Coating processes – Solid particles or fibers applied – Uniting particles to form continuous coating with...
Reexamination Certificate
2001-06-22
2002-03-26
Wu, David W. (Department: 1713)
Coating processes
Solid particles or fibers applied
Uniting particles to form continuous coating with...
C427S195000, C427S201000
Reexamination Certificate
active
06361826
ABSTRACT:
FIELD OF THE INVENTION
The invention relates to compositions and methods used in the formation of a polymer coating from a polymer particulate. The coatings of the invention can be made in a uniform continuous structure. Further, floor finishes having appropriate predetermined properties such as hardness, thickness, resiliency, and integrity can be made. One aspect of the invention is a two part coating system. A second aspect of the invention is a method for forming the polymer coating of the invention using the two part system and a number of distinct coating forming protocols. Another aspect of the invention is a floor finish system that results in substantial labor savings.
BACKGROUND OF THE INVENTION
Coating compositions are generally well known and have been formulated using a variety of technologies such as solvent based, aqueous liquid and powder systems. Powder coatings have been electrostatically applied to hard surfaces such as metals and then baked into a hard resistant finish. Reactive liquid coatings have been made by combining reactive materials (such as reactive isocyanates, ethylenically unsaturated reactive systems, reactive epoxy systems, etc.). Such systems have been applied to surfaces and then reacted to form a crosslinked hard surface. Further, coatings have been formed by dissolving typically polymeric materials in organic solvents at a solids concentration of about 10 to 50 wt.- %. Such solutions are applied and the solvent borne materials dry to a hard surface by the evaporation the solvent leaving a polymer coating. In order to increase the add-on of polymeric solids, polymer materials have been dispersed in aqueous media to form finish compositions. Lastly, aqueous technologies are used with active materials at concentrations typically higher than solvent systems. Such aqueous dispersions have been applied to surfaces for the purposes of forming a finish layer by serial application and evaporation of the water. Once the water is removed, the polymer materials form a useful film typically in a multi-coating layer. Solvent or aqueous based systems typically leave a residue of the medium in the coating.
Typical compositions and methods include those in Michio et al., Japanese Patent No. 92243309A. Michio et al. teach a aqueous/solvent coating composition for floors comprising a polymeric material combined with an ether solvent material adapted for reduced odor. Feigin, U.S. Pat. No. 4,131,585, teaches a polyether leveling agent adapted for use in aqueous self-polishing, dry bright coating compositions. Hacket et al., U.S. Pat. Nos. 4,363,835 and 4,704,429 and Zdanowski et al., U.S. Pat. No. 4,517,330, teach a method of forming floor finishes by applying an aqueous dispersion of polymer and materials and then dry buffing the resulting coating at high temperature to either fuse or crosslink the waxy or reactive coating composition. Bolgiano et al., U.S. Pat. No. 4,421,782, teach the formation of a coating from an aqueous system which after drying is radiation cured into a hard tough surface. Craven, U.S. Pat. No. 3,776,752, teaches compositions and methods for finishing surfaces. The method comprises applying a solvent dispersion of a polymer coating material, drying the applied material to form a coating and then forming the resulting coating with a finishing agent. Such finishing agents disclosed by Craven include typical plasticizing compositions. Lovell, Canadian Patent No. 717,495 (U.K. Patent No. 930,919), teaches the application of an organosol polish composition. Lovell discloses that the organosol material, when cosprayed with a solvent material, forms a combined coating which dries to a hard floor surface. Lewis et al., U.S. Pat. No. 4,168,255, and Gehman et al., U.S. Pat. No. 4,017,662, teach a polishing method involving the application of an aqueous coating composition containing a polymer material and finish forming agents. The polymeric materials combine with the agents as the aqueous material evaporates leaving a hard floor finish. Berrido, U.S. Pat. No. 4,747,880, teaches a dry granular floor care product. The dry granular material is formulated such that it can be combined with water to form an aqueous solution or dispersion which can be applied to form a clean shiny appearance after drying.
The prior art coating technology involves heat melted or fused coatings, reactive crosslinking coatings, or coatings that rely on a carrier liquid, an evaporating liquid aqueous or solvent medium for film formation. Such media involve solvents which must evaporate upon application to initiate coalescing the finish layer. Further the prior art aqueous compositions typically require two or more applications to form a finished surface having two or more distinct layers for a complete floor treatment. The typical applications of coatings to floors, walls, ceilings and other environmental hard surfaces can involve rolling, mopping, spray coating and other conventional methods. A combination of a resin, solvent (aqueous or organic), diluent, additives and pigment can be used. A survey of conventional coating composition and techniques is shown in
Kirk
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Othmer Concise Encyclopedia of Chemical Technology
, Fourth Edition, Wiley Interscience Publications, pp. 469-482 (John Wiley & Sons, Inc. 1999).
A need exists for floor coating systems that can be used with minimal labor in forming a reliable coating with as little as one application of the coating system. The coating systems of the invention can be used without substantial heat input for curing or a substantial proportion of an organic carrier solvent or an aqueous medium.
BRIEF DISCUSSION OF THE INVENTION
We have found a two-part system that can be used in a method for forming a continuous hard durable coating on virtually any surface. The two-part system comprises a polymer first part in the form of a finely divided flowable powder or particulate that can be delivered to a surface without an aqueous or organic solvent or other carrier liquid. The second part is a liquid part comprising a liquid coalescent or coalescing agent. In use, the parts are combined on the floor surface or as they are being delivered to the floor surface. The coalescing agent causes the polymer powder uniformly distributed in a finely divided state to coalesce and form a uniform film or coating within a short time after it came in contact with the coalescent. The materials can be applied in one of three application regimens we have defined to date, others may be developed and used. The powder can be uniformly placed on a target surface first followed by a careful uniform application of the coalescing agent. Second, the coalescing agent can be placed on the target surface followed by a careful uniform application of the powder particle. Lastly, the materials can be formed into a fine dispersion of the material in air, combined in an application device and simultaneously delivered to the surface. In such a process, the powder and coalescing agent can be atomized in separate atomizers and combined after atomization to form a spray of the final coating components.
One important application of the coating technology of this invention is to form hard, uniform coatings with regular thickness and integrity on floors. These coatings are typically 1 to 20 microns, preferably 3 to 12 microns, most preferably 4 to 10 thickness. The floor finishes can have properties such as hardness, thickness, resiliency, integrity and wear resistance that meet or exceed requirements of current floor finish technology. Two or more coatings can be made if each coating provides a unique property. Layers of different hardness can be used. A first layer can be formed from a colored layer with a second uncolored clear layer. A first layer can be used with a second layer having a COF additive or biocide. A first acrylic layer can be used with a second urethane layer.
Floor surfaces that can be treated include installed floors, uninstalled sheet vinyl or uninstalled flooring units. The coatings can be applied during manufacture of the flooring as one of the fina
Anderson Bryan M.
Hei Robert D. P.
Olson Keith E.
Ecolab Inc.
Egwim K. C.
Merchant & Gould P.C.
Wu David W.
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