Water-reducible coating composition and use thereof

Abstract: Compositions and a method are provided for forming a coated wood, plastic or metal product having the appearance and texture of wood grain. The joints on a wood surface are concealed by the coating and the coating is capable of accepting conventional wood stain.

Description: The present invention is directed to a method and compositions used therewith for coating wood, metal or plastic to render it capable of receiving wood-grain printing inks and conventional wood stains, while also concealing joints and other imperfections. In the decorative uses of wood, there are many applications in which visible joints in the wood are not desired. For example, in the use of moldings along the edges of doors, window frames, and the like, it is desirable to have each edge constructed of a single length of wood. Moreover, to have a decorative effect, the wood is often stained to a desired color, such as walnut, rosewood, and the like, then covered with a protective coating such as varnish or other conventional clear coating. The use of single lengths of wood is expensive and wasteful, since short lengths of scrap wood are not reusable. There is no practical alternative to using single lengths of wood for molding. Plastics or compounded wood pulp products are usually not desirable since they either do not have sufficient strength and durability or do not have the pleasing wood grain surface texture. A piece of plywood would also be extremely expensive since one or more surfaces of the molding would have to be veneered, making it much more expensive than a solid piece of wood. The use of scrap pieces of wood joined together such as by finger joints, would be desirable. There has been difficulty however, in treating joined pieces of wood to have the appearance of a single piece of wood for decorative purposes. One such method is described in U.S. Patent No. 4,546,133, wherein specialized wood coating and ink compositions are disclosed. US-A-4638022 relates to a method and compositions used therewith for coating wood or plastic to render it capable of receiving wood-grain printing inks and conventional wood stains, while also concealing joints. EP-A-0264897 describes an acrylic polymer for use in an ink composition to be applied to paper of polyvinyl chloride. The present invention provides an improved method and coating for metal or plastic to impart wood-like appearance, or for concealing joints in wood, while still maintaining the appearance and texture of a single piece of wood. The coated product according to the present invention is capable of accepting conventional wood stains. The present invention provides a novel coated product of metal, plastic or wood which will accept conventional wood stains. The present method utilizes a basecoat composition for covering plastic, metal, wood or a wood product comprising a combination of resins, pigments, solvents, and additives for suspension, dispersion, thickening, flowing and defoaming. A printing composition is also provided comprising resins, pigments, solvents, and anti-foaming and wetting agents. Accordingly, the present invention provides a printing composition as specified in claim 1 and claim 2. The present invention further provides a coated product as specified in claim 3. The present invention still further provides a method for forming a coated product as specified in claim 4. The method according to the present invention comprises the steps of applying a liquid basecoat onto metal, plastic, natural wood or a wood product, evaporating volatile solvents to form a solid coating, and applying a novel ink composition in a wood grain pattern onto the solid coating. The starting material for forming a coated product according to the present invention may be any product having a plastic, metal or wood surface, including strips, with or without joints, sheets, including plywood and wood grain paper, or any other product derived from wood or wood pulp, sawdust, and the like. Since a primary purpose for the use of the compositions according to the present invention is to provide a decorative surface, it is desirable, but not necessary, that the starting material have a wood grain texture, since that texture will be substantially retained after the basecoat coating is applied according to the present invention. Generally, the metal, plastic, wood or wood product will be coated with a liquid basecoat composition then dried to remove the volatile solvents. The drying is preferably performed with heat in a conventional oven, but other evaporative methods may be utilized. Then a grain ink formulation according to the present invention is applied in a pattern to simulate a wood grain using a conventional roller having a wood gran pattern using the inks described herein. Apparatus for performing these functions are conventional and known in the art. The basecoat formulation used in forming a coated product according to the present invention comprises the following components: acrylic resins (emulsions and suspensions), styrene-maleic anhydride resins, pigments and fillers, thickener, flow agents, defoaming agents and solvents. The