Abstract:
A method of covering an anomaly in a wall substantially to match a pre-existing texture pattern surrounding the anomaly. The method comprises the following steps. A valve is supported on a container assembly to define a main chamber. Contained material comprising wall material concentrate and propellant material is disposed within the main chamber. An actuator relative is arranged relative to the container assembly such that displacement of a button relative to the valve changes the valve from a closed configuration to an open configuration in which a portion of the propellant material is allowed to force the contained material out of the main chamber through the outlet. A first portion of the contained material is applied to the anomaly by directing the outlet at the anomaly and displacing the button. Optionally, a second portion of the contained material may be applied to the base coat by directing the outlet at the base coat and displacing the button. If applied, the second portion of the contained material forms a desired texture pattern on the base coat that substantially matches the pre-existing texture pattern.

Description:
RELATED APPLICATIONS 
       [0001]    This application (Attorney&#39;s Reference No. P217256) is a continuation of U.S. patent application Ser. No. 12/715,228 filed Mar. 1, 2010. 
         [0002]    U.S. patent application Ser. No. 12/715,228 is a continuation of U.S. patent application Ser. No. 12/080,687 filed Apr. 4, 2008, now abandoned. 
         [0003]    U.S. patent application Ser. No. 12/080,687 claims priority of U.S. Provisional Patent Application Ser. No. 60/922,041 filed on Apr. 4, 2007. 
         [0004]    The contents of all related applications listed above are incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0005]    The present invention relates to systems, methods, and compositions for repairing interior structure surfaces such as walls and ceilings and, more particularly, to such systems, methods, and compositions adapted to form a spackle base and a paintable texture 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]    To repair a hole in an existing wall, two functions are typically performed. First, a structural component is applied to form a bridge across the hole. Second, the structural component is coated substantially to match the coating on the wall surrounding the repair. 
         [0013]    The need exists for systems, methods, and compositions that simplify the two-step process of repairing a hole in an existing wall. 
       SUMMARY 
       [0014]    The present invention may be embodied as a method of covering an anomaly in a wall substantially to match a pre-existing texture pattern surrounding the anomaly, comprising the following steps. A container assembly is provided. A valve is supported on the container assembly to define a main chamber, where the valve operates in a closed configuration and an open configuration. Wall material concentrate is disposed within the main chamber, the wall material concentrate comprising 28.0-38.0% by weight of a solvent/carrier comprising water, 3.0-4.5% by weight of a resin/binder, and 57.4-64.8% by weight of filler material. Propellant material is disposed within the main chamber. The propellant material combines with the wall material concentrate to form a contained material. The propellant material comprises substantially within 5-20% by weight of the contained material. An actuator defining an outlet and a button is provided. The actuator is arranged relative to the container assembly such that displacement of the button relative to the valve changes the valve from the closed configuration to the open configuration, thereby allowing a portion of the propellant material to force the contained material out of the main chamber through the outlet. A first portion of the contained material is applied to the anomaly by directing the outlet at the anomaly and displacing the button. The first portion of the contained material is worked to form a base coat that covers the anomaly. 
         [0015]    The present invention may also be embodied as a method of covering an anomaly in a wall substantially to match a pre-existing texture pattern surrounding the anomaly comprising the following steps. A container assembly is provided. A valve is supported on the container assembly to define a main chamber, where the valve operates in a closed configuration and an open configuration. Contained material comprising propellant and wall material concentrate is disposed within the main chamber. An actuator defining an outlet and a button is provided. The actuator is arranged relative to the container assembly such that displacement of the button relative to the valve changes the valve from the closed configuration to the open configuration, thereby allowing a portion of the propellant material to force the contained material out of the main chamber through the outlet. A first portion of the contained material is applied to the anomaly to form a base coat by directing the outlet at the anomaly and displacing the button. A second portion of the contained material is applied to the base coat by directing the outlet at the base coat and displacing the button. The second portion of the contained material forms a desired texture pattern on the base coat that substantially matches the pre-existing texture pattern. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  is a side elevation view of a first example aerosol dispensing system for wall cover material of the present invention being used to apply the wall cover material; 
           [0017]      FIG. 2  is a perspective view of a first example actuator that may be employed by the first example aerosol dispensing system; 
           [0018]      FIGS. 3 and 4  are top and bottom plan views, respectively, of the first example actuator; 
           [0019]      FIG. 5  is a side elevation, sectional view of the first example actuator; 
           [0020]      FIG. 6  is a side elevation, sectional view of the first example actuator mounted on a container assembly of the first example aerosol dispensing system; 
           [0021]      FIG. 7  is a side elevation view similar to  FIG. 6  illustrating a first mode of operation of the example aerosol dispensing assembly; 
           [0022]      FIG. 8  is a side elevation view similar to  FIG. 6  illustrating a second mode of operation of the example aerosol dispensing assembly; 
           [0023]      FIG. 9  is a side elevation view similar to  FIG. 6  illustrating a third mode of operation of the example aerosol dispensing assembly; 
           [0024]      FIGS. 10A-10C  illustrate a two step process for repairing a wall surface using the example aerosol dispensing assembly; 
           [0025]      FIGS. 11A ,  11 B,  11 C, and  12  illustrate the process of using the example aerosol dispensing assembly to apply a base coat structure at a seam formed by adjacent wall panels of a wall surface; 
           [0026]      FIG. 13  is a top plan view of a second example actuator that may be employed by the first example aerosol dispensing system; 
           [0027]      FIG. 14  is a side elevation, sectional view of the second example actuator; 
           [0028]      FIG. 15  is a bottom plan view of the second example actuator; 
           [0029]      FIG. 16  is a top plan view of a stop member of the second example actuator; 
           [0030]      FIG. 17  is a side elevation view of the stop member depicted in  FIG. 16 ; 
           [0031]      FIGS. 18A ,  18 B, and  18 C illustrate a first mode of operation of the second example actuator; 
           [0032]      FIGS. 19A and 19B  illustrate a second mode of operation of the second example actuator; 
           [0033]      FIGS. 20A and 20B  illustrate a third mode of operation of the second example actuator; 
           [0034]      FIG. 21  illustrates the step of applying a base layer using the second example actuator; 
           [0035]      FIG. 22  illustrates the step of forming a knock-down texture using the example aerosol dispensing assembly; and 
           [0036]      FIGS. 23A-23D  illustrate the process of using the example aerosol dispensing assembly to repair a hole in a wall structure. 
       
