Patent Document

RELATED APPLICATIONS 
       [0001]    This application, (Attorney&#39;s Ref. No. P218634) is a continuation of U.S. patent application Ser. No. 13/798,064 filed Mar. 12, 2013, currently pending. 
         [0002]    U.S. patent application Ser. No. 13/798,064 claims benefit of U.S. Provisional Patent Application Ser. No. 61/664,678 filed Jun. 26, 2012. 
         [0003]    U.S. patent application Ser. No. 13/798,064 is also a continuation-in-part of U.S. patent application Ser. No. 13/560,733 filed Jul. 27, 2012. 
         [0004]    The contents of all related applications listed above are incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0005]    The present invention relates to texture materials and, more specifically, to low odor texture materials. 
       BACKGROUND 
       [0006]    The present invention generally relates to systems and methods for applying texture material to an interior surface such as a wall or ceiling. In particular, buildings are typically constructed with a wood or metal framework. To form interior wall and ceiling surfaces, drywall material is attached to the framework. Typically, at least one primer layer and at least one paint layer is applied to the surface of the drywall material to form a finished wall surface. 
         [0007]    For aesthetic and other reasons, a bumpy or irregular texture layer is often formed on the drywall material after the drywall material has been primed and before it has been painted. The appearance of the texture layer can take a number of patterns. As its name suggests, an “orange peel” texture pattern generally has the appearance of the surface of an orange and is formed by a spray of relatively small droplets of texture material applied in a dense, overlapping pattern. A “splatter” texture pattern is formed by larger, more spaced out droplets of texture material. A “knockdown” texture patter is formed by spraying texture material in larger droplets (like a “splatter” texture pattern) and then lightly working the surfaces of the applied droplets with a knife or scraper so that the highest points of the applied droplets are flattened. In some situations, a visible aggregate material such as polystyrene chips is added to the texture material to form what is commonly referred to as an “acoustic” or “popcorn” texture pattern. The principles of the present invention are of primary significance when applied to a texture material without visible aggregate material. 
         [0008]    For larger applications, such as a whole room or structure, the texture layer is typically initially formed using a commercial texture sprayer. Commercial texture sprayers typically comprise a spray gun, a hopper or other source of texture material, and a source of pressurized air. The texture material is mixed with a stream of pressurized air within the texture gun, and the stream of pressurized air carries the texture material in droplets onto the target surface to be textured. Commercial texture sprayers contain numerous points of adjustment (e.g., amount of texture material, pressure of pressurized air, size of outlet opening, etc.) and thus allow precise control of the texture pattern and facilitate the quick application of texture material to large surface areas. However, commercial texture sprayers are expensive and can be difficult to set up, operate, and clean up, especially for small jobs where overspray may be a problem. 
         [0009]    For smaller jobs and repairs, especially those performed by non-professionals, a number of “do-it-yourself” (DIY) products for applying texture material are currently available in the market. Perhaps the most common type of DIY texturing products includes aerosol systems that contain texture material and a propellant. Aerosol systems typically include a container, a valve, and an actuator. The container contains the texture material and propellant under pressure. The valve is mounted to the container selectively to allow the pressurized propellant to force the texture material out of the container. The actuator defines an outlet opening, and, when the actuator is depressed to place the valve in an open configuration, the pressurized propellant forces the texture material out of the outlet opening in a spray. The spray typically approximates only one texture pattern, so it was difficult to match a variety of perhaps unknown preexisting texture patterns with original aerosol texturing products. 
         [0010]    A relatively crude work around for using an aerosol texturing system to apply more than one texture pattern is to reduce the pressure of the propellant material within the container prior to operating the valve. In particular, when maintained under pressure within the container, typical propellant materials exist in both a gas phase and in a liquid phase. The propellant material in the liquid phase is mixed with the texture material, and the texture material in the gas state pressurizes the mixture of texture material and liquid propellant material. When the container is held upright, the liquid contents of the container are at the bottom of the container chamber, while the gas contents of the container collect at the top of the container chamber. A dip tube extends from the valve to the bottom of the container chamber to allow the propellant in the gas phase to force the texture material up from the bottom of the container chamber and out of the outlet opening when the valve is opened. To increase the size of the droplets sprayed out of the aerosol system, the container can be inverted, the valve opened, and the gas phase propellant material allowed to flow out of the aerosol system, reducing pressure within the container chamber. The container is then returned upright and the valve operated again before the pressure of the propellant recovers such that the liquid contents are forced out in a coarser texture pattern. This technique of adjusting the applied texture pattern result in only a limited number of texture patterns that are not highly repeatable and can drain the can of propellant before the texture material is fully dispensed. 
         [0011]    A more refined method of varying the applied texture pattern created by aerosol texturing patterns involved adjusting the size of the outlet opening formed by the actuator structure. Initially, it was discovered that the applied texture pattern could be varied by attaching one of a plurality of straws or tubes to the actuator member, where each tube defined an internal bore of a different diameter. The straws or tubes were sized and dimensioned to obtain fine, medium, and coarse texture patterns appropriate for matching a relatively wide range of pre-existing texture patterns. Additional structures such as caps and plates defining a plurality of openings each having a different cross-sectional area could be rotatably attached relative to the actuator member to change the size of the outlet opening. More recently, a class of products has been developed using a resilient member that is deformed to alter the size of the outlet opening and thus the applied texture pattern. 
         [0012]    Existing aerosol texturing products are acceptable for many situations, especially by DIY users who do not expect perfect or professional results. Professional users and more demanding DIY users, however, will sometimes forego aerosol texturing products in favor of commercial texture sprayers because of the control provided by commercial texture sprayers. 
         [0013]    The need thus exists for improved aerosol texturing systems and methods that can more closely approximate the results obtained by commercial texture sprayers. 
       SUMMARY 
       [0014]    The present invention may be embodied as a texture material composition formulated to be applied from an aerosol assembly to a target surface to form a desired texture pattern that substantially matches a pre-existing texture pattern on the target surface, comprising a first solvent material comprising between 1.0% and 20.0% by weight of the texture material, where the first solvent material is arranged in the aerosol assembly, a second solvent material comprising between 8.0% and 57.0% by weight of the texture material, where the second solvent material is combined with the first solvent material in the aerosol assembly, a binder, where the binder is combined with the first and second solvent materials in the aerosol assembly such that the binder is dissolved by the first and second solvent materials, pigment material, dispersant material, and filler material. The second solvent material is ethanol. 
         [0015]    The present invention may also be embodied as a texture material composition formulated to be applied from an aerosol assembly to a target surface to form a desired texture pattern that substantially matches a pre-existing texture pattern on the target surface, comprising a solvent material comprising between 11.0% and 72.0% by weight of the texture material, where the solvent material is arranged in the aerosol assembly and comprises at least one of diacetone alcohol and ethanol, a binder, where the binder is combined with the solvent material in the aerosol assembly such that the binder is dissolved by the solvent material, pigment material, anti-settling material, dispersant material, and filler. 
         [0016]    The present invention may also be embodied as An aerosol system for forming a desired texture pattern on a target surface that substantially matches a pre-existing texture pattern on the target surface, the aerosol system comprising an aerosol container, a valve system for controlling flow of fluid out of the aerosol container, at least one flow adjustment system for adjusting the flow of fluid out of the aerosol container, texture material arranged within the aerosol container, and propellant material arranged within the aerosol container. The texture material comprises a solvent material comprising between 11.0% and 72.0% by weight of the texture material, where the solvent material is arranged in the aerosol assembly and comprises at least one of diacetone alcohol and ethanol, a binder, where the binder is combined with the solvent material in the aerosol assembly such that the binder is dissolved by the solvent material, pigment material, anti-settling material, dispersant material, and filler. The propellant material pressurizes the texture material within the aerosol container such that operation of the valve system causes the pressurized texture material to flow out of the container and through the at least one flow adjustment system and operation of the at least one flow adjustment system determines the desired texture pattern. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1  schematically represents a first example general class of aerosol texturing system of the present invention; and 
           [0018]      FIG. 2  schematically represents a second example general class of aerosol texturing system of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    The present invention may be embodied as a texture material composition adapted to be combined with an aerosol and dispensed using an aerosol dispensing system. 
         [0020]    In the following discussion, example generic texture material compositions formulated in accordance with the principles of the present invention will first be described. After the description of the example generic texture material composition, two specific example texture material compositions formulated in accordance with the principles of the present invention will be described. 
         [0021]    Next, several example aerosol assemblies for dispensing the example texture material compositions will be described with reference to  FIGS. 1 and 2 . 
         [0022]    Finally, examples of stored material obtained by combining, in an aerosol dispensing assembly, texture material concentrate obtained using the example formulations described herein with propellant material will be described. 
       I. Generic Texture Material Formulation Examples 
       [0023]    In this section, example generic formulations of texture material compositions of the present invention will be provided. Each of these formulations yields a texture material concentrate that is combined with a propellant and possibly other materials in an aerosol assembly as will be described in further detail below. 
       A. First Example Generic Formulation 
       [0024]    The following Table IA-1 contains a first example generic formulation of a texture material composition of the present invention. In the following Table IA-1, components of the first example generic formulation are listed in the first column, and first and second ranges of these components are listed by percentage weight of the total weight of the composition in the second and third columns. 
         [0000]    
       
