METAL ARTICLE HAVING THREE-DIMENSIONAL WOOD GRAIN AND STAINABLE COATING

Abstract: A metal article is made to look like wood by impressing a three-dimensional wood grain pattern in its surface, coating the pattern with a translucent film, and straining the film. The stainable film is an acrylic resin filled with an extender pigment whose mean particle size is from about 5 to about 7 microns.

Description: METAL ARTICLE HAVING THREE-DIMENSIONAL WOOD GRAIN AND STAINABLE COATING This invention relates to a translucent, stain absorbent film which is applied as a coating of a filled acrylic latex to a substrate such as a metal or a plastic. More particularly, the invention relates to an aqueous, film-forming composition comprising an acrylic latex and a soft, water-insoluble extender pigment. Still more particularly, it relates to A metal articles having an integral, three-dimensional, simulated wood grain in its surface and a stain-absorbent coating on its surface. The translucent film of this invention is distinguished from a transparent one in that it is slightly opaque, permitting the imperfect transmission of light relected from the substrate. The film is capable of absorbing an applied stain while still exposing the color and markings of the substrate. Various techniques have been used over the years to simulate a wood grain on metal panels. Among these is the lamination on such a panel of a vinyl film having a wood grain pattern printed thereon. The film is subject to delamination and permanent disfigurement by tearing or scuffing actions. Another technique is the printing of the wood grain pattern directly on the metal. The printed pattern is very susceptible to scratching and scuffing. Restoration to the original statee is exceedingly difficult. A technique requiring artistic ability is the manual staining of a metal panel to give a streaked appearance resembling a wood grain. Furthermore, as the patentees in U.5. Patent No. 3.811,9i5 observe, such simulated wood grains have the disadvantage of looking and feeling flat as compared to the three-dimensional look and feel of most natural woods. In said patent, there is taught a method for simulating a threedimensional wood grain without the need for recourse to techniques such as mechanical embossing. Rne method taught comprises applying a conventional background-forming groundcoat to a substrate, printing a wood grain on the dried groundcoat with a graining ink containing a silicone f3uid, and covering the printed groundcoat with a conventional top coat Tne patentees teach that the groundcoat is normally pigmented to provide the desired contrast with the graining ink. In the past, coatings intended as stainable base coats generally were pigmented so that an opaque film would be formed on the substrate. Groundcoats of this sort are used in the inventions described in U.S. Patent Nos. 1,651,136, 2,248,254; and 3,847,646. A method for producing a crackled" antique finish is described in U.S. Patent No. 3,692,557. Said method utilizes a composition comprising an acrylic resin emulsion, finely ground marble, polyurethane, and water. The composition may be applied as both the first and third coatings on a substrate, the second coating being a water soluble dye, or, in the case where the substrate is non-absorbent, the water soluble dye is applied first and the acrylic/polyurethane emulsion is applied over the dried dye. In either case, the water soluble dye is said to "bleed through" upwards into the third or uppermost coating to form the antigue looking finish having a cracked surface. In many instances, piaments which provide color and opacity to a groundcoat also have the effect of sealing the film so that a stain is not absorbed or, at best, it is absorbed unevenly. Now, it has been discovered that a substantially colorless, translucent film capable of absorbing an applied stain may be formed on a substrate by coating the substrate with an aqueous composition comprising an acrylic latex and a water-insoluble extender pigment having a mean particle size of from about 5 to about 7 microns, then drying said coating by a suitable method. The acrylic lattices used in this invention are aqueous emulsions of acrylic-resins; the emulsions have a solids content of fror.. about 3Dz to about 45% by weight. The resins constitute substantially all of the solids present. Homopolymers and copolymers of alkyl acrylates and methacrylates and copolymers of such monomers with acrylonitrile, acrylic and methacrylic acids, styrene, and similar vinyl monomers are examples of the acrylic resins which are useful as the film forming constituents of the composition of this invention. The term "alkyl" is used herein to mean an alkyl group having from 1 to 8 carbon atoms. Acrylates and methacrylates in which the alkyl group contains from 1 to 3 carbon atoms are