U.S. patent application number 13/800848 was filed with the patent office on 2013-10-31 for film forming formulation for textured surfaces.
This patent application is currently assigned to SHURTAPE TECHNOLOGIES, LLC. The applicant listed for this patent is SHURTAPE TECHNOLOGIES, LLC. Invention is credited to Nilufer Tanrikulu.
Application Number | 20130289196 13/800848 |
Document ID | / |
Family ID | 49477415 |
Filed Date | 2013-10-31 |
United States Patent
Application |
20130289196 |
Kind Code |
A1 |
Tanrikulu; Nilufer |
October 31, 2013 |
FILM FORMING FORMULATION FOR TEXTURED SURFACES
Abstract
A film forming formulation and applicator device for use with
the film forming formulation for obtaining sharp paint lines on
textured surfaces is described. The formulation comprises a binder
as a film forming component. The binder is selected from the group
consisting of acrylic, styrene-butadiene rubber (SBR), polyvinyl
acetate (PVAc), and ethylene-vinyl acetate (EVA). The binder
comprises at least 90 percent by weight of the formulation.
Inventors: |
Tanrikulu; Nilufer; (Denver,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SHURTAPE TECHNOLOGIES, LLC |
Hickory |
NC |
US |
|
|
Assignee: |
SHURTAPE TECHNOLOGIES, LLC
Hickory
NC
|
Family ID: |
49477415 |
Appl. No.: |
13/800848 |
Filed: |
March 13, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61640136 |
Apr 30, 2012 |
|
|
|
Current U.S.
Class: |
524/521 ;
524/515; 524/523 |
Current CPC
Class: |
B05C 1/00 20130101; C09D
133/08 20130101; C09D 133/00 20130101; A46B 2200/202 20130101; C09D
4/00 20130101; C09D 133/20 20130101; B05C 17/00 20130101; A46B
11/0041 20130101; A46B 11/0089 20130101 |
Class at
Publication: |
524/521 ;
524/515; 524/523 |
International
Class: |
C09D 133/20 20060101
C09D133/20; C09D 133/08 20060101 C09D133/08; C09D 133/00 20060101
C09D133/00 |
Claims
1. A formulation comprising: a binder as a film forming component
in a formulation for use in obtaining sharp paint lines on a
textured surface, wherein the binder is selected from the group
consisting of acrylic, styrene-butadiene rubber (SBR), polyvinyl
acetate (PVAc), and ethylene-vinyl acetate (EVA), and the binder
comprises at least 90 percent by weight of the formulation.
2. The formulation according to claim 1, wherein the binder is in a
form of an emulsion.
3. The formulation according to claim 2, wherein the emulsion is a
styrene acrylic emulsion.
4. The formulation according to claim 3, wherein the styrene
acrylic emulsion is hydrophobic.
5. The formulation according to claim 1, wherein the styrene
acrylic emulsion comprises at least 92% by weight of the
formulation.
6. The formulation according to claim 3, wherein the styrene
acrylic emulsion comprises an acrylic polymer in a concentration of
50% to 52%, residual monomers in a concentration of less than 500
ppm, aqua ammonia in a concentration of 0% to 0.2%, and water in a
concentration of 48% to 50%.
7. The formulation according to claim 6, wherein the acrylic
polymer is selected from the group consisting of vinyl acrylic
polymer, methyl methacrylate, and butyl acrylate.
8. The formulation according to claim 7, wherein the vinyl acrylic
polymer is vinyl acetate, butyl acrylate, or a combination
thereof.
9. The formulation according to claim 1, wherein the formulation
further comprises a defoamer, a thickener, a dilutant, a matting
agent, anti-settling agent, a biocide, a coalescent agent, or a
combination thereof.
10. The formulation according to claim 9, wherein the biocide is
present in a range of 0.04% to 0.25% by weight of the
formulation.
11. The formulation according to claim 10, wherein the biocide is
present in a range of 0.07% to 0.10% by weight of the
formulation.
12. The formulation according to claim 9, wherein the defoamer is
present in a range of 0.01% to 1% by weight of the formulation.
13. The formulation according to claim 9, wherein the thickener is
an alkali soluble, acrylic thickener.
14. The formulation according to claim 13, wherein the alkali
soluble, acrylic thickener has a pH in a range of about 2.8 to
3.0.
15. The formulation according to claim 13, wherein the alkali
soluble, acrylic thickener is present in a range of about 0.05% to
2% by weight of the formulation.
16. The formulation according to claim 13, wherein the thickener is
optionally diluted with a dilutant.
17. The formulation according to claim 16, wherein the dilutant is
water.
18. The formulation according to claim 9, wherein the thickener is
a non-ionic liquid associative thickener.
19. The formulation according to claim 18, wherein the non-ionic
liquid associative thickener is present in a range of about 0.05%
and 0.09% by weight of the formulation.
20. The formulation according to claim 1, wherein the formulation
further comprises an additive.
21. The formulation according to claim 20, wherein the additive is
selected from the group consisting of a UV stabilizer, dispersant,
plasticizer, other stabilizer, and a combination thereof.
22. The formulation according to claim 1, wherein the formulation
has a viscosity in a range of about 100 cps to 1200 cps when
measured at a temperature of 73.4.+-.3.6.degree. F. using a
Brookfield RVT viscometer with spindle #2 at 50 rpm.
23. The formulation according to claim 1, wherein the formulation
has a viscosity in a range of about 1500 to 2500 cps when measured
at a temperature of 73.4.+-.3.6.degree. F. using a Brookfield RVT
viscometer with spindle #4 at 50 rpm.
24. A formulation comprising: a binder as a film forming component
in a formulation for use in obtaining sharp paint lines on a
textured surface, and a color shift indicator or an acid-base (pH)
indicator, wherein the binder is selected from the group consisting
of acrylic, styrene-butadiene rubber (SBR), polyvinyl acetate
(PVAc), and ethylene-vinyl acetate (EVA).
