Patent Abstract:
A system for dispensing texture material in a desired spray pattern that substantially matches an existing texture pattern on a target surface has a container assembly, an actuator assembly, and a concentrate comprising a solvent/carrier comprising water, wall texture material comprising at least one filler and a resin/binder, a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester, and a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite. At least one of the first and second anti-corrosion materials forms a film on the inner surface of the container assembly while the concentrate is stored within the container assembly. The film inhibits corrosion of the corrodible material forming at least part of the inner surface of the container assembly. The first and second anti-corrosion materials together comprise 0.125-7.00% by weight of the concentrate.

Full Description:
RELATED APPLICATIONS 
     This application, U.S. patent application Ser. No. 15/236,507 filed Aug. 15, 2016, is a continuation of U.S. patent application Ser. No. 14/338,231 filed Jul. 22, 2014, now U.S. Pat. No. 9,415,927, which issued on Aug. 16, 2016. 
     U.S. patent application Ser. No. 14/338,231 is a continuation of U.S. patent application Ser. No. 14/047,195 filed Oct. 7, 2013, now U.S. Pat. No. 8,784,942, which issued on Jul. 22, 2014. 
     U.S. patent application Ser. No. 14/047,195 is a continuation of U.S. patent application Ser. No. 13/610,743 filed Sep. 11, 2012, now U.S. Pat. No. 8,551,572, which issued Oct. 8, 2013. 
     U.S. patent application Ser. No. 13/610,743 is a continuation of U.S. patent application Ser. No. 13/396,538 filed Feb. 14, 2012, now abandoned. 
     U.S. patent application Ser. No. 13/396,538 is a continuation of U.S. patent application Ser. No. 13/181,326 filed Jul. 12, 2011, now abandoned. 
     U.S. patent application Ser. No. 13/181,326 is a continuation of U.S. patent application Ser. No. 12/837,254 filed Jul. 15, 2010, now abandoned. 
     U.S. patent application Ser. No. 12/837,254 is a continuation of U.S. patent application Ser. No. 12/080,096 filed Mar. 31, 2008, now abandoned. 
     U.S. patent application Ser. No. 12/080,096 claims benefit of U.S. Provisional Patent Application Ser. No. 60/922,041 filed Apr. 4, 2007. 
     The contents of all related patent applications listed above are incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to materials for forming a textured coating on a target surface and, more particularly, to compositions of water-based texture materials and systems and methods for dispensing water-based texture materials from either aluminum or tin-plated steel containers. 
     BACKGROUND 
     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. 
     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. 
     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. 
     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. 
     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. 
     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. 
     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. 
     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. 
     The need thus exists for formulations of either water based or water/solvent based texture materials that may be used in either aluminum or tin-plated steel aerosol container assemblies without significant risk of corrosion. 
     SUMMARY 
     The present invention may also be embodied as a system for dispensing texture material in a desired spray pattern that substantially matches an existing texture pattern on a target surface comprising a container assembly, an actuator assembly, and a concentrate. The container assembly defining an inner surface formed at least in part of a corrodible material. The actuator assembly defines an outlet opening having an adjustable cross-sectional area. The concentrate comprises a solvent/carrier comprising water, wall texture material comprising at least one filler and a resin/binder, a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester, and a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite. The concentrate is disposed within the container assembly such that the water is exposed to the inner surface of the container assembly. At least one of the first and second anti-corrosion materials forms a film on the inner surface of the container assembly while the concentrate is stored within the container assembly, where the film inhibits corrosion of the corrodible material forming at least part of the inner surface of the container assembly. The concentrate passes through the outlet opening in a spray pattern that forms the desired texture pattern on the target surface. The first and second anti-corrosion materials together comprise 0.125-7.00% by weight of the concentrate. 
     The present invention may also be embodied as a texture material concentrate to be dispensed in a desired spray pattern from a container assembly defining an inner surface formed at least in part of a corrodible material using an actuator assembly defining an outlet opening having an adjustable cross-sectional area, where the desired spray pattern that substantially matches an existing texture pattern on a target surface. The texture material concentrate comprises a solvent/carrier comprising water, wall texture material comprising at least one filler and a resin/binder, a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester, and a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite. The concentrate is disposed within the container assembly such that the water is exposed to the inner surface of the container assembly. At least one of the first and second anti-corrosion materials forms a film on the inner surface of the container assembly while the concentrate is stored within the container assembly, where the film inhibits corrosion of the corrodible material forming at least part of the inner surface of the container assembly. The concentrate passes through the outlet opening in a spray pattern that forms the desired texture pattern on the target surface. The first and second anti-corrosion materials together comprise 0.125-7.00% by weight of the concentrate. 
     The present invention may also be embodied as a method for dispensing texture material in a desired spray pattern that substantially matches an existing texture pattern on a target surface comprising the following steps. A container assembly defining an inner surface formed at least in part of a corrodible material is provided. An actuator assembly defining an outlet opening having an adjustable cross-sectional area is supported relative to the container assembly. A concentrate is arranged within the container assembly. The concentrate comprises a solvent/carrier comprising water, wall texture material comprising at least one filler and a resin/binder, a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester, and a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite. The first and second anti-corrosion materials together comprise 0.125-7.00% by weight of the concentrate. The concentrate is arranged within the container assembly such that the water is exposed to the inner surface of the container assembly and at least one of the first and second anti-corrosion materials forms a film on the inner surface of the container assembly while the concentrate is stored within the container assembly, where the film inhibits corrosion of the corrodible material forming at least part of the inner surface of the container assembly. The actuator assembly is operated such that the concentrate passes through the outlet opening in a spray pattern that forms the desired texture pattern on the target surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a section view of a first example aerosol dispensing system for texture material of the present invention; 
         FIGS. 2A-2B  are side elevation views depicting the process of using the aerosol dispensing system of  FIG. 1  to apply texture material to a destination wall surface; 
         FIG. 3  is a section view of a second example aerosol dispensing system for texture material of the present invention; and 
         FIGS. 4A-4B  are side elevation views depicting the process of using the aerosol dispensing system of  FIG. 3  to apply texture material to a destination ceiling surface. 
     
