Surface coating and method of use

Abstract

A multi-layer coating assembly for surface coating comprises at least one coating layer and at least one metal layer, said at least one metal layer is positioned on top of or under said at least one coating layer or embedded between or within the at least one coating layer; wherein said at least one metal layer is heated to melt the at least one coating layer, thus, to produce at least one molten coating layer and wherein as said at least one molten coating layer cools, it adheres to the surface, thus, forming a surface coating, wherein each of said at least one coating layer and said at least one metal layer is placed over the entire area of said surface to form a tight seal with said surface over the entire surface area, thereby said tight seal between the multi-layered coating assembly and the entire surface area is crucial for detection of leaks since liquid is kept in the leak area and cannot flow over the well-sealed surface.

Description

[0001] SURFACE COATING AND METHOD OF USE

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to coatings. More specifically, the present invention relates to water-proof coatings and methods for producing safe and environmentally friendly water-proof coatings.

[0004] BACKGROUND OF THE INVENTION

[0005] Coatings are covering layers applied to surfaces of objects that may have different functions, such as decorative, functional, and the like. Examples of surface coatings are water-proof coatings developed to protect surfaces, such as, roof surfaces, wall surfaces of buildings and houses and the like.

[0006] Water-proof coatings are added to surfaces such as roofs, walls, and the like to extend their life expectancy. Sealing a roof / walls provides an extra layer of protective coating that can help prolong damage from extreme climates and other hazards, including sun, rain and ice.

[0007] Roof / walls coatings, therefore are an outer skin which is applied to the framework of roofs / walls.

[0008] Roof coatings are therefore applied on the outer surface of roofs, i.e., on the side of roofs that faces the environment, and not on the inside, i.e., the side facing the interior of buildings.

[0009] Roof coatings are especially useful for roof types that collect water and debris, such as flat roofs. They can also be used on other angled roof types as they age to protect from long term damage. Roof coatings can make the roof a little more fire-resistant and prevent the growth of mold and algae.

[0010] Until not many years ago, buildings were sealed mainly by applying tar to the walls of the basements and the roof of the building. This process requires a manual filling of the boiler with blocks of sealant. This creates a risk of splashing, which can lead to severe skin burns. Filling tar cans from the boiler is another risk, as this requires the use of a tap out of which hot sealant flows, so due care and attention is always required, to control the flow correctly.

[0011] In addition, the work of sealing clutches has traditionally meant walking with cans of hot liquid tar, to then fill the length of the clutch. During this process, spillages and bums can easily occur and bending over to fill the clutch in this way can also lead to musculoskeletal problems.

[0012] In the early 1980s, the use of industrial bituminous sealing assemblies developed. Applying the assemblies by gluing with a burner to a foundation layer that is applied directly on top of a concrete roof. Such process can be dangerous as breathing in the fumes of the bitumen sealant can cause respirator}' tract infections and performing any of these tasks whilst wearing PPE is extremely hard.

[0013] Therefore, the present invention is aimed to provide sealant waterproofing assemblies and a method of use for waterproofing roofs / walls and other surfaces in a safe manner without hazardous gases, which is environmentally friendly.

[0014] SUMMARY OF THE INVENTION

[0015] In accordance with some embodiments of the present invention, there is thus provided, a multi-layer coating assembly for surface coating. The multi-layer coating assembly comprises: at least one coating layer and at least one metal layer positioned either on top of or under or in between or within the at least one coating layer; wherein said at least one metal layer is heated to melt the at least one coating layer, thus, to produce at least one molten coating layer and wherein as said at least one molten coating layer cools, it adheres to the surface, thus, forming a surface coating. Furthermore, in accordance with some embodiments of the present invention, the multi-layer coating assembly further comprises at least one reinforcement layer to reinforce the multi-layer coating assembly.

[0016] Furthermore, in accordance with some embodiments of the present invention, the at least one reinforcement layer is made of fiberglass, or polymeric material, or a combination thereof.

[0017] Furthermore, in accordance with some embodiments of the present invention, the polymeric material is polyester.

[0018] Furthermore, in accordance with some embodiments of the present invention, the multi-layer coating assembly further comprising at least one insulation layer to block gas(es) that can be produced while heating the multi-layer coating assembly from escaping (spreading) into the environment.