    
    
     DETAILED DESCRIPTION 
       [0037]    Referring initially to  FIG. 1  of the drawing, depicted therein is an example aerosol dispensing system  20  constructed in accordance with, and embodying, the principles of the present invention. As will be described in further detail below, the aerosol dispensing system  20  is adapted to apply wall cover material  22  to a wall surface  24 . 
         [0038]    The example aerosol dispensing system  20  comprises an aerosol assembly  30  comprising a container assembly  32 , a valve  34  ( FIGS. 1 and 6 ), and an actuator  36 . The container assembly  32  and the valve  34  are or may be conventional and will be described herein only to the extent helpful for a complete understanding of the present invention. When combined to form the aerosol assembly  30 , the example container assembly  32  and valve  34  define a main chamber  38 . 
         [0039]    The main chamber  38  contains a liquid material  40  and a vapor material  42 . The liquid material  40  comes into contact with at least a portion of the container assembly  32  and the valve  34 . The liquid material  40  comprises texture material and propellant material in liquid form. The vapor material  42  comprises propellant material in vapor form. The liquid material  40  comprises propellant material in liquid form and a texture material concentrate. The combination of the liquid material  40  and the vapor material  42  in the aerosol assembly  30  will be referred to as the contained material  44 . 
         [0040]    When the valve  34  is in a closed configuration, the flow of fluid out of the main chamber  38  is substantially prevented. However, the vapor material  42  pressurizes the liquid material  40  within the main chamber  38  such that, when the valve  34  is in an open configuration, the vapor material  42  forces the liquid material  40  out of the main chamber  38 . 
         [0041]    The example texture material concentrate is formulated as described in the following table: 
       General Example of Wall Cover Material Concentrate 
       [0042]      
         [0000]    
       
         
               
               
               
               
             
           
               
                   
                   
               
               
                   
                   
                 FIRST 
                 SECOND 
               
               
                   