         
               
               
               
             
           
               
                 TABLE IA-1 
               
               
                   
               
               
                 Component 
                 First Range 
                 Second Range 
               
               
                   
               
             
             
               
                 medium evaporating 
                 3.0-8.0 
                  1.0-20.0 
               
               
                 solvent 
                   
                   
               
               
                 slow evaporating solvent  
                 2.0-3.0 
                   0-10.0 
               
               
                 fast evaporating solvent 
                 12.5-28.0 
                  8.0-57.0 
               
               
                 binder 
                 4.0-6.0 
                  3.0-10.0 
               
               
                 pigment 
                 1.0-2.0 
                 0.5-3.0 
               
               
                 anti-settling agent 
                 0.05-0.10 
                 0.01-0.25 
               
               
                 dispersant 
                 0.25-2.25 
                 0.20-3.0  
               
               
                 filler/extender 
                 60.0-70.0 
                 50.0-80.0 
               
               
                   
               
             
          
         
       
     
         [0025]    In the forgoing Table IA-1, the medium evaporating solvent evaporates at a slower rate than the fast evaporating solvent and at a higher rate than the slow evaporating solvent. 
         [0026]    The following Table IA-2 lists, for each of the components of Table IA-1, an example material or example materials that may be used to perform those functions. 
         [0000]    
       
         
               
               
             
           
               
                 TABLE IA-2 
               
               
                   
               
               
                 Component 
                 Material(s) 
               
               
                   
               
             
             
               
                 medium evaporating 
                 Diacetone alcohol; 
               
               
                 solvent 
                   
               
               
                 slow evaporating solvent 
                 Propylene Carbonate; 
               
               
                 fast evaporating solvent 
                 Denatured Ethanol; 
               
               
                 binder 
                 Acrylic resin/binder; 
               
               
                 pigment 
                 Clay Pigment; 
               
               
                 anti-settling agent 
                 fumed silica; 
               
               
                 dispersant 
                 Solution of a partial amide and 
               
               
                   
                 alkylammonium salt of a lower 
               
               
                   
                 molecular weight unsaturated 
               
               
                   
                 polycarboxylic acid polymer and a 
               
               
                   
                 polisiloxane copolymer Lactimon 
               
               
                   
                 (example registered tradename) 
               
               
                   
                 BYK-Chemie Corp. 
               