[0019] Furthermore, in accordance with some embodiments of the present invention, the at least one metal layer is embedded between two of said at least one coating layer.

[0020] Furthermore, in accordance with some embodiments of the present invention, the at least one coating layer is made of material(s) selected from acrylics, asphalts, polyurethanes, silicones, resin(s), fluoropolymer, PMMA, polyester, silyl terminated polyether (STPE), polyuria, PUMA, SEBS, styrene-acrylics, or a combination thereof.

[0021] Furthermore, in accordance with some embodiments of the present invention, the at least one coating layer is a bituminous layer.

[0022] Furthermore, in accordance with some embodiments of the present invention, the at least one metal layer is selected from gray and ductile iron, steel, copper and copper-based alloys, aluminum, zinc, reactive metals, precious metals, or a combination thereof.

[0023] Furthermore, in accordance with some embodiments of the present invention, the at least one metal layer is at least one metal mesh positioned either on top of, or under, or in between or within the at least one coating layer. Furthermore, in accordance with some embodiments of the present invention, the size of said at least one mesh is determined by heating capabilities of an induction welding machine used to heat said at least one metal mesh.

[0024] Furthermore, in accordance with some embodiments of the present invention, the at least one metal layer is at least one solid metal layer positioned either on top of, or under, or in between or within the at least one coating layer.

[0025] Furthermore, in accordance with some embodiments of the present invention, the at least one metal layer is in the form of metal particles positioned either on top of, or under, or in between or within the at least one coating layer.

[0026] Furthermore, in accordance with some embodiments of the present invention, the at least one metal layer is either rigid or semi-rigid, or flexible.

[0027] Furthermore, in accordance with some embodiments of the present invention, the multi-layer coating assembly is formed in size and shape compatible with the size and shape of the surface intended to be sealed.

[0028] Furthermore, in accordance with some embodiments of the present invention, the multi-layer coating assembly is placed either on a roof surface or on walls.

[0029] Furthermore, in accordance with some embodiments of the present invention, the multi-layer coating assembly is placed on top of means for absorbing water for drainage in roofs.

[0030] Furthermore, in accordance with some embodiments of the present invention, the means for absorbing water for drainage in roofs are drainage and / or ventilation openings.

[0031] Furthermore, in accordance with some embodiments of the present invention, the multi-layer coating assembly is used as a reinforcement assembly along the perimeter of the roof.

[0032] Furthermore, in accordance with some embodiments of the present invention, there is also provided an induction welding machine for heating the multi-layer coating assembly, thus, for adhering the multi-layer coating assembly to a surface. The induction welding machine comprises: a thermal induction head, at least one temperature sensor, an energy generator to supply energy to the induction heater, a controller, and a user interface for operating the induction welding machine, and rolling / scanning means for rolling / scanning said thermal induction head over the multi-layer coating assembly situated on / in proximity to a surface to be sealed, wherein said induction welding machine is rolling / scanning over the multi-layer coating assembly, causing the at least one metal layer to heat.

[0033] Furthermore, in accordance with some embodiments of the present invention, the induction welding machine delivering an alternating magnetic current to the at least one metal layer, said alternating magnetic current creates a resistance in the metal, causing it to heat.

[0034] Furthermore, in accordance with some embodiments of the present invention, the induction welding machine is rolled / scanned over the at least one multi-layer coating assembly by a user.

[0035] Furthermore, in accordance with some embodiments of the present invention, the induction welding machine is operated automatically, rolling / scanning over the at least one multi-layer coating assembly independently without a user.

[0036] Furthermore, in accordance with some embodiments of the present invention, the induction welding machine is operable via electricity, a rechargeable battery or solar energy.

[0037] Furthermore, in accordance with some embodiments of the present invention, there is also provided a method for adhering the multi-layer coating assembly onto a surface, the method comprising:

[0038] (a) providing a multi-layer coating assembly; (b) positioning the multi-layer coating assembly on top of a surface to be sealed;

[0039] (c) providing an induction welding machine for induction-based heating the multi-layer coating assembly;

[0040] (d)rolling / scanning the induction welding machine over the multi-layer coating assembly for transferring energy to the at least one metal layer to heat / melt the at least one metal layer;

[0041] (e) melting the at least one coating layer via the heated / melted at least one metal layer; and

[0042] (f) cooling the at least one coating layer to adhere it to the surface.