                   
                 PREFERRED 
                 PREFERRED 
               
               
                   
                 COMPONENT 
                 RANGE 
                 RANGE 
               
               
                   
                   
               
             
             
               
                   
                 solvent/carrier 
                 31.5-34.0%  
                 28.0-38.0% 
               
               
                   
                 resin/binder 
                  3.0-4.5% 
                  2.5-5.0% 
               
               
                   
                 fillers 
                 57.4-64.8% 
                 51.5-71.5% 
               
               
                   
                 defoamer 
                 0.15-0.22% 
                 0.10-0.30% 
               
               
                   
                   
               
             
          
         
       
     
         [0043]    The texture material concentrate described in the table set forth above is combined in the container assembly  32  with the propellant material to obtain the contained material  44 . The preferred amount of propellant material used to form the example dispensing system  20  is approximately 10.0% of the contained material  44  by weight and is preferably within a first preferred range of 7.5-12.5% by weight of the contained material  44  and is in any event preferably within a second preferred range of 5-20% by weight. 
         [0044]    The texture material concentrate is preferably formulated and combined with propellant material as follows. If used, anti-corrosion materials are initially dissolved in the water. The remaining materials are then mixed with the water solution to obtain the wall cover material concentrate. The wall cover material concentrate is introduced into the container assembly  32 , and the valve  34  is mounted onto the container assembly  32  to form the aerosol assembly  30 . The propellant material is then introduced into the container assembly  32  through the valve  34  to form the dispensing system  20 . 
         [0045]    With the foregoing general understanding of the present invention, the details of several example formulations of the wall cover material concentrate and the construction and use of the example aerosol dispensing system  20  will now be described in further detail. 
         [0046]    Referring now to  FIGS. 2-5 , it can be seen that the actuator  36  comprises a base  120 , an outlet  122 , and a button  124 . A valve stem  126  ( FIG. 6 ) extends from the valve  34  into the button  124 . Optionally, the valve stem  126  may extend from the button  124  into the valve  34 . 
         [0047]    An actuator passageway  130  between an outlet opening  132  formed in the outlet  122  and a valve opening  134  formed in the button  124 . The base  120  is sized and dimensioned to be mounted on the container assembly  32  such that a valve stem  126  extends into the valve opening  134 . The outlet  122  defines an elongate outlet portion  136  of the actuator passageway  130 . 
         [0048]    The button  124  is pivotably supported by the base  120  such that pressing the button  124  causes the button  124  to move relative to the base  120  from an undeformed or proximal position  140  ( FIG. 6 ) to a fully deformed or distal position  142  ( FIG. 9 ). 
         [0049]    When button  124  is in the proximal position, the valve stem  126  is in a fully extended position, and the valve  24  is in its closed position. As the button  124  pivots relative to the base  120  from the proximal position to the distal position, the button  124  displaces the valve stem  126 , placing the valve  34  in an open configuration. The valve  34  is variable in that, as the valve stem  126  moves from the fully extended position, as size of a valve opening defined by the valve  34  increases. Many conventional aerosol valves operate in this way, and the dispensing system  20  may use any aerosol valve that defines a variable valve opening and can handle the viscosity of the liquid material  40 . 
         [0050]    The size of the valve opening determines how the liquid material  40  is dispensed by the dispensing system  20 . As shown in  FIG. 7 , when the button  124  is displaced into a first intermediate position  144  between the proximal and distal positions, the valve opening is relatively small, and the liquid material  40  is dispensed in relatively large discrete portions. In particular, the viscosity of the liquid material  40  is such that the vapor material  42  cannot drive the liquid material  40  out of the main chamber  38  in a steady stream, and not much of the propellant is entrained within the dispensed liquid material  40 . Accordingly, the wall cover material  22  is deposited on the wall surface  24  in a relatively rough coat of relatively large droplets  150 . 
         [0051]    As shown in  FIG. 8 , when the button  124  is displaced into a second intermediate position  146  between the proximal and distal positions, the valve opening is slightly larger, and the liquid material  40  is dispensed in medium-sized discrete portions. In particular, with the valve opening slightly larger, the viscosity of the liquid material  40  is such that the vapor material  42  drives more of the liquid material  40  out of the main chamber  38  in a steady stream, and more of the propellant material is entrained within the dispensed liquid material  40 . The entrained propellant material breaks up the liquid material  40  such that the wall cover material  22  is deposited on the wall surface  24  in a medium coat of medium-sized droplets  152 . 