25. The formulation according to claim 24, wherein the color shift
indicator or the acid-base (pH) indicator is thymolphthalein stock
solution or phenolphthalein.
26. The formulation according to claim 22, wherein the
thymolphthalein stock solution has a color transition range in a pH
range of about 9.3 to 10.5.
27. The formulation according to claim 22, wherein the
phenolphthalein has a color transition range in a pH range of about
8.2 to 10.
28. The formulation according to claim 27, wherein the
phenolphthalein is pink at a pH above 10.
29. The formulation according to claim 27, wherein the
phenolphthalein is clear at a pH of 8.2 or below.
30. A formulation comprising: a binder in a form of an emulsion as
a film forming component in a formulation for use in obtaining
sharp paint lines on a textured surface, wherein the formulation
has a glass transition temperature (Tg) of at least 10 degrees
Celsius.
31. The formulation according to claim 30, wherein the binder is
selected from the group consisting of acrylic, styrene-butadiene
rubber (SBR), polyvinyl acetate (PVAc), and ethylene-vinyl acetate
(EVA).
32. The formulation according to claim 31, wherein the binder is in
a form of an emulsion.
33. The formulation according to claim 32, wherein the emulsion is
a styrene acrylic emulsion.
34. The formulation according to claim 30, wherein the binder
comprises at least 90 percent by weight of the formulation.
35. The formulation according to claim 30, wherein the formulation
further comprises a color shift indicator, an acid-base (pH)
indicator, or any other indicator of wetness or dryness.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. provisional
patent application No. 61/640,136, filed on Apr. 30, 2012,
incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a formulation for use on
textured surfaces to obtain sharp paint lines on textured
surfaces.
BACKGROUND OF THE INVENTION
[0003] Textured wall, floor or ceiling surfaces having three
dimensional or otherwise textured surface effects present
difficulties when applying masking tapes to such surfaces in
preparation for painting. Masking tapes generally create gaps and
an interrupted bond with the textured surface depending upon the
irregularity of the surface. As a result, it is difficult to obtain
sharp paint lines on the painted surfaces as the paint often bleeds
under the masking tape when there are such gaps and
irregularities.
[0004] At the present time, caulking the tape edges is the
predominant method for obtaining sharp paint lines on textured
surfaces. The use of caulk is typically at least a two-step
process. The first step is applying the caulk to seal the tape
edges and, after drying, the second step is painting the unmasked
area. However, the method requires skilled labor which adds
additional expense. There is also pre-paint and post-paint clean up
due to the stickiness of caulk. This clean-up is on the painted
surface, tools, and surrounding areas. The profile of the caulk is
thick and causes a "step" or abrupt change in the thickness of the
transition. This "step" is undesirable. The caulk often is never
completely removed and remains sticky. Within a few months, the
stickiness attracts and adheres dirt, making a dark, dirty line at
the color transition point which is very undesirable.
[0005] Thus, there is a need for a method that reduces the cost of
labor which is the most significant factor on a painting job.
Additionally, there is a need for a method which eliminates or
requires less clean-up and the use of skilled labor. Finally, there
is a need for a method that improves the quality of the paint job
by creating sharper paint lines on textured surfaces.
SUMMARY OF THE INVENTION
[0006] The present invention describes a film forming formulation
and variations thereof for use in painting textured surfaces such
as textured walls, floors or ceilings. The present invention also
describes an applicator device(s) and method for use in applying
the film forming formulation of the present invention.
[0007] In an aspect of the present invention, the formulation
comprises a binder as a film forming component in the formulation
for use in obtaining sharp paint lines on a textured surface. The
binder is selected from the group consisting of acrylic,
styrene-butadiene rubber (SBR), polyvinyl acetate (PVAc), and
ethylene-vinyl acetate (EVA). The binder comprises at least 90
percent by weight of the formulation.
[0008] In another aspect of the present invention, the formulation
comprises a binder as a film forming component in a formulation for
use in obtaining sharp paint lines on a textured surface and a
color shift indicator or an acid-base (pH) indicator. The binder is
selected from the group consisting of acrylic, styrene-butadiene
rubber (SBR), polyvinyl acetate (PVAc), and ethylene-vinyl acetate
(EVA).
[0009] In still yet another aspect of the present invention, the
formulation comprises a binder in a form of an emulsion as a film
forming component in a formulation for use in obtaining sharp paint
lines on a textured surface. The formulation has a glass transition
temperature (Tg) of at least 10 degrees Celsius.
[0010] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter.
It should be understood that the detailed description and specific
examples, while indicating the preferred embodiment of the
invention, are intended for purposes of illustration only and are
not intended to limit the scope of the invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an exploded perspective view of an applicator
device in accordance with aspects of the present invention.
[0012] FIG. 2 is a cross-sectional side view of the applicator
device of the present invention in accordance with aspects of the
present invention.
[0013] FIG. 3 is a horizontal cross-sectional view of the
applicator head of the applicator device of FIG. 1.
[0014] FIG. 4 is a horizontal cross-sectional view in the direction
toward the bottom of the reservoir of the applicator device of FIG.
1.
[0015] FIG. 5 is a vertical cross-sectional view of the applicator
head (without bristles inserted) in accordance with aspects of the
present invention.
[0016] FIG. 6 is a vertical cross-sectional view of the applicator
head (with bristles inserted) in accordance with aspects of the
present invention.
[0017] FIG. 7A is a perspective view of the applicator device
having contoured bristles in accordance with aspects of the present
invention.
[0018] FIG. 7B is side profile view of the applicator head of FIG.
7A.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The following detailed description of the embodiment(s) is
merely exemplary in nature and is in no way intended to limit the
invention, its application, or uses.