               
                 filler/extender 
                 Calcium carbonate; 
               
               
                   
                 Nepheline syenite 
               
               
                   
               
             
          
         
       
     
       B. Second Example Generic Formulation 
       [0027]    The following Table IB-1 contains a first example generic formulation of a texture material composition of the present invention. In the following Table IB-1, components of the first example generic formulation are listed in the first column, and first and second ranges of these components are listed by percentage weight of the total weight of the composition in the second and third columns. 
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                 TABLE IB-1 
               
               
                   
               
               
                 Component 
                 First Range 
                 Second Range 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 solvent 
                 17.5-39.0 
                 11.0-72.0 
               
               
                 binder 
                 4.0-6.0 
                 3.0-8.0 
               
               
                 pigment 
                 1.0-2.0 
                 0.5-3.0 
               
               
                 anti-settling agent 
                 0.05-0.10 
                 0.01-0.20 
               
               
                 dispersant 
                 0.25-2.25 
                 0.20-3.0  
               
               
                 filler/extender 
                 60.0-70.0 
                 50.0-80.0 
               
               
                   
               
             
          
         
       
     
         [0028]    The following Table IB-2 lists, for each of the components of Table IB-1, an example material or example materials that may be used to perform those functions. 
         [0000]    
       
         
               
               
               
             
           
               
                   
                 TABLE IB-2 
               
               
                   
                   
               
               
                   
                 Component 
                 Material(s) 
               
               
                   
                   
               
             
             
               
                   
                 solvent 
                 Diacetone alcohol; 
               
               
                   
                   
                 Propylene Carbonate; 
               
               
                   
                   
                 Denatured Ethanol; 
               
               
                   
                 resin/binder 
                 Acrylic resin/binder; 
               
               
                   
                 pigment 
                 Clay Pigment; 
               
               
                   
                 anti-settling agent 
                 fumed silica; 
               
               
                   
                 dispersant 
                 Solution of a partial amide and 
               
               
                   
                   
                 alkylammonium salt of a lower 
               
               
                   
                   
                 molecular weight unsaturated 
               
               
                   
                   
                 polycarboxylic acid polymer and a 
               
               
                   
                   
                 polisiloxane copolymer (e.g., 
               
               
                   
                   
                 Lactimon) (example registered 
               
               
                   
                   
                 tradename) BYK-Chemie Corp. 
               
               
                   
                 filler/extender 
                 Calcium carbonate; 
               
               
                   
                   
                 Nepheline syenite 
               
               
                   
                   
               
             
          
         
       