         [0052]    As shown in  FIG. 9 , when the button  124  is displaced into the distal position  142 , the valve opening is at its largest, and the liquid material  40  is dispensed in relatively small discrete portions. In particular, with the valve opening at its largest, the vapor material  42  drives a relatively large quantity of the liquid material  40  out of the main chamber  38  in a steady stream, with correspondingly more of the propellant material entrained within the stream of dispensed liquid material  40 . Accordingly, the increased amount of entrained propellant material tends to atomize the wall cover material  22  such that the wall cover material  22  is deposited on the wall surface  24  in a fine coat of small droplets  154 . 
         [0053]      FIGS. 10A-10C  illustrate one example of how the example dispensing system  20  may be used. Initially, a base coat  160  comprising a relatively large amount of wall cover material  22  is applied to the wall surface  24 . The base coat  160  may be formed by continuous application of wall material  22  that builds up to form the base coat  160 . Optionally, as shown in  FIG. 10B , a tool  162  may be used to work the applied wall cover material  22  to form a relatively smooth surface  164  on the base coat  160 . 
         [0054]    Other portions of the wall surface  24  may be textured, which defines a pre-existing texture pattern. If so, once the base coat  160  has been formed, a texture coat  166  may be formed on the base coat  160  by again applying the wall cover material  22  to the base coat  160 . When forming the texture coat  166 , the button  124  is depressed to a desired position between the proximal and distal positions when applying the texture coat  166 . In this desired position, the wall cover material  22  is dispensed in droplets sized and dimensioned such that the texture pattern of the applied texture coat  166  substantially matches the pre-existing texture pattern. 
         [0055]    The dispensing system  20  thus allows a product to form both the base coat  160  and the texture coat  166 . Optionally, the dispensing system  20  may be used to form only the base coat  160  or only the texture coat  166 . The dispensing system  20  of the present invention thus provides the user with significant flexibility to perform a wide variety of wall repair functions with a single product. 
         [0056]      FIGS. 11A-11C  illustrate another example of the use of the dispensing system  20 . As shown in  FIG. 11A , in this second example of use of the dispensing system  20 , the wall surface  24  is formed by first and second wall panels  170  and  172 . A gap  174  is formed between the wall panels  170  and  172 . Drywall tape  176  is adhered to the wall panels  170  and  172  such that the tape  176  extends across the gap  174 . 
         [0057]    A base coat  180  is formed by applying a raw layer  182  of the wall cover material  22  to the wall surface  24  over the drywall tape  176 . The raw layer  182  is worked with the tool  162  such that the resulting base coat  180  defines a relatively smooth surface  184 . The base coat  180  may also be sanded when dry or otherwise worked. A texture coat may or may not be formed on the base coat  180 . 
         [0058]      FIG. 12  illustrates that the dispensing system  20  may be used to form a texture coat  190  on the wall surface  24  without first forming a base coat using the wall cover material  22 . 
         [0059]    Referring now to  FIGS. 13-20 , described therein is a second example actuator  36   a  that may be used in place of the actuator  36  described above. 
         [0060]    The second example actuator  36   a  comprises a base member  220  and a stop member  222 . The base member  220  comprises a base  230 , an outlet  232 , and a button  234 . 
         [0061]    An actuator passageway  240  between an outlet opening  242  formed in the outlet  232  and a valve opening  244  formed in the button  234 . The base  230  is sized and dimensioned to be mounted on the container assembly  32  such that a valve stem extends into the valve opening  244 . The outlet  232  defines an elongate outlet portion  246  of the actuator passageway  240 . 
         [0062]    The stop member  222  defines a main surface  250  and first, second, and third stop surfaces  252 ,  254 , and  256 . First, second, third, and fourth indicia  260 ,  262 ,  264 , and  266  are on the main surface. The first, second, and third indicia  260 ,  262 , and  264  are associated with the first, second, and third stop surfaces  252 ,  254 , and  256 , respectively, and the fourth indicia is associated with the main surface  250 . 
         [0063]    The button  234  is pivotably supported by the base  230  such that pressing the button  234  causes the button  234  to move relative to the base  230  from an undeformed or proximal position  270  ( FIG. 14 ) to a fully deformed or distal position  272  ( FIG. 20B ). 
         [0064]    When button  234  is in the proximal position, the valve stem  236  is in a fully extended position, and the valve  24  is in its closed position. As the button  234  pivots relative to the base  230  from the proximal position to the distal position, the button  234  displaces the valve stem  236 , placing the valve  34  in an open configuration. Again, the valve  34  is variable in that, as the valve stem  236  moves from the fully extended position, as size of a valve opening defined by the valve  34  increases. Many conventional aerosol valves operate in this way, and the dispensing system  20  may use any aerosol valve that defines a variable valve opening and can handle the viscosity of the liquid material  40 . 
         [0065]    The size of the valve opening determines how the liquid material  40  is dispensed by the dispensing system  20 . As shown in  FIG. 18C , when the button  234  is displaced into a first intermediate position  274  between the proximal and distal positions, the valve opening is relatively small, and the liquid material  40  is dispensed in relatively large discrete portions. In particular, the viscosity of the liquid material  40  is such that the vapor material  42  cannot drive the liquid material  40  out of the main chamber  38  in a steady stream, and not much of the propellant is entrained within the dispensed liquid material  40 . Accordingly, the wall cover material  22  is deposited on the wall surface  24  in a relatively rough coat of relatively large droplets  150 . 
