Note: Descriptions are shown in the official language in which they were submitted.
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TITLE
COMPOSITION FOR APPLICATION TO A SURFACE
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Blank
[0002] Blank
[0003] Blank
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0004] Enhancement of surfaces that may be permanently or temporarily re-
designed,
decorated, and/or re-colored is disclosed herein.
2. Description of the Background of the Invention
[0005] Improving the aesthetics in homes has long been practiced by many
consumers.
There is a plethora of home products and techniques for cleaning surface areas
of soft
surfaces such as carpets, rugs, draperies, curtains, upholstery, and the like.
However, for
more sullied and/or worn surfaces, subtractive processes (for example, a
process that
chemically or physically removes something from the carpet, such as cleaning
or shaving)
cannot truly restore the surface to its original state; this is often very
frustrating for
consumers. Oftentimes, spots and stains reappear after treatment.
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[0006] Additive processes (for example, a process that layers, covers, or
masks
something undesirable underneath) and techniques for improving the aesthetics
of surfaces
include painting, faux painting, stenciling, bordering, wallpapering, tiling,
wainscoting,
paneling, decorative plastering, adding appliques (for example, pictures, cut-
outs, stickers, or
the like), laminating, and molding (for example, crown, shoe, and chair) are
also known.
However, these products and techniques have not been applied to soft surfaces
such as
carpets, rugs, draperies, curtains, upholstery, and the like.
[0007] In some instances, color of worn, faded fabric is restored or
rejuvenated with a
composition containing water soluble and/or water dispersible polymers and a
surfactant
capable of forming a bilayer structure to provide a more durable color
restoration and/or color
rejuvenation benefit that lasts at least after one washing cycle, preferably
at least after two or
more washing cycles. The composition may be applied to the fabric by a spray
container.
[0008] In other instances, a method of redyeing partially bleached fabric or
garments
includes dyeing the fabric or garment with a background color and then
gathering an area to
restrict access to further reagents. The gathered area is then bleached to
remove the
background colors from the area outside the gathered area and then the
bleached areas are
redyed with a second color.
[0009] In yet further instances, a digital printing device has a rotatable
wheel, a liquid
dispenser for depositing a liquid paint, ink, or dye on the wheel along an
outer edge, and an
air jet positioned adjacent the outer edge for removing the liquid from the
outer edge and
directing the liquid toward a print medium as the wheel rotates through the
air jet. A plurality
of devices is used to produce a full color digital image.
SUMMARY OF THE INVENTION
[0010] According to one aspect of the present disclosure, a composition for
applying a
colorant to a surface includes about 0.3 to about 13.5% by weight a fluid
matrix component
including about 0.1 to about 4% by weight of a rheology modifier, about 0.15
to about 3.5%
by weight of a multi-component suspension stabilizer comprising at least one
of an acrylic
acid copolymer or a surfactant, about 0.05 to about 2% by weight an
anticorrosive agent,
about 0 to about 2% by weight of a propylene glycol, and about 0 to about 2%
by weight of a
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water soluble polymer. The composition further includes about 3 to about 10%
by weight
substantially homogeneous particles having a mean particle size of about 35 gm
to about 75
gm and having a colorant, an additive, and at least one of a thermoplastic or
a thermoset
resin. The composition further includes a liquid carrier.
[0011] According to another aspect of the present disclosure, a suspension for
applying a
colorant to a surface includes a fluid matrix having about 0.1 to about 4% by
weight of a
rheology modifier including at least one of a cellulosic, a gum, a
cellulosics, hydrophobically
modified ethoxylated urethanes, a surfactant gel, a clay, a polyester, and a
chitin. The matrix
further includes about 0.1 to about 0.5% by weight of an acrylic acid
copolymer, about 0.05
to about 2% by weight of a surfactant, about 0 to about 2% by weight of a
propylene glycol,
about 0 to about 2% by weight of a water soluble polymer, and about 0.05 to
about 2% by
weight an inorganic salt. The suspension further includes about 3 to about 10%
by weight
substantially homogeneous particles for suspension within the matrix. The
substantially
homogeneous particles have a mean particle size of about 35 gm to about 75 gm
and include
a colorant, an additive, and at least one of (a) an epoxy resin and a
curative, (b) an epoxy
resin, an acid-terminated polyester resin, and a accelerant, (c) an acid-
terminated polyester
resin and a polyester-triglycidyl isocyanurate curative, (d) an acid-
terminated polyester resin
and a beta-hydroxyl alkyl amide curative, and (e) a hydroxyl-terminated
polyester resin and a
triazole blocked polyisocyanate cross-linking agent. The suspension further
includes a liquid
carrier.