water-reducible basecoat used in forming a coated product according to the invention will contain the following: % by volume Water 20 - 30 Organic Solvents 1 - 5 Styrene-maleic anhydride resins 0.5 - 3 Acrylic resin emulsions and suspensions having an acrylic resin content of 44.3% by volume 45 - 55 Pigments and inorganic fillers 10 - 20 Organic thickener up to 1 Defoaming agents up to 3 Flow agents up to 5 Suspension agent up to 1 Nut shell flour 1 - 5 A particularly preferred basecoat composition useful for coating wood contains the following (percentages given by volume). % by volume Water 23.50 Organic Solvents 1.72 Styrene-maleic anhydride resins 0.8 Acrylic resin emulsions and suspensions having an acrylic resin content of 44.3% by volume 51.10 Pigments and inorganic fillers 15.98 Organic thickener 0.17 Defoaming agents 1.02 Flow agents 3.33 Suspension agent 0.18 Nut shell flour 2.20 In a preferred formulation, the acrylic resins and styrene-maleic anhydride resins are the commercially available resins Joncryl 89 (Johnson & Johnson), Rhoplex AC-507 (Rohm & Haas), and SMA-1440 (Sartomer Company). Absorption pigments and inert fillers which may be utilized include commercial pigments such as Asbestine 325 (U.S. Mica), titanium dioxide, talc, Hitox (Benilite), and the like. The composition will also contain an organic pigment, pecan shell flour, preferably ground to an average size of about 40 micron. The base coat composition will also contain suspension agents, thickeners, flow agents and defoaming agents. Suspension agents include Colloid 711 made by Colloid Co. A preferred thickener is Cellosize, made by Union Carbide. Flow agents such as Minusil (P.G.S., Inc.), Super Adit (Nuodex) may be utilized. Defoaming agents such as Surfynol (Air Products) may be used. Typical organic solvents include dimethyl ethanol, carbitol (diethylene glycol monomethyl ether) methyl ethyl ketone, acetone, MIBK (methyl isobutyl ketone), methyl and ethyl alcohol, ethyl acetate, amyl acetate, and the like. The several portions of any vehicle used in comparing one of the decorative coatings are generally composed of the same basic materials although they may have varied amounts of thinners, solvents, fillers and the like so as to vary their viscosities and other physical properties, but there may be a combination of unrelated resins used on the same panel to provide texture and growth lines. The pulverized pecan nut shell flour utilized in the base coat composition as an absorption pigment will be in the form of a fine powder, typically grain size of about 35 to 45 micrometers (microns) (preferably 40 average micrometers (microns)). The particular proportions of the various components used may be generally in the proportions given above. A particularly preferred coating composition comprises the following: parts (volume) Water 24.88 Dimethyl ethanol 0.19 Carbitol 1.63 Styrene-maleic anhydride resin SMA-144 (H) 0.84 Rhoplex AC-507 acrylic resin emulsions and suspensions having an acrylic resin content of 43.49% by volume 41.33 Joncryl 89-acrylic resin emulsions and suspensions having an acrylic resin content of 47% by volume 12.75 TiPure R900, titanium dioxide 0.79 Hitox pigment 2.17 Asbestine 325 pigment 10.46 Nytal 300 talc filler 3.50 Pecan shell flour (40 micron) 2.33 Cellosize QP-09-H thickener 0.18 Defoamer 6-475 (Drew Chemical) 0.23 Surfynol T.G. (Air Products) 0.85 Minusil 10 flour additive 3.40 Super Adit flow additive 0.13 Colloid 711 suspension agent 0.19 In addition to the various pigments mentioned above, the base coat may contain various typical inorganic pigments useful for wood grain such as those iron pigments ranging in color from yellow through red, reddish brown, brown to black, similar to those found in natural wood. These iron pigments include yellow ocher, raw and burnt sienna, and raw and burnt umber. Other useful inorganic color pigments include chrome yellow, cadmium sulfide, zinc yellow, cobalt blue, ultramarine blue, iron oxide, chrome green, chromium oxide green, chromium hydroxide green, lamp black carbon, and white pigments such as titanium dioxide, titanium calcium, zinc dioxide, zinc sulfide, antimony oxide, lithopone, etc. Organic pigments may also be utilized such as toluidine red, phthalocynaine blue and green, VanDyke brown, alizarin, madder lake, lythol red, etc. After applying the base coat, it is dried, for example in a conventional oven to remove the volatile solvents, thereby forming a hardened base coat. An ink formulation is then applied to the base coat with a roller having a wood grain pattern. The ink formulation comprises: resins, pigments and fillers, thickeners, defoaming agents, flow agents, suspension agents, solvents, and wax. The resins utilized in the above ink formulation include acrylic resins such as Joncryl 74, and latex resins such as BALAB and UCAR-SCT 100. The pigments include various pigments utilized to simulate wood grain colors, as described above and include specifically yellow 895-000-1801 (Nuodex), burnt umber (I-347), red oxide 895-1003 (Harshaw), Mearlin silk white (an iridescent pigment). As an absorption pigment Phoschek P/30 may be utilized. As a tinting agent a