         [0066]    As shown in  FIG. 19B , when the button  234  is displaced into a second intermediate position  276  between the proximal and distal positions, the valve opening is slightly larger, and the liquid material  40  is dispensed in medium-sized discrete portions. In particular, with the valve opening slightly larger, the viscosity of the liquid material  40  is such that the vapor material  42  drives more of the liquid material  40  out of the main chamber  38  in a steady stream, and more of the propellant material is entrained within the dispensed liquid material  40 . The entrained propellant material breaks up the liquid material  40  such that the wall cover material  22  is deposited on the wall surface  24  in a medium coat of medium-sized droplets  152 . 
         [0067]    As shown in  FIG. 20B , when the button  234  is displaced into the distal position  272 , the valve opening is at its largest, and the liquid material  40  is dispensed in relatively small discrete portions. In particular, with the valve opening at its largest, the vapor material  42  drives a relatively large quantity of the liquid material  40  out of the main chamber  38  in a steady stream, with correspondingly more of the propellant material entrained within the stream of dispensed liquid material  40 . Accordingly, the increased amount of entrained propellant material tends to atomize the wall cover material  22  such that the wall cover material  22  is deposited on the wall surface  24  in a fine coat of small droplets  154 . 
         [0068]    The stop member  222  is arranged such that the main surface  250  corresponds to the distal position  272  and the first, second, and third stop surfaces  252 ,  254 , and  256  correspond to the proximal position  270 , the first intermediate position  274 , and the second intermediate position  276 , respectively, of the button  234 . In particular, the example stop member  222  is arranged to rotate relative to the base member  220  such that the main surface  250  and the stop surfaces  252 ,  254 , and  256  limit the travel of the button  234  as perhaps best shown by a comparison of  FIGS. 18B and 18C . 
         [0069]      FIG. 21  illustrates that the dispensing system  20  may be used to form a thin, relatively smooth cover coat  320 . In particular, operating the valve by placing the button in the distal position applies small droplets that accumulate to form a thin, relatively smooth layer. 
         [0070]      FIG. 22  illustrates that the dispensing system  20  may be used to form what is referred to as a knock down texture pattern. In particular, relatively large droplets  330  have been formed on the wall surface  24 , and the tool  162  used to flatten the tops of these droplets  330  to obtain a knockdown texture  332 . 
         [0071]      FIGS. 23A-23D  illustrate that a drywall panel  420  defines a hole  422  to be repaired. Existing texture material  424  defines a pre-existing texture pattern on the panel  420 . A patch  426  is to be used to cover the hole  422 . The existing texture material  424  may be removed in a repair area indicated by reference character  430 . The patch  426  is adhered to the panel  420  over the hole  422 . A cover coat  432  is applied to the repair area  430  over the patch  426 . The wall repair material  22  dispensed by the system  20  may be applied such that the texture pattern of the cover coat  432  substantially matches the pre-existing texture pattern. 
         [0072]    Because at least a portion of the container assembly  32  is metal and thus may be susceptible to corrosion, the wall cover material concentrate is formulated to have anti-corrosion properties. The example wall cover material concentrate thus comprises at least one anti-corrosion material. The anti-corrosion material should be in a first range of approximately 0.5-3.0% by weight and in any event should be in a second range of 0.125-7.0%. 
         [0073]    The example wall cover material concentrate comprises first and second anti-corrosion materials. The first anti-corrosion material is in a first preferred range of approximately 0.5-2.0% by weight of the wall cover material concentrate and in any event should be within a second preferred range of approximately 0.1-5.0% by weight. The second anti-corrosion material is in a first preferred range of approximately 0.05-1.0% by weight of the wall cover material concentrate and in any event should be within a second preferred range of approximately 0.025-2.0% by weight. 
         [0074]    The example first anti-corrosion material is an anionic, phosphate ester. The first anti-corrosion material is or may be Elfugin, 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 wall cover material concentrate is sodium nitrite. In the general example described above, approximately 0.200% (±5%) of the first anti-corrosion material is preferably used. The exact amount of the first and second anti-corrosion materials depends upon the nature of the remaining components of the wall cover material concentrate and the propellant. 
       Example of 
     Wall Cover Material Concentrate 
       [0075]    When sprayed onto a target surface as will be described in further detail below, the first example wall cover material concentrate forms what is commonly referred to as a “knockdown” spray texture pattern. A knockdown spray texture is formed by a bumpy, irregular texture pattern that is lightly worked with a tool after application to the target surface such that the tops of the bumps formed by the wall cover material are flattened. 
         [0000]    
       