     
       II. Specific Example Texture Material Compositions 
     A. First Specific Example 
       [0029]    The attached Exhibit A contains Tables A-1 and A-2 containing examples of a texture material composition adapted to be combined with an aerosol and dispensed using an aerosol dispensing system in accordance with the principles of the present invention. Each value or range of values in Tables A-1 and A-2 represents the percentage of the overall weight of the example texture material composition formed by each material of the texture material composition for a specific example, a first example range, and a second example range. 
         [0030]    One example of a method of combining the materials set forth in Tables A-1 and A-2 is as follows. Materials A, B, C, and D are combined to form a first sub-composition. The first sub-composition is mixed until material D is dissolved (e.g., 30-40 minutes). Materials E and F are then added to the first sub-composition to form a second sub-composition. The second sub-composition is mixed until materials E and F are well-dispersed (e.g., at high speed for 15-20 minutes). Material G is then added to the second sub-composition to form a third sub-composition. The third sub-composition is mixed well (e.g., 10 minutes). Typically, the speed at which the third sub-composition is mixed is reduced relative to the speed at which the second sub-composition is mixed. Next, materials H, I, and J are added to the third sub-composition to form the example texture material composition of the present invention. The example texture material composition is agitated. Material K may be added as necessary to adjust (e.g., reduce) the viscosity of the example texture material composition. 
       B. Second Specific Example 
       [0031]    The attached Exhibit B contains a Table B containing examples of a texture material composition adapted to be combined with an aerosol and dispensed using an aerosol dispensing system in accordance with the principles of the present invention. Each value or range of values in Table B represents the percentage of the overall weight of the example texture material composition formed by each material of the texture material composition for a specific example, a first example range, and a second example range. 
         [0032]    One example of a method of combining the materials set forth in Table B is as follows. Materials A, B, C, and D are combined to form a first sub-composition. The first sub-composition is mixed until material D is dissolved (e.g., 30-40 minutes). Materials E and F are then added to the first sub-composition to form a second sub-composition. The second sub-composition is mixed until materials E and F are well-dispersed (e.g., at high speed for 15-20 minutes). Material G is then added to the second sub-composition to form a third sub-composition. The third sub-composition is mixed well (e.g., 10 minutes). Typically, the speed at which the third sub-composition is mixed is reduced relative to the speed at which the second sub-composition is mixed. Next, materials H, I, and J are added to the third sub-composition to form the example texture material composition of the present invention. The example texture material composition is agitated. Material K may be added as necessary to adjust (e.g., reduce) the viscosity of the example texture material composition. 
         [0033]    The example texture material composition of the present invention may be combined with an aerosol propellant in an aerosol dispensing system to facilitate application of the example texture material composition to a surface to be textured. Alternatively, the example texture material composition may be entrained in a stream of pressurized fluid such as air and deposited on a surface to be textured. Example methods for applying the example texture material thus include an aerosol dispensing system, hand-operated spray pump, hopper spray gun, or the like. 
       III. Example Aerosol Dispensing Systems 
       [0034]    In this section, several example aerosol assemblies for dispensing texture material compositions of the present invention will be described. In addition to the example aerosol assemblies described herein, the texture material compositions of the present invention may be dispensed using aerosol assemblies such as those depicted and described in U.S. Pat. Nos. 7,278,590 and 7,500,621 and U.S. Patent Application Publication Nos. US/2013/0026252 and US/2013/0026253. 
       A. First Example Aerosol Assembly 
       [0035]    Referring now to  FIG. 1  of the drawing, depicted at  20   a  therein is a first example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. The first example dispensing system is adapted to spray droplets of dispensed material  22   a  onto a target surface  24   a . The example target surface  24   a  has a textured portion  26   a  and an un-textured portion  28   a . Accordingly, in the example use of the dispensing system  20   a  depicted in  FIG. 1 , the dispensed material  22   a  is or contains texture material, and the dispensing system  20   a  is being used to form a coating on the un-textured portion  28   a  having a desired texture pattern that substantially matches a pre-existing texture pattern of the textured portion  26   a.    
         [0036]      FIG. 1  further illustrates that the example dispensing system  20   a  comprises a container  30   a  defining a chamber  32   a  in which stored material  34   a  and pressurized material  36   a  are contained. The stored material  34   a  is a mixture of texture material and propellant material in liquid phase, while the pressurized material is propellant material in gas phase. 
         [0037]      FIG. 1  further illustrates that the first example aerosol dispensing system  20   a  comprises a conduit  40   a  defining a conduit passageway  42   a . The conduit  40   a  is supported by the container  30   a  such that the conduit passageway  42   a  defines a conduit inlet  44   a  arranged within the chamber  32   a  and a conduit outlet  46   a  arranged outside of the chamber  32   a . The conduit outlet  46   a  may alternatively be referred to herein as an outlet opening  46   a . The example conduit  40   a  is formed by an inlet tube  50   a , a valve housing  52   a , and an actuator structure  54   a . The conduit passageway  42   a  extends through the inlet tube  50   a , the valve housing  52   a , and the actuator structure  54   a  such that the valve housing  52   a  is arranged between the conduit inlet  44   a  and the actuator structure  54   a  and the actuator structure  54   a  is arranged between the valve housing  52   a  and the conduit outlet  46   a.    
         [0038]    Arranged within the valve housing  52   a  is a valve system  60   a . A first flow adjustment system  70   a  having a first adjustment member  72   a  is arranged to interface with the valve system  60   a . A second flow adjustment system  80   a  having a second adjustment member  82   a  is arranged in the conduit passageway  42   a  to form at least a portion of the conduit outlet  46   a.    
         [0039]    The valve system  60   a  operates in a closed configuration, a fully open configuration, and at least one of a continuum or plurality of partially open intermediate configurations. In the closed configuration, the valve system  60   a  substantially prevents flow of fluid along the conduit passageway  42   a . In the open configuration and the at least one intermediate configuration, the valve system  60   a  allows flow of fluid along the conduit passageway  42   a . The valve system  60   a  is normally in the closed configuration. The valve system  60   a  engages the actuator member structure  54   a  and is placed into the open configuration by applying deliberate manual force on the actuator structure  54   a  towards the container  30   a.    
         [0040]    The first flow adjustment system  70   a  is supported by the container  30   a  to engage the actuator structure such that manual operation of the first adjustment member  72   a  affects operation of the valve system  60   a  to control the flow of fluid material along the conduit passageway  42   a . In particular, the first adjustment system  70   a  and the valve system  60   a  function as a flow restrictor, where operation of the first adjustment member  72   a  results in a variation in the size of the conduit passageway  42   a  within the valve system  60   a  such that a pressure of the fluid material upstream of the first flow adjustment system  70   a  is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system  70   a.    
         [0041]    In general, a primary purpose of the first flow adjustment system  70   a  is to alter a distance of travel of the dispensed material  22   a . The first flow adjustment system  70   a  may also have a secondary effect on the pattern in which the dispensed material  22   a  is sprayed. 
         [0042]    The second adjustment system  80   a  is supported by the actuator structure  54   a  downstream of the first adjustment system  70   a . Manual operation of the second adjustment member  82   a  affects the flow of fluid material flowing out of the conduit passageway  42   a  through the conduit outlet  46   a . In particular, the second adjustment system  80   a  functions as a variable orifice, where operation of the second adjustment member  82   a  variably reduces the size of the conduit outlet  46   a  relative to the size of the conduit passageway  42   a  upstream of the second adjustment system  80   a.    
         [0043]    A primary purpose of the second flow adjustment system  80   a  is to alter a pattern in which the dispensed material  22   a  is sprayed. The first flow adjustment system  70   a  may also have a secondary effect on the distance of travel of the dispensed material  22   a.    
