Patent Publication Number: US-2012041107-A1

Title: Wood filler composition with kevlar

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/373,088 filed on Aug. 12, 2010 and entitled “Wood Filling Composition with Kevlar”, the disclosure of which is hereby incorporated by reference herein in its entirety and made part of the present U.S. utility patent application for all purposes. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to a wood filling composition, and more specifically to a stainable wood filling composition that includes a relatively low level of Kevlar for improving the abrasion resistance of a dried film of the composition. 
     Wood fillers are traditionally used to repair blemishes, holes, and other defects in common household items such as wood furniture and/or wood flooring. Recent formulations research has improved the durability of such products by the inclusion of ceramic microspheres; see, for example, U.S. Pat. No. 6,956,069 (2005) and U.S. Pat. No. 7,504,447 (2009), both of which are incorporated by reference herein in their entirety for all purposes. However, for applications involving heavy traffic or wear there is still a need to further improve the long-term durability of such repair products. 
     SUMMARY OF THE INVENTION 
     The following provides a summary of certain exemplary embodiments of the present invention. This summary is not an extensive overview and is not intended to identify key or critical aspects or elements of the present invention or to delineate its scope. 
     In accordance with one aspect of the present invention, a wood filling composition is provided. This composition includes a predetermined weight percent of ceramic microspheres; and a predetermined weight percent of polyaramid fiber, such as KEVLAR. This composition may also include a predetermined weight percent of at least one colored pigment; at least one bactericide; at least one mildewcide; at least one surfactant; at least one dispersant; at least one freeze-thaw stabilizer; at least one defoamer; at least one polymer; at least one adhesion promoter; at least one thickener; at least one filler; water; wood flour, glass bubbles; or combinations thereof. 
     In accordance with another aspect of the present invention, an alternate wood filling composition is provided. This composition includes a predetermined weight percent of ceramic microspheres; a predetermined weight percent of polyaramid fiber, such as KEVLAR; and a predetermined weight percent of at least one colored pigment. This composition may also include a predetermined weight percent of at least one bactericide; at least one mildewcide; at least one surfactant; at least one dispersant; at least one freeze-thaw stabilizer; at least one defoamer; at least one polymer; at least one adhesion promoter; at least one thickener; at least one filler; water; wood flour, glass bubbles; or combinations thereof. 
     In yet another aspect of this invention, another wood filling composition is provided. This composition includes a predetermined weight percent of ceramic microspheres; a predetermined weight percent of polyaramid fiber, such as KEVLAR; a predetermined weight percent of at least one colored pigment; and a predetermined weight percent of wood flour. This composition may also include a predetermined weight percent of at least one bactericide; at least one mildewcide; at least one surfactant; at least one dispersant; at least one freeze-thaw stabilizer; at least one defoamer; at least one polymer; at least one adhesion promoter; at least one thickener; at least one filler; water; glass bubbles; or combinations thereof. 
     Additional features and aspects of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the exemplary embodiments. As will be appreciated by the skilled artisan, further embodiments of the invention are possible without departing from the scope and spirit of the invention. Accordingly, the drawings and associated descriptions are to be regarded as illustrative and not restrictive in nature. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Exemplary embodiments of the present invention are now described with reference to the examples provided herein. Although the following detailed description contains many specifics for purposes of illustration, a person of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention. 
     In accordance with the present invention, the incorporation of KEVLAR, a polyaramid fiber, improves the wear and abrasion resistance of wood filling products. KEVLAR is known to be a difficult material to blend into most formulas; however, when KEVLAR is mixed with the ceramic microspheres contained in the exemplary formulas of the present invention, the abrasiveness of the ceramic microspheres has been shown to facilitate dispersion of the KEVLAR into the formula. Thus, in the absence of ceramic microspheres, effective incorporation of KEVLAR would likely be problematic, especially for a waterborne formulation. 
     In addition to polyaramid fiber and KEVLAR, the wood filling compositions of the present invention include various additional ingredients that increase the effectiveness of the compositions or otherwise enhance their performance and stability. As previously stated, these ingredients include a predetermined weight percent of at least one colored pigment; at least one bactericide; at least one mildewcide; at least one surfactant; at least one dispersant; at least one freeze-thaw stabilizer; at least one defoamer; at least one polymer; at least one adhesion promoter; at least one thickener; at least one filler; water; wood flour, glass bubbles; or combinations thereof. 
     Having generally described this invention, a further understanding can be obtained by reference to certain specific examples detailed below, which are provided for purposes of illustration only and are not intended to be all inclusive or limiting unless otherwise specified. In addition to specific ingredients and general descriptions thereof, manufacturers or sources of the various ingredients are provided below, as is an exemplary manufacturing process or procedure for each formulation. 
     Example 1 
       
