U.S. patent application number 14/077099 was filed with the patent office on 2014-03-13 for pigmented spray texture material compositions, systems, and methods.
This patent application is currently assigned to Homax Products, Inc.. The applicant listed for this patent is Homax Products, Inc.. Invention is credited to Randal W. Hanson, John Kordosh.
Application Number | 20140072714 14/077099 |
Document ID | / |
Family ID | 49517992 |
Filed Date | 2014-03-13 |
United States Patent
Application |
20140072714 |
Kind Code |
A1 |
Kordosh; John ; et
al. |
March 13, 2014 |
PIGMENTED SPRAY TEXTURE MATERIAL COMPOSITIONS, SYSTEMS, AND
METHODS
Abstract
A method of applying a coating material to a target surface
defined by a wall comprises providing a pigmented texture material,
combining the texture material with a propellant in a main chamber,
operating a valve assembly to allow the propellant material to
force the texture material out of the main chamber in discrete
droplets, and arranging the container assembly such that the
discrete droplets are deposited on the target surface. The binder
material, filler material, and pigment material are combined such
that the discrete droplets define a physical structure that is
visibly distinct from the target surface, where the binder material
is provided in an amount sufficient to maintain the physical
structure of and to bind the discrete droplets to the target
surface. The discrete droplets also define a texture color
associated with a color of the pigment material. When dry, the
discrete droplets are sufficiently durable to function as part of a
final wall surface.
Inventors: |
Kordosh; John; (Chula Vista,
CA) ; Hanson; Randal W.; (Bellingham, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Homax Products, Inc. |
Bellingham |
WA |
US |
|
|
Assignee: |
Homax Products, Inc.
Bellingham
WA
|
Family ID: |
49517992 |
Appl. No.: |
14/077099 |
Filed: |
November 11, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13312893 |
Dec 6, 2011 |
8580349 |
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14077099 |
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12080638 |
Apr 3, 2008 |
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13312893 |
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60922119 |
Apr 5, 2007 |
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Current U.S.
Class: |
427/261 ;
239/337; 427/256 |
Current CPC
Class: |
B65D 83/752 20130101;
E04F 13/00 20130101; B05B 1/3073 20130101 |
Class at
Publication: |
427/261 ;
239/337; 427/256 |
International
Class: |
B65D 83/14 20060101
B65D083/14 |
Claims
1. A method of applying a coating material to a target surface
defined by a wall, comprising the steps of: providing a pigmented
texture material comprising 31-51% by weight of filler material
comprising pigment material, binder material, and carrier material;
combining the pigmented texture material and a propellant material
within a main chamber defined by a container assembly and a valve
assembly; and operating the valve assembly to allow the propellant
material to force the pigmented texture material out of the main
chamber, where the carrier material is provided in an amount
sufficient to cause the pigmented texture material forced out of
the main chamber to form discrete droplets; arranging the container
assembly such that the discrete droplets of pigmented texture
material are deposited on the target surface, where the binder
material, filler material, and pigment material are combined such
that the discrete droplets define a physical structure that is
visibly distinct from the target surface, where the binder material
is provided in an amount sufficient to maintain the physical
structure of and to bind the discrete droplets to the target
surface, define a texture color associated with a color of the
pigment material, and when dry, are sufficiently durable to
function as part of a final wall surface.
2. A method as recited in claim 1, in which the step of providing
the texture material further comprises the step of adding at least
one of biocides, dispersants, and defoamers.
3. A method as recited in claim 1, in which: the step of providing
the container assembly comprises the step of forming at least a
portion of the container assembly of tin-plated steel; and the step
of providing the texture material base further comprises the step
of adding at least one anti-corrosion material.
4. A method as recited in claim 1, in which: the step of providing
the container assembly comprises the step of forming at least a
portion of the container assembly of tin-plated steel; and the step
of providing the texture material further comprises the step of
adding first and second anti-corrosion materials to the texture
material to form a thin protective film on surfaces formed by the
tin-plated steel of the container assembly.