    
    
     DETAILED DESCRIPTION 
     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. The example 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 . 
     The main chamber  28  contains a liquid material  30  and a vapor material  32 . The liquid material  30  comprises texture material and propellant material in liquid form. The vapor material  32  comprises propellant material in vapor form. The liquid material  30  comprises propellant material in liquid form and a texture material concentrate. 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 . 
     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 . 
     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. 
     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 . 
     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 . 
     Because the interior metal surface  58  of the container assembly  22  is metal and is thus susceptible to corrosion, the texture material concentrate is formulated to have anti-corrosion properties. The example texture material concentrate is generally formulated as follows. 
     
       
         
               
             
               
               
               
               
             
           
               
                   
               
               
                 GENERAL EXAMPLE OF TEXTURE 
               
               
                 MATERIAL CONCENTRATE 
               
             
          
           
               
                   
                   
                 FIRST 
                 SECOND 
               
               
                   
                   
                 PREFERRED 
                 PREFERRED 
               
               
                   
                 COMPONENT 
                 RANGE 
                 RANGE 
               
               
                   
                   
               
               
                   
                 solvent/carrier 
                 30-60% 
                 25-65% 
               
               
                   
                 resin/binder 
                 4.5-5.5% 
                 3-7% 
               
               
                   
                 fillers 
                 40-60% 
                 20-70% 
               
               
                   
                 additives 
                 0.250-0.750% 
                 0.000-1.000% 
               
               
                   
                 first anti-corrosion 
                 0.5-2%   
                 0.1-5.0% 
               
               
                   
                 material 
                   
                   
               
               
                   
                 second anti-corrosion 
                 0.05-1%   
                 0.025-2.0%  
               
               
                   
                 material 
               
               
                   
                   
               
             
          
         
       
     
     The texture material concentrate described in the table set forth above 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 12.5% of the texture material concentrate by weight and is preferably within a first preferred range of 10-15% and is in any event preferably within a second preferred range of 5-20%. 
     In the context of the example container assembly  22  comprising tin-plated steel components, the 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 concentrate. 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. 
     In the example texture material concentrate, 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 concentrate 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 concentrate and propellant. 
     The texture material concentrate 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 concentrate. 
     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 concentrate 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 . 
     With the foregoing general understanding of the present invention, the details of several example formulations of the texture material concentrate and the construction and use of the example aerosol dispensing system  20  will now be described in further detail. 
     As described above, the present invention is of particular significance when applied to aerosol dispensing systems for dispensing texture material. Texture materials are sold in different forms depending upon such factors as dry time, ease of application, and the type of texture pattern desired. Set forth below are four tables containing formulations of example texture material concentrates. 
     The example contained materials incorporating the following texture material concentrates are preferably formed by first combining the first and second anti-corrosion materials with the water. The remaining materials are then mixed into the combination of the water and the anti-corrosion materials to form the texture material concentrates identified in the tables below. The resulting texture material concentrate is then mixed with the propellant material to form the contained material as generally described above. 
     First Example of Texture Material Concentrate 
     When sprayed onto a target surface as will be described in further detail below, the first example texture 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 texture material are flattened. 
     
