U.S. patent application number 11/002975 was filed with the patent office on 2005-10-27 for silica-free surface abrasion compositions and their uses.
This patent application is currently assigned to Cal-West Specialty Coatings, Inc.. Invention is credited to Mesa, Robert, Woodhall, Edward W..
Application Number | 20050239381 11/002975 |
Document ID | / |
Family ID | 34681524 |
Filed Date | 2005-10-27 |
United States Patent
Application |
20050239381 |
Kind Code |
A1 |
Mesa, Robert ; et
al. |
October 27, 2005 |
Silica-free surface abrasion compositions and their uses
Abstract
This invention provides for provides for abrasive compositions
and methods of use of these compositions for the preparation of
surfaces for the application of various coatings such as paints,
lacquers and varnishes. The abrasive compositions of this invention
provide rapid cleaning and dulling of the underlying surface
rendering it suitable for the application of paints or other
finishes.
Inventors: |
Mesa, Robert; (Santa Clara,
CA) ; Woodhall, Edward W.; (Los Altos, CA) |
Correspondence
Address: |
QUINE INTELLECTUAL PROPERTY LAW GROUP, P.C.
P O BOX 458
ALAMEDA
CA
94501
US
|
Assignee: |
Cal-West Specialty Coatings,
Inc.
|
Family ID: |
34681524 |
Appl. No.: |
11/002975 |
Filed: |
December 1, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60609701 |
Sep 13, 2004 |
|
|
|
60527090 |
Dec 3, 2003 |
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Current U.S.
Class: |
451/54 |
Current CPC
Class: |
C09K 3/1409 20130101;
C09K 3/1463 20130101; C09G 1/02 20130101; C11D 3/14 20130101; B24B
29/00 20130101 |
Class at
Publication: |
451/054 |
International
Class: |
B24B 001/00 |
Claims
What is claimed is:
1. A composition for preparing a plastic surface for application of
paint or other overcoating, said composition comprising: about 1.0%
to about 80%, by weight, a particulate abrasive; and about 0.1% to
about 10%, by weight a suspension agent, wherein said composition
lacks an aliphatic hydrocarbon cleaning agent.
2. The composition of claim 1, wherein said particulate abrasive is
selected from the group consisting of a pumice, calcium carbonate,
ninex, boron nitride, metal carbides, diamond dust, aluminum oxide,
and iron oxide.
3. The composition of claim 1, wherein said particulate abrasive
comprises a feldspar.
4. The composition of claim 1, wherein said particulate abrasive
has a mohs hardness of 9.
5. The composition of claim 1, wherein said particulate abrasive
comprises fused aluminum oxide.
6. The composition of claim 1, wherein said particulate abrasive
comprises Minspar 3.TM..
7. The composition of claim 1, wherein said particulate abrasive
has a particle size and hardness sufficient to dull a paint finish
on said plastic surface.
8. The composition of claim 7, wherein said plastic surface is a
surface of a plastic automobile part.
9. The composition of claim 7, wherein said plastic surface is a
surface of a plastic automobile bumper.
10. The composition of claim 1, wherein said suspension agent is
selected from the group consisting of a cellulose, a starch, an
acrylic polymer, a polymer emulsion, and a clay.
11. The composition of claim 10, wherein said suspension agent
comprises a copolymers of acrylic acid and a polyalkenyl
polyether.
12. The composition of claim 11, wherein said suspension agent is a
Carbopol.TM. copolymer.
13. The composition of claim 11, wherein said suspension agent is
selected from the group consisting of CARBOPOL EZ-1.TM., and
CARBOPOL EZ-3.TM..
14. The composition of claim 1, wherein said composition further
comprises a surfactant.
15. The composition of claim 14, wherein said surfactant comprises
a high HLB surfactant and a low HLB surfactant.
16. The composition of claim 14, wherein said surfactant further
comprises an ionic surfactant.
17. The composition of claim 14, wherein said surfactant comprises
a nonionic surfactant.
18. The composition of claim 14, wherein said surfactant comprises
a nonionic surfactant.
19. The composition of claim 18, wherein said surfactant comprises
an ethoxylated linear alcohol.
20. The composition of claim 18, wherein said surfactant comprises
a poly (3) oxyethylene C.sub.12-15 alcohol.
21. The composition of claim 18, wherein said surfactant comprises
a poly (7) oxyethylene C.sub.12-15 alcohol.
22. The composition of claim 1, wherein said composition further
comprises a humectant.
23. The composition of claim 22, wherein said humectant ranges from
about 0.1 to about 20%, by weight, of said composition.
24. The composition of claim 22, wherein said humectant comprises
glycerine.
25. The composition of claim 22, wherein said humectant comprises
polyethylnene glycol.
26. The composition of claim 1, wherein said composition further
comprises a pH adjuster.
27. The composition of claim 1, wherein said composition further
comprises: a surfactant; a humectant; and a pH adjuster.
28. The composition of claim 27, wherein said surfactant comprises
Tomadol 25-7, Tomadol 25-3, and Aerosol OT-75; said humectant
comprises glycerine and polyethylene glycol 400; said suspension
agent comprises Carbopol EZ-1; said pH adjuster comprises
triethanolamine; and water.
29. A method of coating a plastic surface with paint or other
overcoating, said method comprising: abrading said plastic surface
with a composition according to any one of claims 1 through 28;
removing composition from said surface; and applying said paint or
other overcoating to said plastic surface.
30. The method of claim 72, wherein said plastic surface is not
pre-baked prior to application of said paint or other
overcoating.
31. The method of claim 72, wherein said plastic surface is not
degreased prior to application of said paint or other
overcoating.
32. The method of claim 72, wherein said plastic surface is a
surface of a component for a motor vehicle.
33. The method of claim 72, wherein said plastic surface is a
surface of a bumper for a motor vehicle.
34. A method of preparing a plastic surface for coating with paint
or other overcoating material, said method comprising: providing an
article of manufacture comprising a plastic surface; and abrading
said plastic surface with a composition according to any one of
claims 1 through 28.
35. The method of claim 33, wherein said plastic surface is not
pre-baked prior to coating with paint or other overcoating.
36. The method of claim 33, wherein said plastic surface is not
degreased prior to coating with paint or other overcoating.
37. The method of claim 33, wherein said plastic surface is a
surface of a component for a motor vehicle.
38. The method of claim 33, wherein said plastic surface is a
surface of a bumper for a motor vehicle.
39. A composition for preparing a surface for application of paint
or other overcoating, said composition comprising: about 1.0% to
about 80%, by weight, a particulate abrasive, wherein said
particulate abrasive lacks silica; and about 0.1% to about 10%, by
weight a suspension agent.
40. The composition of claim 39, wherein said particulate abrasive
is selected from the group consisting of a pumice, calcium
carbonate, ninex, boron nitride, metal carbides, diamond dust,
aluminum oxide, and iron oxide.
41. The composition of claim 39, wherein said particulate abrasive
comprises alundum.
42. The composition of claim 39, wherein said particulate abrasive
comprises nepheline syenite.
43. The composition of claim 39, wherein said particulate abrasive
has a mohs hardness of 9.
44. The composition of claim 39, wherein said particulate abrasive
comprises fused aluminum oxide.
45. The composition of claim 39, wherein said composition lacks an
aliphatic hydrocarbon cleaning agent.
46. The composition of claim 39, wherein said particulate abrasive
has a particle size and hardness sufficient to dull a paint finish
on said surface.
47. The composition of claim 39, wherein said surface is a surface
of a motor vehicle.