5. A method of forming a final wall surface defined by a wall,
comprising the steps of: providing a paint material, where the
paint material is associated with a first color; applying the paint
material to a target surface defined by the wall to form a paint
coat; providing a pigmented texture material comprising 31-51% by
weight of filler material comprising pigment material, binder
material, and carrier material; combining the pigmented texture
material and a propellant material within a main chamber defined by
a container assembly and a valve assembly; and operating the valve
assembly to allow the propellant material to force the pigmented
texture material out of the main chamber, where the carrier
material is provided in an amount sufficient to cause the pigmented
texture material forced out of the main chamber to form discrete
droplets; arranging the container assembly such that the discrete
droplets of pigmented texture material are deposited on the target
surface, where the binder material, filler material, and pigment
material are combined such that the discrete droplets define a
physical structure that is visibly distinct from the target
surface, where the binder material is provided in an amount
sufficient to maintain the physical structure of and to bind the
discrete droplets to the wall, define a texture color associated
with a color of the pigment material, and when dry, are
sufficiently durable to function as part of a final wall
surface.
6. A method as recited in claim 5, further, comprising the steps
of: providing a primer material; applying the primer material to
the target surface to form a primer coat, where the paint coat is
formed on top of the primer coat.
7. A method as recited in claim 5, in which the step of providing
the texture material further comprises the step of adding at least
one of biocides, dispersants, and defoamers.
8. A method as recited in claim 5, in which: the step of providing
the container assembly comprises the step of forming at least a
portion of the container assembly of tin-plated steel; and the step
of providing the texture material further comprises the step of
adding at least one anti-corrosion material.
9. A method as recited in claim 5, in which: the step of providing
the container assembly comprises the step of forming at least a
portion of the container assembly of tin-plated steel; and the step
of providing the texture material further comprises the step of
adding first and second anti-corrosion materials to the texture
material to form a thin protective film on surfaces formed by the
tin-plated steel of the container assembly.
10. A coating system for forming a decorative coating on a target
surface, comprising the steps of: a container assembly; a valve
assembly mounted onto the container assembly to define a main
chamber; pigmented texture material comprising 31-51% by weight of
filler material comprising pigment material, binder material, and
carrier material; and propellant material; wherein the pigmented
texture material and the propellant material are arranged within
the main chamber; and the valve assembly is operated to allow the
propellant material to force the pigmented texture material out of
the main chamber, where the carrier material is provided in an
amount sufficient to cause the pigmented texture material forced
out of the main chamber to form discrete droplets; the discrete
droplets of pigmented texture material are deposited on the target
surface, where the binder material, filler material, and pigment
material are combined such that the discrete droplets define a
physical structure that is visibly distinct from the target
surface, where the binder material is provided in an amount
sufficient to maintain the physical structure of and to bind the
discrete droplets to the target surface, define a texture color
associated with a color of the pigment material, and when dry, are
sufficiently durable to function as part of a final wall
surface.
11. A coating system as recited in claim 10, in which the texture
material further comprises at least one of biocides, dispersants,
and defoamers.
12. A coating system as recited in claim 10, in which: the
container assembly comprises tin-plated steel; and the texture
material further comprises at least one anti-corrosion
material.
13. A coating system as recited in claim 10, in which: the
container assembly comprises tin-plated steel; and the texture
material further comprises first and second anti-corrosion
materials sufficient to form a thin protective film on surfaces
formed by the tin-plated steel of the container assembly.
Description
RELATED APPLICATIONS
[0001] This application (Attorney's Ref. No. P217678) is a
continuation of U.S. patent application Ser. No. 13/312,893 filed
Dec. 6, 2011, currently pending.
[0002] U.S. patent application Ser. No. 13/312,893 is a
continuation of U.S. patent application Ser. No. 12/080,638 filed
Apr. 3, 2008, now abandoned.