       
         
               
               
               
               
             
           
               
                   
               
               
                   
                   
                 FIRST 
                 SECOND 
               
               
                   
                   
                 PREFERRED 
                 PREFERRED 
               
               
                 COMPONENT 
                 PREFERRED 
                 RANGE 
                 RANGE 
               
               
                   
               
             
             
               
                 solvent/carrier (water) 
                 48.72% 
                 43-53% 
                 38-58% 
               
               
                 first anti-corrosion 
                  1.0% 
                 0.5-2.0% 
                 0.1-5.0% 
               
               
                 material (Elfugin) 
                   
                   
                   
               
               
                 second anti-corrosion 
                  0.25% 
                 0.05-1.0%  
                 0.025-2%    
               
               
                 material (Sodium 
                   
                   
                   
               
               
                 Nitrite) 
                   
                   
                   
               
               
                 additive (biocide) 
                  0.10% 
                 0.05-0.50% 
                 0.25-0.10% 
               
               
                 Homax Wall Texture 
                 50.93 
                 46-56% 
                 41-61% 
               
               
                   
               
             
          
         
       
     
     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. 
     The Homax Wall Texture ingredient is a proprietary mixture supplied to the Applicant by Hamilton Materials Northwest. Generally speaking, the Homax Wall Texture ingredient comprises a binder (starch), pigments like calcium carbonate, talc, mica, attapulgite clay, and possibly others. Additionally, this type of material typically comprises a biocide and defoamers. 
     The ratio of the first example contained material to propellant should be within a first range of approximately 7:1 to 15:1 and in any event should be within a second range of approximately 5:1 to 20:1. To obtain the example contained material  34 , one part DME (propellant) is combined with 9.42 parts of the first example texture material described in the foregoing table. 
     Second Example of Texture Material Concentrate 
     When sprayed onto a target surface as will be described in further detail below, the second example texture material concentrate forms what is commonly referred to as an “orange peel” spray texture pattern. An orange peel spray texture comprises rounded, irregular bumps on the target surface that generally resemble the surface of an orange. By varying the parameters of the spray pattern, the size and depth of the bumps can be varied to obtain different aesthetic looks. The second example texture material concentrate further changes color while drying such that the color indicates when the texture material is sufficiently dry for the application of a top coat such as a coat of primer or paint. 
     
       
         
               
               
               
               
             
           
               
                   
               
               
                   
                   
                 FIRST 
                 SECOND 
               
               
                   
                   
                 PREFERRED 
                 PREFERRED 
               
               
                 COMPONENT 
                 PREFERRED 
                 RANGE 
                 RANGE 
               
               
                   
               
             
             
               
                 solvent/carrier (water, 
                 34.965%  
                 30-40% 
                 25-45% 
               
               
                 proponal) 
                   
                   
                   
               
               
                 first anti-corrosion 
                 1.000% 
                 0.5-2.0% 
                 0.1-5.0% 
               
               
                 material (Elfugin) 
                   
                   
                   
               
               
                 second anti-corrosion 
                 0.100% 
                 0.05-1.0%  
                 0.025-2%    
               
               
                 material (Sodium 
                   
                   
                   
               
               
                 Nitrite) 
                   
                   
                   
               
               
                 additives (biocides, 
                 0.530% 
                 0.250- 
                    0.000%- 
               
               
                 defoamer, dispersant) 
                   
                 0.750% 
                 1.000% 
               
               
                 resin/binder (latex) 
                 5.127% 
                 4.100- 
                 2.600- 
               
               
                   
                   
                 6.100% 
                 7.600% 
               
               
                 filler (thickener, clay, 
                 58.275%  
                 53-63% 
                 48-68% 
               