[0012] According to a further aspect of the present disclosure, a composition
for
applying a colorant to a surface includes about 0.12 to about 0.3% by weight
of a thickener,
about 0.05 to about 0.1% by weight of a gum, about 1.0 to about 1.5% by weight
of a clay,
about 0.1 to about 0.75% by weight of a sodium dioctyl sulfosuccinate, about
0.75 to about
1.25% by weight of propylene glycol, about 0.1 to about 1% by weight of an
anticorrosive
agent, about 0.1 to about 0.5% by weight of a biocide, substantially
homogeneous particles
comprising a colorant and a resin, and a liquid carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an illustration of one possible method of applying a decor
product to a
surface;
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[0014] FIG. la is a partial sectional view of an aerosol container for
dispensing a decor
product;
[0015] FIG. 2 is a photomicrograph of applied decor particles on a surface;
[0016] FIG. 3 is an illustration of one possible method of affixing a decor
product to a
surface;
[0017] FIG. 4 is a photomicrograph of a decor product affixed to a surface;
[0018] FIG. 5 is a trimetric view of a design device incorporating multiple
layers
including support layers according to one embodiment;
[0019] FIG. 6 is a cross-sectional view taken generally along the lines 6-6 of
FIG. 5
depicting the design device;
[0020] FIG. 7 is a plan view of a design device having a peripheral design as
well as a
cutout portion according to one embodiment;
[0021] FIG. 8 is a perspective view of a peg that may be used in a method for
orientating
a design device on a surface according to one embodiment;
[0022] FIG. 9 is a perspective view of a layout tool used to orient pegs on a
surface
according to one embodiment;
[0023] FIG. 10 is a perspective view of pegs arrayed on a surface according to
one
embodiment;
[0024] FIG. 11 is a partial cutaway trimetric view a stencil-mounted peg
interfacing with
a second peg arrayed on a surface according to one embodiment;
[0025] FIG. 12 is a flow diagram illustrating a method of applying a design to
a carpet;
[0026] FIG. 13 is plan view of a design device for use with the method of FIG.
12;
[0027] FIG. 13A is a bottom plan view of the design device of FIG. 13;
[0028] FIG. 14 is a cross-sectional view depicting an alternate embodiment of
the design
device;
[0029] FIG. 15 is a cross-sectional view taken generally along the lines 15-15
of FIG. 13
depicting an alternative embodiment of the design device;
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[0030] FIG. 16 is an isometric view of a border design device, having a color-
coding strip
thereon, for use with the method of FIG. 12;
[0031] FIG. 17 is an isometric view of a corner design device, having a color-
coding strip
thereon, for use with the method of FIG. 12;
[0032] FIG. 18 is an isometric view of a first end design device, having a
color-coding
strip thereon, for use with the method of FIG. 12;
[0033] FIG. 19 is an isometric view of a second end design device, having a
color-coding
strip thereon, for use with the method of FIG. 12;
[0034] FIG. 20 is a plan view of a placement of the corner design device of
FIG. 17,
according to a set of instructions;
[0035] FIG. 21 is a plan view of a placement of first and second border design
devices of
FIG. 16 according to a set of instructions;
[0036] FIG. 22 is a plan view of a placement of the first and second end
design devices of
FIGS. 18 and 19, respectively, according to a set of instructions;
[0037] FIG. 23 is a plan view of a decor product affixed to a carpet according
to the
placement of the design devices as disclosed in FIGS. 20-22;
[0038] FIG. 24 is a grid pattern for use with one or more design devices
according to the
method of FIG. 12; and
[0039] FIG. 25 is an illustration of a consumer aid according to one
embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] The present disclosure is directed to compositions, methods,
apparatuses, kits, and
combinations, for permanently or temporarily re-designing, decorating, and/or
re-coloring a
surface. While several specific embodiments are discussed herein, it is
understood that the
present disclosure is to be considered only as an exemplification of the
principles of the
invention, and it is not intended to limit the disclosure to the embodiments
illustrated.
