Static structures (e.g. – buildings) – Ornamental: color – thickness variation – or dissimilar...
Patent
1996-12-02
1998-09-29
Kent, Christopher
Static structures (e.g., buildings)
Ornamental: color, thickness variation, or dissimilar...
52177, 52519, 5274519, E04D 122
Patent
active
058131833
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
This invention relates to coating materials with a protective coating having a rough, dull or granular surface appearance. The invention relates particularly to building materials such as sheet roofing materials which may be coated to resemble for example, ceramic, slate, stone, cement or terracotta tiles.
BACKGROUND OF INVENTION
In WO9322523A there is described a shaped and embossed pressed sheet metal roof tile. In order to both protect the sheet metal, usually steel, and to give it the appearance of slate, or stone, etc., it is desirable for the surface to have a textured effect. It may also be desirable to coat mineral fibre filled cement roofing sheets in order to provide a uniform appearance and so that they resemble slate, stone, or other traditional roofing materials.
STATEMENT OF INVENTION
The present invention provides a protective coating especially for building materials which has the desired surface texture for resemblance to traditional materials.
According to the invention there is provided a method of coating a component part with a protective coating having a rough surface appearance wherein at least a portion of its surface is covered with a first layer of powder coating, a particulate material is spread over the first layer whilst said layer is in a soft condition, and a second layer of powder coating is applied over the particulate material and first layer and caused to coalesce.
The polymers used for powder coating can be divided into two groups, thermosetting powders and thermoplastic powders. Thermosetting powders are low molecular weight materials that cross link on heating after being applied to substrates. Thermosetting powders typically include epoxy resins, acrylics, and polyesters. Thermoplastic powders do not involve a chemical reaction and typically melt on application to either to hot substrates or by the subsequent application of heat. Thermoplastic powders include cellulose acetate butyrate, polyesters, vinyl polymers, polyamides, polyolefines and Ionomers.
Preferably the first layer is a thermoplastic powder coating material and the second layer may be the same material or is preferably a thermosetting powder coating, preferably a polyester.
The component part may be a metal part or a mineral part.
Mineral includes ceramics, asbestos, glass, and cement, as well as naturally occurring minerals and preferably the coating is applied to a sheet material such as sheets of mineral fibre filled cement.
Preferably the coating is applied to building materials such as sheet metal roofing materials, mineral fibre filled roofing sheets, sheet metal roofing tiles, or sheet metal or cement wall sections.
Preferably the particulate material is mineral dust or other granular material. The mineral dust may be formed from granite, slate, limestone, quartz, marble, brick dust, cement dust and any mixture thereof.
Granular materials may have an average particle size of between 2-3 mm and may include sand, or metal particles such as steel brass or bronze particles as well as the above minerals.
The presence of mineral dust or granular material helps dull the surface appearance of the sheet materials and can also be used to pigment the powder coating to a desired colour, for example slate dust can pigment white or non-pigmented powder to the colour of slate. It also provides a non-slip surface for roofing materials which may be walked on.
The powder coating can be applied to a metal substrate by either electrostatic fluidized-bed or by electrostatic spray techniques. Preferably the powder coatings are applied by electrostatic spray techniques. In the case of none-conductive materials the power coating can be blown or cascaded onto the surface of the component.
The above method can be utilised in particular for coating fabricated sheet metal roof tiles.
Also according to the invention there is provided a component part which is decorated to give the appearance of a mineral, stone, or ceramic material, wherein at least a portion of the surface of said part is coated
REFERENCES:
patent: 4243696 (1981-01-01), Toth
patent: 4528231 (1985-07-01), Lund
patent: 5475951 (1995-12-01), Litzow
patent: 5632123 (1997-05-01), Erwin
Germain Lee A.
Kent Christopher
Milliken Paul E.
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