[0003] U.S. patent application Ser. No. 12/080,638 claims benefit
of U.S. Provisional Patent Application Ser. No. 60/922,119 filed
Apr. 5, 2007.
[0004] The contents of all related applications listed above are
incorporated herein by reference.
TECHNICAL FIELD
[0005] The present invention relates to coating materials and, more
particularly, to coating materials adapted to provide a desirable
aesthetic look to a surface.
BACKGROUND
[0006] The surfaces of drywall materials defining wall and ceiling
surfaces are commonly coated with texture materials. Texture
materials are coatings that are deposited in discrete drops that
dry to form a bumpy, irregular texture on the destination surface.
Texture materials are commonly applied using a hopper gun connected
to a source of pressurized air. However, when only a small area is
to be coated or an existing textured surface is repaired, texture
materials are typically applied using an aerosol dispensing
system.
[0007] An aerosol dispensing system for dispensing texture material
typically comprises a container assembly, a valve assembly, and an
outlet assembly. The container assembly contains the texture
material and a propellant material. The propellant material
pressurizes the texture material within the container assembly. The
valve assembly is mounted to the container assembly in a normally
closed configuration but can be placed in an open configuration to
define a dispensing path along which the pressurized texture
material is forced out of the container assembly by the propellant
material. Displacement of the outlet assembly places the valve
assembly in the open configuration. The outlet assembly defines a
portion of the outlet path and is configured such that the texture
material is applied to the destination surface in an applied
texture pattern.
[0008] The texture material dispensed by an aerosol dispensing
system may employ a solvent base, a water base, or a base
containing a combination of water and water soluble solvents. A
solvent based texture material dries quickly but can be malodorous
and may require the use of complementary solvent cleaners for clean
up. A water based texture material is typically not malodorous and
can be cleaned using water but can take significantly longer to
dry. A water/solvent based texture material can be cleaned using
water, is typically not unacceptably malodorous, and has a dry time
somewhere between solvent based and water based texture
materials.
[0009] The propellant used by aerosol dispensing systems for
texture materials may simply be a compressed inert gas such as air
or nitrogen. More typically, the propellant used by aerosol
dispensing systems is a bi-phase propellant material, including
mixtures of volatile hydrocarbons such as propane, n-butane,
isobutane, dimethyl ether (DME), and methylethyl ether.
[0010] At room temperature, bi-phase propellant materials typically
exist in both liquid and vapor states within the container
assembly. Prior to use, the vapor portion of the bi-phase
propellant material is pressurized to an equilibrium pressure. When
the valve assembly is placed in its open configuration, the vapor
portion of the bi-phase propellant material forces the texture
material out of the container assembly along the dispensing
path.
[0011] When the valve assembly returns to its closed position, part
of the liquid portion of the bi-phase propellant material changes
to the vapor state because of the drop in pressure within the
container assembly. The vapor portion of the propellant material
returns the pressure within the container assembly to the
equilibrium value in preparation for the next time texture material
is to be dispensed from the aerosol dispensing system.
[0012] The container assembly typically comprises a metal tube
structure formed by a rectangular metal sheet that is rolled and
joined at two overlapping edges to form a seam. A bottom cap and
end cap are welded or crimped onto the tube structure. The valve
assembly and the outlet assembly are typically supported by the end
cap.
[0013] Aerosol container assemblies are typically made of either
tin-plated steel or aluminum. Aluminum container assemblies are
typically used for water based or water/solvent based texture
materials because the water in the formulation promotes corrosion
and aluminum is less susceptible to corrosion. However, the costs
and availability of aluminum and tin-plated steel aerosol container
assemblies may differ.
[0014] To finish a wall using texture materials, a primer coat of
primer is typically applied to the bare surface of a wall
structure. The purpose of the primer coat is to form a layer that
bonds firmly to the bare wall surface and to which any subsequent
layer of coating material securely bonds. The primer coat is
typically pigmented in a neutral cover that can easily be hidden by
any subsequent layer of coating material.