48. The composition of claim 39, wherein said surface is a painted
surface of a motor vehicle.
49. The composition of claim 39, wherein said suspension agent is
selected from the group consisting of a cellulose, a starch, an
acrylic polymer, a polymer emulsion, and a clay.
50. The composition of claim 49, wherein said suspension agent
comprises a copolymer of acrylic acid and a polyalkenyl
polyether.
51. The composition of claim 50, wherein said suspension agent is a
Carbopol.TM. copolymer.
52. The composition of claim 50, wherein said suspension agent is
selected from the group consisting of CARBOPOL EZ-1.TM., and
CARBOPOL EZ-3.TM..
53. The composition of claim 39, wherein said composition further
comprises a surfactant.
54. The method of claim 53, wherein said surfactant comprises a
high HLB surfactant and a low HLB surfactant.
55. The method of claim 53, wherein said surfactant further
comprises an ionic surfactant.
56. The composition of claim 53, wherein said surfactant comprises
a nonionic surfactant.
57. The composition of claim 53, wherein said surfactant comprises
a nonionic surfactant.
58. The composition of claim 57, wherein said surfactant comprises
an ethoxylated linear alcohol.
59. The composition of claim 57, wherein said surfactant comprises
a poly (3) oxyethylene C.sub.12-15 alcohol.
60. The composition of claim 57, wherein said surfactant comprises
a poly (7) oxyethylene C.sub.12-15 alcohol.
61. The composition of claim 39, wherein said composition further
comprises a humectant.
62. The composition of claim 61, wherein said humectant ranges from
about 0.1 to about 20%, by weight, of said composition.
63. The composition of claim 61, wherein said humectant comprises
glycerine.
64. The composition of claim 61, wherein said humectant comprises
polyethylnene glycol.
65. The composition of claim 39, wherein said composition further
comprises a pH adjuster.
66. The composition of claim 39, wherein said composition further
comprises: a surfactant; a humectant; and a pH adjuster.
67. The composition of claim 27, wherein said surfactant comprises
Tomadol 25-7, Tomadol 25-3, and Aerosol OT-75; said humectant
comprises glycerine and polyethylene glycol 400; said suspension
agent comprises Carbopol EZ-3; said pH adjuster comprises
triethanolamine; and water.
68. A method of preparing a surface for application of a finish,
said method comprising: abrading said surface with an abrasive
composition of any one of claims 39 through 67; and removing said
abrasive composition from said surface.
69. The method of claim 68, wherein said surface is a metal
surface.
70. The method of claim 68, wherein said surface is the surface of
a motor vehicle.
71. The method of claim 68, wherein said surface is the painted
surface of an automobile.
72. A method of coating a surface with paint or other overcoating,
said method comprising: abrading said plastic surface with an
abrasive composition of any one of claims 39 through 67; and
removing composition from said surface; and applying said paint or
other overcoating to said surface.
73. The method of claim 72, wherein said surface is a surface of an
automobile or automobile part.
74. The method of claim 72, wherein said surface is a painted
surface of an automobile.
75. The method of claim 72, wherein said removing comprises washing
said surface with water.
76. A method of coating a painted surface, wherein said painted
surfaces comprises nanoceramic particles, said method comprising:
i) abrading said paint surface with a foam or gel comprising: about
1.0% to about 80% by weight of a particulate abrasive wherein said
particulate abrasive is an aluminum oxide having a mohs hardness of
about 9; about 0.1% to about 10% by weight of a suspension agent; a
surfactant; and ii) removing said foam or gel from said
surface.
77. The method of claim 76, wherein said particulate abrasive
comprises about a 360 grit particle size.
78. The method of claim 76, wherein said foam or gel further
comprises a cleaning agent comprising an aliphatic hydrocarbon
79. The method of claim 76, wherein said suspension agent is
selected from the group consisting of a cellulose, a starch, an
acrylic polymer, a polymer emulsion, or a clay.
80. The method of claim 76, wherein said particulate abrasive
comprises about 10% to about 50% by weight of said composition.
81. The method of claim 76, wherein said surfactant comprises a
high HLB surfactant and a low HLB surfactant.
82. The method of claim 76, wherein said surfactant further
comprises an ionic surfactant.
83. The method of claim 76, wherein said cleaning agent comprises
about 0.1% to about 5% by weight of said composition.
84. The method of claim 76, wherein said cleaning agent comprises a
water soluble alcohol.
85. The method of claim 76, wherein said composition further
comprises a neutralizing agent.
86. The method of claim 78, wherein said cleaning agent comprises
one or more agents selected from the group consisting of ethyl
alcohol, propyl alcohol, isopropyl alcohol, methyl alcohol,
ethylene diol, propylene diol, ethanolamine, D-limonine, dodecane,
and isopar G, ethoxylate, and Carvone.
87. The method of claim 78, wherein said cleaning agent is ethyl
alcohol and D-Limonine.
88. The method of claim 76, wherein said composition further
comprises a foam height stabilizer.
89. The method of claim 88, wherein said foam height stabilizer is
ninol.
90. The method of claim 76, wherein said surfactant comprises a
nonionic high HLB surfactant, a nonionic low HLB surfactant, and an
ionic surfactant.
91. The method of claim 76, wherein said particulate abrasive
comprises about 50 to about 85% of said composition by weight.
92. The method of claim 79, wherein: said particulate abrasive
comprises about 75% of said composition by weight. said nonionic
high HLB surfactant and nonionic low HLB surfactant each comprise
about 0.5%, by weight, of said composition; said ionic surfactant
comprises about 0.67%, by weight, of said composition; said
cleaning agent is D-Limonine and comprises about 2%, by weight, of
said composition.
93. The method of claim 92, wherein said composition further
comprises a humectant.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and benefit of U.S. Ser.
No. 60/609,701, filed on Sep. 13, 2004, and U.S. Ser. No.
60/527,090, filed on Dec. 3, 2003, both of which are incorporated
herein by reference in their entirety for all purposes.
STATEMENT AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED
RESEARCH AND DEVELOPMENT
[0002] [Not Applicable]
FIELD OF THE INVENTION
[0003] The present invention relates to abrasive compositions and
their use in the preparation of surfaces for the application of
paint.
BACKGROUND OF THE INVENTION
[0004] The proper application of various finishing materials, in
particular high-gloss paint finishes, typically requires cleaning
and abrasion of the underlying surface in order to provide a
surface that forms a strong adhesive bond with the newly applied
finishing material. Cleaning and abrasion of the underlying surface
is particularly important to the successful finishing of surfaces
that are dirty, oily, greasy, or otherwise soiled and/or have a
preexisting finish (e.g., a primer or undercoat, or a high gloss
finish).
[0005] Surface finishing processes are particularly common in the
automotive industry. Motor vehicles (e.g., cars, trucks,
motorcycles, etc.) are frequently subject to elaborate painting
processes during the manufacture or subsequent refinishing of the
vehicle. These processes often require application of numerous
coats of paint (or other finish) and the application of each coat
typically requires preparation (e.g., cleaning and abrading) of the
underlying surface.
[0006] Vehicle surfaces typically bear high gloss acrylic or
urethane finishes, often with a wax or polybond topcoat. In
addition, vehicle surfaces are often soiled with dirt and/or
grease, either from the manufacturing operation or subsequent use,
and thus provide surfaces that must be cleaned prior to application
of a subsequent coating. Even during vehicle assembly, components
are often supplied with a primers or undercoats that must be
cleaned and abraded to enhance the adhesion of the subsequently
applied coating.
