Coating processes – With pretreatment of the base
Reexamination Certificate
1999-01-15
2001-03-06
Beck, Shrive (Department: 1762)
Coating processes
With pretreatment of the base
C427S385500, C427S386000, C427S407100, C428S407000
Reexamination Certificate
active
06197377
ABSTRACT:
BACKGROUND OF THE INVENTION
The invention relates to a preparation for applying an anti-slip layer to a surface wherein the preparation comprises a coating composition, containing particulate material, and a curing agent.
Such a preparation is known from U.S. Pat. No. 2,793,136 which discloses a preparation for applying a slip-resistant layer to a surface, wherein a layer of a fluid dispersion of finely divided angular or rough resin particles in a liquid plasticiser is applied on a surface as well as articles comprising such a slip-resistant layer. The resin particles must be—partly—soluble or gellable in the plasticiser when the latter is heated. More in particular, after having applied said fluid dispersion on the surface, a layer of embedded hard resin granules is obtained. The size of the granules may vary but is preferably {fraction (1/16)} to ½ inch and a part of the granules should extend above the upper surface of the layer of the cured fluid dispersion. Subsequently, the surface and the respective layer are heated, so that the resin particles partly dissolve into the plasticiser. After cooling, this results in the formation of a solid resilient layer in which the granules are embedded such that at least a part of the granules extend above the upper surface of said layer. The resin particles are preferably copolymers of vinyl chloride and vinyl acetate, polyvinyl chloride, polymethyl methacrylate and copolymers of vinyl chloride and vinylidene chloride, whereas the plasticiser is preferably an ester such as dioctyl phtalate. The coating composition according to U.S. Pat. No. 2,793,136, however, does not contain a curing agent for cross-linking the plasticiser which cross-linking would provide a more wear resistant anti-slip layer.
A preparation of this type is also disclosed in British Patent Application 2 156 672. Said patent application describes a coating composition for providing a rough coating on a sanitary product. The composition comprises a polymer, preferably a polymethyl methacrylate, a filler, a particulate material and a curing agent, preferably benzoyl peroxide. The particulate material preferably consists of glass beads having a size of about 200 to 800 &mgr;m. The coating composition is applied, for example by means of a brush, to the bottom of, for example, a bathtub or a shower tray, as a result of which the bathtub or shower tray is provided with an anti-slip coating.
A disadvantage of the coating according to British Patent Application 2 156 672 is that the surface thereof is relatively polar because the layer consists of an acrylate and glass beads. Water will therefore easily be able to remain between the coated glass beads, which is disadvantageous for the anti-slip properties of the coating. As a result of the presence of water, growth of bacteria and moulds will also easily be able to take place, which is not only hazardous to health but also has an adverse effect on the anti-slip properties of the coating.
Preparations and compositions for applying an anti-slip layer to one or more surfaces of sanitary products are also disclosed in WO 88/00018, DE-A 3 320 929 and U.S. Pat. No. 4,363,145. WO 88/00018 describes a coating composition which contains an elastomer. Said coating composition can be applied to the bottom of a sanitary product, as a result of which the bottom is coated with a coating which has improved friction characteristics.
DE-A 3 320 929 describes a method with which a coating is applied to a sanitary product by the use of a rubber-containing synthetic material, a coating being obtained which is not smooth. It has been found that the bottoms of bathtubs and shower trays which have been provided with coatings obtained using such coating compositions possess inadequate anti-slip properties because the coating compositions do not contain particulate materials, as a result of which the relief of the coating is inadequate.
U.S. Pat. No. 4,363,145 describes a method for applying a coating to an enamel surface, with which method a template provided with openings is placed on the surface after the latter has been cleaned. The finish is then removed from the surface at the locations of the openings by etching with acid and the etched locations are cleaned. A layer of a polyurethane-containing enamel, a layer of silicon dioxide containing sand and a further layer of a polyurethane containing enamel are then applied in succession. The final steps are the removal of the template and curing of the layer obtained. The disadvantage of this method is the laborious nature thereof. A further disadvantage of this method is the use of silicon dioxide containing sand, which usually has a small particle size. When, for example, a shower tray is coated in accordance with the method according to said U.S. patent, the locations which are provided with the sand will be sharp and therefore will feel unpleasant.
SUMMARY OF THE INVENTION
The aim of the invention is, therefore, to overcome the abovementioned disadvantages by providing a preparation for applying an anti-slip layer to a surface, wherein the preparation comprises a coating composition containing a resin and a particulate synthetic material, characterized in that the coating composition further contains a curing agent and that said particulate synthetic material is an apolar material and has a Shore D hardness of 50 to 85. An advantage of the use of synthetic granules is that these are softer than, for example, glass beads and silicon dioxide containing sand. Surfaces which have been provided with an anti-slip layer according to the invention will therefore be pleasant to the touch.
Other advantages of the preparation according to the invention are that an anti-slip layer can be obtained which does not discolour, which is hard and scratch- and wear-resistant and which has an outstanding durability on the outside and a high resistance to chemical substances.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The synthetic granules are produced from an apolar synthetic material. Examples of such apolar synthetic materials are polypropene, polyethene, polystyrene, copolymers of ethene and vinyl acetate, copolymers of ethene and unsaturated alkenes such as, for example, propene, 1-butene, 1-hexene and 1-octene and EPDM rubbers. By using synthetic granules of an apolar synthetic material, a relatively apolar coating is obtained when the preparation according to the invention is applied to a surface, so that no or only very little water remains standing between the coated granules. It is also important that the synthetic material can be combined with the coating composition. According to the invention, the synthetic used is preferably polypropene or EPDM rubber, in particular EPDM rubber granules. The polypropene which is preferably used has the following properties:
Melt flow index (in accordance with ASTM D 238; 5 kg/230° C.): 2 g/10 min to 200 g/10 min.
Density (in accordance with DIN 53479): 0.9-1.2 g/cm
3
Melting point: 60-180° C.
Shore D hardness (ASTM D2240): 60-80
The selection of the suitable synthetic granules depends, inter alia, on the hardness of the synthetic material. If it is desired to use a softer synthetic material, it is possible, for example, to use HDPE (Shore D hardness according to ASTM D2240 is approximately 65-69), LDPE (Shore D hardness according to ASTM D2240 is approximately 60-65) or even poly(1-butene) (Shore D hardness according to ASTM D2240 is approximately 55). According to the invention, the synthetic granules therefore have a Shore D hardness (ASTM D2240) of at least 45 and preferably of at least 50.
The synthetic granules can be of various sizes, the choice of the size depending on the use of the preparation. If, for example, the preparation is used to apply a coating in a bathtub or a shower tray, synthetic granules of a size such that a coating is obtained which is pleasant to the touch will be chosen. According to the invention, the synthetic granules therefore have an average size of 20-400 &mgr;m and preferably of 30-300 &mgr;m. As described above, the size of
Beck Shrive
Boogaard Beheer B.V.
Crockford Kirsten A.
Young & Thompson
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