               
                 talc, calcium 
                   
                   
                   
               
               
                 carbonate) 
                   
                   
                   
               
               
                 color change agent 
                 0.003% 
                 0.002- 
                 0.001- 
               
               
                 (Bromothymol Blue) 
                   
                 0.003% 
                 0.010% 
               
               
                   
               
             
          
         
       
     
     In the foregoing example, the amounts of the first and second anti-corrosion materials are preferably held to the following tolerances. The amount of the first anti-corrosion material used should be substantially within ±5% of the amount specified in the foregoing table. The amount of the first anti-corrosion material used should be substantially within +0% and -5% of the amount specified in the foregoing table. 
     The ratio of the second example contained material to propellant should be within a first range of approximately 7:1 to 15:1 and in any event should be within a second range of approximately 5:1 to 20:1. To obtain the example contained material  34 , one part DME (propellant) is combined with 9.42 parts of the first example texture material described in the foregoing table. 
     Third Example of Texture Material Concentrate 
     When sprayed onto a target surface as will be described in further detail below, the second example texture material concentrate forms what an orange peel spray texture pattern. As with the second example texture material concentrate described above, varying the parameters of the spray pattern varies the size and depth of the bumps forming the orange peel pattern to obtain different aesthetic looks. 
     
       
         
               
               
               
               
             
           
               
                   
               
               
                   
                   
                 FIRST 
                 SECOND 
               
               
                   
                   
                 PREFERRED 
                 PREFERRED 
               
               
                 COMPONENT 
                 PREFERRED 
                 RANGE 
                 RANGE 
               
               
                   
               
             
             
               
                 solvent/carrier (water, 
                 34.970%  
                 30-40% 
                 25-45% 
               
               
                 propanol) 
                   
                   
                   
               
               
                 first anti-corrosion 
                 1.000% 
                 0.500- 
                 0.100- 
               
               
                 material (Elfugin) 
                   
                 2.000% 
                 5.000% 
               
               
                 second anti-corrosion 
                 0.250% 
                 0.050- 
                 0.025-2.00%  
               
               
                 material (Sodium 
                   
                 1.000% 
                   
               
               
                 Nitrite) 
                   
                   
                   
               
               
                 Additives (biocides, 
                 0.530% 
                 0.250- 
                    0.000%- 
               
               
                 defoamer, dispersant) 
                   
                 0.750% 
                 1.000% 
               
               
                 resin/binder (latex) 
                 5.127% 
                 4.100- 
                 2.600- 
               
               
                   
                   
                 6.100% 
                 7.600% 
               
               
                 Filler (thickener, clay, 
                 58.123%  
                 53-63% 
                 48-68% 
               
               
                 talc, calcium 
                   
                   
                   
               
               
                 carbonate) 
               
               
                   
               
             
          
         
       
     
     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. 
     The ratio of the third example contained material to propellant should be within a first range of approximately 7:1 to 15:1 and in any event should be within a second range of approximately 5:1 to 20:1. To obtain the example contained material  34 , one part DME (propellant) is combined with 9.42 parts of the first example texture material described in the foregoing table. 
     Fourth Example of Texture Material Concentrate 
     When sprayed onto a target surface as will be described in further detail below, the fourth example texture material concentrate forms what is commonly referred to as a “popcorn” or “acoustic” spray texture pattern. A popcorn or acoustic spray texture pattern comprises visible particulates that are adhered to the target surface by binders in the base. The particulates somewhat resemble popcorn and provide acoustic dampening qualities that reduce echoing off of the target surface on which the popcorn or acoustic spray texture pattern is formed. 
     
       
         
               
               
               
               
             
           
               
                   
               
               
                   
                   
                 FIRST 
                 SECOND 
               
               
                   
                   
                 PREFERRED 
                 PREFERRED 
               
               
                 COMPONENT 
                 PREFERRED 
                 RANGE 
                 RANGE 
               
               
                   
               
             
             
               
                 solvent/carrier (water) 
                 57.05%  
                 52-62% 
                 47-67% 
               
               
                 first anti-corrosion 
                 1.02% 
                 0.500- 
                 0.100- 
               
               
                 material (Elfugin) 
                   
                 2.000% 
                 5.000% 
               
               
                 second anti-corrosion 
                 0.25% 
                 0.050- 
                 0.025-2.00%  
               
               
                 material (Sodium 
                   
                 1.000% 
                   
               
               