         [0044]    To operate the first example aerosol dispensing system  20 , the container  30   a  is grasped such that the finger can depress the actuator structure  54   a . The conduit outlet or outlet opening  46   a  is initially aimed at a test surface and the actuator structure  54   a  is depressed to place the valve system  60   a  in the open configuration such that the pressurized material  36   a  forces some of the stored material  34   a  out of the container  30   a  and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion  26   a  of the target surface  24   a . If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment systems  70   a  and  80   a  are adjusted to alter the spray pattern of the droplets of dispensed material  22   a.    
         [0045]    The process of spraying a test pattern and comparing it to the pre-existing pattern and adjusting the first and second adjustment members  72   a  and  82   a  is repeated until the dispensed material forms a desired texture pattern that substantially matches the pre-existing texture pattern. 
         [0046]    Leaving the first and second adjustment systems  70   a  and  80   a  as they were when the test texture pattern matched the pre-existing texture pattern, the aerosol dispensing system  20   a  is then arranged such that the conduit outlet or outlet opening  46   a  is aimed at the un-textured portion  28   a  of the target surface  24   a . The actuator structure  54   a  is again depressed to operate the valve system  60   a  such that the pressurized material  36   a  forces the stored material  34   a  out of the container  30   a  and onto the un-textured portion  28   a  of the target surface to form the desired texture pattern. 
       B. Second Example Aerosol Assembly 
       [0047]    Referring now to  FIG. 2  of the drawing, depicted at  20   b  therein is a fifth example aerosol dispensing system constructed in accordance with, and embodying, the principles of the present invention. The fifth example dispensing system is adapted to spray droplets of dispensed material  22   b  onto a target surface  24   b . The example target surface  24   b  has a textured portion  26   b  and an un-textured portion  28   b . Accordingly, in the example use of the dispensing system  20   b  depicted in  FIG. 2 , the dispensed material  22   b  is or contains texture material, and the dispensing system  20   b  is being used to form a coating on the un-textured portion  28   b  having a desired texture pattern that substantially matches a pre-existing texture pattern of the textured portion  26   b.    
         [0048]    The example dispensing system  20   b  comprises a container  30   b  defining a chamber  32   b  in which stored material  34   b  and pressurized material  36   b  are contained. The stored material  34   b  is a mixture of texture material, propellant material in liquid phase, and propellant material in liquid phase. 
         [0049]      FIG. 2  further illustrates that the first example aerosol dispensing system  20   b  comprises a conduit  40   b  defining a conduit passageway  42   b . The conduit  40   b  is supported by the container  30   b  such that the conduit passageway  42   b  defines a conduit inlet  44   b  arranged within the chamber  32   b  and a conduit outlet  46   b  arranged outside of the chamber  32   b . The conduit outlet  46   b  may alternatively be referred to herein as an outlet opening  46   b . The example conduit  40   b  is formed by an inlet tube  50   b , a valve housing  52   b , and an actuator structure  54   b . The conduit passageway  42   b  extends through the inlet tube  50   b , the valve housing  52   b , and the actuator structure  54   b  such that the valve housing  52   b  is arranged between the conduit inlet  44   b  and the actuator structure  54   b  and the actuator structure  54   b  is arranged between the valve housing  52   b  and the conduit outlet  46   b.    
         [0050]    Arranged within the valve housing  52   b  is a valve system  60   b . A first flow adjustment system  70   b  having a first adjustment member  72   b  is arranged to interface with the valve system  60   b . A second flow adjustment system  80   b  having a second adjustment member  82   b  is arranged in the conduit passageway  42   b  to form at least a portion of the conduit outlet  46   b.    
         [0051]    The valve system  60   b  operates in a closed configuration, a fully open configuration, and at least one of a continuum or plurality of partially open intermediate configurations. In the closed configuration, the valve system  60   b  substantially prevents flow of fluid along the conduit passageway  42   b . In the open configuration and the at least one intermediate configuration, the valve system  60   b  allows flow of fluid along the conduit passageway  42   b . The valve system  60   b  is normally in the closed configuration. The valve system  60   b  engages the actuator member structure  54   b  and is placed into the open configuration by applying deliberate manual force on the actuator structure  54   b  towards the container  30   b.    
         [0052]    The first flow adjustment system  70   b  is supported by the container  30   b  to engage the actuator structure such that manual operation of the first adjustment member  72   b  controls the flow of fluid material along the conduit passageway  42   b . In particular, the first adjustment system  70   b  functions as a flow restrictor, where operation of the first adjustment member  72   b  results in a variation in the size of a portion of the conduit passageway  42   b  such that a pressure of the fluid material upstream of the first flow adjustment system  70   b  is relatively higher than the pressure of the fluid material downstream of the first flow adjustment system  70   b.    
         [0053]    In general, a primary purpose of the first flow adjustment system  70   b  is to alter a distance of travel of the dispensed material  22   b . The first flow adjustment system  70   b  may also have a secondary effect on the pattern in which the dispensed material  22   b  is sprayed. 
         [0054]    The second adjustment system  80   b  is supported by the actuator structure  54   b  downstream of the first adjustment system  70   b . Manual operation of the second adjustment member  82   b  affects the flow of fluid material flowing out of the conduit passageway  42   b  through the conduit outlet  46   b . In particular, the second adjustment system  80   b  functions as a variable orifice, where operation of the second adjustment member  72   b  variably reduces the size of the conduit outlet  46   b  relative to the size of the conduit passageway  42   b  upstream of the second adjustment system  80   b.    
         [0055]    A primary purpose of the second flow adjustment system  80   b  is to alter a pattern in which the dispensed material  22   b  is sprayed. The first flow adjustment system  70   b  may also have a secondary effect on the distance of travel of the dispensed material  22   b.    
         [0056]    To operate the fifth example aerosol dispensing system  20   b  (of the second example class of dispensing systems), the container  30   b  is grasped such that the finger can depress the actuator structure  54   b . The conduit outlet or outlet opening  46   b  is initially aimed at a test surface and the actuator structure  54   b  is depressed to place the valve system  60   b  in the open configuration such that the pressurized material  36   b  forces some of the stored material  34   b  out of the container  30   b  and onto the test surface to form a test texture pattern. The test texture pattern is compared to the pre-existing texture pattern defined by the textured portion  26   b  of the target surface  24   b . If the test texture pattern does not match the pre-existing texture pattern, one or both of the first and second adjustment systems  70   b  and  80   b  are adjusted to alter the spray pattern of the droplets of dispensed material  22   b.    
         [0057]    The process of spraying a test pattern and comparing it to the pre-existing pattern and adjusting the first and second adjustment members  72   b  and  82   b  is repeated until the dispensed material forms a desired texture pattern that substantially matches the pre-existing texture pattern. 
         [0058]    Leaving the first and second adjustment systems  70   b  and  80   b  as they were when the test texture pattern matched the pre-existing texture pattern, the aerosol dispensing system  20   b  is then arranged such that the conduit outlet or outlet opening  46   b  is aimed at the un-textured portion  28   b  of the target surface  24   b . The actuator structure  54   b  is again depressed to operate the valve system  60   b  such that the pressurized material  36   b  forces the stored material  34   b  out of the container  30   b  and onto the un-textured portion  28   b  of the target surface to form the desired texture pattern. 
       IV. Stored Material Examples 
       [0059]    As generally described above, a texture material concentrate is combined with a propellant to form stored material that is arranged within an aerosol assembly. In this section, several examples of such stored material formulations will be described. 
         [0060]    The following Table IV-1 contains a first example stored material in which the concentrate portion is formed by the first example generic formulation described above in Table IA-1. In this Table IV-1, the generic material is listed in column 1, the function of each generic material is listed in column 2, and first and second ranges of the generic materials as a percentage of the total stored material are listed in columns 3 and 4. 
         [0000]    
       
