U.S. patent application number 09/799211 was filed with the patent office on 2002-11-14 for wood replacement system and method.
Invention is credited to Anderson, Robert Phillip, Schaefer, Louis Paul, Whitley, Kimberly Ann.
Application Number | 20020166495 09/799211 |
Document ID | / |
Family ID | 25175310 |
Filed Date | 2002-11-14 |
United States Patent
Application |
20020166495 |
Kind Code |
A1 |
Anderson, Robert Phillip ;
et al. |
November 14, 2002 |
WOOD REPLACEMENT SYSTEM AND METHOD
Abstract
Methods, compositions and boat hulls are disclosed using and
forming a wood replacement surface. The wood replacement surface is
used as a replacement or substitute for wood surfaces. The wood
replacement surface of the present invention has improved
characteristics, such as strength and water resistance, compared to
conventional wood surfaces. The wood replacement surface is
resistant to environmental conditions such as water, heat and
sunlight. The wood replacement surface is easier to apply than
conventional wood surfaces.
Inventors: |
Anderson, Robert Phillip;
(Westchester, OH) ; Whitley, Kimberly Ann;
(Hamilton, OH) ; Schaefer, Louis Paul;
(Cincinnati, OH) |
Correspondence
Address: |
KILLWORTH GOTTMAN HAGAN & SCHAEFF, LLP
ONE DAYTON CENTRE, SUITE 500
ONE SOUTH MAIN STREET
DAYTON
OH
45402-2023
US
|
Family ID: |
25175310 |
Appl. No.: |
09/799211 |
Filed: |
March 5, 2001 |
Current U.S.
Class: |
114/357 ;
114/358 |
Current CPC
Class: |
C08K 5/0025 20130101;
C08L 67/00 20130101; B32B 2367/00 20130101; E04C 2/20 20130101;
C08K 3/346 20130101; C08K 3/013 20180101; C08F 283/02 20130101;
C09D 167/06 20130101; C08F 290/064 20130101; B32B 27/08 20130101;
B32B 27/36 20130101; B29K 2067/00 20130101; C09D 163/10 20130101;
B32B 2605/12 20130101; B29C 70/58 20130101; B63B 2231/52 20130101;
C09D 163/10 20130101; C08L 63/10 20130101; C08L 67/00 20130101;
B63B 2231/72 20130101; B63B 5/24 20130101; C08L 2666/18 20130101;
B32B 27/20 20130101; C08L 2666/22 20130101 |
Class at
Publication: |
114/357 ;
114/358 |
International
Class: |
B63B 005/24 |
Claims
What is claimed is:
1. A method of repairing a wood surface with a wood replacement
surface comprising: removing a wood surface from a structure to
form an open area; spraying or pouring a wood replacement
composition and a catalyst onto said open area, to form a wood
replacement surface, said wood replacement composition comprising:
a resin selected from the group polyester resins, vinyl ester
resins, and combinations thereof; a monomer; a thickening agent;
accelerators; and fillers, wherein the resin, the monomer, the
thickening agent, the accelerators, and the fillers are thoroughly
mixed together prior to being used as a wood replacement
composition.
2. The method of claim 1, wherein the catalyst is methyl ethyl
ketone peroxide.
3. The method of claim 1, wherein the structure is a wood deck.
4. The method of claim 1, wherein the structure is a boat hull.
5. The method of claim 1, wherein the wood replacement surface is
able to hold a fastener.
6. The method of claim 1, wherein the wood replacement composition
comprises by weight:
2 10-20% vinyl ester resin 40-60% polyester resin 0-20% monomer
1-15% thickening agent 0-3% fumed silica 0.1-5% accelerators, and
1-25% fillers.
7. A method of making a sprayable, pourable composition comprising:
providing a vinyl ester resin of 10-20 weight percent of the
composition; providing a polyester resin of 40-60 weight percent of
the composition; providing a monomer of 0-20 weight percent of the
composition; providing 1-15% thickening agent; mixing for about 15
minutes; providing 0.1-5 weight percent accelerators selected from
the group consisting of DMPT, DMA, DMAA cobalt octoate, potassium
octoate, copper naphthanate, quaternary ammonium salts and mixtures
thereof and 0-3 weight percent fumed silica; mixing for about 5
minutes; providing filler of 1-25 weight percent of the
composition; and mixing for about 20 minutes.
8. The method of claim 7 further comprising: filtering the
composition through a mesh filter.
9. A sprayable, pourable composition useful as substitute for wood
comprising: a resin selected from the group consisting of polyester
resins, vinyl ester resins, and combinations thereof; a monomer; a
thickening agent; accelerators; and fillers; wherein the resin, the
monomer, thickening agent; the accelerators, and the fillers are
thoroughly mixed together and added to a catalyst prior to being
used as a wood substitute.
