Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
1999-06-23
2001-01-23
Nutter, Nathan M. (Department: 1711)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C427S207100, C427S299000, C427S302000, C427S303000, C427S322000, C427S323000, C427S324000, C427S325000, C427S326000, C427S327000, C427S331000, C427S337000, C427S340000, C427S407100, C427S407200, C427S407300, C427S408000, C427S409000, C427S411000, C427S412000, C427S412100, C427S413000, C427S414000
Reexamination Certificate
active
06177496
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present application is a continuation-in-part of Luzon pending application Ser. No. 09/014,255 Jan. 27, 1998 and relates to coating formed solid synthetic organic and natural organic materials intended for later color and adhesive application, specifically, to aromatic oil-modified polyurethane coatings as applied to prepared solid synthetic organic, natural organic, and composite surfaces.
2. Description of the Related Art
Synthetic organic materials have been used extensively as molding treatments, as flooring, in marine applications, as insulating agents, and in other applications because the characteristics of these materials allow flexibility, durability to weather, cost advantages, and general performance advantages. Solid synthetic organic and natural organic materials are selected from the group consisting of formed materials which may include, in whole or in part, synthetic polymers, natural polymers, plastic, cellulose, rubber, silicon, stone, clay, wax, ceramics, starch, synthetic resins, natural resins, fibers, protein resins, and metals provided said materials when formed are sufficiently firm to receive a coating. Some of these materials have had the general disadvantage of being difficult or impossible to after-treat with coloring agents such as paint, wood stain, pigment, dye, etc. because of the chemical nature of the aforementioned synthetic organic material, as, for example, petroleum-based plastics. Prior to this invention, these materials have been produced either by using pigmented base material prior to substrate formation or by after-coloring using a variety of processes including heat-transfer printing, solvent ink imprinting, paper and vinyl overlays, or by sophisticated industrial processes not available to ordinary crafts-persons or laypersons. Plasters, polyester resins, and other materials have also been used with the general disadvantage of being too expensive for widespread use.
Coatings described in Smith U.S. Pat. No. 3,940,385 Feb. 24, 1976 all contain pigments and, though claim
2
refers to application on a composition containing an elastomer, this invention does not suggest use on inexpensive plastics, such as polyvinyl chloride (PVC). The patent assignee, The Sherwin-Williams Co., does not offer this invention nor any other product at the time of this application for uses similar to the present invention. Coatings described in Graham et al U.S. Pat. No. 3,979,343 Sep. 7, 1976 also include pigments in the coatings, do not refer to applications on plastics, and are not presented as bases for later-applied colorants. Vasta U.S. Pat. No. 4,307,000 Dec. 22, 1981 shows a coating used primarily in automotive applications on metal, but (a) does not suggest absorption of paints and stains, for example, which would visually simulate natural wood alternatives, (b) is not feasible for use by ordinary persons in non-professional environments, and (c) is not offered for sale by E.I. DuPont Nemours and Company, the patent assignee, for uses related to the present invention.
Accordingly, the object of the present invention is to allow solid synthetic organic and natural organic material, which has been chemically and/or mechanically prepared and has been treated with an aromatic oil-modified polyurethane coating as described in this invention, to accept commonly available paints, stains, inks, dyes, other coloring agents, and adhesives which may be applied by professionals or laypersons for extended periods of time (more than 12 months) subsequent to the coating application. Furthermore, this invention allows the use of less expensive substrate materials, for example, PVC, where previously more expensive substrates were used. It also allows, when the coating contains pigments or dyes, a one-step coloring process for some materials, PVC as an example, previously thought to be resistant to paints and stains.
BRIEF SUMMARY OF THE INVENTION
A process wherein an aromatic oil-modified polyurethane coating is applied to synthetic organic and natural organic solid surfaces which have been either mechanically or chemically abraded if necessary, wherein the coating is a liquid comprised by weight but not limited to approximately 18-41% aromatic oil-modified polyurethane resins, approximately 55-78% aliphatic hydrocarbons, under 1% metal catalysts as drying agents, approximately 1% anti-skinning agents, and approximately 2% N-methyl-2-pyrrolidone as softening agent to promote mechanical adhesion, to which coating pigments and dyes may or may not be added.
DETAILED DESCRIPTION OF THE INVENTION
The process of this invention is the application of an aromatic oil-modified polyurethane coating which has been enhanced by anti-skinning agents and softeners to a solid synthetic organic or natural organic substrate which has been prepared either by means of chemical or material additives to the substrate or by chemical or mechanical abrasion applied to the surface of the substrate intended for coating, or both. The aforementioned substrate, for example, but not limited to, PVC, Polypropylene, and other plastics, may be formed using any of the methods commonly employed, including extrusion, RF molding, transfer molding, injection molding, compression molding, and other methods.
Substrate Preparation:
There are at least two (2) basic types of substrate preparation,
I. Additives: Chemical and material additives can be mixed with synthetic organic material prior to forming the substrate, for the purpose of increasing the potential for adhesion of the coating described in a later section. There are potentially a great number of such additives; two examples are given:
(A) a solvent-soluble acrylic resin with self-crosslinking properties in crystal form with a density of 8.6 lbs/gal and a specific gravity of (water=1) 1.20, which in this example is compatible with PVC when intended for extrusion, is added to the material bath prior to extrusion in such a volume as has been determined optimal for a given end-use. As an additive, this resin promotes mechanical adhesion that the PVC itself cannot provide due to its molecular nature; this resin also has a tendency to inhibit the migration of plasticizers to the surface of formed plastics, which is a primary factor contributing to the minimal porosity or non-porosity of PVC and other plastic compounds. The inventor believes that some oxidation also occurs, which contributes to the lack of porosity.
(B) a blowing agent, azocol, as one example, is added to PVC prior to forming, which forces the molecules apart, thereby encouraging better mechanical adhesion of the coating described in a later section. Blowing agents may be used in conjunction with substrate additives as described in (A) above.
II. Abrasion: Applied to the surface of the formed substrate, abrasion may be accomplished by chemical or mechanical means; for some substrates normal exposure to weather over a period of time will abrade them, but this method is not recommended for the purposes of this invention. Abrasion is necessary to defeat the “skin” resulting from the aforementioned migration of plasticizers and, perhaps, oxidation in the forming process. Abrasion is performed specifically to increase the potential for mechanical adhesion of the coating described in a later section. These examples are given, though other methods might be used:
(A) Abrasive papers, such as 120 Grade Sandpaper, can be applied to flexible and rigid PVC of durometers 60-90 (Shore A, points) by hand, wheel, sander, or other means. Types of abrasive means in this method would be designed according to the formulation, durometer, dimensions, etc. of the substrate, and also by the conditions under which the abrasion is to be performed. Those conditions might include industrial settings, construction jobsites, or residential situations.
(B) Chemical abrasion may be achieved by treating the surface of the substrate with, for example, but not limited to, butanol or butyl alcohols (C
4
H
9
OH) subsequent to substrate formation, prior to th
LandOfFree
Process for making organic materials receptive to coloring... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Process for making organic materials receptive to coloring..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Process for making organic materials receptive to coloring... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2471183