         
               
               
               
               
             
           
               
                 TABLE IV-1 
               
               
                   
               
               
                   
                   
                 First 
                 Second 
               
               
                 Material 
                 Function 
                 Range 
                 Range 
               
               
                   
               
             
             
               
                 Concentrate portion 
                 Texture Base 
                 85-93% 
                 80-95% 
               
               
                 Water 
                 Foaming agent 
                 0.1-3.0% 
                 0.1-5%   
               
               
                 Hydrocarbon propellant 
                 Propellant Material 
                  7-13% 
                  1-20% 
               
               
                   
               
             
          
         
       
     
         [0061]    The propellant material is any hydrocarbon propellant material compatible with the remaining components of the stored material. The hydrocarbon propellant in Table IV-1 is typically one or more liquidized gases either organic (such as dimethyl ether, alkanes that contain carbons less than 6, either straight chain or branched structure, or any organic compounds that are gaseous in normal temperature), or inorganic (such as carbon dioxide, nitrogen gas, or compressed air). The propellants used in current formulations are dimethyl ether (DME) and A-70. 
         [0062]    The following Table IV-2 contains a second example stored material in which the concentrate portion is formed by the second example generic formulation described above in Table IA-2. In this Table IV-2, the generic material is listed in column 1, the function of each generic material is listed in column 2, and first and second ranges of the generic materials as a percentage of the total stored material are listed in columns 3 and 4. 
         [0000]    
       
         
               
               
               
               
             
           
               
                 TABLE IV-2 
               
               
                   
               
               
                   
                   
                 First 
                 Second 
               
               
                 Material 
                 Function 
                 Range 
                 Range 
               
               
                   
               
             
             
               
                 Concentrate portion 
                 Texture Base 
                 85-93% 
                 80-95% 
               
               
                 Water 
                 Foaming agent 
                 0.1-3.0% 
                 0.1-5%   
               
               
                 Hydrocarbon propellant 
                 Propellant Material 
                  7-13% 
                  1-20% 
               
               
                   
               
             
          
         
       
     
         [0063]    The propellant material is any hydrocarbon propellant material compatible with the remaining components of the stored material. The hydrocarbon propellant in Table IV-2 is typically one or more liquidized gases either organic (such as dimethyl ether, alkanes that contain carbons less than 6, either straight chain or branched structure, or any organic compounds that are gaseous in normal temperature), or inorganic (such as carbon dioxide, nitrogen gas, or compressed air). The propellants used in current formulations are dimethyl ether (DME) and A-70. 
         [0064]    The following Table IV-3 contains a third example stored material in which the concentrate portion is formed by the first example specific formulation of Tables A of Exhibit A. In this Table IV-3, the generic material is listed in column 1, the function of each generic material is listed in column 2, and an example and first and second ranges of the generic materials as a percentage of the total stored material are listed in columns 3, 4, and 5, respectively. 
         [0000]    
       
         
               
               
               
               
               
             
           
               
                 TABLE IV-3 
               
               
                   
               
               
                   
                   
                   
                 First 
                 Second 
               
               
                 Material 
                 Function 
                 Example 
                 Range 
                 Range 
               
               
                   
               
             
             
               
                 Concentrate  
                 Texture Base 
                   
                 85-93% 
                 80-95% 
               
               
                 portion 
                   
                   
                   
                   
               
               
                 Water 
                 Foaming agent 
                   
                 0.1-3.0% 
                 0.1-5%   
               
               
                 Hydrocarbon 
                 Propellant 
                   
                  7-13% 
                  1-20% 
               
               
                 propellant 
                 Material 
               
               
                   
               
             
          
         