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 WOOD FILLER MAX -- STAINABLE (TUB &amp; TUBE FORMULA) 
               
            
           
           
               
               
               
               
               
            
               
                   
                   
                 % BY 
                   
                   
               
               
                   
                 INGREDIENT 
                 WEIGHT 
                 DESCRIPTION 
                 MANUFACTURER 
               
               
                   
                   
               
            
           
           
               
               
               
               
               
            
               
                 1 
                 Water 
                 12.000 
                 solvent 
                 Fischer Scientific 
               
               
                 2 
                 Acticide LA 
                 0.100 
                 bactericide 
                 Thor USA 
               
               
                 3 
                 Triton X-405 
                 0.500 
                 surfactant 
                 Dow Chemical 
               
               
                 4 
                 Tamol 851 
                 0.500 
                 dispersant 
                 Dow Chemical 
               
               
                 5 
                 Propylene Glycol 
                 1.500 
                 freeze-thaw stabilizer 
                 Dow Chemical 
               
               
                 6 
                 Foamaster NXZ OR Defoamer XZ 
                 0.030 
                 defoamer 
                 Cognis 
               
               
                 7 
                 Tint-Ayd CW-5509 OR Resotint Umber 2TC 
                 0.060 
                 colored pigment 
                 Elementis/CRI 
               
               
                 8 
                 Aqua Yellow 597-49 OR Resotint Yellow TC 
                 0.250 
                 colored pigment 
                 Elementis/CRI 
               
               
                 9 
                 Water 
                 1.000 
                 solvent 
                 Fischer Scientific 
               
               
                 10 
                 Rhoplex E330 
                 10.350 
                 polymer 
                 Rohm &amp; Haas 
               
               
                 11 
                 Rhoplex AC-2235M 
                 4.950 
                 polymer 
                 Rohm &amp; Haas 
               
               
                 12 
                 Kevlar 1F538 
                 0.150 
                 polyaramid fiber 
                 Dupont 
               
               
                 13 
                 Maple Wood Flour 4010 
                 3.100 
                 wood flour 
                 American Wood Fibers 
               
               
                 14 
                 #10 White OR Huber G325 
                 32.350 
                 filler 
                 Imerys OR Huber 
               
               
                 15 
                 Calwhite OR Hubercarb G6 
                 15.800 
                 filler 
                 Imerys OR Huber 
               
               
                 16 
                 Methocel E4M 
                 0.400 
                 thickener 
                 Dow Chemical 
               
               
                 17 
                 Acticide 45 
                 0.100 
                 mildewcide 
                 Thor USA 
               
               
                 18 
                 Silane A-187 
                 0.100 
                 adhesion promoter 
                 Momentive 
               
               
                 19 
                 Extendosphere TG 
                 16.000 
                 ceramic microspheres 
                 Sphere One/Kish Co. 
               
               
                 20 
                 Foamaster NXZ OR Defoamer XZ 
                 0.030 
                 defoamer 
                 Cognis 
               
               
                 21 
                 Water - adjusting 
                 0.730 
                 solvent 
                 Fischer Scientific 
               
               
                   
                   
                 100.00 
               
               
                   
               
               
                 Manufacturing Procedure for Example 1: 
               
               
                 1. In a clean, dry tank, add items 1, 2, 3, 4, 5 and 6. 
               
               
                 2. Add items 7 and 8 and use item 9 to rinse the container used to weigh the pigments. 
               
               
                 3. Continue mixing and add items 10, 11, 12 and 13. 
               
               
                 4. Continue mixing. Start high speed mixer and add items 14, 15 and 16. PRE-MIX ITEM 16 WITH SOME OF ITEM 15 TO AVIOD LUMPING. Mix thoroughly until lump free. Turn OFF high speed mixer at this stage but continue mixing with wiper and auger blades. 
               
               
                 5. Add items 17, 18, 19 and 20. 
               
               
                 6. Seal the lid tight on the mixing tank. Continue mixing with wiper blade only and turn on vacuum for two minutes. 
               
               
                 7. Turn off vacuum and mixer and remove a sample for Q.C. check. 
               
               
                 8. Adjust viscosity with item 21 as necessary by adding in small increments and keep testing until the viscosity is in specified range. 
               