[0043] BRIEF DESCRIPTION OF THE INVENTION

[0044] Fig. 1 is a schematic view7of one multi-layer coating assembly for coating surfaces in accordance with some embodiments of the present invention.

[0045] Fig. 2 is a schematic view7of another multi-layer coating assembly for coating surfaces in accordance with some embodiments of the present invention.

[0046] Fig. 3 is a schematic illustration of an induction welding machine in accordance with some embodiments of the present invention.

[0047] Fig. 4 is an illustration of an optional induction welding machine in accordance with some embodiments of the present invention.

[0048] Fig. 5 illustrates a method for adhering the multi-layer coating assembly of the present invention onto a surface such as a roof surface, a wall surface and the like.

[0049] DETAILED DESCRIPTION OF THE INVENTION

[0050] Fig. 1 is a schematic view of a multi-layer coating assembly 100 for coating surfaces such as, for instance, roof surfaces, walls, parking lot surfaces and the like in accordance with some embodiments of the present in vention. In accordance with some embodiments of the present invention, the multi-layer coating assembly 100 may comprise at least one coating layer such as coating layer 102 and at least one metal layer such as metal layer 104. hi accordance with some embodiments of the present invention, the multi-layer coating assembly may comprise additional layers as shown in Fig. 2.

[0051] Fig. 2 is a schematic view of another multi-layer coating assembly 200 for coating surfaces such as, for instance, roof surfaces, walls, parking lot surfaces and the like in accordance with some embodiments of the present invention. The multi-layer coating assembly 200 may comprise at least one coating layer such as at least one coating layer 202A-C and at least one metal layer such as at least one metal layer 204.

[0052] The multi-layer coating assembly 200 may further comprise at least one reinforcement layer such as at least one reinforcement layer 206 which may be made of fiber glass, a polymeric material such as polyester, a combination thereof and the like. The at least one reinforcement layer 206 may reinforce and strengthen the multi-layer coating assembly 200.

[0053] The multilayer coating assembly 200 may comprise at least one insulating layer 208 to block gases that can be produced while heating the multilayer coating assembly 200 from escaping (spreading) into the environment, thus preventing air pollution.

[0054] As seen in the figure, the at least one metal layer 204 may be embedded between two coating layers, for instance, coating layer 202A and coating layer 202B.

[0055] In accordance with some embodiments of the present invention, the coating layer 102, 202 A-C may be a bituminous layer, for instance, SBS or APPtype bituminous layer.

[0056] The coating layer 102, 202 A-C may be made of other material(s) such as acrylics, asphalts, polyurethanes, silicones, resin(s) such as butyl resins, fluoropolymer, PMMA, polyester, silyl terminated poly ether (STPE), polyuria, PUMA, SEBS, styrene-acrylics, a combination thereof and the like.

[0057] In accordance with some embodiments of the present invention, the at least one metal layer 104, 204 may be metals such as, for instance, materials including, gray and ductile iron, steel, copper and copper-based alloys, aluminum, zinc, reactive metals, precious metals, and the like.

[0058] In accordance with some embodiments of the present invention, the at least one metal layer 104, 204 may be a metal mesh positioned on top of, under, in between or within the at least one coating layer 102, 202 A-C.

[0059] The thickness of the mesh and the mesh size, i.e., the number of openings in one square inch of a screen, may be determined by the induction welding machine (described below). More specifically, the thickness of the mesh and the mesh size may be determined by the heating capabilities of the induction welding machine.

[0060] Alternatively, the at least one metal layer 104, 204 may be a solid layer positioned on top of, under, in between or within the at least one coating layer 102, 202 A-C. The thickness of the solid layer may be determined by the heating capabilities of the induction welding machine.

[0061] Alternatively, the at least one metal layer 104, 204 may be metal particles embedded in the at least one coating layer 102, 202A-C, or encapsulated by the at least one coating layer 102, 202A-C.

[0062] In accordance with some embodiments of the present invention , the m etal particles may be positioned on top of, under, in between or within the at least one coating layer 102, 202 A-C.