[0020] The present invention describes a film forming formulation
and variations thereof for use in painting textured surfaces such
as textured walls, floors or ceilings. The film forming formulation
is used with tape and applied to masked areas on textured
surfaces.
[0021] The term "film forming" or "film former", as used herein
refers to, a substance capable of forming a film upon application
to a solid surface. The film forming formulation of the present
invention is preferably a latex formulation. The film forming
formulation of the present invention after application dries in air
fairly quickly creating strong, clear and anti-glare film
properties.
[0022] The film forming formulation of the present invention
comprises a binder as a film forming component. Preferably, the
binder is in the form of an emulsion. Components which are
optionally present in the formulation include, but are not limited
to, defoamer, a thickener, a dilutant, a matting agent,
anti-settling agent, a biocide, a coalescent agent, or a
combination thereof. The formulation also optionally comprises
other additives such as UV stabilizers, dispersants, plasticizers
and other stabilizers.
[0023] Suitable binders include, but are not limited to, acrylic
polymer and copolymer, styrene-butadiene rubber (SBR), polyvinyl
acetate (PVAc), and ethylene-vinyl acetate (EVA), among others.
Examples of suitable acrylic polymers and copolymers are vinyl
acrylic polymer, methyl methacrylate, and butyl acrylate, among
others. Examples of suitable vinyl acrylics are vinyl acetate and
butyl acrylate, among others.
[0024] Properties of a styrene acrylic emulsion suitable for use in
accordance with the present invention are hydrophobic, with
excellent water resistance, fast drying and excellent film
formation. The styrene acrylic emulsion preferably comprises an
acrylic polymer in a concentration of 50% to 52%, residual monomers
in a concentration of less than 500 ppm, aqua ammonia in a
concentration of 0% to 0.2%, and water in a concentration of 48% to
50%.
[0025] With regard to biocides, a biocide is a type of preservative
that is added to avoid bacterial growth and/or mildew. Examples of
commercially available biocides include, but are not limited to,
Proxel GXL commercially available from Arch Chemicals, a Division
of Lonza Corporation. In a preferred aspect of the present
invention, a biocide is present in the formulation of the present
invention to keep bacteria from growing in the film forming
formulation and to extend the shelf life of the formulation. A
suitable range for a biocide in the formulation of the present
invention, if present in the formulation, is 0.04% to 0.25% by
weight. More preferably, the biocide is present in a range of 0.07%
to 0.10% by weight.
[0026] With regard to defoamers, a defoamer is used to eliminate or
control foaming. For example, a defoamer is used to control the
foam during manufacturing such as during blending and filling of
the bottles and containers with the formulation. The defoamer also
is useful to control the foam during application of the formulation
for continuous film formation. Examples of commercially available
defoamers include, but are not limited to, Drew Plus Y-250 and
Drewplus L 140 foam control agents, commercially available from
Ashland Chemicals. A suitable range for a defoamer in the
formulation of the present invention, if present in the
formulation, is 0.01% to 1% by weight.
[0027] Thickeners (also referred to as rheology modifiers) are
suitable for use in the film forming formulation of the present
invention. An alkali soluble, acrylic thickener having a pH in a
range of about 2.8 to 3.0 is preferred. The thickener amount varies
depending upon the desired viscosity for the application. A typical
range for a thickener, if present, in the formulation of the
present invention is about 0.05% to 2%. A thickener is optionally
diluted with a dilutant such as water, as needed.
[0028] In addition to alkali soluble acrylic thickeners,
associative thickeners are optionally added to improve rheological
properties of the film forming formulation. Shear thinning behavior
of the film forming formulation makes the latex formulation flow
out smoothly when applied with a brush and/or applicator brush
assembly but not drip excessively. The thickener impacts how thick
the film forming formulation is applied and how well it flows under
a high shear rate. The film forming formulation of the present
invention preferably comprises one or more thickeners. Examples
include, but are not limited to, Acrysol ASE 95NP is a
non-associative alkali soluble, acrylic thickener from Dow Chemical
Company; Borchi Gel 75N is a polyurethane based, non-ionic liquid
associative thickener from OMG Americas Inc. that acts as a flow
promoter in emulsion paints; Aeorodisp W 7520 is low viscosity
water based dispersion of fumed silica, with a slightly alkaline pH
from Evonik Industries that reduces anti-settling and improves
leveling and matting agent efficiency. The film forming formulation
preferably comprises between 0.05% and 0.09% by weight of a
non-ionic liquid associative thickener.
[0029] With regard to coalescent agents, a coalescent agent is used
to lower the minimum film forming (MFFM) temperature. Examples of
commercially available coalescent agents include, but are not
limited to, Texanol (ester alcohol) commercially available from
Eastman.
[0030] With regard to matting agents, a matting agent is used to
reduce gloss. Examples of commercially available matting agents
include, but are not limited to, ACEMATT OK 412 commercially
available from Evonik Industries. Matting agents that are
organically surface treated and are easily dispersible with
desirable suspension behavior are preferred.
[0031] The film forming formulation of the present invention
without a thickener present in the formulation typically has a
viscosity in a range of about 100 to 1200 cps (centipoise),
preferably 200 to 600 cps. This viscosity range is for measurements
taken at room temperature and with Brookfield RVT Spindle#2 at 50
rpm (revolutions per minute). When a thickener is present in the
formulation, the film forming formulation of the present invention
typically has a viscosity in a range of about 1500 cps to 2500 cps.
This viscosity range is for measurements taken at a temperature of
73.4.+-.3.6.degree. F. with Brookfield RVT Spindle#4 at 50 rpm
(revolutions per minute)
[0032] The film forming formulation of the present invention has a
glass transition temperature (Tg) of at least 10 degrees Celsius. A
significant advantage of the film forming formulation having a
glass transition temperature in this range is that it forms a film
that is both strong enough to withstand the mechanical forces in
the application such as the relative movement between the surfaces,
impact/abrasion of the paint application methods (rubbing, dabbing,
poking, etc.). But more significantly is that when the tape is
removed, the film has a very clean fracture, making the paint line
very sharp and clean. This is a significant improvement as compared
to caulk or other known tape sealants having lower glass transition
temperatures such as the tape sealant described in US Patent Pub.