[0015] If a texture pattern is desired, a coat of texture material
is then applied to the primer coat. As described above, the texture
material is formulated to form a texture coat in a desired
three-dimensional texture pattern that is aesthetically pleasing
and which also helps hides imperfections and structural components
of the wall structure. The texture material is primarily formulated
to be deposited onto the primer coat in the desired texture pattern
and such that the texture coat dries in the desired texture
pattern. The texture coat formed by conventional texture material
is not durable; the texture coat may easily be removed,
intentionally or inadvertently.
[0016] Accordingly, a finish coat of paint material is typically
applied over the texture coat. The finish coat is thin, even, and
highly durable and is also pigmented for aesthetic purposes. The
thin finish coat follows the contours of the texture pattern formed
by the texture coat, so the finished surface is both textured and
pigmented.
[0017] Once the base layer is formed, the process of forming a
durable, pigmented, textured finished surface thus requires the
application of at least two separate coats: a texture coat and a
finish coat.
[0018] The need exists for formulations of either water based or
water/solvent based texture materials that may be used to form a
texture pattern that is both pigmented and durable in a single
coat.
SUMMARY
[0019] A method of applying a coating material to a target surface
defined by a wall, comprising the following steps. A pigmented
texture material comprising 31-51% by weight of filler material
comprising pigment material, binder material, and carrier material
is provided. The pigmented texture material and a propellant
material are combined within a main chamber defined by a container
assembly and a valve assembly. The valve assembly is operated to
allow the propellant material to force the pigmented texture
material out of the main chamber. The carrier material is provided
in an amount sufficient to cause the pigmented texture material
forced out of the main chamber to form discrete droplets. The
container assembly is arranged such that the discrete droplets of
pigmented texture material are deposited on the target surface. The
binder material, filler material, and pigment material are combined
such that the discrete droplets define a physical structure that is
visibly distinct from the target surface, where the binder material
is provided in an amount sufficient to maintain the physical
structure of and to bind the discrete droplets to the target
surface. The discrete droplets also a texture color associated with
a color of the pigment material. When dry, the discrete droplets
are sufficiently durable to function as part of a final wall
surface.
[0020] The present invention may also be embodied as a method of
forming a final wall surface defined by a wall, comprising the
following steps. A paint material is provided, where the paint
material is associated with a first color. The paint material is
applied to a target surface defined by the wall to form a paint
coat. A pigmented texture material is provided, where the pigmented
texture material comprises 31-51% by weight of filler material
comprising pigment material, binder material, and carrier material.
The pigmented texture material and a propellant material are
combined within a main chamber defined by a container assembly and
a valve assembly. The valve assembly is operated to allow the
propellant material to force the pigmented texture material out of
the main chamber. The carrier material is provided in an amount
sufficient to cause the pigmented texture material forced out of
the main chamber to form discrete droplets. The container assembly
is arranged such that the discrete droplets of pigmented texture
material are deposited on the target surface. The binder material,
filler material, and pigment material are combined such that the
discrete droplets define a physical structure that is visibly
distinct from the target surface, where the binder material is
provided in an amount sufficient to maintain the physical structure
of and to bind the discrete droplets to the wall. The discrete
droplets also define a texture color associated with a color of the
pigment material. When dry, the discrete droplets are sufficiently
durable to function as part of a final wall surface.
[0021] The present invention may also be embodied as a coating
system for forming a decorative coating on a target surface. The
coating system comprises a container assembly, a valve assembly
mounted onto the container assembly to define a main chamber,
pigmented texture material, and propellant material. The pigmented
texture material comprises 31-51% by weight of filler material
comprising pigment material, binder material, and carrier material.