[0007] Surface abrasion is often accomplished with the use of
scuff-pads, abrasive pads, sanding, or sand blasting. These
approaches are typically expensive, time-consuming, and laborious
and usually require subsequent cleaning and degreasing.
[0008] While the use of abrasive compositions for surface cleaning
and abrasion is generally known, most abrasive compositions do not
provide a surface well suited to the subsequent application of
finishes. Typical abrasive compositions include polishing or
rubbing compounds, abrasive cleansers, and abrasive compositions
for the removal of oxidation layers (e.g., rust removal
compositions). Of these, rust removal and abrasive cleansers are
most appropriate for the preparation of surfaces for subsequent
coating operations as rubbing compounds tend to increase polish and
shine rather than dully underlying surfaces.
[0009] Abrasive cleansers (scouring powders) and rust removal
compounds, however, have proven unsatisfactory as surface
preparatives. Scouring powders often fail to provide adequate or
consistent (uniform) dulling of the underlying surface. In
addition, scouring powders typically include a soap that leaves a
residual film which has proven difficult to remove and which
interferes with the adhesion of subsequently applied finishes. A
similar problem has been observed with various abrasive pastes.
[0010] Rust removal compositions typically include an acid
degreaser use of which entails some health risk and requires
protective equipment. The acid component of rust removal
compositions may also attack chrome trim which may be present on
the surface. Finally, paste-like silicate abrasives which are more
easily removed from the underlying surfaces, tend to dry out to
powders which become airborne and provide a significant airborne
health hazard.
SUMMARY OF THE INVENTION
[0011] The present invention provides for abrasive compositions and
methods of use of these compositions for the preparation of
surfaces for the application of various coatings or finishes such
as paints, lacquers and varnishes. The abrasive compositions of the
present invention provide rapid cleaning and dulling of the
underlying surface with little effort, increase the useful life of
abrasive devices such as scuff pads, are easily removed from the
abraded surface with only a water rinse, and provide no significant
environmental impact.
[0012] In certain embodiments, this invention provides a
composition for preparing a plastic surface for application of
paint or other overcoating. The composition typically comprises
about 1.0% to about 80%, by weight, a particulate abrasive; and
about 0.1% to about 10%, by weight a suspension agent, where the
composition lacks an aliphatic hydrocarbon cleaning agent.
[0013] In certain embodiments this invention provides compositions
for preparing a plastic surface for application of paint or other
overcoating material. The compositions typically include about 1.0%
to about 80%, by weight, a particulate abrasive; and about 0.1% to
about 10%, by weight a suspension agent, where the composition
lacks an aliphatic hydrocarbon cleaning agent. In certain
embodiments the particulate abrasive is selected from the group
consisting of a pumice, calcium carbonate, ninex, boron nitride,
metal carbides, diamond dust, aluminum oxide, and iron oxide. In
certain embodiments the particulate abrasive comprises a feldspar.
Certain preferred particulate abrasives have a mohs hardness of 9.
In certain embodiments the particulate abrasive comprises fused
aluminum oxide (e.g., Minspar 3.TM.). Typically the particulate
abrasive has a particle size and hardness sufficient to dull a
paint finish on said plastic surface (e.g., a surface of a plastic
automobile part such as an automobile bumper or other part). In
various embodiments the suspension agent is selected from the group
consisting of a cellulose, a starch, an acrylic polymer, a polymer
emulsion, and a clay. In various embodiments the suspension agent
comprises a copolymers of acrylic acid and a polyalkenyl polyether
(e.g., Carbopol.TM. copolymer). In certain embodiments the
suspension agent is selected from the group consisting of CARBOPOL
EZ-1.TM., and CARBOPOL EZ-3.TM.. In various embodiments the
composition further comprises a surfactant (e.g., a high HLB
surfactant and a low HLB surfactant). In certain embodiments the
surfactant further comprises an ionic surfactant and/or a nonionic
surfactant. In certain embodiments the surfactant comprises an
ethoxylated linear alcohol (e.g., a poly (3) oxyethylene
C.sub.12-15 alcohol, a poly (7) oxyethylene C.sub.12-15 alcohol,
etc.). The composition can optionally, further comprise a
humectant. When present, the humectant typically ranges from about
0.1 to about 20%, by weight, of the composition. In certain
embodiments the humectant comprises glycerine and/or polyethylnene
glycol. In certain embodiments the composition further comprises a
pH adjuster. In various embodiments the composition further
comprises a surfactant (e.g., Tomadol 25-7, Tomadol 25-3, and/or
Aerosol OT-75), a humectant (e.g., glycerine and/or polyethylene
glycol 400), and a pH adjuster (e.g., triethanolamine).
[0014] In another embodiment, this invention provides a method of
coating a plastic surface with paint or other overcoating. The
method typically involves abrading the plastic surface with a
composition as described above, removing the composition from the
surface; and applying the paint or other overcoating to the plastic
surface. In certain embodiments the plastic surface is not
pre-baked and/or degreased prior to application of the paint or
other overcoating. In certain embodiments the plastic surface is a
surface of a component (e.g., a bumper or other component) of a
motor vehicle.
[0015] This invention also provides a method of preparing a plastic
surface for coating with paint or other overcoating material. The
method typically involves providing an article of manufacture
comprising a plastic surface; and abrading the plastic surface with
a composition s described above. In certain embodiments the plastic
surface is not pre-baked and/or not degreased prior to application
of the overcoating. In certain embodiments the plastic surface is a
surface of a component (e.g., a bumper) for a motor vehicle.
[0016] In another embodiment, this invention provides a composition
for preparing a surface for application of paint or other
overcoating. The composition typically includes about 1.0% to about
80%, by weight, a particulate abrasive, where the particulate
abrasive lacks silica; and about 0.1% to about 10%, by weight a
suspension agent. In certain embodiments the particulate abrasive
is selected from the group consisting of a pumice, calcium
carbonate, ninex, boron nitride, metal carbides, diamond dust,
aluminum oxide, and iron oxide. In certain embodiments the
particulate abrasive comprises alundum. In certain embodiments the
particulate abrasive comprises nepheline syenite. In certain
embodiments the particulate abrasive has a mohs hardness of 9. In
certain embodiments the particulate abrasive comprises fused
aluminum oxide. In various embodiments the composition lacks an
aliphatic hydrocarbon cleaning agent. In various embodiments the
particulate abrasive typically has a particle size and hardness
sufficient to dull a paint finish on said surface (e.g., the
surface of a motor vehicle, a painted surface of a motor vehicle,
etc.). In various embodiments the suspension agent is selected from
the group consisting of a cellulose, a starch, an acrylic polymer,
a polymer emulsion, and a clay. In various embodiments the
suspension agent comprises a copolymer of acrylic acid and a
polyalkenyl polyether. In various embodiments the suspension agent
is a Carbopol.TM. copolymer (e.g., CARBOPOL EZ-1.TM., and/or
CARBOPOL EZ-3.TM.). In various embodiments the composition further
comprises a surfactant (e.g., a high HLB surfactant and a low HLB
surfactant). In various embodiments the surfactant further
comprises an ionic surfactant and/or a nonionic surfactant. In
certain embodiments the surfactant comprises an ethoxylated linear
alcohol (e.g., a poly (3) oxyethylene C.sub.12-15 alcohol, a poly
(7) oxyethylene C.sub.12-15 alcohol, and/or the like). In various
embodiments the composition further comprises a humectant (e.g.,
glycerine, polylethylene glycol, etc.). In various embodiments the
humectant ranges from about 0.1 to about 20%, by weight, of said
composition. In various embodiments the composition further
comprises a pH adjuster. In various embodiments the composition
further comprises: a surfactant (e.g., Tomadol 25-7, Tomadol 25-3,
and/or Aerosol OT-75), a humectant (e.g., glycerine and/or
polyethylene glycol 400), and a pH adjuster (e.g.,
triethanolamine).