                 Nitrite) 
                   
                   
                   
               
               
                 Additives (biocide) 
                 0.10% 
                 0.050- 
                 0.250- 
               
               
                   
                   
                 0.500% 
                 0.100% 
               
               
                 Homax Wall Texture 
                 40.76%  
                 36-46% 
                 31-51% 
               
               
                 particulate (Melamine 
                 0.82% 
                 0.6-1.5% 
                 0.25-5.0%  
               
               
                 Foam) 
               
               
                   
               
             
          
         
       
     
     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. 
     The ratio of the fourth example contained material to propellant should be within a first range of approximately 12:1 to 15:1 and in any event should be within a second range of approximately 10:1 to 20:1. To obtain the example contained material  34 , one part DME (propellant) is combined with 13.29 parts of the fourth example texture material described in the foregoing table. 
     Referring again to  FIG. 1  of the drawing, the details of construction and operation of the example dispensing system  20  will now be described in further detail. 
     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 . 
     The outlet assembly  26  comprises an actuator member  70 , a resilient member  72 , and a clamp member  74 . The actuator member 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 . 
     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. 
     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 fourth passageway  98  defined by the resilient member  72 . 
     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 portion  122 . In the case of a repair to the wall member  120 , existing spray texture material  124  typically surrounds the target surface portion  122 . 
     Initially, the dispensing system  20  is arranged such that the outlet opening  84  faces the target surface portion  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 . 
     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. In the case of a knockdown texture pattern, the texture coating  134  is worked to flatten the high points of the texture pattern when still wet. In the case of a color changing texture material, the texture coating  134  will be one color when wet and another color when dry. 
     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 applied texture pattern substantially matches the existing pattern of the existing texture material  124 . 
     The popcorn or acoustic texture material described above is best dispensed using a second example dispensing system  220  as depicted in  FIG. 3 . The aerosol dispensing system  220  comprises a container assembly  222 , a valve assembly  224 , and an outlet assembly  226 . The container assembly  222  and valve assembly  224  define a main chamber  228 . 
     The main chamber  228  contains a liquid material  230  and a vapor material  232 . The liquid material  230  comprises texture material and propellant material in liquid form. The vapor material  232  comprises propellant material in vapor form. The liquid material  230  comprises propellant material in liquid form and a texture material concentrate. The combination of the liquid material  230  and the vapor material  232  in the container assembly  222  will be referred to as the contained material  234 .  FIG. 3  further illustrates that the contained material  234  comprises particulate material  238  as identified in the table above describing the example popcorn or acoustic texture material concentrate. 
     When the valve assembly  224  is in a closed configuration, the flow of fluid out of the main chamber  228  is substantially prevented. However, the vapor material  232  pressurizes the liquid material  230  within the main chamber  228  such that, when the valve assembly  224  is in an open configuration, the vapor material  232  forces the liquid material  230  out of the main chamber  228 . 
     As perhaps best shown in  FIG. 3 , the example container assembly  222  comprises a main member  240 , a bottom cap  242 , and an end cap  244  formed of tin-plated steel. The tin-plated steel used to form the main member  240 , bottom cap  242 , and end cap  244  comprises a thin sheet of steel coated on one side by an even thinner layer (approximately 0.5 microns) of tin. 
     The main member  240  is a rectangular sheet that is rolled into a cylinder and welded along a seam  250  to define first and second end openings  252  and  254 . The bottom cap  242  is a shaped tin-plated steel member that is crimped onto the cylindrical main member  240  to seal the first end opening  252 . The end cap  244  is also a shaped tin-plated steel member defining a mounting opening  256 ; the end cap  244  is crimped onto the main member  240  such that fluid may not flow through the second opening  254  between the end cap  244  and the main member  240 . The main member  240 , bottom cap  242 , and end cap  244  define an interior metal surface  258  of the container assembly  222 . 
     With the bottom cap  242  covering the first opening  252 , the end cap  244  covering the second opening  254 , and the valve assembly  224  supported by the end cap  244 , the aerosol dispensing system  220  defines the main chamber  228 . 