         
               
               
               
               
             
           
               
                   
               
               
                   
                   
                 FIRST 
                 SECOND 
               
               
                   
                   
                 PREFERRED 
                 PREFERRED 
               
               
                 COMPONENT 
                 PREFERRED 
                 RANGE 
                 RANGE 
               
               
                   
               
             
             
               
                 solvent/carrier (water) 
                 32.840% 
                 31.5-34.0 
                 28-38 
               
               
                 resin/binder (Wacker 
                  3.850% 
                 3.0-4.5 
                 2.5-5.0 
               
               
                 RE5028N) 
                   
                   
                   
               
               
                 defoamer (Henkel A-7) 
                  0.185% 
                 0.15-0.22 
                 0.10-0.30 
               
               
                 first anti-corrosion 
                   1.0% 
                 0.5-1.5% 
                 0.1-5.0% 
               
               
                 material (Elfugin) 
                   
                   
                   
               
               
                 second anti-corrosion 
                   0.2% 
                 0.15-0.25 
                 0.05-0.35 
               
               
                 material (NaNo2) 
                   
                   
                   
               
               
                 Biocide (CS1135) 
                  0.10% 
                  0.8-0.12 
                 0.5-2.0 
               
               
                 Thickening Clay 
                  1.370% 
                 1.2-1.5 
                 0.5-2.0 
               
               
                 (Minugel FG) 
                   
                   
                   
               
               
                 Silica Filler (SilcoSil 
                  2.750% 
                 2.20-3.30 
                 1.0-4.5 
               
               
                 CT450) 
                   
                   
                   
               
               
                 Calcium Carbonate 
                 57.505% 
                 54.0-60.0 
                 50.0-65.0 
               
               
                 Filler (Imasco200x 
                   
                   
                   
               
               
                 CaCO3) 
                   
                   
                   
               
               
                 Shear-sensitive 
                   0.2% 
                   0-0.40 
                   0-1.0 
               
               
                 Thickener (Accusol 
                   
                   
                   
               
               
                 320 R&amp;H) 
               
               
                   
               
             
          
         
       
     
         [0076]    In the foregoing example, the amounts of the first and second anti-corrosion materials are preferably held to tolerances of substantially ±5% of the amounts specified in the foregoing table.