No. 2009/0119175A1. Caulk, for example, is highly rubbery and
sometimes pulls the paint resulting in damage to the textured
surface, an irregular line, or a combination thereof. In the lower
viscosity formulation of the present invention, the profile of the
film formed by the formulation of the present invention is very low
or thin as compared to caulk or other known tape sealants such as
described in US Patent Pub. No. 2009/0119175A1.
[0033] Another significant improvement is that the film resulting
from application of the film forming formulation of the present
invention dries to the touch quickly. Additionally, the film of the
present invention is such that it does not require any clean up or
post touch up operations.
[0034] Color Shift
[0035] Another variation of the film forming formulation of the
present invention is where the film forming formulation comprises a
color shift indicator or an acid-base (pH) indicator. Color shift
in this context, refers to a change from a defined color (i.e.
contrasting color to show presence) to no longer visible.
[0036] For example, thymolphthalein stock solution may be added to
the film forming formulation to change from blue to clear as the
formulation dries. The transition range of thymolphthalein is in a
pH range of about 9.3 to 10.5. Another example of a potential color
shift indicator is phenolphthalein which has a transition in a pH
range of about 8.2 to 10. Its color is pink above 10 but gets clear
or colorless at 8.2 or below. The above examples are non-exclusive
as other chemicals or chemical compositions are optionally present
in the formulation as an indicator of the degree of wetness or
dryness of the applied formulation.
[0037] When applying a film forming formulation having a color
shift or pH indicator, the film forming formulation goes on the
surface with a contrasting color to show what has been applied to
the surface and then disappears as it dries. The contrasting color
is visible for a period of time such that a person applying the
formulation achieves the desired coverage, but subsequently the
contrasting color disappears.
[0038] The function of the color shift is achievable in many ways,
including but not limited to, by controlling reactivity. In one
aspect of the invention, a material is selected such that
formulation is air reactive whereby the material reacts with normal
air. It reacts, for example, either due to exposure to oxygen
(O.sub.2) or carbon dioxide (CO.sub.2). In another aspect of the
invention, a material is present in the formulation to be pH
reactive such that the material reacts with a shift in pH. For
example, a polarized pH material such as ammonia is present that
evaporates and the reduction in the active material via evaporation
causes a pH shift driving the color change or shift.
[0039] Another method of achieving a color shift in accordance with
the present invention is applying the formulation of the present
invention having the shift change material and then applying a
second material that causes the color to permanently shift. This
reaction is immediate with the application of the second
material.
[0040] The color shift material is selected based upon reaction
time. The formulation is such that it could take anywhere from 10
minutes to up to one hour (or longer). A shorter time is more
desirable, such as 10 to 15 minutes and then the color shifts.
There is not a need for the shift to be complete by the time
painting starts but rather just for a reasonable time so the user
is satisfied that the job is complete.
[0041] Method
[0042] The present invention sets forth a method of using the film
forming formulation in combination with a tape to mask areas on
textured surfaces. The method of the present invention generally
comprises applying tape to the area or surface to be masked
(typically with finger pressure especially at the tape edges) and
then applying the film forming formulation at the intersection of
the tape and surface referred to herein as a tape and surface
junction. The application of the film forming formulation results
in a strong, clear and anti-glare film to be subsequently painted.
The film forming formulation is preferably applied to the tape and
surface junction in a width of about 3/4 to one inch with brush
strokes to sweep the material towards the tape for maximum
desirable results. The method further comprises applying the paint.
Note that paint is applied to the unmasked areas but brush strokes
may also paint a portion or portions of the tape. When paint
touches the tape and surface junction, the film created at the
first step shields any bleeding occurring under the masking tape.
The clear film created by the film forming formulation is scored at
the edges of the tape during the removal creating sharp paint lines
on textured surfaces.
[0043] Pressing of the tape into place along the surface without
the use of the film forming formulation of the present invention to
reduce the gap between the tape edges and the textured surface is
very difficult to do consistently. The film forming formulation
ensures that the film former protects the tape and surface junction
to create sharp paint lines.
[0044] Any tape including, but not limited to, traditional masking
tape or painting tape is suitable for use in conjunction with the
film forming formulation of the present invention. Although a
traditional masking tape or painting tape may be used in accordance
with the present invention, the film forming formulation of the
present invention is also suitable for use in conjunction with a
tape having been treated, preferably on the edges, with a
superabsorbent polymer. The superabsorbent polymer absorbs paint to
prevent paint bleeding. The superabsorbent polymer is capable of
absorbing and retaining water many times its dry weight. A tape
having such properties creates a barrier instantly on smooth
surfaces but also creates a barrier on textured surfaces when used
in conjunction with the film forming formulation of the present
invention. An example of such a tape is FROGTAPE.TM. painting tape,
commercially available from Shurtech Brands, LLC.
[0045] Applicator Device
[0046] As another aspect of the present invention, an applicator
device(s) is described for applying the film forming formulation.
The film forming formulation is preferably applied with a device
such as a brush, a pen with applicator such as a highlighter (with
or without a hard tip), a roll-on applicator, a squeezable tube or
bottle with foam applicator, or other device having the ability to
dispense the film forming formulation in a relatively uniform
manner.
[0047] In one aspect of the application, the applicator has a tip
having a surface for contacting the tape and the wall and for
pushing the film forming formulation into the depressions of a
textured surface. The engineered tip has a specified resilience
(stiffness and softness), and reasonable hand holding shape
(interface with the user) that provides comfortable use, effective
operation (deposit of material and pushing the tape down), and
efficiency (speed, material deposit, etc.).