       
     
         [0065]    The propellant material is any hydrocarbon propellant material compatible with the remaining components of the stored material. The hydrocarbon propellant in Table IV-3 is typically one or more liquidized gases either organic (such as dimethyl ether, alkanes that contain carbons less than 6, either straight chain or branched structure, or any organic compounds that are gaseous in normal temperature), or inorganic (such as carbon dioxide, nitrogen gas, or compressed air). The propellants used in current formulations are dimethyl ether (DME) and A-70. 
         [0066]    The following Table IV-4 contains a fourth example stored material in which the concentrate portion is formed by the first example specific formulation of Table B of Exhibit B. In this Table IV-4, the generic material is listed in column 1, the function of each generic material is listed in column 2, and an example and first and second ranges of the generic materials as a percentage of the total stored material are listed in columns 3, 4, and 5, respectively. 
         [0000]    
       
         
               
               
               
               
               
             
           
               
                 TABLE IV-4 
               
               
                   
               
               
                   
                   
                   
                 First 
                 Second 
               
               
                 Material 
                 Function 
                 Example 
                 Range 
                 Range 
               
               
                   
               
             
             
               
                 Concentrate 
                 Texture Base 
                   
                 85-93% 
                 80-95% 
               
               
                 portion 
                   
                   
                   
                   
               
               
                 Water 
                 Foaming agent 
                   
                 0.1-3.0% 
                 0.1-5%   
               
               
                 Hydrocarbon 
                 Propellant 
                   
                  7-13% 
                  1-20% 
               
               
                 propellant 
                 Material 
               
               
                   
               
             
          
         
       
     
         [0067]    The propellant material is any hydrocarbon propellant material compatible with the remaining components of the stored material. The hydrocarbon propellant in Table IV-4 is typically one or more liquidized gases either organic (such as dimethyl ether, alkanes that contain carbons less than 6, either straight chain or branched structure, or any organic compounds that are gaseous in normal temperature), or inorganic (such as carbon dioxide, nitrogen gas, or compressed air). The propellants used in current formulations are dimethyl ether (DME) and A-70. 
       Exhibit A 
       [0068]      
         [0000]    
       
         
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE A-1 
               
               
                   
               
               
                   
                   
                 Commercial 
                   
                   
                   
                   
               
               
                 Ref. 
                 Material 
                 Example 
                 Function/Description 
                 Example 
                 First Range 
                 Second Range 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 A 
                 Diacetone 
                   
                 Medium-evaporating, 
                 3.85 
                 3.85 ± 5% 
                 3.85 ± 10% 
               
               
                   
                 alcohol 
                   
                 low odor solvent 
               
               
                 B 
                 Propylene 
                   
                 Slow evaporating, low 
                 2.31 
                 2.31 ± 5% 
                 2.31 ± 10% 
               
               
                   
                 Carbonate 
                   
                 odor solvent 
               
               
                 C 
                 Denatured 
                 PM 6193-200 
                 Fast evaporating, low 
                 13.33 
                 13.33 ± 5%  
                 13.33 ± 10%  
               
               
                   
                 Ethanol 
                   
                 odor solvent 
               
               
                 D 
                 Resin 
                 TB-044 resin (Dai) 
                 Acrylic resin/binder 
                 4.93 
                 4.93 ± 5% 
                 4.93 ± 10% 
               
               
                   
                   
                   
                 (soluble in “weak” 
               
               
                   
                   
                   
                 solvents) 
               
               
                 E 
                 Clay 
                 Bentone 34 
                 Anti-settle/anti-sag clay 
                 1.26 
                 1.26 ± 5% 
                 1.26 ± 10% 
               
               
                   
                 Pigment 
                   
                 pigment 
               
               
                 F 
                 Fumed 
                 Aerosil R972 
                 Anti-settle fumed silica 
                 0.08 
                 0.08 ± 5% 
                 0.08 ± 10% 
               
               
                   
                 Silica 
               
               
                 G 
                 Dispersant 
                 Byk Anti-Terra 204 
                 Dispersing aid 
                 0.51 
                 0.51 ± 5% 
                 0.51 ± 10% 
               
               
                 H 
                 Calcium 
                 MarbleWhite 200 
                 filler/extender 
                 33.87 
                 33.87 ± 5%  
                 33.87 ± 10%  
               
               
                   
                 carbonate 
                 (Specialty Minerals) 
               
               
                 I 
                 Nepheline 
                 Minex 4 
                 filler/extender 
                 33.87 
                 33.87 ± 5%  
                 33.87 ± 10%  
               
               
                   
                 syenite 
               
               
                 J 
                 Denatured 
                 PM 6193-200 
                 Fast evaporating, low 
                 4.00 
                 4.00 ± 5% 
                 4.00 ± 10% 
               
               
                   
                 Ethanol 
                   
                 odor solvent 
               
               
                 K 
                 Denatured 
                 PM 6193-200 
                 Fast evaporating, low 
                 1.99 
                 1.99 ± 5% 
                 1.99 ± 10% 
               
               
                   
                 Ethanol 
                   
                 odor solvent 
                   
               
               
                   
                   
                   
                   
                 100 
               
               
                   
               
             
          
         
       
     
       Exhibit A 
       [0069]      
         [0000]    
       
         
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE A-2 
               
               
                   
               
               
                   
                   
                 Commercial 
                   
                   
                   
                   
               
               
                 Ref. 
                 Material 
                 Example 
                 Function/Description 
                 Example 
                 First Range 
                 Second Range 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 A 
                 Diacetone 
                   
                 Medium-evaporating, low 
                 13.73 
                  5-15% 
                 0-20% 
               