[0063] In accordance with some embodiments of the present invention, the at least one metal layer 104, 204 may be rigid, semi-rigid, or flexible. The at least one metal layer 104, 204 is preferably flexible. In accordance with some embodiments of the present invention, the multi-layer coating assembly 100, 200 may be formed in any size and shape according to the size and shape of the surface to be sealed.

[0064] In accordance with some embodiments of the present invention, the multi-layer coating assembly 100, 200 may be square, rectangular, round, oval, or any other shape.

[0065] In accordance with some embodiments of the present invention, each of the at least one coating layer 102, 202A-C and said at least one metal layer 104, 204 is placed over the entire area of the surface to form a tight seal with the surface over the entire surface area, for instance, over the entire surface area of a building roof, hi accordance with some embodiments of the present invention, a tight seal between the multi-layered coating assembly 100, 200 and the entire surface area enables detection of leaks since liquid is kept in the leak area and cannot flow over the well-sealed surface.

[0066] According to some of tlie embodiments of the present invention, the multi-layer coating assembly 100, 200 may be placed on top of various means for absorbing water for drainage in roofs, that is, dramage and / or ventilation openings. According to some embodiments of the present invention, the multi-layer coating assembly 100, 200 may be used as reinforcement assemblies for use along the perimeter of the roof.

[0067] Fig. 3 is a schematic illustration of the induction welding machine 300 in accordance with some embodiments of the present invention.

[0068] The induction welding machine 300 may comprise a portable surface 302, an induction heater 304, at least one temperature sensor 306, an energy generator 308 to supply energy to the induction heater 304, controller 310, and a user interface 312 for operating tlie induction welding machine 300.

[0069] As seen in the figure, the induction welding machine 300 may include rolling means such as wheels and may be rolled over the multi-layer coating assembly 100, 200 over the entire area of the surface to heat the at least one metal layer 104, 204.

[0070] More specifically, while rolling over / scanning the multi-layer coating assembly 100, 200, the induction welding machine 300 delivers an alternating magnetic current to the at least one metal layer 104, 204. Such alternating magnetic current creates resistance in the at least one metal layer 104, 204, causing it to heat and eventually to melt.

[0071] In accordance with some embodiments of the present invention, the heated / melted at least one metal layer 104, 204 heating and / or melting the at least one coating layer 102, 202A-C. Then, as the heated / molten at least one coating layer 102, 202 A-C cools, it adheres to the surface.

[0072] In accordance with some embodiments of the present invention, the induction welding machine 300 may be motorized and may be rolled / scanned over the multi-layer coating assembly 100, 200 by a user. Alternatively, the induction welding machine 300 may be automatically operated, and may roll over the multi-layer coating assembly 100, 200 independently without a user.

[0073] In accordance with some embodiments of the present invention, the induction welding machine 300 may be operable via electricity, a rechargeable battery or solar energy.

[0074] In accordance with some embodiments of the present invention, the induction welding machine 200 may be designed in multiple sizes and shapes to be compatible with multiple regions and infrastructures. An optional design of the induction welding machine is shown and described in Fig. 4.

[0075] Fig. 4 is an illustration of an optional induction welding machine 400 in accordance with some embodiments of the present invention.

[0076] As seen in the figure, the optional induction welding machine 400 may comprise a thermal induction head 402, lead wagon (carrier) 404 for carrying the thermal induction head 402, controller 406 and power supply 408 for operating the thermal induction head 402. The optional welding machine 400 may further comprise wheels 410 and handling means 412 to be grabbed by the user.

[0077] Also seen in the figure is the multi-layer coating assembly 100, 200 on which the lead wagon (earner) 404 is rolled / scanned.

[0078] While the lead wagon (carrier) 404 is rolled / scanned over the multi-layer coating assembly 100, 200, the thermal induction head 402 is “ironing” the multi-layer coating assembly 100, 200 and heating / melting the at least one metal layer 104, 204.

[0079] While the lead carriage (carrier) 404 is rolled / scanned over the multilayer coating assembly 100, 200, the thermal induction head 402 may be in full contact with the multilayer coating assembly 100 , 200 , or may be kept in close proximity to the multilayer coating assembly 100 , 200. As seen in the figure, a space gap 414 is maintained between the thermal induction head 402 and the multilayer coating assembly 100, 200 to allow smooth mobility of the welding machine 400 over the multilayer coating assembly 100, 200.