[0041] For example, a composition useful in the present disclosure includes a
decor
product that is formulated to be applied and affixed to a surface. As
discussed more fully
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below, if desired, the decor product may be substantially removed from the
surface before
being affixed thereto. If a user desires to remove the decor product, the
decor product is
formulated to be removed by a number of methods including, for example,
vacuuming, wet
extraction, chemical application, and the like. If the user desires to affix
the decor product to
the surface in a permanent or semi-permanent manner, the decor product may be
affixed to
the surface by applying energy thereto in the form of, for example, heat,
pressure, emitted
waves, an emitted electrical field, a magnetic field, and/or a chemical. The
decor product
may also be utilized in the form of a kit or in conjunction with a design
device, such as a
stencil, to control the application of the decor product to create, for
example, a pattern on the
surface.
[0042] Any surface is contemplated to which the decor product may be applied
and/or
affixed, including, for example, soft surfaces such as carpets, rugs,
draperies, curtains,
upholstery, and the like. In addition, the decor product may be applied to
hard surfaces as
well, including, for example, wood, metal, ceramic, glass, a polymer, a hard
floor tile, a
painted surface, paper, masonry material, rock, a fiber/composite material,
rubber, concrete,
and the like. It is contemplated that the decor product may be applied to any
prepared
surface, including, for example, pre-dyed, post-dyed, pre-manufactured, and
post-
manufactured surfaces. Further, the decor product may be applied during the
manufacturing
process of a particular good or object that includes a surface in which the
decor product may
be applied. Surfaces to which the decor product may be applied and/or affixed
may be
substantially dry, substantially wet, moist, or humid depending on the
particular decor
product utilized. Further, a decor product of the present disclosure may be
applied to a
substantially flat, smooth, and/or level surface or any other surface
including rough, bumpy,
non-smooth, stepped, sloped, slanted, inclined, declined, and/or disturbed
surfaces.
[0043] Examples of carpets to which the decor product may be applied and/or
affixed
include modular tiles and panels such as Milliken LEGATO , Milliken TESSERAE ,
INTERFACEFLORTM, Tandus/C&A floorcovering, and from manufacturers such as
Mohawk Industries and Shaw Industries, Inc. Additional examples of carpets
include
broadloom carpets, cut pile (velvet/plush, Saxony, frieze, shag), loop pile
(level loop, multi-
level loop, and Berber), and cut and loop pile (random sheared and tip
sheared) carpets.
Additional examples of soft surfaces to which a decor product may be applied
and/or affixed
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thereto include, for example, area rugs (hand woven or machine woven),
draperies, curtains,
upholstery, and cellulosic materials, among others. Constituent materials of
candidate soft
surfaces include, for example, natural fibers such as wool and cotton, or
synthetic fibers such
as nylon 6, nylon 6-6, polyester, polypropylene (olefin), and acrylic, among
others.
[0044] Decor products of the present disclosure may be formulated, designed,
produced,
manufactured, applied, removed, and/or packaged by any formulaic, chemical,
and/or
physical preparation appropriate for the specific embodiment desired, as would
only be
limited by the inherent nature of the constituent ingredients. Illustrative
formulations of the
decor products include a solid that may be dissolved or dispersed in a liquid
to make a liquid-
based decor product, a liquid carrier, an emulsion, a suspension, a colloid, a
sol, a dispersion,
a solution, a gel, a paste, a foam, a powder, a spray, a tablet, a solid, a
gas, a diluent such as
water or other solvent, an aerosol, and combinations thereof. Examples of
chemical
preparations include polyester polymerizations, latex aggregation, chemical
milling, and
microencapsulization, and other methods known to those skilled in the art.
Physical
preparation may consist of physically grinding the decor product ingredients
or other means
known to those skilled in the art. Decor products may be either synthesized
from a molecular
route, in which polymer resin molecules incorporate colorants, dyes, and/or
pigment particles
at the molecular scale, such as in the method of manufacture used in
chemically prepared
toners, or the resin and pigment particles may be physically blended together
and crushed to
appropriate size by mechanical means known to those skilled in the art.
[0045] The decor product may be chosen based on any number of criteria,
including, but
not limited to the surface type, condition, and/or composition to which the
decor product is
applied and/or affixed thereto. Further criteria for choosing a decor product
include desired
lightfastness, color range, intensity, uniformity of colorant, and/or desired
curative and/or
fixation properties of the decor product. Additional choice factors include
enhancement of
the appearance and/or feel of the carpet or other surface, masking a stain
(for example, by
laying an area rug-type decor product), or value adding to a surface (for
example, to extend
the life of a carpet).