The pigmented texture material and the propellant material are
arranged within the main chamber. The valve assembly is operated to
allow the propellant material to force the pigmented texture
material out of the main chamber. The carrier material is provided
in an amount sufficient to cause the pigmented texture material
forced out of the main chamber to form discrete droplets. The
discrete droplets of pigmented texture material are deposited on
the target surface, where the binder material, filler material, and
pigment material are combined such that the discrete droplets
define a physical structure that is visibly distinct from the
target surface, where the binder material is provided in an amount
sufficient to maintain the physical structure of and to bind the
discrete droplets to the target surface. The discrete droplets also
define a texture color associated with a color of the pigment
material. When dry, the discrete droplets are sufficiently durable
to function as part of a final wall surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a side elevation, cross-sectional view depicting a
first example aerosol dispensing system dispensing pigmented
texture material of the present invention onto a target
surface;
[0023] FIG. 2A is a side elevation view depicting the process of
using the example aerosol dispensing system of FIG. 1 to apply
pigmented texture material to form a pigmented texture pattern on a
first example destination wall surface;
[0024] FIG. 2B is a perspective view of the pigmented texture
pattern on the destination wall surface shown in FIG. 2A; and
[0025] FIG. 3 is a side elevation view depicting the process of
using the example aerosol dispensing system of FIG. 1 to apply
pigmented texture material to form a pigmented texture pattern on a
second example destination wall surface.
DETAILED DESCRIPTION
[0026] Referring initially to FIG. 1 of the drawing, depicted
therein is an aerosol dispensing system 20 constructed in
accordance with, and embodying, the principles of the present
invention. The aerosol dispensing system 20 comprises a container
assembly 22, a valve assembly 24, and an outlet assembly 26. The
container assembly 22 and valve assembly 24 define a main chamber
28.
[0027] The main chamber 28 contains a liquid material 30 and a
vapor material 32. The liquid material 30 comprises propellant
material in liquid form and a pigmented texture material. The vapor
material 32 comprises propellant material in vapor form. The
combination of the liquid material 30 and the vapor material 32 in
the container assembly 22 will be referred to as the contained
material 34.
[0028] When the valve assembly 24 is in a closed configuration, the
flow of fluid out of the main chamber 28 is substantially
prevented. However, the vapor material 32 pressurizes the liquid
material 30 within the main chamber 28 such that, when the valve
assembly 24 is in an open configuration, the vapor material 32
forces the liquid material 30 out of the main chamber 28.
[0029] As perhaps best shown in FIG. 1, the example container
assembly 22 comprises a main member 40, a bottom cap 42, and an end
cap 44 formed of tin-plated steel. The tin-plated steel used to
form the main member 40, bottom cap 42, and end cap 44 comprises a
thin sheet of steel coated on one side by an even thinner layer
(approximately 0.5 microns) of tin.
[0030] The main member 40 is a rectangular sheet that is rolled
into a cylinder and welded along a seam 50 to define first and
second end openings 52 and 54. The bottom cap 42 is a shaped
tin-plated steel member that is crimped onto the cylindrical main
member 40 to seal the first end opening 52. The end cap 44 is also
a shaped tin-plated steel member defining a mounting opening 56;
the end cap 44 is crimped onto the main member 40 such that fluid
may not flow through the second opening 54 between the end cap 44
and the main member 40. The main member 40, bottom cap 42, and end
cap 44 define an interior metal surface 58 of the container
assembly 22.
[0031] With the bottom cap 42 covering the first opening 52, the
end cap 44 covering the second opening 54, and the valve assembly
24 supported by the end cap 44, the aerosol dispensing system 20
defines the main chamber 28.
[0032] Alternatively, the container assembly 22 may be made of
aluminum, in which case the bottom cap portion and the end cap
portion may be integrally formed with the main member portion.
[0033] The example texture material base is generally formulated as
follows.
Example of Pigmented Texture Material
TABLE-US-00001 [0034] FIRST SECOND FIRST PREFERRED PREFERRED
COMPONENT EXAMPLE RANGE RANGE solvent/carrier 21.4% 16-31% 10-40%
resin/binder 36.2% 31-41% 26-46% fillers 41.8% 36-46% 31-51%
additives 0.6% 0.2-1.0% 0.0-3%
[0035] The solvent/carrier of the example formulation set forth in
the table above is water, but the solvent/carrier may be formed by
water in combination with water soluble solvents. The resin/binder
is or may be a conventional latex binder containing 55% solids.