[0048] The applicator for applying the film forming formulation of
the present invention has the following possible
configurations.
[0049] In one aspect of the present invention, the applicator is a
bottle or reservoir having a shape suitable for holding of the film
forming formulation for storage and use in application. It is
shaped to allow the bottle to operate inverted with the applicator
on the lower side to facilitate flow through the applicator head.
Other optional features of the applicator of the present invention
include, but are not limited to, angled head, flow controlled
depending upon the material of the applicator interface (such as
brush, sponge, felt, etc.), operating valve (on/off valve) actuated
by an operating lever either hand actuated or press activated (to
the surface) in possible conjunction with orifices of any type for
restriction or control of the flow, and sealing cap. Examples of
applicator interfaces include, but are not limited to, a brush,
pen, sponge, felt, and roller.
[0050] Features of a suitable brush include, but are not limited
to, bristle stiffness and length to allow pressure to press the
tape to the surface but not to damage the film during the formation
time. The brush is made of synthetic or natural materials. In a
preferred aspect of the present invention, the brush is comprised
of a synthetic polymer material, treated natural materials, or
other materials. Examples of suitable materials include, but are
not limited to, nylon, polyester, or a combination thereof.
Polyesters include, but are not limited to, polyethylene
terephthalate (PET) and polybutylene terephthalate (PBT).
[0051] With regard to the brush configuration, the brush is
preferably circular or semi-circular with one or more rows of
bristles. The diameter (cross applicator distance) is to allow for
effective coverage of the tape to wall surface area, efficiency by
reduced material or controlled material application, and ease of
use.
[0052] Features of a suitable sponge include, but are not limited
to, sufficient stiffness to press the tape into place but with
porosity to allow flow of the formulation through the sponge to the
surface. The sponge preferably is engineered to reduce undesired
foaming of the formulation.
[0053] Features of a suitable felt include, but are not limited to,
a flat shape (such as rounded or squared) of varying size with
coverage area sufficient to handle the tape and wall junction.
[0054] Features of a suitable roller include, but are not limited
to, a selected shape, size, and material suitable for the
application. A softer roller is preferred to allow for flex and
distortion at surface contact along with shape (such as a ball or
roller, etc.) that covers the surface in a sufficient width and
contact area to allow for single or few strokes.
[0055] Features of a suitable applicator, include but are not
limited to, an applicator that is flow controlled over the surface
of steel, aluminum, or other metallic applicator and that is shaped
to allow the application of the liquid to the surface. A metal
applicator tip is desirable for tape materials that are flexible or
require pressing onto the surface. The metal applicator can be
ported to facilitate flow to surface. Similar to a metal
applicator, a plastic applicator allows for more complex shapes or
porting.
[0056] An applicator of the present invention has valve and flow
control attributes. An applicator of the present invention
preferably has the following flow control attributes alone or in
combination: operating valve, orifice, applicator attachment,
squeezable bottle or reservoir. The applicator device 100 of the
present invention optionally comprises a siphon tube (not shown). A
siphon tube fits into the flow orifice (shown in FIG. 3) allowing
pressure to be exerted on the reservoir to allow pumping when the
applicator is at the most top vertical position. The siphon tube
allows use of the applicator in an inverted or overhead position,
applicator attachment, squeezable bottle or container.
[0057] An example of a main or primary operating valve is a plastic
push rod that operates in the cap or a rotating type valve. The
push rod type valve is operable by pressing of a lever that is
protruding from the valve assembly within the area of the
applicator (i.e. brush bristles). The rotating type valve rotates
to control function of flow either through the siphon tube in the
supply reservoir or through an alternate feed through the
applicator head location. This allows for feeding in vertical or
inverted positions for overhead, base board or wall positions as
desired. The liquid formulation flows when the valve is operated
from the bottle to the wall or other surface.
[0058] There is a spectrum of potential commercially available
orifices or molded in configuration orifices for use in the
applicator to control the flow of the formulation. For example, the
material of the orifice can be as low complexity as a plastic sheet
with holes punched in it to control the flow. In the case of a
molded in orifice, a precision pin or tooling is optionally used
during the manufacturing or molding process to ensure size and
placement of the orifice in the applicator device for control and
placement of flow from the reservoir through the applicator head to
the wall or other surface.
[0059] A flow sponge is an option for use as material inside of the
lid of the applicator top. The sponge is pushed into the lid where
the applicator is installed, then screwed on or otherwise attached
to the bottle. With the tight fit of the flow sponge to the inside
of the lid, the maximum flow through the applicator head and/or
valve (for shutting off and turning on flow) is controlled by the
flow sponge. A flow sponge is a sponge, typically comprised of
synthetic material that does not absorb material within its
material. The flow sponge is an almost flexible plastic structure
with a defined porosity that controls the flow of liquid through
it, as to impart the control of flow.
[0060] The bottle is preferably made of plastic in a firm, but
squeezable structure. This allows for firm gripping but also allows
added material to flow with a quick squeeze. The bottle preferably
has a large enough opening to allow for insertion of a paint brush
to allow for dipping inside and use of the brush in certain
instances (see below--ceiling approach). For example, if the
material were to be used on a ceiling, then the larger opening
would be utilized. A user potentially dips a paint brush, felt
brush, or sponge applicator brush into the liquid formulation and
then applies a coat to the ceiling.
[0061] Among other features of an applicator for use with the
formulation of the present invention are the opening of the bottle
being angled at 45.degree. or other suitable angle for attachment
of the applicator head, a bottle having a shape and size to allow
for easy, comfortable gripping in multiple orientations and an
optionally textured bottle to aid in gripping, an angled bottle
neck for use when the bottle is upside-down.
[0062] The applicator is engineered to address usage rate versus
surface character.