            
           
         
       
     
     Example 2 
       
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 WOOD FILLER MAX - NATURAL (TUBE FORMULA) 
               
            
           
           
               
               
               
               
               
            
               
                   
                   
                 % BY 
                   
                   
               
               
                   
                 INGREDIENT 
                 WEIGHT 
                 DESCRIPTION 
                 MANUFACTURER 
               
               
                   
                   
               
            
           
           
               
               
               
               
               
            
               
                 1 
                 Water 
                 10.328 
                 solvent 
                 Fischer Scientific 
               
               
                 2 
                 Acticide LA 
                 0.100 
                 bactericide 
                 Thor USA 
               
               
                 3 
                 Triton X-405 
                 0.350 
                 surfactant 
                 Dow Chemical 
               
               
                 4 
                 Tamol 851 
                 0.350 
                 dispersant 
                 Dow Chemical 
               
               
                 5 
                 Propylene Glycol 
                 1.500 
                 freeze-thaw stabilizer 
                 Dow Chemical 
               
               
                 6 
                 Foamaster NXZ OR Defoamer XZ 
                 0.030 
                 defoamer 
                 Cognis 
               
               
                 7 
                 Tint-Ayd CW-5003 Titanium Dioxide 
                 0.994 
                 colored pigment 
                 Elementis 
               
               
                 8 
                 Tint-Ayd CW-5451 Light Lemon Yellow Oxide 
                 0.442 
                 colored pigment 
                 Elementis 
               
               
                 9 
                 Water 
                 0.793 
                 solvent 
                 Fischer Scientific 
               
               
                 10 
                 Rhoplex E330 
                 10.271 
                 polymer 
                 Rohm &amp; Haas 
               
               
                 11 
                 Rhoplex AC-2235M 
                 4.910 
                 polymer 
                 Rohm &amp; Haas 
               
               
                 12 
                 Kevlar 1F538 
                 0.150 
                 polyaramid fiber 
                 Dupont 
               
               
                 13 
                 Maple Wood Flour 4010 
                 3.082 
                 wood flour 
                 American Wood Fibers 
               
               
                 14 
                 #10 White OR Huber G325 
                 32.105 
                 filler 
                 Imerys OR Huber 
               
               
                 15 
                 Calwhite OR Hubercarb G6 
                 12.490 
                 filler 
                 Imerys OR Huber 
               
               
                 16 
                 Methocel E4M 
                 0.350 
                 thickener 
                 Dow Chemical 
               
               
                 17 
                 Acticide 45 
                 0.100 
                 mildewcide 
                 Thor USA 
               
               
                 18 
                 Silane A-187 
                 0.100 
                 adhesion promoter 
                 Momentive 
               
               
                 19 
                 Extendosphere TG 
                 17.870 
                 ceramic microspheres 
                 Sphere One/Kish Co. 
               
               
                 20 
                 Foamaster NXZ OR Defoamer XZ 
                 0.030 
                 defoamer 
                 Cognis 
               
               
                 21 
                 3M Glass Bubbles K20 
                 0.994 
                 thickening agent 
                 3M 
               
               
                 22 
                 Water 
                 0.492 
                 solvent 
                 Fischer Scientific 
               
               
                 23 
                 Water - adjusting 
                 2.169 
                 solvent 
                 Fischer Scientific 
               
               
                   
                   
                 100.00 
               
               
                   
               
               
                 Manufacturing Procedure for Example 2: 
               
               
                 1. In a clean, dry tank, add items 1, 2, 3, 4, 5 and 6. 
               
               
                 2. Add items 7 and 8 and use item 9 to rinse the container used to weigh the pigments. 
               
               
                 3. Continue mixing and add items 10, 11, 12 and 13. 
               
               
                 4. Continue mixing. Start high speed mixer and add items 14, 15 and 16. HINT: PRE-MIX ITEM 16 WITH SOME OF ITEM 15 TO AVIOD LUMPING. Mix thoroughly until lump free. Turn OFF high speed mixer at this stage but continue mixing with wiper and auger blades. 
               
               
                 5. Add items 17, 18, 19 and 20. 
               
               
                 6. Add item 21 and immediately follow up with item 22. 
               
               
                 7. Seal the lid tight on the mixing tank. Continue mixing with wiper blade only and turn on vacuum for two minutes. 
               
               
                 8. Turn off vacuum and mixer and remove a sample for Q.C. check. 
               
               
                 9. Adjust viscosity with item 23 as necessary by adding in small increments and keep testing until the viscosity is in specified range. 
               