[0036] The fillers may comprise any conventional pigments,
extenders, and thickeners. The example formulation set forth in the
table above uses a polymeric thickener such as Acusol 820 or its
equivalent. The polymeric thickener provides desirable viscosity
characteristics that allow the pigmented texture material to be
dispensed using an aerosol structure but still form desired
three-dimensional texture patterns as will be described elsewhere
herein. The example formulation comprises approximately 3.3% by
weight of the polymeric thickener. The polymeric thickener should
be within a first preferred range of substantially between 2% and
5% and in any event should be within a second preferred range of
substantially between 1% and 10%.
[0037] If used, the additives forming part of the formulation
described in the table set forth above typically comprise
conventional biocides, dispersants, and defoamers.
[0038] To the texture material base described above is added a
color pigment or combination of color pigments such that the
texture material base is a desired color. The color pigment
material or materials may be conventional, and conventional systems
for determining appropriate amounts of one or more individual color
pigment materials may be used or modified to determine the amounts
of individual color pigment materials necessary to obtain the
desired final color to the texture material base.
[0039] The addition of one or more color pigments to a paint
material base is common practice in the paint industry. At the
factory level, pigments are added to the paint material base to
obtain prepackaged, colored paints. The customer thus may select
from the limited number of colors provided by the manufacturer. In
addition, pigments are added to containers of paint material base
at the retail level to allow consumers to select from virtually an
unlimited number of colors.
[0040] The texture material base described above may also be
pigmented at the factory or at the retail level. Currently,
retailers typically have the facilities to add texture material to
non-pressurized containers of paint base, but do not typically have
the facilities to add pigment to aerosol containers of paint base.
Accordingly, while it is possible that the color pigment can be
added to the texture material base at the retail level, the color
pigment will more likely be added to the texture material base at
the factory level when the pigmented texture material is sold in an
aerosol form as described herein.
[0041] The exact amount of color pigment added to the texture
material base will be determined based on the particular color
desired. Typically, color pigment is added to the texture material
base described in the table above in a first acceptable range of
between approximately 0.5% and 1.0% by weight; however, the color
pigment may be added to the texture material base described in the
table above in a second acceptable range of between approximately
0.0% and 5.0% by weight.
[0042] The texture material base described in the table set forth
above, along with any color pigment included therein, is combined
in the container assembly 22 with the propellant material to obtain
the contained material 34. The preferred amount of propellant
material used to form the example dispensing system 20 is
approximately 15.4% of the texture material base by weight and is
preferably within a first preferred range of substantially between
12% and 18%% and is in any event preferably within a second
preferred range of substantially between 8% and 22%. The propellant
material is typically dimethyl ether (DME).
[0043] In the context of the example container assembly 22
comprising tin-plated steel components, the texture material base
may be formulated to have anti-corrosion properties. In this case,
the texture material base may further comprise first and second
anti-corrosion materials are included to promote passive corrosion
behavior of the metal interior surface 58 of the container assembly
22 in contact with the texture material base. Passive corrosion
behavior occurs when the interaction between a metal structure and
the environment forms a thin protective film on the surface of the
metal structure. Passive corrosion produces essentially no
corrosion of the metal structure and thus is very desirable.
[0044] In the example texture material base, the first
anti-corrosion material is Elfugin, which is an anionic, phosphate
ester. Elfugin is a proprietary product sold by Clariant Paper
Chemicals as an antistatic for application to paper products. In
the general example described above, approximately 1.00% (.+-.5%)
of the first anti-corrosion material is preferably used. The second
anti-corrosion material of the example texture material base is
sodium nitrite. In the general example described above,
approximately 0.100% (.+-.5%) or 0.250% (.+-.5%) of the first
anti-corrosion material is preferably used, depending upon the
nature of the remaining components of the texture material base and
propellant.