10. The composition of claim 9, wherein the accelerators comprise
at least one material selected from the group consisting of DMPT,
DMA, DMAA cobalt octoate, potassium octoate, copper napthanate,
quaternary ammonium salts, and mixtures thereof.
11. The composition of claim 9, wherein the fillers comprise hollow
microspheres and at least one material selected from the group
consisting of potassium aluminum silicate and calcium silicate and
wherein said thickening agent is thixotropic clays.
12. The composition of claim 11, wherein the hollow microspheres
are comprised of a material selected from the group consisting of
silicate glass, ceramic and plastic microspheres.
13. The composition of claim 11, further including fumed
silica.
14. The composition of claim 13, wherein the composition comprises
by weight:
3 10-20% vinyl ester resin; 40-60% polyester resin; 0-20% monomer;
1-15% thickening agent; 0-3% fumed silica; 0.1-5% accelerators, and
1-25% fillers.
15. A boat hull comprising: at least one fiber reinforced synthetic
plastic layer, an intermediate layer of a desired thickness formed
from mixing resin, a monomer, thickening agent, accelerators,
filler, and a catalyst, and an outer layer.
16. The boat hull of claim 15, wherein said intermediate layer is
formed from a composition comprising by weight:
4 10-20% vinyl ester resin; 40-60 polyester resin; 0-20% monomer;
1-15% thickening agent; 0-3% fumed silica; 0.1-5% accelerators, and
1-25% filler, mixed with a catalyst.
17. The boat hull of claim 16 wherein the filler comprises hollow
microspheres and at least one material selected from potassium
aluminum silicate and calcium silicate, and wherein said thickening
agent is thixotropic clays.
18. The boat hull of claim 17 wherein the hollow microspheres are
comprised of a material selected from the group consisting of
silicate glass, ceramic and plastic microspheres.
19. The boat hull of claim 18 wherein said accelerators comprise at
least one material selected from the group consisting of DMPT, DMA,
DMAA cobalt octoate, potassium octoate, copper napthanate,
quaternary ammonium salts, and mixtures thereof.
20. The boat hull of claim 15, wherein said intermediate layer has
a shear strength of about 705 psi, a compressive strength of about
2544 psi, and a water absorption of about 0.2 percent.
Description
FIELD OF THE INVENTION
[0001] This invention relates to environmentally resistant
fabrication materials, and more particularly, to a barrier coat
layer and core material to be used in combination with other
manufactured materials to provide an environmentally resistant
structure which can be used in place of wood surfaces.
BACKGROUND OF THE INVENTION
[0002] Wood has long been used as a material for structures used in
intense environmental conditions. Wood is used for structures such
as decks, boat hulls, docks and the like. These structures face a
wide variety of environmental conditions such as water, heat, sun
and humidity. These conditions can cause the wood to suffer damage
such as blistering, weakening, warping, deforming and rotting. This
damage is highly undesirable and can cause disastrous results in
structures such as boat hulls.
[0003] Various methods have been used to prevent damage to wood
subjected to environmental conditions. These methods usually employ
stains, marine varnishes and other protective coatings that are
physically applied to the wood surface to attempt to protect the
wood. These methods require repeated maintenance and monitoring and
even then often fail. Additionally, they require a large amount of
costly manual labor.
[0004] Some methods and systems have avoided the problems of wood
being exposed to environmental conditions by building structures,
such as boat hulls, out of other materials, such as fiberglass or
aluminum, instead of wood. One such method is U.S. Pat. No.
5,601,049, Hordis et al, where a boat hull is protected against
blistering on the underwater surface by using successive layers of
fiber reinforced synthetic plastic and having an outer gelcoat
layer and a barrier coat material of microspheres thoroughly mixed
in a synthetic resin. Another method and system is disclosed by
U.S. Pat. No. 5,277,145, Hordis, which teaches inserting a core of
syntactic foam between an inner transom wall and an outer transom
wall.
[0005] Another method of avoiding problems of wood being exposed to
environmental conditions is seen in fabricating high strength boat
transoms. Many transoms are fabricated using marine or exterior
grade plywood with layers of fiberglass and resin on each face.
[0006] However, after a short time, small leaks develop in the
plastic skin and fastener holes. This causes water to be soaked up
by the plywood core which in turn causes the plywood to suffer
damage. U.S. Pat. No. 5,036,788, Unger, describes a method of doing
so and attempts to avoid leaks by applying an outer skin to the
wood while the transom is still in the hull mold. However, Unger
requires the use of molds and forms which can make it difficult in
application.
[0007] Another method and system is disclosed by U.S. Pat. No.
