected to the outlet 121, the suction hose being itself connected to a suction system for extracting accumulated coating material from the lower portion 122.

[0044] In practice, it has been found that the runs of coating material formed on the capturing section 110 can be effectively guided as means of capturing a substantial amount of coating material from the overspray. Also, the effect of extracting the coating material accumulations is capable of avoiding drips of coating material from happening. Therefore, the device 100 can be operated to capture the overspray in an effective manner.

[0045] As mentioned above, the axis A-A' shown in Figure 1 may be generally aligned with the path of the spray towards the surface being coated. The axis A-A' crosses through the device 100, from a side A' (illustrated closer to the right-hand side of Fig. 1) of the device 100 to an opposite side A (illustrated closer to the left-hand side of Fig. 1) facing towards the surface being coated.

[0046] During use of the device 100, the surface being coated can be imagined as being provided on the left-hand side in Figure 1, the surface being intersected by the left-hand side A of the axis A-A'. The source of the spray, such as an airbrush or a spray gun, can be provided in several ways. For example, it can be positioned within the device 100 and oriented towards the left-hand side A of the axis A-A'. In other embodiments, the source of the spray may be positioned outside of the device 100 so that the spray is directed towards the left-hand side A of the axis A-A' while passing through the volume delimited by the capturing section 110 of the device 100.

[0047] The device embodiment 100 shown in Figure 1 includes two openings 130,131. A first opening 130 is usable as an output of spray particles towards the surface being coated. Although not directly visible, the first opening 130 is provided on the left-hand side in Figure 1. A second opening 131 is shown closer to the right-hand side in Figure 1, opposite to the first opening 130, and it can be useful for allowing an input of air into the device 100. In some embodiments, the spray source may be provided outside of the device 100 and oriented so that the spray enters the device 100 through the second opening 131, travels through the device 100, exits the first opening 130, and adheres to the surface being coated. It will be appreciated that the second opening 131 may be optionally provided when the spray tool is positioned within the device 100.

[0048] Turning now to Figure 2, it shows in more detail the shape of the extractor 120 and the interior of the capturing section 110. In this device embodiment 100, the extractor 120 is configured to be operated in two orientations of use of the device 100. A first orientation of use is shown in Figure 2 in the normal orientation of the page. The first orientation of use provides a vertically elongated profile having the lowest portion 122 previously described, and can be useful for spraying coating paths in a horizontal direction. The second orientation of use of the device 100 can be visualized by rotating the page of Figure 2 by 90 degrees, clockwise. Thus, it can be seen that the extractor 120 is now shown with a horizontally elongated profile, in which a second lowest portion 122' of the extractor 120 can be seen. The second orientation of use is useful for spraying coating paths vertically. The extractor 120 includes a second outlet 121' for extracting accumulations of coating material from the second lowest portion 122'.

[0049] This implementation thus provides two substantially perpendicular orientations of use of the device 100 that are advantageous in spray applications for surfaces. These two orientations of use are suitable for performing horizontal and vertical coating paths and with the widest elongation arranged perpendicularly to the coating path. Providing the widest elongation perpendicularly to the coating path is advantageous in achieving a wide coating path and in coating a larger area over a path length.

[0050] It is also possible to see in Figures 1 and 2 that the capturing section 110 enlarges along the axis A-A' as it gets closer to the extractor 120. This embodiment is advantageous in that it promotes the guidance of runs of coating material towards the extractor 120 by effect of gravity. Thus, in the orientations of use of the device 100, the capturing section 110 is shaped so that gravity causes runs of coating material to run towards the extractor

[0051] 120. In Figure 2, it is possible to see that, for both orientations of use, the capturing section 110 is also provided in a valley shape that ends at the respective lowest portions 122, 122' of the extractor 120. That is, the capturing section 110 is shaped so that, in a crosssection perpendicular to the direction of the spray along the axis A-A', gravity causes a run of coating material to flow towards an accumulating portion, i.e. the bottom of the "valley", of the capturing section 110. The accumulating portion can be understood to be the lowest portion of the perpendicular cross section in an orientation of use of the device 100.

[0052] This embodiment is advantageous in achieving a concentrating effect of the runs of coating material, in that it promotes the accumulation of runs of coating towards the bottom of the valley shape, i.e. accumulating portions of the capturing section 110, which can then flow more efficiently towards the extractor 120.

[0053] In Figures 1 and 2 it is possible to see that some fastening means 128 are provided on the outside of the extractor 120 (only one fastening means 128 is identified with a reference numeral for the purpose of simplifying the number of reference numerals appearing in the figures). The fastening means 128 is provided as part of a detachable lid 127 included in the extractor 120, the detachable lid 127 being advantageous when performing maintenance tasks after using the device 100. For example, it can be advantageous after use of the device 100 to detach the lid 127 and thus clean the extractor 120 more easily.

[0054] The fastening means 128 shown in the figures are implemented as latch snap locks, which are well known and simple to operate manually. It will be appreciated that other fastening means 128 may be implemented without the use of inventive skills.

[0055] Turning now to Figure 3 it shows a cross section of the extractor 120 in the first orientation of use shown in Figure 2. The cross section in Figure 3 illustrates an end portion of the inner surface 111 of the capturing section 110, the end portion of the inner surface 111 establishing a part of the capturing section 110 from which the runs of coating material get transferred to the extractor 120. Once a run of coating material runs onto the extractor 120, the run encounters a few inlets 124 to deviate the run of coating material into the extractor 120. In particular, the inlets 124 shown in Figure 3 are implemented as an arrangement of slits 124 provided on the detachable lid 127.