[0017] In certain embodiments this invention provides a method of
preparing a surface for application of a finish. The method
typically involves abrading the surface with an abrasive
composition as described above and removing said abrasive
composition from said surface. In various embodiments the surface
is a painted or otherwise coated metal surface or a bare metal
surface. In various embodiments the surface is the surface of a
motor vehicle (e.g., an automobile).
[0018] This invention also provides a method of coating a surface
(e.g., a plastic surface) with paint or other overcoating. The
method typically involves abrading said plastic surface with an
abrasive composition as described herein and removing the
composition from the surface; and applying paint or other
overcoating to the surface. In various embodiments the surface is a
surface of an automobile or automobile part. In certain embodiments
the surface is a painted surface of an automobile. In various
embodiments the removing comprises washing the surface with
water.
[0019] In still another embodiment, this invention provides a
method of coating a painted surface, where said painted surfaces
comprises nanoceramic particles. The method typically involves
abrading the paint surface with a foam or gel comprising: about
1.0% to about 80% by weight of a particulate abrasive wherein said
particulate abrasive is an aluminum oxide having a mohs hardness of
about 9; about 0.1% to about 10% by weight of a suspension agent;
and a surfactant; and removing said foam or gel from said surface.
In certain embodiments the particulate abrasive comprises about a
360 grit particle size. In certain embodiments the foam or gel
further comprises a cleaning agent (e.g., an aliphatic
hydrocarbon). In various embodiments the suspension agent is
selected from the group consisting of a cellulose, a starch, an
acrylic polymer, a polymer emulsion, or a clay. In various
embodiments the particulate abrasive comprises about 10% to about
50% by weight of the composition. In various embodiments the
surfactant comprises a high HLB surfactant and a low HLB
surfactant. In various embodiments the surfactant further comprises
an ionic surfactant. In certain embodiments the cleaning agent
comprises about 0.1% to about 5% by weight of the composition. In
various embodiments the cleaning agent comprises a water soluble
alcohol. In various embodiments the composition further comprises a
neutralizing agent. In certain embodiments the cleaning agent
comprises one or more agents selected from the group consisting of
ethyl alcohol, propyl alcohol, isopropyl alcohol, methyl alcohol,
ethylene diol, propylene diol, ethanolamine, D-limonine, dodecane,
and isopar G, ethoxylate, and Carvone. In certain embodiments the
cleaning agent is ethyl alcohol and D-Limonine. In various
embodiments the composition further comprises a foam height
stabilizer (e.g., ninol). In various embodiments the surfactant
comprises a nonionic high HLB surfactant, a nonionic low HLB
surfactant, and an ionic surfactant. In certain embodiments the
particulate abrasive comprises about 50 to about 85% of said
composition by weight. In certain embodiments the particulate
abrasive comprises about 75% of said composition by weight, the
nonionic high HLB surfactant and nonionic low HLB surfactant each
comprise about 0.5%, by weight, of said composition; the ionic
surfactant comprises about 0.67%, by weight, of said composition;
the cleaning agent is D-Limonine and comprises about 2%, by weight,
of said composition. In certain embodiments the composition further
comprises a humectant.
DETAILED DESCRIPTION
[0020] The present invention provides for abrasive compositions and
methods of use of these compositions for the preparation of
surfaces for the application of various coatings such as paints,
lacquers and varnishes. The abrasive compositions of the present
invention provide rapid cleaning and dulling of the underlying
surface with little effort, increase the useful life of abrasive
devices such as scuff pads, are easily removed from the abraded
surface with only a water rinse, and provide no significant
environmental impact.
[0021] In certain embodiments, this invention contemplates abrasive
coatings particularly well suited for preparing plastic surfaces
for painting or coatings with other overcoatings (e.g., clear coat,
lacquer, varnish, etc.). In certain preferred embodiments, such
abrasive coatings comprise aqueous mixtures/suspensions comprising
a about 1.0% to about 80%, by weight, a particulate abrasive; and
about 0.1% to about 10%, by weight a suspension agent. The
compositions can additionally and optionally include a humectant,
and/or a surfactant, and/or a biocide, and/or a colorant, and/or a
scent, and the like, e.g., as described herein.
[0022] It was a surprising discovery that such abrasive
compositions, particularly those lacking an aliphatic hydrocarbon
cleaning agent (e.g., d-limonene) are highly effective for
preparing plastic surfaces for painting or other overcoating
operations. Thus, in certain embodiments, the abrasive compositions
lack an aliphatic hydrocarbon cleaning agent.
[0023] It was a surprising discovery that use of such abrasive
compositions reduces or eliminates the need for expensive
pre-baking of new plastic parts before painting. (Most paint
manufactures at one time or another recommended or still recommend
pre-baking). In addition the use of the compositions typically
eliminates the need for initial and sometimes repetitive
de-greasing of new and used plastic parts. This is particularly
advantageous sin reducing total VOC output in preparing a part. It
is also noted that use of the abrasive compositions on plastics
greatly reduces the likelihood of paint adhesion failures. In
certain instances, a 20% failure rate on painted plastic bumpers
has been observed when using the paint manufacturer's preparation
instructions. After using the compositions of this invention, the
failure rate dropped to less that 1% it was no longer necessary to
pre-bake the plastic parts.
[0024] In certain embodiments, this invention provides novel
abrasive compositions for use on essentially any surface, but most
preferably a painted surface of an automobile. Such compositions
typically comprise an aqueous mixture/suspension of about 1.0% to
about 80%, by weight, a particulate abrasive, where the particulate
abrasive lacks silica; and about 0.1% to about 10%, by weight a
suspension agent. The compositions can additionally and optionally
include a humectant, and/or a surfactant, and/or a biocide, and/or
a colorant, and/or a scent, and the like, e.g., as described
herein. In certain particularly preferred embodiments, the
particulate abrasive comprises alundum and/or nepheline
syenite.
[0025] In addition to the aforementioned advantages, the abrasive
compositions of the present invention provide unusually consistent
abrasion. Unlike sanding and other techniques that often result in
an irregularly dulled surface, the compositions of this invention
provide and extremely uniform dulling with a minimum of individual
scratches visible to the naked eye. This results in particularly
even distribution of subsequent finishes. This is especially
important to the application of metallic and multiple stage paints
which tend to render even minor underlying discontinuities highly
visible.
[0026] With the use of less aggressive solvent systems in paints
and other finishes, due to concern over environmental impact,
surface preparation has become increasingly important to ensure
adhesion of the finish. The extremely consistent and effective
dulling of the underlying surface coupled with easy and complete
removal of the abrasive composition with only a water wash has been
shown to result in unusually effective adhesion of subsequently
applied finishes.
[0027] Thus, in one embodiment, this invention provides for a
method of preparing a surface (e.g., a plastic bumper, a painted
automobile surface, etc.) for application of a coating. The method
involves abrading the surface with one of the abrasive compositions
of this invention and then removing the abrasive composition from
the surface.
[0028] One of skill in the art will appreciate that the abrasive
compositions of this invention may be used on virtually any
surface. However, in a preferred embodiment, the abrasive
compositions will be used on a metal, rubber, or plastic surface.