[0045] Generally speaking, the first anti-corrosion material should
be within a first preferred range of substantially between 0.5% and
2% and in any event should be within a second preferred range of
substantially between 0.1 and 5.0%. The second anti-corrosion
material should be within a first preferred range of substantially
between 0.05% and 1.0% and in any event should be within a second
preferred range of substantially between 0.025% and 2.0%. The
amount of water set forth in the foregoing table should be reduced
by the amount of the first and second anti-corrosion materials
used.
[0046] If the anti-corrosion materials are used, the texture
material base is preferably formulated and combined with propellant
material as follows. The first and second anti-corrosion materials
are initially dissolved in the water. The remaining materials are
then mixed with the water solution to obtain the texture material
base.
[0047] If the container assembly 22 is formed of tin-plated steel,
the bottom cap 42 is crimped onto the main member 40 to form a
container subassembly 22a. The valve assembly 24 is combined with
the end cap 44 to form a cap subassembly 22b. The texture material
base is placed within the container subassembly 22a. The cap
subassembly 22b is crimped onto the container subassembly 22a to
form the container assembly 22. The propellant material is then
introduced into the container assembly 22 through the valve
assembly 24. The outlet assembly 26 is then engaged with the valve
assembly to form the aerosol dispensing system 20.
[0048] With the foregoing general understanding of the present
invention, the details of several example formulations of the
texture material base and the construction and use of the example
aerosol dispensing system 20 will now be described in further
detail with reference to FIG. 1.
[0049] The example valve assembly 24 comprises a valve housing 60,
a valve seat 62, a valve member 64, and a valve spring 66. The end
cap 44 supports the valve housing 60 and the valve seat 62 adjacent
to the mounting opening 56. The valve housing 60 supports the valve
spring 66 such that the valve spring 66 biases the valve member 64
against the valve seat 62 in a normally closed position. An intake
tube 68 extends from the valve housing 60 to the end of the main
member 40 closed by the bottom cap 42.
[0050] The outlet assembly 26 comprises an actuator member 70, a
resilient member 72, and a clamp member 74. The actuator member 70
defines a stem portion 76 and a plurality of finger portions 78.
The stem portion 76 extends through the mounting opening 56 and
engages the valve member 64. The actuator member 70 supports the
resilient member 72 such that the resilient member 72 is held
within the finger portions 78. The clamp member 74 engages the
actuator member 70 such that displacement of the clamp member 74
relative to the actuator member 70 bends the finger portions 78
towards each other to deform the resilient member 72.
[0051] A dispensing path 80 extends between an inlet opening 82
defined by the intake tube 68 and an outlet opening 84 defined by
the resilient member 72. Fluid is prevented from flowing along the
dispensing path 80 when the valve assembly 24 is in the closed
configuration as defined above. Fluid may flow along the dispensing
path 80 when the valve assembly 24 is in the open configuration.
The spray pattern of liquid flowing out of the main chamber 28
through the outlet opening 84 may be varied by deforming the
resilient member 72 as described above.
[0052] More specifically, the valve spring 66 normally biases the
valve member 64 against the valve seat 62 to close the dispensing
path 80. When the actuator member 70 is displaced towards the
container assembly 22, the valve member 64 is displaced away from
the valve seat 62 against the force of the valve spring 66 to place
the valve assembly 24 in its open configuration. In this open
configuration, the example dispensing path 80 extends through a
first passageway 90 defined by the intake tube 68, a valve chamber
92 defined by the valve housing 60, a gap 94 between valve member
64 and the valve seat 62, a second passageway 96 defined by the
actuator member 70, and a third passageway 98 defined by the
resilient member 72.
[0053] Turning now to FIGS. 2A-2B of the drawing, depicted therein
is an example of use of the example dispensing system 20 described
above. The example dispensing system 20 is used to apply texture
material to a wall member 120 defining a target surface 122. Formed
on the target surface 122 is a primer coat 124 and a paint coat
126. In this example, the finished surface is what is referred to
as a smooth coat, and no texture material has been applied between
the primer coat 124 and the paint coat 126.
