Coating processes – Solid particles or fibers applied
Reexamination Certificate
2000-03-29
2001-10-02
Parker, Fred J. (Department: 1762)
Coating processes
Solid particles or fibers applied
C427S195000, C427S198000, C427S348000, C427S368000, C427S421100
Reexamination Certificate
active
06296902
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a sealing process for surface pores of construction parts, particularly parts in the form of cover plates and/or face plates, both prefabricated and made from natural rock.
This invention to applicable in sealing surface pores of tiles, stoneware and porcelain both enamelled and not. Likewise, it is applicable to granites, rock, marble, earth ware, hydraulics, earth, cotto and in general to all materials used in construction, those used for floors or tiles susceptible of having surface pores and therefore susceptible of being stained or attacked by certain acids.
Construction materials which have surface pores, either due to their intrinsic nature or to polishing processes suffer from corrosion more than others due to the possible penetration of certain acids or aggressive agents through their pores. Likewise, in these surface pores may enter dyes and other staining substances which are hard to remove.
In order to avoid these problems the surface pores may be sealed or covered. Presently, two industrial processes are known for sealing surface pores in construction parts.
One of these processes is based on using waxes which are introduced in the pores to thus seal or cover them. The main drawback of waxes is that they tend to get dirty themselves due to their own nature and by contact with the surroundings, as they are easily contaminated by contact with any external element. Their subsequent cleaning is virtually impossible. A further problem presented by this system is that waxes are not resistant to solvents, and thus with the use of solvents in detergents they are gradually removed from the pores and over time are completely eliminated after successive cleaning, so that the pore is again uncovered.
The second known process used industrially to date is application of silicone sprays or hydrophobic liquids, that is, liquids whose principal characteristic is that they repel an aqueous base. The main problems presented by use of the liquid is that cleaning of the excess in the product manufacture stage is more difficult. Additionally, they are not very resistant to solvents so that we find the same problem mentioned above in sealing pores permanently. Sealing processes based on non-polymerisable liquids also suffer from their removal by solvents, leaving the pore exposed once again.
SUMMARY OF THE INVENTION
The object of the present invention is to solve the aforementioned problems by a sealing process for surface pores of simple application, indefinite duration and which maintains its properties over time, so that it does not show problems of dirtying or fading.
The process of the invention consists of applying resin powder which may be cured on the surface of the parts to be treated. The powder is incrusted in the surface pores mechanically and the resin is then cured, obtaining a permanent seal for the pores since the resin is cured inside the pore itself.
The process of the invention is applicable to sealing open surface pores created during the polishing process or due to the intrinsic nature of the product surface.
Sealing with resins according to the invention eliminates the risk of stain formation and reduces or eliminates the risk of attack by certain acids.
The invention is applicable to any industrial process which intends to seal pores produced after polishing or due to the intrinsic nature of the materials employed, particularly of interest in the industry of ceramic tiles and floor tiles in all their forms, including the industry of granite, marble, earth ware, etc.
The process of the invention may use curable resins of three different types:
a) Heat curing. Those cured by heat.
b) Resins with photoinitiators. Those cured by light.
c) Heat curing and with photoinitiators, i.e. they begin the curing process with light and end it with heat.
The technical properties of the resins specifically used in the process of the invention are the following:
a) Chemical nature:
1) Epoxy: good adherence (particularly on metals) but not too stable to light, so that they are used mainly for construction materials meant to be used indoors.
2) Polyester: good photostability, so that they may be used for materials which are to be used outdoors.
3) Epoxy-polyester hybrids: seek the positive properties of both.
4) Polyurethane hybrids: their main properties are good adherence to most materials, good resistance to solvents and stability with light, which makes these resins suitable for the purpose of this invention.
b) Particle size:
The size of the particles used in this process and their granulometric intervals will depend on the average size of the pores to be covered, as the size of these pores can vary considerably for the different surfaces to be treated.
c) Colour of the powder:
The process may use colourless or coloured powder indifferently, depending on the requirements of the material whose open surface pores are to be covered.
REFERENCES:
patent: 4810533 (1989-03-01), Smith
patent: 5516551 (1996-05-01), Anderson et al.
“Powder Coating: The Complete Finisher's Handbook”, Ed by Nicholas P. Liberto, pp.1-2, 1994.
Ostrolenk Faber Gerb & Soffen, LLP
Parker Fred J.
Venis, S.A.
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