The surface can be bare metal, oxidized metal, metal already coated
with a primer or undercoat, or metal coated with a final or finish
coat. Similarly, suitable plastic or rubber surfaces may be bare or
coated with a primer, undercoat, or finish coat. The abrasive
compositions of this invention may be used on any coatings known to
those of skill in the art, including, for example, paints (e.g.,
acrylic or urethane), varnishes, lacquers, and the like.
[0029] As indicated above, use of the abrasive compositions on
plastic surfaces typically obviates the need for pre-baking and/or
degreasing of the plastic.
[0030] The abrasive compositions may be used on any metal (or
other) surface that is to be subsequently coated with a finish.
This may include, but are not limited to metallic (e.g., aluminum)
siding, metallic fencing, appliance sidings, metallic components of
virtually any article of manufacture. The abrasive compositions of
the present invention, however, are particularly well suited to the
preparation of vehicles, in particular to the metal or plastic
surfaces of motor vehicles such as cars, trucks, motorcycles,
multi-purpose vehicles (MPVs), and the like. In a particularly
preferred embodiment, the abrasive compositions are used to prepare
metal or plastic surfaces for the application of acrylic automotive
paints.
[0031] Typically, the abrasive composition is applied either
directly to the surface to be prepared or to an applicator, a
device that will be used to apply the abrasive composition to the
surface. Application directly to the surface or to the applicator
may be by any means well known to those of skill in the art
including pouring directly on the surface, dipping the surface,
spraying, application by roller, pumping, and the like. The
applicator can additionally contain a reservoir that is filled with
the abrasive composition and that delivers the composition to the
surface of the applicator through one or more channels. The
composition may be delivered through the channels by passive flow
or under pressure, for example, by pumping or pressurized gas.
[0032] After application to either the surface or the applicator,
the abrasive composition is rubbed against the underlying surface
thereby cleaning and abrading the surface. In a preferred
embodiment, the applicator is used to rub the abrasive against the
surface. Suitable applicators are well known to those of skill in
the art and include, but are not limited to cloth or cloth pads,
scouring pads, sponges, scuff pads, brushes, sandpaper, abrasive
matrix materials, and the like.
[0033] The rubbing action can be provided by manual manipulation of
the application device or through use of a motorized application
device such as a rotary sander or buffer, random orbital sander,
belt sander, roller applicators, and the like which are well known
to those of skill in the art.
[0034] Visual inspection is sufficient to determine when the
underlying surface is sufficiently abraded (dulled) to permit
successful application of the subsequent finish. However, because
of the extremely uniform and consistent abrasion provided by the
abrasive compositions of this invention, the methods of this
invention are suitable for automated determination of the
appropriate endpoint for the abrasive process. This may be
accomplished simply by running an automated abrasion device for a
fixed time period, of by the use of an optical system that detects
dullness of the underlying surface and stops the abrasion process
at the appropriate endpoint.
[0035] When the underlying surface is sufficiently cleaned and
abraded, the abrasive composition is removed. This may be
accomplished by any convenient mechanical and/or chemical means.
Suitable mechanical means include scrapers, squeegees, wiping (as
with a cloth, brush, or sponge) and the like. The mechanical means
may be used alone, or in conjunction with an appropriate solvent.
In one particularly preferred embodiment, removal is by washing
with water.
[0036] The surface can then be dried by any means generally known
to those of skill in the art including, but not limited to, air
drying or force drying, for example, by the application of heat
(e.g., radiant heating, oven baking, or hot air blowers), the
reduction of air humidity, an increase in air movement or any
combination of these means. One of skill will appreciate that
certain finishes (e.g., water soluble latex paints) may not require
drying of the surface prior to application of the finish.
[0037] The cleaned and dulled surface is then ready for application
of a suitable finishing material such as a paint, or other
overcoating including, but not limited to lacquer, or varnish,
according to standard methods well known to those of skill in the
art.
[0038] In certain embodiments, the abrasive compositions of the
present invention are aqueous suspensions of a particulate
abrasive. Thus, the compositions typically include an abrasive
component and a suspension agent (to keep the abrasive component in
suspension) with water generally providing the remainder of the
composition. In various preferred embodiments, the compositions can
additionally include surfactants to provide lubrication and to
improve wetting of the underlying surface, and/or hydration agents
(humectants) to prevent dehydration of the abrasive composition
during use. The composition can also include various other
additives such as pigments or dyes for coloration, fragrances, UV
blocking components, neutralizing compounds to regulate pH, foam
height stabilizers, to maintain gel consistency, and the like.
While certain cleaning agents can be included to provide additional
degreasing and cleaning activity, it was a surprising discovery
that such aliphatic hydrocarbon cleaning agents (e.g., d-limonene)
are not necessary and indeed, are often preferably omitted.
[0039] The particulate abrasive used in the abrasive composition
may include any material having suitable strength, integrity,
hardness and the like to provide the required abrading treatment to
the surface to be treated. It will be appreciated that the
requirements for the abrasive material will vary depending upon the
surface to be treated and the desired effect on the surface.
Generally, the particulate abrasive is selected so as to give
effective abrasive action that uniformly dulls an underlying finish
without undue scratching. Relatively soft abrasive materials can be
suitable in certain applications and indeed may be desirable where
the surface is of a consistency that cannot withstand severe
treatment. However, on most surfaces, relatively hard particulate
abrasives are preferred. Suitable abrasives include pumice, silica,
calcium carbonate, ninex, boron nitride, various metal carbides,
diamond dust, various metal oxides such as aluminum oxide, iron
oxide, and the like.
[0040] While various silicates, especially various alkalai metal
silicates (e.g., feldspar) can provide an effective abrasive, it
was also a surprising discovery that certain silica-free
embodiments are equally or even more efficacious. In certain
preferred silica-free embodiments, the particulate abrasive
comprises nepheline syenite and/or alundum.
[0041] One of skill will appreciate that preferred particle size
varies with the hardness of the particle and the finish on the
surface that is to be abraded. Particle size can be adjusted
according to methods well known to those of skill in the art. For
example, an abrasive gel composition of the present invention is
made up with a particular particle size and used on a
representative test panel. If excessive scratching is observed,
then the particle size is reduced. Conversely, if the composition
shows inadequate abrasive action, the particle size is
increased.
[0042] In certain embodiments, a suitable abrasive particle has a
mean particle size of about 12 .mu.m and a Mohs hardness ranging
from about 6.0 to about 6.5. A preferred particle size distribution
is one in which substantially the whole of the particulate
material, when dry, passes through a 100 Mesh Sieve and at least
50%, more preferably 75% and most preferably about 90% passes
through a 325 mesh sieve. Particularly preferred abrasives include
feldspars comparable to MINSPAR 170 and MINSPAR 200, Minspar 3, and
crystalline silicas comparable to TAMSIL-75 and TAMSIL-150 (Unimin
Specialty Minerals Inc., Tamms, Ill.) which are illustrated in
Table 1.
1TABLE 1 Particle size distribution of MINISPAR, TAMSIL-75 and
TAMSIL-150. MINSPAR 200 TAMSIL-75 TAMSIL-150 50 Mesh Sieve, %
retained -- 0.00 0.00 70 Mesh Sieve, % retained -- 0.00 0.01 100
Mesh Sieve, % retained trace 0.02 1.11 140 Mesh Sieve, % retained
0.02 0.15 3.71 170 Mesh Sieve, % retained 0.08 -- -- 200 Mesh
Sieve, % retained 0.30 2.00 8.81 270 Mesh Sieve, % retained -- 7.69
16.01 325 Mesh Sieve, % retained 3.60 11.10 20.11
[0043] In certain embodiments, the particulate abrasive lacks
silica. Suitable formulations include, but are not limited to,
formulations comprising alundum (e.g., acid treated alundum (Saint
Gobain 38 alundum acid treated) and/or nepheline syenite (Unimin
Co.).