[0054] Initially, the dispensing system 20 is arranged such that
the outlet opening 84 faces the target surface 122. The actuator
member 70 is then displaced to place the valve assembly 24 in its
open configuration. The pressurized propellant material causes a
portion of the contained material 34 to be dispensed from the
container assembly 22 through the dispensing path 80.
[0055] Because of the formulation of the contained material 34 and
the geometry of the resilient member 72, the contained material
exits the container assembly 22 in a spray 130 comprising discrete
droplets 132. The droplets 132 are deposited onto the target
surface 122 to form a texture coating 134 in an applied texture
pattern. The texture coating 134 is initially wet but dries when
exposed to air.
[0056] By appropriately selecting the cross-sectional area of the
outlet opening 84, the applied texture pattern of the texture
coating 134 can be formed such that the pigmented texture material
is applied in a desired texture pattern. As shown by FIG. 2A, the
desired texture pattern formed by the texture coating 134 extends
away from the surface of the paint coat 126. As shown by FIG. 2B,
the example desired texture pattern formed by the texture coating
134 is of a different color (shown as white) from the color (shown
by cross-hatching) of the paint coat 126.
[0057] It may be possible to pigment the pigmented texture material
such that the texture coating 134 is the same color as the paint
coat 126. In this case, the color of the texture coating 134 will
be the same or almost the same as that of the paint coat 126, but
the texture coating 134 will still extend away from the paint coat
126.
[0058] Turning now to FIG. 3 of the drawing, depicted therein is a
second example of use of the example dispensing system 20 described
above. The example dispensing system 20 is used to apply texture
material to a wall member 220 defining a target surface 222. Formed
on the target surface 222 are a first primer coat 224a and a paint
coat 226. In this example, the finished surface is textured, and a
conventional coat 228 of texture material has been applied between
the primer coat 224a and the paint coat 226.
[0059] Ideally, a second primer coat 224 is formed after the
texture coat 228 has been formed; the example texture coat 228 is
thus between the first and second primer coats 224a and 224b, and
the paint coat 226 is formed on the second primer coat 224b. It
should be recognized that the principles of the present invention
may be implemented without one or more of the primer coats 224a and
224b, but the appearance and function of the resulting finish
surface may not be as desired.
[0060] Initially, the dispensing system 20 is arranged such that
the outlet opening 84 faces the target surface 222. The actuator
member 70 is then displaced to place the valve assembly 24 in its
open configuration. The pressurized propellant material causes a
portion of the contained material 34 to be dispensed from the
container assembly 22 through the dispensing path 80.
[0061] Because of the formulation of the contained material 34 and
the geometry of the resilient member 72, the contained material
exits the container assembly 22 in a spray 130 comprising discrete
droplets 132. The droplets 132 are deposited onto the target
surface 222 to form a texture coating 134 in an applied texture
pattern. The texture coating 134 is initially wet but dries when
exposed to air.
[0062] By appropriately selecting the cross-sectional area of the
outlet opening 84, the applied texture pattern of the texture
coating 134 can be formed such that the pigmented texture material
is applied in a desired texture pattern. As shown by FIG. 3, the
desired texture pattern formed by the texture coating 134 extends
away from the surface of the paint coat 226. Typically, the example
desired texture pattern formed by the texture coating 134 is of a
different color from the color of the paint coat 226. The color of
the texture coating 134 thus contrasts with that of the paint coat
226.
[0063] In the example dispensing system 20 described above, the
outlet opening 84 is varied using the collar 74 to deform the
fingers 78 and thus the resilient member 72. Alternatively, the
outlet opening of the dispensing system 20 may be varied using any
of the structures described, for example, in U.S. Pat. No.
6,536,633, and the teachings of that patent are incorporated herein
by reference.
[0064] The scope of the present invention should be determined by
the claims appended hereto and not the foregoing description of
details of examples of the invention.
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