5,207,172, Wolter, which discloses forming a boat deck surface
comprising at least two layers. One layer contains a slow hardening
elastic resin and a solid particulate and another layer contains a
slow hardening elastic resin, a solid particulate and a coloring
agent. Wolter is generally used for repairing boat decks. Wolter
uses a flowable epoxy and requires forming a first layer, curing,
then forming a second layer and curing.
[0008] Other methods attempt to reinforce plywood or wood. However,
the inherent weakness of wood in resisting flexibility and
resisting environmental exposure remains causing the results of
these methods to be less than desirable.
[0009] What is needed is a method and system for replacing wood
surfaces with a non-wood surface that is highly resistant to
environmental conditions and easy to fabricate and apply.
SUMMARY OF THE INVENTION
[0010] This need is met by the present invention by providing an
easily applied coating or surface that is highly resistant to
environmental conditions.
[0011] A method of replacing a wood surface with a wood replacement
surface according to one embodiment of the present invention is
disclosed. A wood surface is removed from a structure. A wood
replacement composition is sprayed or poured on the surface of the
structure. The wood replacement composition is catalyzed forming
the wood replacement surface. The wood replacement surface is
resistant to environmental conditions.
[0012] Also disclosed is a composition and a method of fabricating
a sprayable, pourable composition which can be used to produce
articles and surfaces where wood or particle board might otherwise
be used. One or more resins are provided. A monomer is provided. A
thickening agent such as clay is provided. The provided materials
are mixed. Fumed silica (optional) and one or more accelerators are
provided. The provided materials are mixed. Hollow spheres and
other fillers are then provided. The provided materials are mixed
forming the composition.
[0013] A boat hull according to another embodiment of the present
invention is disclosed. The boat hull includes at least one
laminated fiber layer and a wood replacement layer. The at least
one laminated fiber layer has an outer surface, which includes a
gel coat. The wood replacement layer is formed from mixing resin, a
monomer, thickening agent, accelerators, hollow spheres and other
fillers. The wood replacement layer is formed interiorly of the gel
coat layer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0014] The following detailed description of the present invention
can be best understood when read in conjunction with the
accompanying drawings, where like structure is indicated with like
reference numerals.
[0015] FIG. 1 illustrates a method of fabricating a sprayable,
pourable composition according to one embodiment of the present
invention.
[0016] FIG. 2 illustrates a method of replacing a wood surface with
a wood replacement surface according to another embodiment of the
invention.
[0017] FIG. 3 is a cross-section of a boat hull according to
another embodiment of the present invention.
[0018] FIG. 4 is a cross-section of a boat hull according to
another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1 illustrates a method of fabricating a sprayable,
pourable composition which can be used to produce articles and
surfaces where wood or particle board might otherwise be used. One
or more resins are provided at block 101. Typically, a polyester
resin of 40-60 percent, by weight, of the composition and a vinyl
ester resin of 10-20 percent are provided. Suitable resins can be
obtained from Reichhold Chemical. A monomer may be added in an
amount of 0-20%.
[0020] The monomer is provided at block 102. The monomer, which may
be a styrene monomer, typically is 5-20 percent of the composition.
By using lower amounts of the styrenic component, a low VOC
composition is produced. It is also possible to use non-styrenic,
VOC compliant materials in place of the styrene monomer. A
thickening agent, such as thixotropic clays, provided at block 103.
Suitable thixotropic clays can be purchased from Southern Clay
Products, Inc. They may be present in an amount of 1-15%. The
provided materials are mixed together for about 15 minutes at block
104. They can be mixed in a conventional mixer.
[0021] Fumed silica is provided at block 105. The preferred amount
fumed silicon is 0-3%. It may be added before or after block 104.
Fumed silicas can be obtained from D Gussa Co. among others. One or
more accelerators are provided at block 106. The one or more
accelerators can be DMPT, DMA, DMAA, cobalt octoate, potassium
octoate, copper napthanate and quaternary ammonium salts. The
accelerators generally comprise 0.1-5 percent of the composition.
The provided materials are mixed together for about 5 minutes at
block 107.
[0022] Fillers, i.e. hollow spheres or microspheres and optionally
other fillers, are provided at block 108. Hollow microspheres can
be obtained from PQ Corporation, Expencel Inc., and others. Other
fillers include wallostonite fibers (available from Nyco Minerals,
Inc.) and mica fillers (available from Zenca Industrial Minerals).
The fillers generally comprise 1-25 percent of the total
composition. The provided materials are mixed together for about 20
minutes at block
[0023] 109 forming the sprayable, pourable composition. The
composition is filtered through a mesh filter at block 110.
[0024] This composition can then be poured or sprayed along with a
catalyst to form an article or surface which is environmentally
resistant. It is useful in producing boat hulls, docks, decks,
floors, buildings and other structures which are used in harsh
environmental conditions.