preferred. Copolymers of such esters with each other and/or with one or more of the monomers specifically mentioned above are particularly preferred. The films deposited by the acrylic latices useful in this invention are generally characterized by good resistance to water, high humidity, salt spray, oil and solvents. The aqueous composition of this invention comprises from about 108 to about 15% of the acrylic resin by weight. Water constitutes from about 10t to about 40% of the weight of the composition; this includes water in the acrylic latex and added water. The size of the extender pigment particles is critical. Although a mean particle size of from about 5 to about 7 microns is generally acceptable, it is preferred that it be no greater than about 6 microns. A maximum particle size of about 25 microns is also preferable. It is also important that the extender pigment be a soft material, i.e., one having a hardness on the Moh scale of about 4 or less. Materials such as calcium carbonate, zinc phosphate and barium sulfate are examples of the water-insoluble, soft extender pigments useful in this invention. Particularly useful are a zinc phosphate having an average particle size of about 6 microns and calcium carbonate having a mean particle size of about 5.5 microns. The weight ratio of extender pigment to acrylic resin ranges from about 1.5:1 to about 3.6:1. A preferred ratio is from about 2.5 to about 3.6. The amount of extender pigment in the aqueous composition is from about 15t to about 50e, preferably from about 25t on up. The viscosity of the aqueous compositions containing such large amounts of extender pigment is reduced by titanat coupling agents such as those described in U.S. Patent Nos. 4,069,192; 4,080,353; 4,057,402; 4,094,853; 4,098,758; and 4,122,062, which are incorjiorated herein. Examples of such coupling agents include isopropyl triisosteartl titanatc, titanium di- (dioctylpyrophosphate) oxyacetate, and di-(dioctylpyropllosphato) ethylene titanate. Quarternary ammonium salts of those titanate coupling agents having an acidic function are particularly useful and are preferred components of the compositions of this invention. Especially preferred are the quaternary ammonium salts of 2-dimethylamino methyl propanol with either titanium di-(dioctylpyrophosphate) oxyacetate or di-(dioctylpyrophosphato) ethylene titanate. The aqueous composition of this invention contains from about 0.25% to about 0 758 of the titanate coupling agent, based on the weight of the extender pigment. A preferred amount is from about 0.38 to about O.St. Water soluble solvents such as ethylene glycol, propylene glycol, isopropanol, butyl cellosolve and the like may be added to the aqueous composition in order to improve sprayability of the composition and to regulate the drying time during film formation. The amounts used will depend on the nature and amounts of the other components and the desired drying time but such solvents usually constitute from about 4t to about 106 of the total weight of the aqueous composition. Mixtures of the solvents are especially useful for the purposes. The viscosity of the aqueous compositions may be adjusted as desired by the addition of cellulosic thickeners such as the methylcellulose ethers, e.g. hydroxypropyl methylcellulose, and carboxymethyl cellulose. Crosslinked acrylic or methacrylic acid copolymer emulsions also function as thickeners when activated by a base such as ammonium hydroxide. From about 0.1E to about 0.5t by weight of the aqueous composition is a generally sufficient amount of thickener. Non-ionic surfactants and/or silicones may be used in minor amounts to control foaming of the aqueous composition during its preparation. Fig. 1 is a photograph of a stained metal panel illustrative of this invention. The metal article is preferably made of steel but other metals such as aluminum, copper, tin, and inherently colored alloys such as brass and bronze are also contemplated as the substrate in this invention. The article may be simply sheet metal or it may be a shaped article made lv bending sheet metal or by molding the metal. Steel doors for houses and other buildings, i.e., architectural doors; door jambs, cabinetry and decoratixr trim exemplify articles for which the advantages of this invention are of ten :.ou9ht. The three-dimensional simulation of-wood grain in the metal surface may be accomplished, for example, by embossing, coining, or etchinq the metal to form the grooves and the consequent thread-like ridges or tics and plateaus. The grooves and, therefore, the tics and plateaus are of random length and width. The depth of the grooves is also not uniform. Although the tics are for the most part parallel, they and the plateaus appear to converge and diverge because of the varying lengths and widths of the grooves. Before being coated, the