[0056] Within the extractor 120, the accumulated coating material runs downwards towards the lowest portion 122 of the extractor 120 in the orientation of use of the device 100, at which point it encounters the outlet 121 provided at the bottom of the lowest portion 122.

[0057] In the cross-sectional view shown in Figure 3, it is possible to see that the extractor 120 includes an internal space 125 that allows the coating material to run towards the lowest portion. In this specific embodiment of the device 100, this internal space 125 of the extractor 120 additionally implements a suction chamber 125 for providing a suction effect on a part of the overspray that may not have been intercepted by the capturing section 110. The suction 125 chamber shown in Figure 3 is complemented with suction outlets 126, 126', 126” (shown in Figure 1) for providing suction to the suction chamber 125.

[0058] It is also possible to see in Figure 1 that the suction outlets 126, 126', 126” are uniformly arranged around the extractor 120. This arrangement is advantageous in providing an isotropic extractive effect of the overspray by means of suction of air.

[0059] It is further possible to see in Figure 3 that the capturing section 110 includes an end 112 that overlaps on the detachable lid 127 of the extractor 120. This embodiment is advantageous in that it blocks coating material from entering the interface between the detachable lid 127 and the capturing section 110. Thus, this makes it easier to perform maintenance tasks after the device 100 has been used, such as cleaning the extractor 120.

[0060] It is also possible to see that there are two regions of slits provided on the detachable lid 127. A first region is provided at a proximal location relative to the capturing section 110, the first region including a plurality of slits 124 arranged in a mesh pattern. In practice, it has been found that this first region is effective at deviating runs of coating material into the extractor 120.

[0061] A second region of slits is provided at a distal position relative to the capturing section

[0062] 110, the second region providing further inlets into the extractor 120. The second region can be useful as a fallback in case a run of coating material runs over the first region, as an additional inlet for sucking overspray into the suction chamber 125, or both.

[0063] It will be appreciated that a skilled person will know how a coating material may be sprayed onto a surface. For example, a spray tool, such as an airbrush or a spray gun, may be used for emitting the spray of coating material particles in a pressurized manner and directed towards the surface being coated.

[0064] It will be appreciated that the coating material mentioned in the foregoing description may relate to any known coating materials without requiring inventive skill. For example, it may relate to paint, varnish, or any other material suitable for coating the surface. It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. Use of the verb "comprise" and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. The article "a" or "an" preceding an element does not exclude the presence of a plurality of such elements.

Claims

C l a i m s1. A device for capturing an overspray resultant from a spray of coating material being directed towards a surface, wherein the device comprises:- an extractor for extracting coating material accumulated on the device; and- a capturing section for surrounding the spray of coating material and being, at least partially, coated by the overspray, the capturing section being configured to guide a run of coating material formed on the capturing section towards the extractor, and wherein the extractor is configured to extract an accumulation of coating material from at least one portion of the extractor, each of the at least one portion of the extractor being the lowest portion of the extractor in a respective orientation of use of the device.

2. Device according to claim 1, wherein each of the at least one portion of the extractor comprises an outlet for draining the accumulation of coating material from the portion of the extractor, the outlet being positioned, in the respective orientation of use of the device, at the bottom of the portion of the extractor.

3. Device according to any of the preceding claims, wherein the extractor is configured to extract an accumulation of coating material from two portions of the extractor, each of the two portions of the extractor being the lowest portion of the extractor in a respective one of two orientations of use of the device, wherein the two orientations of use are substantially perpendicular to each other.

4. Device according to any of the preceding claims, wherein the extractor further comprises at least one suction outlet for providing a pressure differential so that a part of the overspray is directly captured by the extractor.

5. Device according to claim 4, wherein the extractor is configured so that the at least one suction outlet is arranged uniformly around the spray.

6. Device according to any of the preceding claims, wherein the extractor comprises at least one inlet for deviating the run of coating material into the extractor.

7. Device according to claim 6, wherein the at least one inlet is arranged in a mesh pattern.

8. Device according to any of the claims 6 to 7, wherein each of the at least one inlet is a slit provided on the extractor.

9. Device according to any of the preceding claims, wherein the extractor comprises a detachable lid.

10. Device according to claim 9, wherein the capturing section comprises an end overlapping on the detachable lid.

11. Device according to any of the preceding claims, wherein the capturing section is shaped so that, in a cross-section perpendicular to the direction of the spray, gravity causes the run of coating material to flow towards an accumulating portion of the capturing section, the accumulating portion being the lowest portion of the cross section in an orientation of use of the device.

12. Device according to any of the preceding claims, wherein the device comprises a first opening for outputting the spray of coating material onto the surface, the first opening being enclosed by the extractor.

13. Device according to any of the preceding claims, wherein the device comprises a second opening opposite to the first opening, the second opening being configured to receive air into a volume surrounded by the capturing section.

14. A system comprising:- a spray tool for directing a spray of a coating material towards a surface; and- a device for capturing an overspray resultant from directing the spray towards the surface, the device being as described in any of the preceding claims.

15. A robot for treating a hull of a ship, the robot comprising a system as described in claim 14.

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