[0025] FIG. 2 illustrates a method of replacing a wood surface with
a wood replacement surface according to another embodiment of the
present invention. A wood surface is removed from a structure at
block 201. The wood surface may be comprised of a material such as
plywood or any other wood material or product commonly used. The
structure can be a boat hull, a dock, a deck floor, building or
other structure. Generally, the present invention can be used as a
replacement for wood anywhere the wood surface and structure are
subjected to intense environmental conditions such as water,
humidity and sunlight. The damaged wood surface can be removed by
any number of conventional methods such as sanding, sawing or
cutting.
[0026] A wood replacement composition, which is the same as the
composition discussed above, is sprayed or poured on the surface of
the structure in areas where the wood surface was previously
removed at block 202. The composition is added to a catalyst and
applied. When sprayed, it can be mixed with a catalyst either
externally or internally of the spray nozzle as disclosed in U.S.
Pat. No. 5,371,117, which is incorporated herein by reference. A
suitable catalyst is methyl ethyl ketone peroxide, however other
materials may be used as a catalyst. The wood replacement surface
formed is resistant to environmental conditions such as water,
humidity and sunlight. The wood replacement surface forms a barrier
against water vapor transmission and is highly resistant to rot.
Additionally, the wood replacement surface has good compressive,
shear, flexural, and tensile strength, has good memory and is able
to hold a fastener.
[0027] In alternate embodiments, the wood replacement surface can
be formed on the surface of structures without removing a wood
surface. The wood replacement surface can be formed on top of an
existing wood surface or can be formed on the surface of the
structure instead of forming a wood surface.
[0028] FIG. 3 illustrates a boat hull according to another
embodiment of the present invention. The boat hull comprises at
least one fiber reinforced synthetic plastic layer 301 and a wood
replacement layer 302. The boat hull also has an outer surface 303.
Laminated fiber layers are commonly used in boat hull construction,
see Hordis U.S. Pat. No. 5,601,049, which is hereby incorporated by
reference.
[0029] The wood replacement layer 302 is formed between the outer
surface 303 and inner surface of at least one layer 301. The outer
surface 303 may for example be gel coat 304, barrier layer 305 and
skin coat 306 of the type described in Hordis U.S. Pat. No.
5,601,049. The wood replacement layer is formed with a desired
thickness by mixing the wood replacement composition, i.e. resin, a
monomer, accelerators, thickening agent and fillers with a catalyst
and applying it by spraying or pouring.
[0030] FIG. 4 is similar to FIG. 3 except that the wood replacement
layer 302 of the present invention is used in place of barrier
layer 305 of FIG. 3 and the core 307 may be another wood
replacement layer like 302, a standard core material as shown in
Hardis U.S. Pat. No. 5,601,049, or a foam core as in Hordis U.S.
Pat. No. 5,277,146.
[0031] The desired thickness of the wood replacement layer 302 can
vary between 1 and 750 mils. However, an example of a desired
thickness is {fraction (3/8)} of an inch. With such a thickness,
the wood replacement layer would have a shear strength of about 705
psi, a compressive strength of about 2544 psi and a water
absorption of about 0.2 percent.
[0032] Table 1 shows experimental results of a 3/8 inch thick wood
replacement layer formed according to an embodiment of the present
invention compared with 3/8 inch thick plywood and 3/8 inch balsa.
It can be readily seen that the wood replacement layer provides
shear strength and compressive strength. Furthermore, the wood
replacement layer is superior at preventing water absorption.
1 TABLE 1 3/8 Balsa 3/8 Plywood wood rep. sur. Shear Strength (psi)
358 263 705 Shear Modulus (psi) 5347 6210 6538 Flex Strength (psi)
11025 7917 19427 Flex Modulus (msi) 1.03 0.97 0.88 Tensile Strength
(psi) 10,091 9,019 7,191 Tensile Modules (msi) .8 1.23 .55
Compressive Str. (psi) 604 901 2544 Compressive Mod. (psi) 4739
8917 49645 Fastener Withdrawal (lbs) 290 294 371 Water Absorption
(%) 4.7 15.3 0.2
[0033] The wood replacement surface of the present invention is
easier to apply than conventional wood surfaces. The surface can be
sprayed or poured on. Multiple layers of the wood replacement
surface are allowable, but not required unlike other conventional
surfaces.
[0034] Many variations of the disclosed embodiment are possible in
accordance with the present invention. The embodiments can be used
with boat hulls, decks, docks, floors, buildings or any surface
exposed to environmental conditions.
[0035] Having described the invention in detail and by reference to
preferred embodiments thereof, it will be apparent that
modifications and variations are possible without departing from
the scope of the present invention defined in the appended claims.
Other suitable materials may be substituted for those specifically
recited herein.
* * * * *