               
                   
                 alcohol 
                   
                 odor solvent 
               
               
                 B 
                 Propylene 
                   
                 Slow evaporating, low odor 
                 2.11 
                 1-3% 
                 0-5%  
               
               
                   
                 Carbonate 
                   
                 solvent 
               
               
                 C 
                 Denatured 
                 PM 6193-200 
                 Fast evaporating, low odor 
                 10.56 
                  5-15% 
                 0-20% 
               
               
                   
                 Ethanol 
                   
                 solvent 
               
               
                 D 
                 Resin 
                 TB-044 resin 
                 Acrylic resin/binder 
                 4.93 
                 2-6% 
                 1-10% 
               
               
                   
                   
                 (Dai) 
                 (soluble in “weak” solvents) 
               
               
                 E 
                 Clay 
                 Bentone 34 
                 Anti-settle/anti-sag clay 
                 1.26 
                 0.5-1.5% 
                 0.1-2.0%  
               
               
                   
                 Pigment 
                   
                 pigment 
               
               
                 F 
                 Fumed 
                 Aerosil R972 
                 Anti-settle fumed silica 
                 0.08 
                   0-0.20% 
                     0-0.50% 
               
               
                   
                 Silica 
               
               
                 G 
                 Dispersant 
                 Byk Anti-Terra 
                 Dispersing aid 
                 0.51 
                 0.3-0.7% 
                 0.1-1.5%  
               
               
                   
                   
                 204 
               
               
                 H 
                 Calcium 
                 MarbleWhite 
                 filler/extender 
                 33.87 
                 20-40% 
                 0-70% 
               
               
                   
                 carbonate 
                 200 (Specialty 
               
               
                   
                   
                 Minerals) 
               
               
                 I 
                 Nepheline 
                 Minex 4 
                 filler/extender 
                 33.87 
                 20-40% 
                 0-70% 
               
               
                   
                 syenite 
               
               
                 J 
                 Titanium 
                   
                 White pigment 
                 0.00 
                 0-5% 
                 0-20% 
               
               
                   
                 Dioxide 
               
               
                 K 
                 Calcined 
                 Optiwhite 
                 White extender pigment 
                 0.00 
                  0-10% 
                 0-20% 
               
               
                   
                 clay 
               
               
                 L 
                 Hexane 
                   
                 Very fast evaporating, low 
                 0.00 
                  0-10% 
                 0-20% 
               
               
                   
                   
                   
                 odor solvent 
               
               
                   
               
             
          
         
       
     
       Exhibit B 
       [0070]      
         [0000]    
       
         
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                 TABLE B 
               
               
                   
               
               
                   
                   
                 Commercial 
                   
                   
                   
                   
               
               
                 Ref. 
                 Material 
                 Example 
                 Function/Description 
                 Example 
                 First Range 
                 Second Range 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 A 
                 Diacetone 
                   
                 Medium-evaporating, 
                 6.53 
                 6.53 ± 5% 
                 6.53 ± 10% 
               
               
                   
                 alcohol 
                   
                 low odor solvent 
               
               
                 B 
                 Propylene 
                   
                 Slow evaporating, low 
                 2.31 
                 2.31 ± 5% 
                 2.31 ± 10% 
               
               
                   
                 Carbonate 
                   
                 odor solvent 
               
               
                 C 
                 Denatured 
                 PM 6193-200 
                 Fast evaporating, low 
                 9.03 
                 9.03 ± 5% 
                 9.03 ± 10% 
               
               
                   
                 Ethanol 
                   
                 odor solvent 
               
               
                 D 
                 Resin 
                 TB-044 resin (Dai) 
                 Acrylic resin/binder 
                 4.73 
                 4.73 ± 5% 
                 4.73 ± 10% 
               
               
                   
                   
                   
                 (soluble in “weak” 
               
               
                   
                   
                   
                 solvents) 
               
               
                 E 
                 Clay 
                 Bentone SD-2 
                 Anti-settle/anti-sag clay 
                 1.26 
                 1.26 ± 5% 
                 1.26 ± 10% 
               
               
                   
                 Pigment 
                   
                 pigment 
               
               
                 F 
                 Fumed 
                 Aerosil R972 
                 Anti-settle fumed silica 
                 0.08 
                 0.08 ± 5% 
                 0.08 ± 10% 
               
               
                   
                 Silica 
               
               
                 G 
                 Dispersant 
                 Byk Lactimon 
                 Dispersing aid 
                 1.95 
                 1.95 ± 5% 
                 1.95 ± 10% 
               
               
                 H 
                 Calcium 
                 MarbleWhite 200 
                 filler/extender 
                 32.54 
                 32.54 ± 5%  
                 32.54 ± 10%  
               
               
                   
                 carbonate 
                 (Specialty Minerals) 
               
               
                 I 
                 Nepheline 
                 Minex 4 
                 filler/extender 
                 32.54 
                 32.54 ± 5%  
                 32.54 ± 10%  
               
               
                   
                 syenite 
               
               
                 J 
                 Denatured 
                 PM 6193-200 
                 Fast evaporating, low 
                 7.05 
                 7.05 ± 5% 
                 7.05 ± 10% 
               
               
                   
                 Ethanol 
                   
                 odor solvent 
               
               
                 K 
                 Diacetone 
                   
                 Medium-evaporating, 
                 1.98 
                 1.98 ± 5% 
                 1.98 ± 10% 
               
               
                   
                 alcohol 
                   
                 low odor solvent 
                   
               
               
                   
                   
                   
                   
                 100

Technology Category: 8