[0044] An abrasive content of about 10% to about 85% has been found
suitable, with about 10% to about 70% being preferred, about 20% to
about 65% being more preferred and about 30% to about 60% being
most preferred. In a number of embodiments, about 55% to about 60%
particulate abrasive has proven particularly effective.
[0045] The abrasive compositions of the present invention
preferably include a suspension agent to maintain the particulate
abrasive in an aqueous suspension. Without being bound to a
particular theory, it is believed that the inclusion of a
suspension agent improves the homogeneity of the composition and
prevents clumping of the particulate abrasive. In use, a
composition comprising a homogeneously distributed particulate
abrasive results greater uniformity of abrasive action over the
underlying surface. The suspension agent thereby facilitates the
even dulling of the underlying surface without distinct or visible
scratches. The reduction of distinct or visible scratches is
desirable because such discontinuities tend to accumulate the
subsequently applied coating resulting in an uneven finish.
[0046] In addition, it is believed the suspension agent acts to
suspend particles abraded off of the underlying surface. By
clearing (suspending) the abraded particles away from the
underlying surface, new surface is constantly exposed to the
abrasive particles thereby causing rapid abrasion of the underlying
surface. In addition, the material abraded off, does not clump and
is less likely to act as an abrasive particle itself which might
otherwise unduly scratch the underlying surface. Finally,
suspension of the abraded particles prevents clogging or "filling"
of the application device. This effectively prolongs the useful
life of the applicator (e.g., scouring pad, sandpaper, or
brush).
[0047] Essentially any water soluble thickener can act as a
suitable suspension agent. However, preferred suspension agents are
easily washed off of the underlying surface without leaving a
residual film that may interfere with subsequently applied
coatings. Particularly preferred suspension agents form a gel or
foam (as opposed to a paste or film) that is easily removed with
water. Thickening agents are well known to those of skill in the
art and include natural product thickeners such as cellulose,
cellulose derivatives (e.g., hydroxycellulose, methylcellulose,
hydroxyethylcellulose, hydroxymethylcellulose, etc.), starch or
modified starches, dextrins, and the like.
[0048] Various natural and synthetic clay type suspension agents
can also be used. Suitable natural clays include attapulgite and
bentonite. An example of a synthetic clay is an inorganic complex
silicate clay. Several grades of synthetic clay are available as
Laponite.TM. (e.g., from Laporte Industries Limited). Other useful
suspending agents are the finely divided hydrophobicly treated
clays such as a reaction product of a clay, such as a bentonite,
hectorite or Laponite, with, for example, dimethyldisteryl ammonium
chloride. These suspending agents are the hydrophobically treated
montmorillonite or hectorite clays available under the tradename
BENTONE.RTM. which are prepared by reacting a clay such as
bentonite or hectorite in a cation exchange system with a variety
of amines. Different amines are reacted to obtain different
BENTONE.RTM. suspending agents which may also differ in proportions
of SiO.sub.2, MgO and AlO.sub.3. Examples of useful BENTONE.RTM.
suspending agents are Bentone-27 which is a stearaluminum
hectorite, Bentone-34 which is a quaternium 18 bentonite,
Bentone-38 which is a quaternium 18 hectorite and Bentone-14 which
is a clay extended quaternium 18 hectorite, all of which have a
particle size of below about 5 microns and are commercially
available.
[0049] Particularly preferred thickeners include various polymer or
polymer emulsion thickeners such as silicone based thickeners,
acrylic emulsion thickeners (e.g., CARBOPOL.RTM. EP1, CARBOPOL.RTM.
1324, etc.) and acrylic copolymers (e.g., CARBOPOL.RTM. EZ-1,
CARBOPOL.RTM. EZ-3) and the like.
[0050] The amount of suspension agent in the abrasive composition
is variable, however, in a preferred embodiment, the amount of
suspension agent is adjusted to provide a gelatinous or foam-like
consistency. In a preferred embodiment, the thickener can be
present at about 0.1% to about 10%, preferably at about 0.1% to
about 7% by weight, more preferably at about 0.2% to about 5%, by
weight of the total composition. Typically, clay and polymer
thickeners are preferably present at a lower concentration (e.g.,
about 1.5% to about 3%, by weight) than polymer emulsions (e.g.,
about 6% to about 7%, by weight).
[0051] As indicated above, the abrasive compositions of the present
invention typically do not include a cleaning agent, however, in
certain embodiments, such a cleaning agent can be present. When
present, the cleaning agent acts to remove grease, oils, and other
soiling materials. Preferred cleaning agents are those that leave
no residual film or contaminant that may interfere with the
subsequent bonding of a coating material (e.g., acrylic paint).
While water insoluble cleaning agents are suitable, to facilitate
compounding into an aqueous based abrasive composition and to
facilitate removal of the composition once the underlying surface
is suitably cleaned and abraded, water-soluble cleaning agents are
preferred.
[0052] Particularly preferred water soluble cleaning agents include
one or more water soluble alcohols and/or one or more aliphatic
hydrocarbons. Water soluble alcohols are well known to those of
skill in the art and include, but are not limited to ethyl alcohol,
methyl alcohol, propyl alcohol, isopropyl alcohol, ethylene diol,
propylene diol, ethanolamine, and the like. Absolute alcohols are
suitable although 95% alcohols are preferred.
[0053] The alcohols generally increase wetting of the underlying
surface by the abrasive composition. In addition the alcohols
facilitate the dispersion of low HLB surfactants, if they are
present.
[0054] When an alcohol is present in the abrasive composition, it
is preferably present at about 0.1% to about 5%, more preferably
about 0.5 to about 3.0% and most preferably about 1.0% to about
2.0%, by weight, of the total abrasive composition.
[0055] When present, the cleaning agent can comprise one or more
aliphatic hydrocarbon cleaning solvents, alone or in combination
with the alcohol. Preferred hydrocarbon cleaning solvents
relatively nontoxic. Suitable aliphatic hydrocarbon cleaning agents
are well known to those of skill in the art and include, but are
not limited to, cyclic monoterpenes such as Carvone or Limonine, or
other hydrocarbon cleaning agents such as dodecane, isopar-G, and
the like.
[0056] When an aliphatic hydrocarbon cleaning solvent is present,
it is preferably present at about 0.1% to about 5%, more preferably
about 1% to about 3% and most preferably at about 1.0% to about
2.0%, by weight, of the total composition.
[0057] When present, in certain preferred embodiments, the cleaning
agent includes both a water soluble alcohol and a hydrocarbon
cleaning solvent. In a particularly preferred embodiment, the ratio
of alcohol to hydrocarbon solvent is about 1:2, by weight. In one
preferred embodiment, the abrasive composition comprises about 1%,
by weight, alcohol and about 2%, by weight hydrocarbon solvent,
with a combination of ethyl alcohol and limonine being particularly
suitable.
[0058] In certain embodiments, the abrasive compositions of the
present invention can include one or more surfactants. The
surfactants improve wetting of the underlying surface, facilitate
solubilization of oils, greases and other soiling materials, and
provide lubrication for the abrading process, as well.
[0059] Suitable surfactants include ionic surfactants (cationic or
anionic), nonionic surfactants, and amphoteric surfactants.
