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.

Description:
RELATED APPLICATIONS 
       [0001]    This application (Attorney&#39;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 
       [0034]      
         [0000]    
       
         
               
               
               
               
             
           
               
                   
               
               
                   
                   
                 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  22   a.  The valve assembly  24  is combined with the end cap  44  to form a cap subassembly  22   b.  The texture material base is placed within the container subassembly  22   a.  The cap subassembly  22   b  is crimped onto the container subassembly  22   a  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  224   a  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  224   a  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  224   a  and  224   b,  and the paint coat  226  is formed on the second primer coat  224   b.  It should be recognized that the principles of the present invention may be implemented without one or more of the primer coats  224   a  and  224   b,  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.