Enhanced surface for wood

Details Enhanced surface for wood Enhanced surface for wood

2000-05-15

2001-07-24

Cameron, Erma (Department: 1762)

Coating processes

With post-treatment of coating or coating material

Solid treating member or material contacts coating

C427S393000, C427S408000

Reexamination Certificate

active

06265027

ABSTRACT:

BACKGROUND OF THE INVENTION
This invention relates generally to a method for treating wood surfaces with a sprayable coating composition to produce a smooth finish.
Typically, during preparation of a wood surface, such as wood fiberboard, for finishing, the wood grain is raised. The raised grain requires several coating and sanding steps to produce an acceptably smooth surface. First, a filler is applied to the surface, and the surface is sanded. Then, a primer is applied, and the surface is sanded again. Finally, a top coat is applied. This process, with its multiple coating and sanding steps, is time-consuming. In addition, the process still results in a part rejection rate of about 10%.
Thus, the need remains for an improved method for treating wood surfaces.
SUMMARY OF THE INVENTION
This need is met by the present invention which provides a method for treating wood surfaces. The wood surface is coated with a coating including (a) a filler/primer component comprising a mixture of from about 20% to about 50% by weight of the filler/primer component of a resin selected from vinyl ester resins and vinyl ester resins in combination with polyester resins, from about 5% to about 35% by weight of the filler/primer component of a sprayable filler selected from calcium carbonate, talc, and combinations thereof, from about 5% to about 10% by weight of the filler/primer component of a pigrnent, from about 1% to about 15% by weight of the filler/primer component of a mixture of thixotropic clays, from about 0% to about 2% by weight of the filler/primer component of activated fumed silica, from about 1% to about 10% by weight of the filler/primer component of a phosphosilicate, from about 0% to about 2% by weight of the filler/primer component of an accelerator, and from about 0% to about 20% by weight of the filler/primer component of an organic solvent, and (b) a catalyst component.
The catalyst component may be present in an amount of from about 1% to about 50%, and preferably 2% to 4% by weight of the total coating (filler/primer component and catalyst) as applied. That is, preferably the filler/primer component comprises about 96% to 98% by weight the total coating, and the catalyst component comprises about 2% to about 4% by weight of the total coating.
The accelerator is preferably selected from dimethyl aniline, cobalt naphthenate, copper naphthenate, potassium hexanoate, dimethyl para toluidine, cobalt neodecanoate, and mixtures thereof. The accelerator preferably comprises from about 0.2% to about 2% by weight of the filler/primer component.
The filler/primer component may further include about 0% to about 12% styrene monomer by weight of the filler/primer component.
When the resin in the filler/primer component is a combination of a vinyl ester resin and a polyester resin (the polyester resin is preferably present in an amount of about 2% to about 10% by weight of the filler/primer component), there may also be about 0 to about 8% by weight of the filler/primer component of an acrylic resin.
The solvent is preferably a blend of 50% acetone and 50% ethyl acetate. The solvent is preferably present in an amount of about 10% to about 20% by weight of the filler/primer component.
The phosphosilicate is preferably calcium strontium zinc phosphosilicate.


REFERENCES:
patent: 4011195 (1977-03-01), Self
patent: 4557889 (1985-12-01), Masuda et al.
patent: 5358779 (1994-10-01), McGarry
patent: 5371117 (1994-12-01), Parish et al.
patent: 5373036 (1994-12-01), Parish et al.
patent: 5374669 (1994-12-01), Parish et al.
patent: 5549969 (1996-08-01), Parish
patent: 5843221 (1998-12-01), Parish

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