[0080] In accordance with some embodiments of the present invention, the user may walk over the multi-layer coating assembly 100, 200 while pushing / pulling the induction welding machine 300, 400. The induction welding machine 300, 400 may generate magnetic waves and deliver an alternating magnetic current to the at least one metal layer 104, 204, said alternating magnetic current creates a resistance in the metal, causing it to heat. The at least one heated metal layer 104, 204 melts the at least one coating layer 102, 202A-C which sticks / adheres to the surface as it cools.

[0081] In accordance with some embodiments of the present invention, the induction welding machine 300, 400 may be a robotic machine that may be programmed to move independently / semi-independently over the at least one multi-layer coating assembly 100, 200.

[0082] The induction welding machine 300, 400 may be operated via wires, batteries, solar energy and the like. In accordance with some embodiments of the present invention, heating the at least one metal layer 104, 204 may be done by electric means. In this case, the multi-layer coating assembly 100, 200 may be connected to a power source, battery(s), solar energy, and the like, and the produced electric current may heat the at least one metal layer 104, 204 which in turn may melt the at least one coating layer 102, 202 A-C.

[0083] As such, the method 500 described below does not require the use of gas and fire, thus eliminating pollution and being environmentally friendly.

[0084] Fig. 5 illustrates a method 500 for adhering the multi-layer coating assembly 100, 200 onto a surface such as a roof surface, walls and the like.

[0085] The method 500 comprising the following stages:

[0086] Stage 502: providing a multi-layer coating assembly 100, 200;

[0087] Stage 504: positioning the multi-layer coating assembly 100, 200 on top of a surface to be sealed, e.g., on a roof surface, walls and the like;

[0088] Stage 506: providing an induction welding machine 300, 400 for inductionbased heating the multi-layer coating assembly 100, 200;

[0089] Stage 508: rolling / scanning the induction welding machine 300, 400 over the multi-layer coating assembly 100, 200 for transferring energy to the at least one metal layer 104, 204 to heat / melt the at least one metal layer 104, 204;

[0090] Stage 510: melting the at least one coating layer 102, 202A-C via the heated / melted at least one metal layer 104, 204;

[0091] Stage 512: adhering the at least one coating layer 102, 202A-C to the surface - as the molten at least one coating layer 102, 202A-C cools, it adheres to the surface.

[0092] The method 500 of the present invention is advantageous for the following reasons:

[0093] - It enables high adhesion efficiency, and thus, facilitates the detection of leaks since the water is kept in the leak area and cannot flow over the well-sealed surface. The methods that exist today allow a relatively low adhesion efficiency, thus making it difficult to detect leaks.

[0094] - It does not involve working with direct fire. In contrast to the various methods that exist today which include heating the coating materials by direct fire and burning which bums chemicals such as bitumen and causes black smoke and air pollution (Such contamination is dangerous to the worker and the environment.), the method 500 of the present invention does not involve burning bitumen and releasing gases from the burning, and therefore, is environmentally friendly.

[0095] - The process can be insured by an insurance company since it does not involve heating the coating material via direct fire.

[0096] - Lower costs - no gas consumption and a minimal number of employees.

Claims

CLAIMS1. A multi-layer coating assembly for surface coating comprises: at least one coating layer and at least one metal layer, said at least one metal layer is positioned on top of or under said at least one coating layer or embedded between or within the at least one coating layer; wherein said at least one metal layer is heated to melt the at least one coating layer, thus, to produce at least one molten coating layer and wherein as said at least one molten coating layer cools, it adheres to the surface, thus, forming a surface coating, wherein each of said at least one coating layer and said at least one metal layer is placed over the entire area of said surface to form a tight seal with said surface over the entire surface area, thereby said tight seal between the multi-layered coating assembly and the entire surface area is crucial for detection of leaks since liquid is kept in the leak area and cannot flow over the well-sealed surface.

2. The multi-layer coating assembly of claim 1 further comprising at least one reinforcement layer to reinforce the multi-layer coating assembly.

3. The multi-layer coating assembly of claim 2, wherein said at least one reinforcement layer is made of fiberglass, or polymeric material, or a combination thereof.