[0063] Coverage Profile Examples
TABLE-US-00001 Example Surface Texture Surface Light Medium Heavy
Comments Knock-Down Single-Lite Medium to Probable Frequency and
surface Coat Heavy Coat Second Coat height variations are the
primary influence of material usage. Orange Peel Single-Lite Single
Light Potential The amount and viscosity Coat to Medium Second Coat
of the material applied Coat includes the surface character and
subsequent material usage. Hawk & Trowel Single-Lite Single
Light Medium Amount of material used Coat to Medium Coat and
surface height Coat variations influence the material usage.
Pop-Corn Single-Light Single Lite Medium to The amount and
viscosity Coat to Medium Heavy Coat of the material applied Coat
includes the surface character and subsequent material usage.
Stucco Single-Lite Single Light Potential Frequency and surface
Coat to Medium Second Coat height variations are the Coat primary
influence of material usage.
[0064] There are other surfaces fabricated in slightly different
ways. The consideration is the three dimensional profile requiring
sealing, frequency of these profiles, and the individual's
technique. All surfaces have the same or similar characteristics
that can be discussed in the same manner as above for relevance for
approach, material usage, and other factors. The aspect of material
usage is in the complete coverage and film's integrity. It is a
robust material not requiring precision, training, or difficult
approach. Just the consistency of a good application with
sufficient material applied.
[0065] On conventional surfaces, typically called medium knock-down
or orange peal, there is an application rate of about 1 oz. per 10
yards along edge of tape surface. It is more or less, depending
upon the surface character and the manner in which the formulation
is applied such as evenly, with sufficient coverage. On lighter
surfaces, there is less material used. On severe surfaces, where
the surface has greater level and frequency of irregularity, the
consumption potentially increases by approximately 60% in using it
on a second coat.
[0066] Referring to the figures, FIG. 1 is an exploded perspective
view of an applicator device particularly suitable for use with the
film forming formulation on textured surfaces and in accordance
with aspects of the present invention. Applicator device 100, shown
in FIG. 1, comprises a protective cap 110, applicator head 120, and
bottle or supply reservoir 130.
[0067] Protective cap 110 serves numerous functions. Protective cap
110 keeps the brush 122 of applicator head 120 clean from
particulate matter prior, during, and after use. Protective cap 110
seals the applicator device 100 to prevent airflow in order to keep
the brush 122 from prematurely drying out when saturated with film
forming formulation. Additionally, protective cap 110 protects the
applicator device 100 from physical damage. A feature of the
protective cap 110 is a rim 112 that forms a seal with the
applicator head 120 of the applicator device 100 at the protective
cap seal edge 126 (shown in FIG. 6). Preferably the protective cap
110 has a height of from about 28 mm to 55 mm and a width of from
about 19 mm to 29 mm.
[0068] Also shown in FIG. 1 is supply reservoir 130. A primary
function of supply reservoir 130 is to hold a film forming solution
in accordance with aspects of the present invention. Among other
purposes and functions of supply reservoir 130 are flow control and
ease of handling and use. With regard to flow control, supply
reservoir 130 facilitates flow control of film forming solution by
providing wall stiffness and wall shape. Wall stiffness is
controlled primarily by selection of wall material, wall density,
and wall thickness. Supply reservoir 130 is comprised of a
polymeric material that is deformable upon pressure, initiates flow
but also is of sufficient stiffness to prevent collapsing or
excessive compression. Examples of suitable polymeric materials for
supply reservoir 130 include, but are not limited to, polyethylene
(high density and low density), polyethylene terephthalate,
polybutylene terphthalate, and other polymers. Wall shape is an
important feature of supply reservoir 130. The rectangular,
flat-like wall shape of supply reservoir 130 allows for ease of
holding and ease of squeezing yet provides control of the film
forming solution. With regard to handling and use, applicator
device 100 is suitable for use over extensive periods of time.
Supply reservoir 130 is ergonomically designed. The shape resembles
that of a tool versus a typical bottle.
[0069] FIG. 2 is a cross-sectional side view of the applicator
device 100 of the present invention in accordance with aspects of
the present invention. FIG. 2 illustrates locations of
cross-sectional views 3-3 and 4-4 illustrated in FIGS. 3 and 4,
respectively. FIG. 3 is a horizontal cross-sectional view of the
applicator head 120 of the applicator device 100 of FIG. 1. Flow
orifice 310 of applicator head 120 is shown in FIG. 3. FIG. 4 is a
horizontal cross-sectional view in the direction of the bottom of
supply reservoir 130 of applicator device 100 of FIG. 1.
[0070] The applicator device 100 of the present invention
optionally comprises a siphon tube (not shown). A siphon tube fits
into the flow orifice 310 allowing pressure to be exerted on the
supply reservoir to allow pumping when the applicator is at the
most top vertical position. The siphon tube allows use of the
applicator in an inverted or overhead position.
[0071] FIG. 5 is a vertical cross-sectional view of the applicator
head 120 (without bristles inserted) in accordance with aspects of
the present invention. FIG. 5 illustrates brush retainer 128 that
forms a tube and brush holder base 129. Brush retainer 128 holds
brush 122 comprised of bristles in vertical alignment. Brush holder
base 129 supports brush 122. Brush retainer 128 is preferably
molded of a polymeric material.
[0072] FIG. 6 is a vertical cross-sectional view of applicator head
120 (with bristles inserted) in accordance with aspects of the
present invention. Referring to FIG. 6, the bristles of the brush
122 are aligned and are molded or glued at room temperature to form
the bristle retainer 124. Examples of suitable epoxy adhesives
include, but are not limited to, polyurethane (one part or two,
moisture cured polyurethane/urethane or UV cured), reactive
(polyester, polyols, acrylic resins), and polyvinyl acetate
(PVA).