tint paste such as Benzidine yellow (W-1041) may be utilized. A wetting agent such as glycol ether (PM) is used. Various solvents may be utilized such as DMAE (Union Carbide), water and ethylene glycol. The pigments which are utilized in the ink formulation will depend upon the colour of the wood grain desired. The pigments must, of course, impart a colour to the ink formulation which is different from the color of the dried base coat in order to provide contrast. Usually, colorants which impart yellow or brown tones to the base coat will be useful. Typically, the base coat, after application of the ink formulation, will be stained with a conventional wood stain, which usually enhances the contrast between the base coat and the ink. The ink according to the present invention will contain as follows: % by volume Water 2 - 8 Organic Solvents 1 - 5 Acrylic resin emulsions and suspensions having an acrylic resin content of 47% by volume 30 - 60 Yellow pigment 8 - 12 Brown pigment 10 - 20 Red Pigment up to 3 Iridescent white pigment up to 1 Inert pigment up to 5 Wetting agent 2 - 8 Wax 5 - 15 A typical ink formulation according to the present invention may comprise the following (parts by volume): Manufacturer Joncryl 74 52.24 Acrylic resin emulsions and suspensions having an acrylic resin content of 47% by volume Johnson & Johnson BALAB 3056A .73 Resin (latex) Witco Ethylene glycol 2.32 Solvent Chem Central DMAE .58 Solvent Union Carbide Tap Water 5.15 Solvent UCAR SCT100 1.20 Resin (latex) Union Carbide Glycol Ether PM 6.41 Wetting agent Ashland 895-000-1801 Yellow 6.22 Pigment Nuodex W-1041 Benzidine Yellow 4.90 Tint paste Harshaw I-347 Bt. Umber 16.77 Pigment Harshaw 895-1003 Red Oxide .79 Pigment Nuodex Mearline Silk White .22 Iridescent pigment Mearl Phos Chek P/30 fine 2.45 Absorption pigment Monsanto Slip Ayd-459-1029 10.00 Wax After application of the graining ink formulation and air drying, the final product may be utilized as is, or stained with a conventional wood stain, then coated with a conventional varnish or other clear preservative. The base coat and ink formulation may be applied to any metal, plastic or wood surface, including paper, if desired.

Claims: A printing composition characterised by comprising:- % by volume Water 2-8 Organic solvents 1-5 Acrylic resin emulsions and suspensions having an acrylic resin content of 47% by volume 30-60 Yellow pigment 8-12 Brown pigment 10-20 Red pigment up to 3 Iridescent white pigment up to 1 Inert pigment up to 5 Wetting agent 2-8 Wax 5-15 A printing composition characterised by comprising by volume about: PARTS (VOL) Acrylic resin emulsions and suspensions having an acrylic resin content of 47% by volume 52.24 Latex resin 1.93 Ethylene glycol 2.32 DMAE .58 Water 5.15 Wetting agent 6.41 Yellow pigment 6.22 Yellow tint 4.90 Burnt umber pigment 16.77 Red oxide pigment .79 Iridescent pigment .22 Absorption pigment 2.45 Wax 10.00 A coated product comprising a wood, plastic or metal substrate and a coating over said substrate formed by placing a liquid coating over said substrate, said liquid comprising: % by volume Water 20-30 Organic solvents 1-5 Styrene-maleic anhydride resins 0.5-3 Acrylic resins emulsions and suspensions having an acrylic resin content of 44.3% by volume 45-55 Pigments and inorganic fillers 10-20 Organic thickener up to 1 Defoaming agents up to 3 Flow agents up to 5 Suspension agent up to 1 Nut shell flour 1-5 and drying said liquid coating to remove volatile solvents, characterised by comprising a printed pattern upon said coating, said pattern formed by imprinting a liquid ink composition upon said coating, said liquid ink composition comprising: % by volume Water 2-8 Organic Solvents 1-5 Acrylic resin emulsions and suspensions having an acrylic resin content of 47% by volume 30-60 Yellow pigment 8-12 Brown pigment 10-20 Red pigment up to 3 Iridescent white pigment up to 1 Inert pigment up to 5 Wetting agent 2-8 Wax 5-15 and drying said ink composition to remove volatile solvents. A method for forming a coated product characterised by a printed wood grain pattern, comprising the steps of: (a) applying a liquid coating onto a wood, plastic or metal product, said coating comprising: % by volume Water 20-30 Organic solvents 1-5 Styrene-maleic anhydride resins 0.5-3 Acrylic resins emulsions and suspensions having an acrylic resin content of 44.3% by volume 45-55 Pigments and inorganic fillers 10-20 Organic thickener up to 1 Defoaming agents up to 3 Flow agents up to 5 Suspension agent up to 1 Nut shell flour 1-5 (b) evaporating volatile solvents to form a solid coating; (c) applying an ink composition in a wood grain pattern onto said solid coating, said ink composition comprising: % by volume Water 2-8 Organic solvents 1-5 Acrylic resin emulsions and suspensions having an acrylic resin content of 47% by volume 30-60 Yellow pigment 8-12 Brown pigment 10-20 Red pigment up to 3 Iridescent white pigment up to 1 Inert pigment up to 5 Wetting agent 2-8 Wax 5-15

Inventors: COPE CARROLL W, COPE, CARROLL W.
Applicants: MARLEY MOULDINGS INC, MARLEY MOULDINGS INC.
Application year: 1989
Main classification: B44F9
IPC codes: C09D5, C09D133, B05D7, C09D11, B05D5