            
           
         
       
     
     Example 3 
       
     
       
         
           
               
             
               
                 TABLE 3 
               
             
            
               
                   
               
               
                 WOOD FILLER MAX - CHERRY (TUBE FORMULA) 
               
            
           
           
               
               
               
               
               
            
               
                   
                   
                 % BY 
                   
                   
               
               
                   
                 INGREDIENT 
                 WEIGHT 
                 DESCRIPTION 
                 MANUFACTURER 
               
               
                   
                   
               
            
           
           
               
               
               
               
               
            
               
                 1 
                 Water 
                 10.421 
                 solvent 
                 Fischer Scientific 
               
               
                 2 
                 Acticide LA 
                 0.100 
                 bactericide 
                 Thor USA 
               
               
                 3 
                 Triton X-405 
                 0.350 
                 surfactant 
                 Dow Chemical 
               
               
                 4 
                 Tamol 851 
                 0.350 
                 dispersant 
                 Dow Chemical 
               
               
                 5 
                 Propylene Glycol 
                 1.500 
                 freeze-thaw stabilizer 
                 Dow Chemical 
               
               
                 6 
                 Foamaster NXZ OR Defoamer XZ 
                 0.030 
                 defoamer 
                 Cognis 
               
               
                 7 
                 Tint-Ayd CW-5509 Burnt Umber OR Resotint 
                 1.760 
                 colored pigment 
                 Elementis or CRI 
               
               
                   
                 Umber 2TC 
               
               
                 8 
                 Tint-Ayd CW-5451 Light Lemon Yellow Oxide 
                 0.330 
                 colored pigment 
                 Elementis 
               
               
                 9 
                 Tint-Ayd CW-5611 Red Iron Oxide Medium 
                 0.110 
                 colored pigment 
                 Elementis 
               
               
                 10 
                 Tint-Ayd CW-5317 Tinting Black 
                 0.022 
                 colored pigment 
                 Elementis 
               
               
                 11 
                 Water 
                 0.803 
                 solvent 
                 Fischer Scientific 
               
               
                 12 
                 Rhoplex E330 
                 10.325 
                 polymer 
                 Rohm &amp; Haas 
               
               
                 13 
                 Rhoplex AC-2235M 
                 4.950 
                 polymer 
                 Rohm &amp; Haas 
               
               
                 14 
                 Kevlar 1F538 
                 0.150 
                 polyaramid fiber 
                 Dupont 
               
               
                 15 
                 Maple Wood Flour 4010 
                 3.103 
                 wood flour 
                 American Wood Fibers 
               
               
                 16 
                 #10 White OR Huber G325 
                 32.503 
                 filler 
                 Imerys OR Huber 
               
               
                 17 
                 Calwhite OR Hubercarb G6 
                 12.582 
                 filler 
                 Imerys OR Huber 
               
               
                 18 
                 Methocel E4M 
                 0.350 
                 thickener 
                 Dow Chemical 
               
               
                 19 
                 Acticide 45 
                 0.100 
                 mildewcide 
                 Thor USA 
               
               
                 20 
                 Silane A-187 
                 0.100 
                 adhesion promoter 
                 Momentive 
               
               
                 21 
                 Extendosphere TG 
                 17.583 
                 ceramic microspheres 
                 Sphere One/Kish Co. 
               
               
                 22 
                 Foamaster NXZ OR Defoamer XZ 
                 0.030 
                 defoamer 
                 Cognis 
               
               
                 23 
                 3M Glass Bubbles K20 
                 1.000 
                 thickening agent 
                 3M 
               
               
                 24 
                 Water 
                 0.502 
                 solvent 
                 Fischer Scientific 
               
               
                 25 
                 Water - adjusting 
                 0.946 
                 solvent 
                 Fischer Scientific 
               
               
                   
                   
                 100.00 
               
               
                   
               
               
                 Manufacturing Procedure for Example 3: 
               
               
                 1. In a clean, dry tank, add items 1, 2, 3, 4, 5 and 6. 
               
               
                 2. Add items 7, 8, 9, 10 and use item 11 to rinse the container used to weigh the pigments. 
               
               
                 3. Continue mixing and add items 12, 13, 14 and 15. 
               
               
                 4. Continue mixing. Start high speed mixer and add items 16, 17 and 18. HINT: PRE-MIX ITEM 18 WITH SOME OF ITEM 17 TO AVIOD LUMPING. Mix thoroughly until lump free. Turn OFF high speed mixer at this stage but continue mixing with wiper and auger blades. 
               
               
                 5. Add items 19, 20, 21 and 22. 
               
               
                 6. Add item 23 and immediately follow up with item 24. 
               
               
                 7. Seal the lid tight on the mixing tank. Continue mixing with wiper blade only and turn on vacuum for two minutes. 
               
               
                 8. Turn off vacuum and mixer and remove a sample for Q.C. check. 
               
               
                 9. Adjust viscosity with item 25 as necessary by adding in small increments and keep testing until the viscosity is in specified range. 
               
            
           
         
       
     
     While the present invention has been illustrated by the description of exemplary embodiments thereof, and while the embodiments have been described in certain detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to any of the specific details, representative devices and methods, and/or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant&#39;s general inventive concept.