[0046] A decor product useful in the present disclosure may comprise any one
or
combination of a colorant that includes, for example, a coloring agent, a dye,
an ink, a toner,
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a paint, a patch, a carpet glitter, a fluorescent material, a composite
thermal transfer sheet, a
particle, a coating, a pigment, a luminescent material, a microparticle,
magnetically
responsive particles, a virtual colorant which is not colored until activated,
and/or a colorant
with hybrid pigment molecules, an additive, and combinations thereof.
Illustratively, a decor
product composition contains a colorant in an amount of greater than about
0.01% or less
than about 95%, or between about 0.01% to about 70%, or between about 0.03% to
about
15%, or about 0,05% to about 10%, or between about 0.1% to about 5%, of the
total weight
of the decor product.
[0047] Any imaginable color of the decor product is contemplated in the
present
disclosure including, but not limited to cyan, yellow, magenta, black, green,
orange, violet,
blue, red, purple, white silver, gold, metallic, clear, neutral, or non-
neutral, and any
combination thereof. Color may be imparted to the decor product by combining
varying
amounts of monochromic decor product particles of different colors or by
combining varying
amounts of polychromic decor product particles having different colors.
Further, a specific
decor product color may be achieved by combining predetermined amounts of
monochromic
particles of different colors or by combining predetermined amounts of
polychromic decor
product particles of different colors. In this way, all imaginable colors may
be incorporated
into the decor product.
[0048] The decor product may also comprise a virtual colorant that is not
apparently
colored until activated and/or deactivated. As an example, phosphorous
containing colorants
may be incorporated into a decor product to add special effects via
fluorescent properties.
Further, virtual colorants may add special visual effects by altering the
apparent decor
appearance according to light intensity, light angle, angle of view, and/or
illumination of the
decor product. Such activation of the virtual colorant includes, for example,
exposing a
phosphorous containing virtual colorant to various wavelengths of light. As
known to those
skilled in the art, phosphor containing compounds luminesce or fluoresce when
exposed to
light. When exposed to visible light, phosphor gives off visible white light.
Exposure of a
phosphor containing virtual colorant to sunlight may also make whites appear
brighter
because the ultraviolet light in sunlight gives the appearance that the whites
in the virtual
colorant glow brighter than "normal" white. When exposed to black light from,
for example,
a substantially ultraviolet-A wavelength emitting light bulb, phosphorous
containing
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compounds glow with a purple hue. Black light can be provided, for example,
from a tube
black light that is basically a fluorescent lamp with a modified phosphor
coating. This
modified coating absorbs harmful shortwave ultraviolet-B and ultraviolet-C
wavelengths and
emits ultraviolet-A wavelengths. The tube of the tube black light is black so
as to block most
visible light while emitting mostly long-wave ultraviolet-A wavelengths.
Another useful type
of black light includes black light provided from an incandescent black light
bulb. The black
light emitting incandescent black light bulb is similar to a normal household
light bulb, but
incorporates a filter that absorbs most visible light while emitting infrared
and ultraviolet-A
light.
[0049] In a further embodiment, decor products containing virtual colorants
may serve as
night lights, indicate routes from room to room, exit routes, and/or escape
routes.
[0050] Any number of products may be used in the decor product to impart
reversible
coloring to a surface. Such products include, for example, dyes, toners,
powder paints, inks,
and combinations thereof. Examples of dyes that may be used include water-
based dyes such
as LIQUIDTAINTTM and VERSATINT by Milliken Chemical Company. Examples of
toners that may be used include reactive toners such as powder toners.
Examples of useful
powder toners include those that are available from Sawgrass Technologies,
Inc., such as
NATURATM powder toners, as well as the formulations and/or compositions
individually
disclosed in the U.S. patents provided below in Table No. 1.
[0051] Table No. 1. Powder toner formulations.
Patent No. Patent No. Patent No.