minimum depth of the grooves is about 2.2 times the thickness of the dry film which is to be deposited from the coating composition. A particularly pleasing and realistic effect is achieved by a preferred arrangement of the tics so that there are from about 80 to about 85 tics per square inch (about 12-13 per square centimeter). The average width of the tics in such arrangement is about 16 mils (about 0.4mm) and the average depth of the grooves is about 5 mils (about 0.13mm). The bare metal surface is, of course, only suggestive of a wood grain. It is the translucent coating which enables one to complete the effect by rubbing and wiping a selected stain over the pattern. The translucent coating is substantially colorless and is capable of absorbing a decorative stain while still exposing the color and markings of the substrate. When, as is usually the case, the color of the metal is not a desirable base for the simulation of wood grain, a pigmented primer is applied to the metal before the stainable coating is applied. In some instances, however, the color of the metal, e.g., copper, bronze and the like, may serve well for special effects. The stainable, translucent film is formed on the wood grained surface of the metal by spraying, roller-coating, or applying the aqueous composition by any other suitable method and then drying the composition. The drying temperature may range from just above the freezing point of the composition to just below its decomposition temperature but it is preferably from about room temperature to about 350or (about 1770C). At the particularly preferred temperature of about 1600F (about 700 C) , the film is sufficiently dry after about 10 to 15 minutes; the drying time will be correspondingly longer at lower temperatures and shorter at higher temperatures. The film is usually from about 0.5 to about 1 mil thick after drying but it may be thicker if desired. The film accepts a decorative stain evenly much like wood does. Staining of the film may be accomplished without runs even when the surface of the substrate is vertical. Water-based, alkyl, and oil-based stains are readily absorbed. The advantages of this invention are more pronounced when non-absorbent, i.e. water impervious, substrates such as metal or plastic are to be decorated by staining but substrates such as hardboard, particle board, plasterboard, and plywood may also be coated with the stainable film of this invention in order to prepare them for decorative staining. The invention is illustrated more specifically by the following examples wherein all parts are by weight unless otherwise stated. The scope of the invention is not restricted to the specific details of these examples. Example 1 A mixture of water (66 parts), an anti-foaming agent comprising a nonionic surfactant and a silicone sold under the trademark NOPCO NXZ(0 2 part), ethylene glycol (8 parts), the quaternary ammonium salt of 2-dimethylamino methyl propanol and di(dioctylpyrophosphato) ethylene titanate (1.2 parts), zinc phosphate having an average particle size of 6 microns and sold under the product designation J0852 by Mineral Pigments Corporation (175 parts) is dispersed at high speed in a Cowles mixer for 10 minutes. Then 120 parts of an acrylic latex having a solids content of about 43% by weight, a pH of 9 4 to 10, a viscosity at 250C. of from 500 to 2000 ops. and wherein the particle size of the all-acrylic resin is less than 0.1 micron is added along with 15 parts of isopropanol and 2 parts of a crosslinked, acidic acrylic emulsion copolymer as a thickening agent. Ammonium hydroxide (3 parts) is added to activate the thickening agent. The mixture is thoroughly blended at room temperature. The acrylic latex is sold under the trademark thoplex MV-23 by Robin & Haas. A stainable film having a porous surface resulted when the composition thus prepared was applied to a substrate and dried. Example 2 The general procedure of Example 1 is repcated except that the acrylic latex used is an aqueous emulsion of an acrylic/styrene copolymer sold by Polyvinyl Chemical Industries under the trademark Neocryl A-623 and 10 parts of butyl cellosolve are used in addition to the ethylene glycol. The acrylic latex has a solids content of 35t by weight, a pH of 7.5, and a Brookficld viscosity at 250C. of 320 cps. This composition also provided a stainable, porous film when applied to a substrate and dried. In contrast to the results of Examples 1 and 2, compositions prepared by the general procedure of Example 2 but substituting an equal weight of a finely divided silica (Imsil A-10, sold by Illinois Mineral Co.), or terra alba (finely divided gypsum), or a finely divided clay for the zinc phosphate give films having a seal ted surface that do not accept a decorative stain. Example 3 A mixture of 150 parts of water, 18 parts of ethylene