Examples of nonionic surfactants include monoethers of polyethylene
glycols and long chain alkanols in which the alkanol has 10 to 16
carbon atoms and the polyethylene glycol has 5 to 15 oxyethylene
units. Such monoethers of polyethylene glycol are generally made by
reacting the alkanol with ethylene oxide. Such nonionic surfactants
are well known to those of skill in the art and are commercially
available. For example, commercially available TOMADOL.RTM. 25-7, a
nonionic surfactant, is an adduct of 7 mols of ethylene oxide and 1
mol of a mixture of alkanols of 12 to 15 carbon atoms. Other
related nonionic surfactants include TOMADOL.RTM. 25-3, NEODOL.RTM.
4511, NEODOL.RTM.2503, ALFONIC.RTM. 1618-65, PLURAFAC.RTM. B26, and
the like.
[0060] Ionic surfactants include anionic and cationic surfactants.
Suitable anionic surfactants are well known to those of skill in
the art and include, but are not limited to various carboxylates,
N-acylsarcosinates, acylated protein hydrolysates including various
sulfonates, ethoxylated and/or sulfonated alkylphenols, and the
like. Cationic surfactants are also well known to those of skill in
the art and include, but are not limited to aliphatic mono-, di-
and polyamines derived from fatty and rosin acids, quaternary
ammonium salts, and the like.
[0061] Suitable amphoteric surfactants include, but are not limited
to, the alkylbetaines, alkyldimethylamines, amphoteric
imidazolinium derivatives, and the like.
[0062] In certain embodiments, the surfactant includes two nonionic
surfactants, one a low hydrophile-lipophile balance (HLB)
surfactant and the other a high (HLB) surfactant. (The
hydrophile-lipophile balance is an expression of the relative
simultaneous attraction of surfactant for water and for oil [or for
the two phases of the emulsion system being considered]). Without
being bound to a particular theory, it is believed that the low HLB
surfactant partitions into the hydrocarbon (hydrophobic) phase of
the abrasive composition (which will also include oily contaminants
on the underlying surface) effectively incorporating some water
into the hydrophobic phase. The high HLB surfactant then acts as an
emulsifier effectively solubilizing the HLB surfactant. In a
particularly preferred embodiment, nonionic low HLB and high HLB
surfactants are combined with a high foaming ionic surfactant which
provides foam height and helps lift abraded particles, dirt and oil
up away from the underlying surface.
[0063] As used herein, a low HLB surfactant is one which has an HLB
number ranging from about 3 to about 8, while a high HLB surfactant
is one which has an HLB number ranging from about 9 to about 2.
[0064] In certain embodiments, the surfactant comprises
TOMADOL.RTM. 25-3 (Tomah, Inc.) as the low HLB surfactant (HLB
number about 7.8) and TOMADOL.RTM. 25-7 (Tomah, Inc.) as the high
HLB surfactant (HLB number about 12.3) and RHODAPLEX.RTM. CO 436,
sodium dodecyl sulfate, dioctylsodiumsulfosuccinate (e.g.,
ACROSOL.RTM. OT-75), STEOL.RTM. CA-460, or STEOL.RTM. CS-460 as the
high foaming surfactant. Other suitable high HLB, low HLB and high
foaming surfactants will be known to those of skill in the art.
[0065] The total surfactant comprises about 0.01% to about to about
6.0%, more preferably about 0.01 to about 3.0% and most preferably
about 0.1% to about 2.0% of the total composition. The high and low
HLB surfactants are preferably present in equal concentration with
the concentration of each ranging from about 0.01% to about 2%,
more preferably about 0.01% to about 1% and most preferably about
0.01% to about 0.5% of the total abrasive composition. The high
foaming surfactant is preferably present in a concentration
equivalent to the combined high and low HLB surfactants, with a
concentration preferably ranging from about 0.01% to about 2%, more
preferably from about 0.01% to about 1.5%, and most preferably from
about 0.01% to about 1% of the total abrasive composition.
[0066] To improve foam height and thereby particle suspension
properties, the abrasive composition can include a foam height
stabilizer. Preferred foam height stabilizers, especially the fatty
acid amides, also increase detergency and adhere to metals surfaces
thereby improving lubricicity. Again, preferred foam height
stabilizers are easily removed with a water wash. Suitable foam
height stabilizers include, but are not limited to, various
substituted fatty acid amides such as Ninol, Maypon, Sarkosyl,
Igepon, Hallcomid, Acraswx, Kemamide, Armowax, Ethomid, and the
like.
[0067] The foam height stabilizer, when present, comprises about
0.1% to about 5%, by weight, more preferably about 0.5% to about 3%
and most preferably about 1% to about 2%, by weight, of the total
abrasive composition.
[0068] Particularly where polymer emulsions are used as thickeners
or amphoteric surfactants are present, the abrasive composition may
additionally include a "neutralizer" to adjust the pH of the
composition. Means of adjusting pH are well known to those of skill
in the art. Particularly where a polymer emulsion is present it is
desirable to add a base to neutralize the emulsion. This may be
accomplished by the addition of one of a number of water soluble
bases well known to those of skill in the art. These include, but
are not limited to sodium hydroxide, sodium bicarbonate and amine
bases such as pyridine and ethylamine and ammonia. In certain
preferred embodiments, the neutralizer is triethanolamine and the
abrasive composition is adjusted to a neutral pH.
[0069] In order to reduce water loss and drying, the abrasive
compositions of this invention can contain a hydration agent or
humectant. Suitable humectants are well known to those of skill in
the art and include, but are not limited to glycerine, and/or
polyethylene glycol, and/or polypropylene glycol, and the like.
[0070] In certain embodiments, the comprises glycerine and/or
polyethylene glycol (PEG). In certain embodiments, the humectant
comprises a combination of glycerine and polylethylene glycol
(e.g., PEG 400). In certain embodiments, the humectant is present
at about 1% to about 15%, more preferably about 2% to about 10%,
and most preferably about 3% to about 7%, by weight, of the total
abrasive composition.
[0071] In certain embodiments, the abrasive compositions of the
present invention are made up as aqueous solutions. Thus, in
addition to the components recited above, the compositions are
largely water (e.g., distilled or deionized water). One of skill
will appreciate however, that the compositions can include other
components such as dyes, fragrances, various gases to improve foam
formation, and the like.
[0072] While the abrasive compositions can comprise simply a
particulate abrasive and a suspension agent, one preferred
embodiment additionally includes a surfactant and/or a humectant,
and where necessary to obtain a neutral pH, a neutralizer (e.g.,
triethanolamine). In certain particularly preferred embodiments,
the humectant, when present is a composition of glycerine and
polyethylene glycol, while the surfactant, when present, comprises
a poly (3) oxyethylene C.sub.12-15 alcohol (e.g., TOMADOL.RTM.
25-3), a poly (7) oxyethylene C.sub.12-15 alcohol (e.g.,
TOMADOL.RTM. 25-7), and dioctylsodiumsulfosuccinate (e.g.,
ACROSOL.RTM. OT-75). In certain embodiments, particular
embodiments, lacking silica, the particulate abrasive comprises a
combination of nepheline syenite and alundum.
[0073] As explained herein the abrasive composition of this
invention can be optimized for preparation of plastics (e.g.,
automobile bumpers) for painting operations. Certain "plastic prep"
embodiments are illustrated in Table 1.
