Abstract:
A sand texture finish material in the form of a sprayable composition includes a polymer, sand, filler and a solvent which is either water or a volatile organic compound. The sand texture finish material is storable and dispensable from a pressurized dispenser having a delivery nozzle or other spray dispensing device. An aerosol system with a spray nozzle is included on the container for selective discharge of the textured material onto a prepared patch area or other substrate so as to match and blend with the surrounding sand texture finish in order to provide a continuous and unbroken coextensive surface texture of mechanically and visually matched material.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to surface texture materials, and more particularly to a novel pressurized substance in liquid or semi-liquid form that is storable and dispensable from an air-tight pressurized container to be sprayed onto a substrate that requires a sand texture finish so that after subsequent curing and hardening, a matching surface texture is provided with that of the material having a sand texture surrounding the area. 
     It has been conventional practice in the procedure of repairing or patching materials having a sand texture finish to remove the damaged portion and subsequently fill any holes, depressions, chips or the like with a prepared patch material. The patch or replacement material is applied by means of a trowel or other flat tool that will press the patch material into the hole or depression and that will prepare and provide a surface area to receive a finish surface coating. After the patch material has cured and adhered to the original support material, a smooth surface is provided that receives the final coating. This coating leaves a smooth surface that is not matched to the surrounding sand texture finished surface. 
     The present invention may also be applied to those materials having a sand texture finish where a portion of the texture has been chipped or flaked off. In that instance, the underlying surface may or may not have to be prepared in the above-described manner. 
     A sand texture finish usually presents a surface texture that has a roughened texture that is similar to sandpaper. The color of the texture coating may vary with that of the sand utilized in the spray. Such a texture and appearance cannot be attained through the use of smoothing tools or patch tools once a patch material has been applied to the damaged or repaired area. Therefore, difficulties and problems have been encountered that stem largely from the fact that the use and application of conventional patching materials on materials having a sand texture finish leaves a surface texture that does not match the surrounding area and is noticeable after the repair has been completed. 
     U.S. Pat. No. 4,563,491, to Commune, (the “&#39;491” patent), discloses a stucco coating composition which is designed both for its protective qualities against environmental influences and for its aesthetic effect. Sand may be one ingredient of this coating. The stucco composition is designed to be applied by techniques including troweling, spraying or rolling. However, preparation of this composition entails the use of a rotatable mixing chamber and the composition, once prepared, dries in three to four hours. Given these factors, the composition is not suitable for quick, easy patching or being dispensed in the form of an aerosol spray. 
     U.S. Pat. No. 5,813,183, to Attley, (the “&#39;183” patent) discloses a method of coating material with a protective coating having a rough, dull or granular surface appearance. One such coating includes sand (claim  9 ). The sand or equivalent particulate material is applied to an undercoating which has been heated to make it tacky or sticky. The particulate material then applied such that it sticks to the undercoating. This invention is not suited to patching or repairing an existing product having a sand texture finish. First, most people probably do not have the oven of the &#39;183 patent or similar means to heat existing products to soften an undercoating. Secondly, the heat may damage that which the coating is applied to. Additionally, this is a relatively involved process for the simple patching of a damaged product. 
     Therefore, there is a need for a sprayable sand finish texture material that may be applied to a damaged area or to a repaired or patched area, and that may be contained in a hand-held applicator and dispensed using only one hand, so that the material may be conveniently stored as well as applied to the required area in a simple and convenient manner. 
     SUMMARY OF THE INVENTION 
     An object of the present invention is to provide a sand finish texture that is easily storable and readily available for easy dispensing. 
     Another object of the present invention is to provide a texture finish that will match and blend with existing sand texture finished materials. 
     Another object of the present invention is to provide a relatively quick and simple means for repairing damaged sand finished objects. 
     Another object of the present invention is to provide a sand finish texture that is easily applied. 
     Another object of the present invention is to provide a sand finish texture that may be applied by one who is not skilled in the art of repair. 
     Accordingly, the above problems and difficulties are obviated by the present invention, which provides a novel material that is storable and dispensable from a convenient dispenser including a pressurized container holding a quantity of the sand finish texture material in a liquid or semi-liquid condition so that upon depression of a dispensing nozzle, the material will be discharged and directed to a patch area or seam intended to receive the surface texture material. 
     In an embodiment of the present invention, the sand texture spray system may include: sand, fillers such as calcium carbonate or clay, a solvent such a water or a volatile organic compound (VOC), a polymer, antifreeze, a fungicide and a pressurized carrier for dispensing the material. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 illustrates the direct application of the spray-on surface texture material from the dispenser for repairing a sand finish surface in accordance with an embodiment of the present invention. 
     FIG. 2 illustrates a transverse cross-sectional view of the repaired or patched area shown in FIG. 1 showing the dissimilarity in surface texture between the original sand finish surface and the surface of the patched area. 
     FIG. 3 illustrates a transverse cross-sectional view of the repaired or patched area on a sand texture finished material and shows matching of surface texture between the surface of the patch and the surrounding sand finish surface after use of the novel spray-on surface textured material of the present invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring in detail to FIG. 2, a fragmentary view is shown of a typical piece of material including a sand finish texture and is identified by the number  10 . The surface texture of the sand texture finish can be broadly defined as resembling sand in look and feel. The sand texture finish may be on a material which may be supported by boards or other means of support  11 . The material on which there is a sand texture finish has been damaged and a repair to the damaged area has been performed in the form of a patch  12 . An embodiment of the present invention may also be applied to areas where only the sand texture finish has been chipped or otherwise damaged. 
     After curing, the patch becomes solidified and adheres to the edge marginal region of support material  11  or the edge marginal region of damaged area  13 . 
     In FIG. 2, it can be seen that the patch  12  displays a smooth surface  15  usually attained by repeatedly drawing the edge of a hand tool, such as a trowel, across the surface. After drying or curing, the material of the patch  12  becomes hard and the surface  15  remains smooth and unmatched with the surrounding sand texture finish  14  carried on the material  10 . Although the surface  15  will accept a variety of coatings such as paint or the like in a conventional situation, the surface texture of the coating will not simulate or blend with the surrounding irregular surface of the sand texture finish  14 . Visually, flat patch area  15  will always be noticeable and indicate the presence of a repair. 
     Referring now in detail to FIGS. 1 and 3, the surface textured material  16  discharged from a dispenser  17  is illustrated as being applied to the smooth surface  15  of patch  12 . In this connection, a sand texture finish is placed on the flat surface  15  so as to be compatible with, blend with and be coextensive with the surrounding surface area  14 . By employment of the present invention, the surface texture of both the patch  12  and the surrounding sand texture finish  14  are substantially identical and matched so that no visual indication is presented or noticeable pertaining to a repair or patch. The material being applied is broadly indicated by number  16  which is contained within the dispenser  17  and applied in the form of a spray in either liquid or semi-liquid condition. Application is achieved by depression of a pump or spray nozzle which permits discharge of the pressurized material carried within the container  17 . Such an application of the material occurs directly on the desired area  19  by the user who hand-carries the container  17  and operates the nozzle  18  on the site with one hand. 
     While these figures depict the covering of a patched area, the present invention my also be used to cover areas having a sand finish that is cracked or chipped. 
     An appropriate nozzle for spraying the present invention is the Spraytex Aerosol Valve Assembly for Spraying Viscous Materials or Materials with Large Particulates (patent application pending). In the Spraytex Valve Assembly, the valve opening is located at the bottom of the container rather than the top. This allows highly viscous materials or materials having large particulates to be sprayed without clogging of the valves. 
     Of course, the Spraytex valve is offered by way of example, not limitation. Any valve that is appropriate for spraying the material of the present invention may be used. 
     Waste and loss of material is avoided since the discharge is under the control of the user through the application of the discharge nozzle  18 . Therefore, there is no residue or excess material that is not used which requires disposal. Furthermore, the material  16  is gritty and, after curing on surface  15 , provides an sand texture finish that is roughened and compatible with and matching the surrounding sand finish texture material. Additionally, the material in the container is considered a finished product and does not require additives of any kind. The labeling on the container may provide identification numbers and laboratory information. 
     Preferably, an example of the material  16  comprises filler, sand, a natural or synthetic polymer and a solvent. The filler may be any material that can serve as an extender or bodifier such as calcium carbonate, clay or similar substance, or mixtures thereof. The filler may also be made of a paint-based material. The solvent may be water or a volatile organic compound (VOC) such as a hydrocarbon, dimethyl ether, propane, butane, carbon dioxide, nitrogen, or any combination of the above said compounds or any other compounds used in the aerosol industry, such as hydrofluorocarbons. The material of the present invention may be under pressure to facilitate dispensing. The material of the present invention may also include antifreeze and/or a fungicide. 
     By way of an example, the hardenable flowable material  16  of the present invention may have the following composition by percentage weight: 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Filler 
                 20-60% 
               
