Coating processes – Restoring or repairing
Reexamination Certificate
1999-12-30
2002-05-07
Beck, Shrive P. (Department: 1762)
Coating processes
Restoring or repairing
C427S407100, C427S407300
Reexamination Certificate
active
06383557
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a restorative process for glossy, hard surface fixtures. More particularly, the present invention relates to such a process and compositions therefor which can be accomplished without need of respiratory protective gear or special ventilation apparatus(es) and/or spray equipment.
2. Brief Description of the Relevant Art
Bathroom and/or kitchen fixtures and the like often have a glossy or semi-glossy outer surface finish. These fixtures may include bathtubs, stall showers, sinks, water closets, countertops and the like. After years of use, the outer surfaces of these fixtures often become dulled, soiled or otherwise aesthetically displeasing. In order to improve the outer surface finish, consumers may resort to replacing the fixture(s) altogether. As can be readily appreciated, this course of action is quite costly, and may prove cost prohibitive in many cases. In addition to being costly, in the case of bathtubs, it may be almost impossible to replace the fixture. In most residential buildings, the bathtub is generally set in place before the walls, doorways, etc. are completed. As such, the finished floor plan of some residential buildings may be such that the removal of a bathtub is inordinately difficult and costly such that most residential owners would not attempt such a project.
As an alternative to replacing a fixture altogether, some consumers put a fiberglass “shell” over the original outer surface. This may solve the problem for a certain period of time; however, the fiberglass shells also become aesthetically displeasing within a relatively short period of time. As a result, in order to maintain a pleasing outer surface, the consumer may be forced to replace the fiberglass shells on a substantially regular basis. This may also be too costly a proposition in many cases.
Attempts have also been made to return the fixture to its original factory finish. These attempts generally include the spraying of harsh chemical solvents and reglazing materials having many volatile organic compounds. As such, hazardous airborne particulates may be inhaled. This requires the use of special masks and/or other respiratory gear and special ventilation in order to minimize hazardous exposure. However, even with this special gear/ventilation, many noxious fumes, particulates and the like are still inhaled. In addition to this drawback, the use of sprays for reglazing causes airborne particulates such dust, dirt or the like to be applied to the outer surface along with the glazing composition. This results in undesirable surface roughness of the article. Further, such methods generally require that the fixture not be used for at least 24-48 hours after the resurfacing—this can be an unacceptable period of “down time” in many cases.
Thus, it is an object of the present invention to provide a method for restoring the outer surface of a hard substrate such as a bathroom and/or kitchen fixture, which method advantageously is cost effective and simple. It is a further object of the present invention to provide such a method which is advantageously versatile and can be used with enamel, fiberglass, ceramic (e.g. porcelain) and other fixtures. Yet further, it is an object of the present invention to provide a method which uses materials which do not require spraying of resealant and/or reglazing compositions, thus advantageously substantially eliminating the need for special respiratory gear and/or anything other than normal ventilation. Still further, it is an object of the present invention to provide such a method which advantageously substantially eliminates the “down time” of the fixture after restoration. Still further, it is an objective of this present invention to provide a method and a process which advantageously substantially eliminates the need for expensive equipment to apply the process.
SUMMARY OF THE INVENTION
The present invention addresses and solves the above-mentioned problems and meets the enumerated objects and advantages, as well as others not enumerated, by providing a method for restoring the outer surface of a hard substrate. The method comprises the steps of:
preparing the surface to be restored by contacting the surface with a composition capable of cleaning the outer surface to remove stains and altering surface characteristics of the outer surface, preferably producing an outer surface layer characterized by a porous outermost region, the prepared outer surface amenable to permanent contact by a polymeric glossing composition;
applying a resealant composition over the prepared outer surface, the resealant composition capable of penetrating and adhering to porosities created in the outer surface during the surface preparation step; and
applying a glossing composition over the resealed outer surface, the glossing composition capable of essentially permanent adhesion to the applied resealant material in an essentially uniform manner.
Preferably, the various compositions such as the resealing composition and the glossing composition are applied in a thin coat by a wiping action. A composition suitable for cleaning the outer surface may comprise an aqueous gel and/or an abrasive. The resealant composition may comprise a water based urethane copolymer. The glossing composition may comprise a water based, metal interlocking urethane or acrylic copolymer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The method according to the present invention is useful for returning a glossy, hard surface fixture (e.g. a plumbing fixture) to substantially its factory finish without need for complicated equipment or ventilation and/or special respiratory gear (such as special masks and the like), since there are substantially no noxious odors, fumes or airborne particulates/solids. The method is cost effective, efficient, simple and requires a minimum of down time of the fixture. The method is useful on enamel, fiberglass (including fiberglass “shells”), ceramic (e.g. porcelain) and other surfaces over any type of underlying substrate. Examples of some hard surface fixtures include, but are not limited to bathtubs, stall showers, sinks, water closets, countertops and the like.
Previously, the only feasible methods for restoring the lost gloss ans stain resistance to plumbing fixtures and other surfaces involved either removal and replacement of the fixture with the glossy surface or application of paint-like material over the worn surface. Clearly, removal and replacement of the part with the worn surface is time-consuming and expensive. Application of a paint-like refinishing compound can present numerous drawbacks. Such materials can be difficult to apply. Curing or drying of the material can involve the production of noxious fumes. Paint-like materials also have relatively short duration useful lives in such settings. Such materials, once applied, are prone to chipping, staining, yellowing, and peeling after the surface has been used for a while. This leads to more expenses and complications as the repair material must be removed and the process repeated.
The present inventive method comprises the step of cleaning the outer surface to remove stains, marks, paint, dirt, grime or the like. The cleaning step may comprise the step of applying a cleaning composition to the outer surface; and, then scrubbing the outer surface with the cleaning composition. The outer surface of the substrate may preferably be rinsed with water after the cleaning step. The cleaning step also includes the step of allowing the cleaned surface to dry. Air drying may be done, however, in the preferred embodiment, the surface is blow dried with a blow dryer, heat gun and/or a fan. With blow drying, the surface may dry in a relatively short amount of time, such as about 2-3 minutes. With air drying, the surface may dry in a relatively longer amount of time, such as about 10 minutes. The cleaning composition(s) may be sprayed, rolled or squeezed from a container to the surface and then scrubbed with a brush, abrasiv
Beck Shrive P.
Kolb Michener Jennifer
Young & Basile PC
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