glycol, 1.7 parts of the titanate coupling agent of Examples 1 and 2, 22 parts of butyl cellosolve and 350 parts of calcium carbonate having a mean particle size of 5.5 microns (sold under the trademark Snowflake White by Thompson, Weinman and Company) is ground at high speed in a Cowles mixer. Then, 115 parts of water; 0.5 part of an anti-foaming agent; 120 parts of an acrylic. latex comprising a low molecular weight terpolymer of a lower alkyl acrylate, acrylonitrile and styrene and having a solids content of about 418 by weight, a Brookfield viscosity of from 500 to 2000 cps. and a pH of 7.5; 120 parts of the acrylic latex of Example 1, 2 parts of a cellulosic thickener, and 8 parts of propylene glycol are added and the mixture is thoroughly blended at room temperature. The composition thus prepared is sprayed onto several metal panels having a primer coat in place. A film having a thickness of 1 mil (about 25 microns) is formed after drying at 160to (about 700C.) for 12 minutes with 10 minutes of flash off time. A commercial stain is then spread on each panel and wiped in the conventional manner. The stains used are Formby's gelled stain, Cuprinol stain and wood preservative, Pratt & Lambert Penetrating Rustic Stain, Olympic (linseed oil base), Enterprise 2-in-l, Carver Tripps, and dlinwax stain. Excellent stain reception is achieved in each case. The impact strength and adhesion of the film is excellent. Example 4 The general procedure of Example 3 is repeated except that zinc phosphate having an average particle sic of 6 microns is used in place of the calcium carbonate. The film deposited on metal panels by the acqueous composition thus prepared also showed excellent stainability, impact strength and adhesion. In contrast to the results of Examples 3 and 4, a film deposited from a composition prepared by the general procedure of Example 4 except for the replacement of 300 parts of the zinc phosphate by a calcium carbonate having a mean particle size of 2.5 microns showed poor stain reception. Example 5 Sheet steel is embossed to achieve a pattern of generally parallel lines or tics of random length to simulate the pattern of a wood grain. The wood grain effect is obtained by an arrangement of individual tics spaced apart differentially so that there are about 80 to 85 tics per square inch. The average width of a tic.is about 16 mils and the average depth of the grooves between the tics is about 5 mils. A residential steel door is fabricated from the embossed sheet material and the surface intended to be the exterior face is primed with a pigmented base coat having a beige color. An acrylic latex coating composition is prepared by mixing 12,980 parts of water, 116.2 parts of the quaternary ammonium salt of 2-dimethylaminomethyl propanol and di(dioctylpyrophosphato) ethylene titanate, and 23,925 parts of calcium carbonate having a mean particle size of 5.5 microns for 10 minutes in a high speed mixer. Then are added 19,140 parts of an acrylic/styrene copolymer latex-sóid by Polyvinyi Chemical Industries under the trademark Neocryl A-623 and which has a resin content of about 35t and a Brookfield viscosity at 25 > C of 320 cps. An anti-foaming agent (68.3 parts) comprising a non-ionic surfactant and a silicone (sold under the trademark Nopco NXZ), 136.5 parts of a non-ionic surfactant (Tam61"265):, 1503 parts of butyl cellosolve, 68.3 parts of concentrated ammonium hydroxice (28b NH3), 34.1 parts of 2-amino-2-methyl-l-propanol, 136.1 parts of a cellulosic thickener, 1777 parts of ethylene glycol, 15 parts of a bactericide, and an additional 8203 parts of water are addcd and the mixture is thoroughly blended at room temperature. The resulting agueous coating composition is sprayed onto the embossed face of the steel door and dried at 1600F (about 700C) to a translucent, colorless film. The thus coated face of the door is then stained with a semi-transparent oil-based stain (Olympic) by the conventional spreading and wiping technique. An excellent wood-like appearance is achieved upon drying of the stain. In contrast to the results in Example 5, the presence of a ti'gment-at a low level of concentration in an aqueous coating composition otherwise corresponding to that of Example 5 caused a pronounced mottled effect on sheet steel having the simulated wood grain embossed thereon. Use of a pigment at a concentration high enough to obscure the mottling resulted in a coating which would not absorb a stain satisfactorily. A clear protective top coat may be applied over the stain. The top coating composition may be water-based or oil-based. To those skilled in the art to which this invention relates, many changes which do not depart from the spirit and scope of this invention may suggest themselves. The foregoing description is purely illustrative and not restrictive of that spirit and scope.