2TABLE 1 Illustrative formulations for abrasive composition
suitable for preparing plastics for painting. Typical Range (%
active Specific Component ingredient) Formulation Particulate
abrasive 1-80 60 Suspension Agent 0.1-10* 0.275 Humectant 1-20* 7
Surfactant 0.1-5.0* 1.67 pH adjuster 0.1-5* 1.10 Biocide 0.001-0.1*
0.010 Colorant 0.001-2.0* 0.020 Scent 0.001-1.0* 0.01 Water
remainder remainder *When present.
[0074] In certain embodiments, the abrasive compositions of this
invention are formulated as silica-free formulations. Certain
"silica-free" embodiments are illustrated in Table 2.
3TABLE 2 Illustrative formulations for silica-free abrasive
compositions. Typical Range (% active Specific Component
ingredient) Formulation Particulate abrasive 1-80 57.5 Suspension
Agent 0.1-10* 0.350 Humectant 1-20* 7 Surfactant 0.1-5.0* 1.67 pH
adjuster 0.1-5* 0.5 Biocide 0.001-0.1* -- Colorant 0.001-2.0* --
Scent 0.001-1.0* -- Water Remainder Remainder *When present.
[0075] The abrasive composition can be made by conventional means,
typically including the steps of mixing the components of the
abrasive material at substantially atmospheric pressure, so as to
form a substantially homogeneous mixture. The material can then be
packaged in any vessel capable of storing aqueous solutions.
Alternatively, where the applicator device includes a reservoir to
contain the abrasive composition, the composition may be stored in
the applicator device itself.
[0076] For example, an applicator device cam include an abrasive
pad attached to a handle. The handle may provide a reservoir for
storage of the abrasive composition which is then delivered to the
face of the abrasive pad through one or more channels. The channels
may be sealed with a removable seal (e.g., a perforable foil seal)
which may be perforated just prior to use.
[0077] The abrasive composition may also be provided in a sprayer
or a pressurized spray container. The pressurized spray container
may contain a compressed gas that serves both as a propellant and
to aid in foam creation.
[0078] In certain embodiments, the abrasive compositions are
dehydrated and provided as a powder or thick gel. Water can then be
added, e.g., immediately prior to use, to restore the
composition.
EXAMPLES
[0079] The following examples are offered to illustrate, but not to
limit the present invention.
Example 1
Preparation of a Plastic Prep Gel
[0080] The following components (as shown in Table 3) were combined
at room temperature and at atmospheric pressure by slow stirring to
form a abrasive composition for use in the preparation of plastic
surfaces for application of paint or other overcoating.
4TABLE 3 Formulation of a plastic prep gel. Percentage active Batch
ingredient/ Size Ingredient unit (lbs) Particulate abrasive: 6000
Minspar 3 60.000% 3600.000 Humectant: Glycerine 2.000% 120.000 PEG
400 5.000% 300.000 Surfactant: Tomadol 25-7 0.500% 30.000 Tomadol
25-3 0.500% 30.000 Cytec Aerosol OT-75 0.670% 40.200 Suspension
agent: Noveon Carbopol EZ-1 0.275% 16.500 pH Adjuster:
Triethanolamine, Base 1.100% 66.000 Bioicide Rohm and Haas Kathon
LX14 0.010% 0.600 Colorant Sunchemical 6004 0.020% 1.200 Scent
Ocean Fresh Scent 0.025% 1.500 Water 29.900% 1794.000
Example 2
Preparation of a Silica-Free Formulation
[0081] The following components (as shown in Table 4) were combined
at room temperature and at atmospheric pressure by slow stirring to
form a "silica-free" abrasive composition for use in the
preparation of surfaces for application of paint or other
overcoating.
5TABLE 4 Formulation of a "Silica-Free" abrasive gel. Percentage
Percentage Active Active Ingredient Ingredient in per Unit Batch
Ingredient Abrasive Size Ingredient as supplied composition. (lbs)
Particulate Abrasive: Alundum (Saint Gobain, 38 Alundum Acid
Treated - 240) 100% 2.500% 150 Unimin, Nepheline Syenite 100%
55.000% 3300 Humectant: Glycerine 100% 2.000% 120 Polyethylene
Glycol 400 100% 5.000% 300 Surfactant: Tomah, Tomadol, 25-7 100%
0.500% 30 Tomah,Tomadol, 25-3 100% 0.500% 30 Cytec, Aerosol OT-75
75% 0.670% 40.2 Suspension Agent: Noveon, Carbopol EZ-3 100% 0.350%
21 pH Adjuster: Triethanolomine 100% 0.500% 30 Water: Deionized
water 0 6000
Example 3
Formulations for Paint Surfaces Comprising Nanoparticles
[0082] In another embodiment, this invention provides an abrasive
composition particularly well suited for preparing surfaces painted
with new nanoceramic clear coated paint now appearing on
automobiles. Typically, nanoceramic materials are materials
comprising inorganic or organic powders that are manufactured as
sizes less than about 500 nm, preferably less than about 100 nm,
most preferably less than about 50 nm or 80 nm. In certain
embodiments the nanoceramic materials comprise calcium silicates
and/or other ceramics and often provide harder, heat tolerant, and
more wear resistant surfaces.
[0083] The abrasitve compositions fo this invention for use in this
context are referred to as Clear Cut.TM.". In certain embodiments,
Clear Cut.TM. is a liquid or gelled abrasive designed to provide
uniform and effective abrasion of a nanoceramic based paint so that
paint and other overacoating materials can be applied to the
surface. In addition, the compositions are designed to be easily
removed from the abraded/prepared surface, e.g., with a water wash,
and leave the underlying surface clean and ready for application of
paint or other overcoating material.
[0084] In certain embodiments, the ClearCut.TM. abrasive
compositions utilize a a much harder mineral (aluminum oxide) to
cut what we have been told in technical document and industry news
letters is a much harder paint surface. This paint includes
Nanoceramic particles to reduce incidental scratching of a surface,
such as from automatic car washes and the like.
[0085] The technology was recently introduced by Mercedes Benz and
according to industry news reports will find more and more auto
manufactures going to this type of paint in the near future. At
this time PPG and BASF are supplying these paints, (PPG U.S. Pat.
No. 6,657,001). Mercedes Benz has noted which vehicles have this
paint technology by including a "C" prefix to the normal paint
color codes attached to the vehicle.
[0086] We have found that white fused aluminum oxide works well in
this context and we presently favor the "38 Alundum" 360 grit
particle size with a mohs hardness of 9 from Saint Gobain Ceramic
Materials, Worchester, Mass. Different size particles would also
work deending on the surface finish required (see, e.g., Table
5).
6TABLE 5 Illustrative ClearCut .TM. formulations. Ingredient-
Percentage Ingredient- One per unit General embodiment Range
composition Particulate 50%-80% abrasive Saint Gobain, 75.000% 38
Alundum 360 Grit Humectant 1%-15% Glycerine, Humectant 2.000% PEG
400, Humectant 5.000% Surfactant <3% Tomadol 25-7, Surfactant
0.500% Tomadol 25-3, Surfactant 0.500% Cytec OT-75, Surfactant
0.670% Cleaning Agent 0%-10% D-limonine 2.000% Thickener/ 0%-5%
suspension Noveon EZ 3 0.150% agent Ph adjuster 0%-3%
Triethanolamine 0.525% H2O 13.655% Total solids 100.000%
[0087] It is understood that the examples and embodiments described
herein are for illustrative purposes only and that various
modifications or changes in light thereof will be suggested to
persons skilled in the art and are to be included within the spirit
and purview of this application and scope of the appended claims.
All publications, patents, and patent applications cited herein are
hereby incorporated by reference in their entirety for all
purposes.
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