               
                   
                 Sand 
                  5-40% 
               
               
                   
                 Natural or Synthetic Polymer 
                  3-10% 
               
               
                   
                 Solvent 
                 30-70% 
               
               
                   
                   
               
             
          
         
       
     
     Also by way of a more specific example, the hardenable flowable material  16  of the present invention may have the following basic composition by percentage weight: 
     
       
         
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Calcium Carbonate 
                 10-50% 
               
               
                   
                 Clay 
                 10-50% 
               
               
                   
                 Sand 
                  5-40% 
               
               
                   
                 Natural or Synthetic Polymer 
                  3-10% 
               
               
                   
                 Water or VOC 
                 30-70% 
               
               
                   
                   
               
             
          
         
       
     
     The calcium carbonate and clay of the filler are preferably in powder form. Furthermore, the composition of material  15  may contain a fungicide (1-5%) and/or antifreeze (1-5%). 
     As illustrated in FIG. 1, the material  16  is applied directly to the smooth surface  15  and when dried or cured results in a sand texture finish which matches and is compatible with the material having a sand finish surrounding the patch. The patch material  12  is dried and cured in preparation for receiving the material  16 . Even if small amounts of the material  16  extend beyond the surface  15  onto the surrounding material, the surface would still be matched and no unsightly patch edges or dissimilar surface texture would be detectable. 
     Many decorative coatings involving sand must be applied with a trowel or pressed in a mold. Clearly, it would not be practical to use a mold to coat a patch or repair a damaged area on an already finished product. It would be time-consuming and difficult to obtain the correct mold. Further, flat surfaces such as walls are not suited to being repaired by the use of molds. Further, using a trowel to apply textured patch material to a surface evenly requires a certain amount of skill, which many do not possess. 
     In contrast, the product of the present invention may be cleanly and simply applied through the use of a spray can. The present invention provides a means and a method of quickly and easily applying a thin, even application to one specific area. When the material of the present invention dries, there is no obvious unevenness or change in texture to indicate where the sand material was applied. 
     Additionally, an embodiment of the present invention is contained in a spray container. This facilitates clean-up, as the user does not have to clean a trowel or other spreading device. Further, any unused excess remains in the spray container, and may be disposed of with the container. 
     While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention. 
     The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.