     The bottom cap  242  is crimped onto the main member  240  to form a container subassembly  222   a . The valve assembly  224  is combined with the end cap  244  to form a cap subassembly  222   b . The texture material concentrate is placed within the container subassembly  222   a . The cap subassembly  222   b  is crimped onto the container subassembly  222   a  to form the container assembly  222 . The propellant material is then introduced into the container assembly  222  through the valve assembly  224 . The outlet assembly  226  is then engaged with the valve assembly to form the aerosol dispensing system  220 . 
     The example valve assembly  224  comprises a valve housing  260 , a valve seat  262 , and a stem member  264 . The valve seat  262  defines a deformable portion  266 . The end cap  244  supports the valve housing  260  and the valve seat  262  adjacent to the mounting opening  256 . The valve housing  260  supports the deformable portion  266  such that the deformable portion  266  biases the stem member  264  against the valve seat  262  in a normally closed position. An intake tube  268  extends from the valve housing  260  to the end of the main member  240  closed by the bottom cap  242 . 
     The outlet assembly  226  comprises an actuator member  270 . The actuator member  270  is threaded onto a connecting portion  272  of the stem member  264 . The stem member  264  further defines a valve portion  274  and a valve opening  276 . The stem member  264  extends through the valve seat  262  such that the valve seat  262  supports the stem member  264  within the mounting opening  256 . In particular, the stem member  264  extends through the mounting opening  256  such that the valve portion  274  is in contact with the valve seat  262  when the valve assembly  224  is in its closed configuration and not in contact with the valve seat  262  when the valve assembly  224  is in its opening configuration. 
     A dispensing path  280  extends between an inlet opening  282  defined by the intake tube  268  and an outlet opening  284  in the actuator  270 . Fluid is prevented from flowing along the dispensing path  280  when the valve assembly  224  is in the closed configuration as defined above. Fluid may flow along the dispensing path  280  when the valve assembly  224  is in the open configuration. The outlet member  270  is configured to define the outlet opening  284  such that the spray pattern of liquid flowing out of the main chamber  228  through the outlet opening  282  is substantially fan-shaped. 
     More specifically, the deformable portion  266  of the valve seat  262  frictionally engages the stem member  264  such that the deformable portion  266  normally biases the stem member  264  to cause the valve portion  274  to engage the valve seat  262 , thereby closing the dispensing path  280 . When the actuator member  270  is displaced towards the container assembly  222 , the stem member  264  is displaced, deforming the deformable portion  266 , such that the valve portion  274  disengages from the valve seat  262  against the force of the deformable portion  266  to place the valve assembly  224  in its open configuration. The deformable portion  266  may be replaced with an external or internal spring member that similarly biases the valve assembly  224  into the closed configuration. 
     In the open configuration, the example dispensing path  280  extends through a first passageway  290  defined by the intake tube  268 , a valve chamber  292  defined by the valve housing  260 , a gap  294  between stem member  264  and the valve seat  262 , the valve opening  276 , and an outlet passageway  296  defined by the actuator member  270 . 
     The actuator member  270  is configured to define a fan shaped outlet portion  298  of the outlet passageway  296  that forms a spray pattern appropriate for depositing the popcorn or acoustic texture material on the target surface in a desired texture pattern. 
       FIGS. 4A and 4B  illustrate that the actuator member  270  is also configured such that the spray pattern may be directed upwards because popcorn or acoustic texture material is typically applied only to ceiling surfaces. In particular,  FIG. 4A  illustrates a wall member  320  defining a target surface portion  322 . In the case of a repair to the wall member  320 , existing spray texture material  324  typically surrounds the target surface portion  322 . 
     Initially, the dispensing system  20  is arranged such that the outlet portion  298  of the outlet passageway  296  faces the target surface portion  322 . The actuator member  270  is then displaced to place the valve assembly  224  in its open configuration. The pressurized propellant material causes a portion of the contained material  234  to be dispensed from the container assembly  222  through the dispensing path  280 . 
     The contained material exits the container assembly  22  in a spray  330  comprising discrete droplets  332  and the particulate material  238 . The droplets  332  are deposited onto the target surface  322  to form a texture coating  334  in an applied texture pattern. The particulate material  238  is bonded by the texture coating  234  to the target surface  322 . The texture coating  334  is initially wet but dries when exposed to air. The applied texture pattern of the texture coating  334  can be formed such that the applied texture pattern substantially matches the existing pattern of the existing texture material  324 . 
     The scope of the present invention should be determined by the claims appended hereto and not the foregoing detailed discussion of several examples of the present invention.

Technology Classification (CPC): 2