[0073] Examples of suitable hot melts include, but are not limited
to, ethylene vinyl acetate (EVA) and other thermoplastics. In one
aspect of the present invention, depending upon the manufacturing
process, an adhesive bath is provided such that the bristles are
fixed or held and then dipped into the bath. The bristles absorb
the adhesive and then cure. The bath, for example, is in a
stainless steel or release coated container.
[0074] The bristles of brush 122 are also aligned with a pin (not
shown). The pin is inserted in a hole in bristle retainer 124. The
pin ensures that there is a hole through the bristle retainer 124
in direct alignment with flow orifice 125. The flow orifice 125 is
molded into or subsequently drilled in the bristle retainer 124 for
precision and control. Thus, flow orifice 125 is in the bristle
retainer 124 or in the brush holder base 129 or part of adaptor 127
depending upon the size and method of manufacture. The flow orifice
125 has a typical size in a range of from about 0.5 mm to 2.5 mm.
The pin holds the bristles of brush 122 in alignment and out of the
brush reservoir 123. The brush reservoir 123 is an open cavity
formed to allow accumulation of film forming solution for flow to
the tip of the brush 122. The brush reservoir 123 aids in even and
consistent flow throughout the brush 122.
[0075] For ease of assembly, the assembled brush (bristles glued or
molded into the bristle retainer 124) is inserted into the brush
retainer 128 on adaptor 127. The outside diameter of bristle
retainer 124 fits into the inner diameter of adaptor 127. Bristle
retainer 124 is arranged on brush holder base 129 which is a flat
area.
[0076] In an alternate method of manufacture, a one shot molded
assembly process is potentially used to form the brush.
[0077] As shown in FIG. 6, the applicator head 120 comprises a
brush 122 comprised of bristles, brush reservoir 123, bristle
retainer 124, brush retainer 128, flow orifice 125, protective cap
seal edge 126, and adaptor 127. Adaptor 127 is made to fit a given
supply reservoir such as a standard 24-410 (SPI-Standard neck).
[0078] With regard to the brush bristles, a bristle has a diameter
in a range of about 0.05 to 0.125 mm. The bristles are of a
sufficient count to fill the brush retainer 128 depending upon the
overall diameter of the brush assembly. The bristles of the brush
122 are comprised of synthetic polymer materials, treated natural
materials, or other types of materials. Examples of suitable
polymer and other materials include, but are not limited to, nylon,
polybutylene terephthalate (PBT), polyethylene, polypropylene,
polystyrene, carbon fiber, polyvinyl chloride (PVC), polyether
ether ketone (PEEK), polyesters such as polyethylene terephthalate
(PET), and a combination thereof. The diameter and material of the
bristles are selected to allow a flow rate along the surface and
between the bristles to where flow predominantly is from the tip of
the brush and not the sides of the brush. This is engineered or
controlled to the balance of viscosity of the film forming
solution, size of the flow orifice, of the brush reservoir, the
diameter and material of the bristles.
[0079] FIG. 7A is a perspective view of the applicator device 200
having contoured bristles 210 in accordance with aspects of the
present invention. FIG. 7B is side profile view of the applicator
head 200 of FIG. 7A. As illustrated in FIG. 7B, the brush diameter
is in a range of about 0.4 inches to 1.3 inches. The brush retainer
128 has an outer diameter in a range of about 0.25 inches to 1.20
inches. The brush height above the brush retainer 128 is in a range
of about 0.5 inches to 1.1 inches. The applicator head has an
overall height of about 1.5 inches to 2.25 inches. The brush
retainer 128 height is in a range of about 0.4 inches to 1.1
inches.
EXAMPLES
[0080] The following film forming formulations in Table 1 were
prepared and tested.
TABLE-US-00002 TABLE 1 Raw Formula Formula Formula Formula Formula
Formula Materials: 1 2 3 4 5 6 Rhoplex P-376 300 297.5 194 199.3 0
300 (grams) Acronal 0 0 0 0 60 0 S 504 na (grams) Acronal S 728 0 0
0 0 40 0 (grams) Ace Matt 0 1.7 1 0 0 0 TS 100 (grams) Ace Matt 0 0
0 2 2 1.3 OK 412 (grams) Aerodisp 7520 0 0 0 0 0 2.2 (grams) Drew
Plus 0 0 0 0 0 0.25 Y-250 (grams) Drew Plus 0 0 0 0 0 0.15 L 140
(grams) Water (grams) 0 0 8 0 0 20 (This amount was preblended*
with the Borchi Gel in a 10 to 1 ratio) Borchi Gel 0 0 0 0 0 0.2 L
75N (grams) Water (grams) 0 0 0 0 0 0.25 (This amount was
preblended* with the Acrysol in a 1 to 1 ratio) Acrysol 0 0 0 0 0
0.25 ASE 95 (grams) Proxel GXL (grams) 0 0 0 0 0 0.25 Viscosity-
320 cps 224 cps 240 cps 352 cps 260 cps 2,000 cps Brookfield
(spindle (spindle (spindle (spindle (spindle (spindle #4 at 50 RVT
#2 at 50 #2 at 50 #2 at 50 #2 at 50 #2 at 50 rpm and room rpm and
rpm and rpm and rpm and rpm and temp. room room room room room 73.4
.+-. 3.6 .degree.F) temp. temp. temp. temp. temp. 73.4 .+-. 73.4
.+-. 73.4 .+-. 73.4 .+-. 73.4 .+-. 3.6.degree. F.) 3.6.degree. F.)
3.6.degree. F.) 3.6.degree. F.) 3.6.degree. F.) Appearance Glossy
Semi- Semi- Semi- Semi- Semi-glossy glossy glossy glossy glossy
*Pre-blending the thickener with water eliminated shocking of the
latex during compounding
[0081] The following raw materials were used as binders:
[0082] RHOPLEX P-376 is a styrene acrylic emulsion commercially
available from Dow Chemical Company. (Properties: ionic nature:
anionic; solids %: 50; pH: 9.4; viscosity (cps): 200; glass
transition temperature, Tg: +19.degree. C.; density at 25.degree.