Claims: CLAIMS 1. An aqueous composition for forming a translucent, stain absorbent film, said composition comprising an acrylic latex, and a water-insoluble extender pigment having a mean particle size of from about 5 to about 7 microns. 2. The composition of claim 1 wherein the weight percent of said pigment is from about 15% to about 509, 3. The composition of claim 1 wherein the weight percent of the acrylic resin is from about 10% to about 15t of the total weight. 4. The composition of claim 1 wherein the weight ratio of said pigment to the acrylic resin is from about 1.5:1 to about 3.6:1. 5. The e compositidn of claim 1 further comprising a titanate coupling agent. 6. The composition of claim 5 wherein the amount of coupling agent is from about 0 25t to about 0.75t of the weight of the extender pigment. 7. The composition of claim 1 wherein the mean particle size is from about 5 to about 6 microns. 8. The composition of claim 1 wherein the extender pigment is at least one of the class consisting of calcium carbonate and zinc phosphate. 9. The composition of claim 1 wherein the ratio of extender pigment to acrylic resin is from about 2.5:1 to about 3.6:1. 10. The composition of claim 5 wherein the titanate coupling agent is a quaternary ammonium salt. 11. A translucent, stainable coating comprising an acrylic resin ana-- a water-insoluble extender pigment having a mean particle size of from about 5 to about 7 microns. 12. The coating of claim 11 wberein the weight ratio of extender pigment to acrylic resin is from about 1.5:1 to about 3.6:1. 13. The coating of claim 11 wherein the extender pigment is at least one of the class consisting of calcium carbonate and zinc phosphate. 14. The coating of claim 13 wherein the mean particle size of the extender pigment is from about 5 to about 6 microns. 15. A method for imparting stainability to a non-absorbent substrate, said method -comprising coating said substrate with an acrylic latex filled with an extender pigment having a mean particle size of from about 5 to about 7 microns and in which said latex the ratio of extender pigment to acrylic resin is from about 1.5:1 to about 3.6:1. > 6. The method of claim 15 wherein the extender pigment is at least one of the class consisting of calcium carbonate and zinc phosphate. 17. A metal article having an integral, three-dimensional, simulated wood grain in its surface and a stainable translucent coating over said simulated wood grain. 18. The e metal article of claim 17 characterized further in that said translucent coating has an absorbed stain therein. 19. The metal article of claim 17 wherein the coating comprises a filler having an average particle size of from about 5 to about 7 microns. 20. The metal article of claim 17 wherein the coating is a film of a filled acrylic resin wherein the filler/resin ratio is from about 1.5:1 to about 3.6:1 by weight. 21. The metal article of claim 19 wherein the filler is zinc phosphate. * 22. The metal article of claim 19 wherein the filler is calcium carbonate. 23. The metal article of claim 20 wherein the acrylic resin is a styrene/acrylic copolymer. 24. The metal article of claim 17 having a pigmented primer coat under said translucent coating. 25. . A steel architectural door characterized by at least one face having an embossed surface simulating a wood grain and said surface having a stainable, translucent coating thereon.

Inventors: LAT, GERONIMO E., MARTINELLI, LAWRENCE R.
Applicants: UNITED STATES GYPSUM COMPANY
Application year: 1983
Main classification: C09D5
IPC codes: B44F9, C09D5, C09D133