4. The multi-layer coating assembly of claim 3, wherein said polymeric material is polyester.

5. The multi-layer coating assembly of claim 1 further comprising at least one insulation layer to block gas(es) that can be produced while heating the multilayer coating assembly from escaping (spreading) into the environment.

6. The multi-layer coating assembly of claim 1, wherein the at least one metal layer is embedded between two of said at least one coating layer.

7. The multi-layer coating assembly of claim 1, wherein said at least one coating layer is made of material(s) selected from acrylics, asphalts, polyurethanes, silicones, resin(s), fluoropolymer, PMMA, polyester, silyl terminated polyether (STPE), polyuria, PUMA, SEBS, styrene-acrylics, or a combination thereof.

8. The multi-layer coating assembly of claim 1, wherein said at least one coating layer is a bituminous layer.

9. The multi-layer coating assembly of claim 1, wherein the at least one metal layer is selected from gray and ductile iron, steel, copper and copper-based alloys, aluminum, zinc, reactive metals, precious metals, or a combination thereof.

10. The multi-layer coating assembly of claim 1, wherein the at least one metal layer is at least one metal mesh positioned either on top of, or under, or in between or within the at least one coating layer.

11. The multi-layer coating assembly of claim 10, wherein the size of said at least one mesh is determined by heating capabilities of an induction welding machine used to heat said at least one metal mesh.

12. The multi-layer coating assembly of claim 1, wherein the at least one metal layer is at least one solid metal layer positioned either on top of, or under, or in between or within the at least one coating layer.

13. The multi-layer coating assembly of claim 1, wherein the at least one metal layer is in the form of metal particles positioned either on top of, or under, or in between or within the at least one coating layer.

14. The multi-layer coating assembly of claim 1, wherein the at least one metal layer is either rigid or semi-rigid, or flexible.

15. The multi-layer coating assembly of claim 1, wherein the multi-layer coating assembly is formed in size and shape compatible with the size and shape of the surface intended to be sealed.

16. The multi-layer coating assembly of claim 1, wherein the multi-layer coating assembly is placed either on a roof surface or on walls.

17. The multi-layer coating assembly of claim 1, wherein the multi-layer coating assembly is placed on top of means for absorbing water for drainage in roofs.

18. The multi-layer coating assembly of claim 17, wherein the means for absorbing water for drainage in roofs are drainage and / or ventilation openings.

19. The multi-layer coating assembly of claim 17, wherein the multi-layer coating assembly is used as a reinforcement assembly along the perimeter of the roof.

20. The multi-layer coating assembly of any one of claims 1-19, further comprising an i nduction welding machi ne for heati ng the multi -layer coating assembly, thus, for adhering the multi-layer coating assembly to the surface comprising: a thermal induction head, at least one temperature sensor, an energy generator to supply energy to the induction heater, a controller, and a user interface lor operating the induction welding machine, and rolling / scanning means for rolling / scanning said thermal induction head over the multi-layer coating assembly situated on / in proximity to a surface to be sealed, wherein said induction welding machine is rolling / scanning over the multi-layer coating assembly, causing the at least one metal layer to heat.

21. The multi-layer coating assembly of claim 20, wherein said induction welding machine delivering an alternating magnetic current to the at least one metal layer, said alternating magnetic current creates a resistance in the metal, causing it to heat.

22. The multi-layer coating assembly of claim 20, wherein said induction welding machine is rolled / scanned over the at least one multi-layer coating assembly by a user.

23. The multi-layer coating assembly of claim 20, wherein said induction welding machine is operated automatically, rolling / scanning over the at least one multi-layer coating assembly independently without a user.

24. The multi-layer coating assembly of claim 20, wherein the induction welding machine is operable via electricity, a rechargeable batter}'’ or solar energy.

25. A method for adhering the multi-layer coating assembly of claims 1-24 onto a surface, the method comprising:(a) providing a multi-layer coating assembly;(b) positioning the multi-layer coating assembly on top of a surface to be sealed;(c) providing an induction welding machine for induction-based heating the multi-layer coating assembly;(d) rolling / scanning the induction welding machine over the multi-layer coating assembly for transferring energy to the at least one metal layer to heat / melt the at least one metal layer;(e) melting the at least one coating layer via the heated / melted at least one metal layer; and(f) cooling the at least one coating layer to adhere it to the surface.

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