C. (lb/US gallon): 8.7; specific gravity (g/ml): 1.04)
[0083] ACRONAL S 504 na is an aqueous dispersion of an n-butyl
acrylate-acrylonitrile-styrene copolymer commercially available
from BASF (Properties: pH: 7-8, Tg: +4.degree. C., viscosity: 300
cps)
[0084] ACRONAL S 728 is an aqueous dispersion of a styrene/n-butyl
acrylate copolymer commercially available from BASF (Properties:
pH: 7, Tg: +23.degree. C., viscosity: 200 cps)
[0085] The following raw materials were used as matting agents:
[0086] ACEMATT OK 412 is a precipitated silica all-purpose matting
agent commercially available from Evonik Industries. It is an
organically surface treated, easily dispersible matting agent with
outstanding suspension behavior, especially suitable for use in
clear coats.
[0087] ACEMATT TS 100 is a thermal, untreated silica with excellent
matting efficiency and transparency.
COMPARATIVE EXAMPLE
[0088] The tape sealant of U.S. Patent Pub. No. 2009/0119175A1
("tape sealant") was tested as compared to the following film
forming formulation(s) (FFF) of the present invention, including
Formulation 1, Formulation 4 and Formulation 5. The following
observations were made between the Formulations versus tape
sealant:
[0089] Dry time (FFF v. Tape Sealant): about 10 to 15 minutes for
the film forming formulation versus about 30 to 60 minutes for tape
seal
[0090] Viscosity: Ranging from 400-600cps (measured at a
temperature 73.4.+-.3.6.degree. F. using a Brookfield RVT
viscometer with spindle #2 at 50 rpm) of FFF versus 2700 cps
(measured at a temperature 73.4.+-.3.6.degree. F. using a
Brookfield RVT viscometer with spindle #4 at 50 rpm) of the tape
sealant
[0091] Flow referred to two different areas with regard to
flow:
[0092] Application Flow: with the lower viscosity the material
flows easily from the bottle, can be controlled easier (rate, on,
off, etc.).
[0093] Surface Flow: on the surface (tape and wall) the material
flows to an even coat vs. blotchy or uneven coverage. This improves
performance, usage, smoothness of final surface, etc.
[0094] Improved Finish: The film forming formulation of the present
invention has an improved finish for two reasons--improved matte
appearance (low light reflectance) and surface flow rate (no
bumps/unevenness).
[0095] Coverage: With the improved flow there were no gaps or holes
in the coverage. This prevented leaks resulting in paint bleed.
[0096] Reduced Material Usage: with the improved flow rate and
control, get more coverage out of a given amount of solution.
[0097] Fast Form Film (vs. shrinking filler): The material formed a
film over the tape to wall interface v. filling a gap with the
material. The FFF did not have appreciable shrinkage (as with most
slow dry/cure materials) so there was no leakage due to gaps caused
by shrinkage.
[0098] The film forming formulation(s) of the present invention
behaved as a film v. a filler. This provided several advantages set
forth as follows:
[0099] Improved seal: the bridging of the interface versus filling
the holes allowed the material to a function over a wider range of
gaps/textures.
[0100] Clean Fracture: The FFF material cleanly separated at the
tape/wall interface giving a consistent, ridge free line versus
filler type solutions.
[0101] Engineered Invisibility: In FFF, the light reflectance and
transparency was engineered into the film to yield an invisible
layer in order to avoid any clean up, touch up, or visual
issues.
TABLE-US-00003 TABLE Application/Solution Analysis Film Forming
Formulations of Present Invention Tape Sealant Caulk Application
Used the simple Used a paint Carefully Method applicator to brush
to apply applied a caulk put the film the solution to bead to the
former on the the tape/wall tape/wall joint, tape/wall interface
point. wiping off interface point excess. with thorough consistent
coverage. Application Considered Considered Considered Ease very
easy and easy but does medium rapid. require careful difficulty and
"painting" of better done by a the thick liquid skilled to a smooth
craftsman to surface. prevent leaks. Paint step None Material was
Caulk left a filler, so "line" of caulk remnant that both was
material left a visible and step or edge potentially after tape
attracted dirt. removal. Finish Issues None Shiny finish Bead of
caulk potentially attracted dirt showed on flat over period of
paint surfaces. time. Application Rapid Took up to an Was ready to
Speed application and hour to dry. paint within 15 rapid dry (10
minutes, but minutes). Was remained ready to paint sticky.
immediately. Usage Rate About 1 oz./10 About 1 oz./10 Usually a
tube Yd. of single Yd. along edge of caulk can edge tape of tape
but handle the job. treatment. heavy texture Heavy texture can be
2.0 oz./ could require 10 Yd. along 1.5 oz./10 Yd. edge of
tape.
[0102] FTIR scan comparison: FTIR scans indicated that FFF had more
styrene (aromatic content) as compared to tape sealant which had
less.
[0103] It will therefore be readily understood by those persons
skilled in the art that the present invention is susceptible of
broad utility and application. Many embodiments and adaptations of
the present invention other than those herein described, as well as
many variations, modifications and equivalent arrangements, will be
apparent from or reasonably suggested by the present invention and
the foregoing description thereof, without departing from the
substance or scope of the present invention. Accordingly, while the
present invention has been described herein in detail in relation
to its preferred embodiment, it is to be understood that this
disclosure is only illustrative and exemplary of the present
invention and is made merely for purposes of providing a full and
enabling disclosure of the invention. The foregoing disclosure is
not intended or to be construed to limit the present invention or
otherwise to exclude any such other embodiments, adaptations,
variations, modifications and equivalent arrangements.
* * * * *