U.S. 6,649,317 U.S. 5,644,988 U.S. 5,248,363
U.S. 6,673,503 U.S. 6,425,331 U.S. 6,686,314
U.S. 6,618,066 U.S. 6,439,710 U.S. 6,631,984
U.S. 6,840,614 U.S. 6,450,098 U.S. 6,894,087
U.S. 6,849,370 U.S. 5,246,518 U.S. 6,794,426
U.S. 6,887,640 U.S. 5,302,223 U.S. 6,759,450
U.S. 5,734,396 U.S. 5,746,816 U.S. 6,737,450
U.S. 5,488,907 U.S. 6,341,856 U.S. 6,710,102
U.S. 5,487,614 U.S. 6,152,038 U.S. 6,664,311
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U.S. 5,601,023 U.S. 6,348,939 U.S. 6,348,679
U.S. 5,642,141 U.S. 6,402,313 U.S. 7,348,374
U.S. 5,830,263 U.S. 6,486,903 U.S. 6,849,837
U.S. 5,640,180 U.S. 6,540,345 U.S. 6,649,888
U.S. 5,522,317 U.S. 6,105,502 U.S. 6,617,557
U.S. 5,431,501 U.S. 5,326,872 U.S. 6,600,142
U.S. 5,555,813 U.S. 5,177,209 U.S. 6,812,334
U.S. 5,575,877 U.S. 6,103,041 U.S. 6,812,445
U.S. 5,590,600 U.S. 6,447,629 U.S. 6,872,444
[0052] Toner particles useful in the present disclosure may have size
characteristics of
about 90% or more of the particles having a size less than about 100 microns,
or less than
about 25 microns, or less than about 10 microns, or from about 0.1 to about 50
microns, or
from about 1 to about 20 microns, or from about 3 to about 10 microns, or from
greater than
about 750 nm to about 100 microns, or larger or smaller particle sizes
depending on the
desired application. In one embodiment, the toner particle melting point
ranges from about
60 C or less, to about 150 C or higher, or from about 60 C to about 275 C, or
from about
25 C to about 110 C, or from about 80 C to about 100 C.
[0053] Other toners, compositions, additives, and curing processes useful in
the present
disclosure are disclosed in, for example, U.S. Patent No. 6,850,725. Yet other
toners,
compositions, additives, and curing processes useful in the present disclosure
are disclosed
in, for example, U.S. Patent No. 6,713,222. Still other toners, compositions,
additives, and
curing processes useful in the present disclosure are disclosed in, for
example, U.S. Patent
No. 6,680,153.
[0054] Examples of powder paints that may be useful include those with epoxy,
polyester, polyurethane, and hybrid chemistries either as additives or as
decor particles,
described hereinafter. An example of a hybrid chemistry contemplated for use
is an epoxy-
polyester hybrid, which is routinely used in the reactive powder coating
industry. Typical
particle sizes for powder paints can range, for example, from greater than
about 20 microns to
about 50 microns; however, for purposes of the present disclosure, larger and
smaller sizes
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are contemplated and may depend on, for example, the reversibility and/or
affixation
properties desired. Typical powder paints may have melting point temperatures
from around
about 107 C to about 163 C to about 302 C; however, lower and higher
temperatures are
contemplated within the present disclosure.
[0055] Further, the decor product may comprise a colorant with a hybrid
pigment
particle. An example of a hybrid pigment particle may be, for example, a dye
and pigment
combination. In this embodiment, the pigment molecule may coat a fiber
surface, while the
dye molecule penetrates the fiber.
[0056] In another embodiment, the decor product is formulated to include one
or more
thermoplastic resins, thermoset resins, colorants, additives, and/or liquid
carriers. Examples
of thermoplastic resins include polymeric materials such as polyesters,
unsaturated
polyesters, styrene-butadiene copolymers, polyurethanes, styrene-acrylates,
and/or acrylics.
Illustratively, thermoplastic and/or thermoset resins that may be useful in
the present
disclosure have a melting point of about 260 C or less, for example.
[0057] In another embodiment, the decor product may include encapsulated decor
product particles including, for example, nanoencapsulated, microencapsulated,
macroencapsulated, and compartmentalized particles. Illustratively,
microencapsulated decor
product particles may include, for example, one or more outer shells, one or
more inner
compartments, one or more colorants, and/or one or more additives. The one or
more
colorants and/or one or more additives may be in the same or different
compartments. This
microencapsulated decor product particle may, for example, provide advantages
such as to
lengthen the shelf-life of the decor product, enhance decor product
compatibility with
delivery systems, promote bonding of the decor product to the surface, promote
removability
of the decor product from surfaces before and/or after fixation, and/or
promote thermal
fixation of the decor product to a surface. Other benefits associated with
encapsulation of
compounds include, for example, timed release of compounds, and buffering
systems, among
others known to those skilled in the art, and are contemplated in the present
disclosure. The
compartmentalized and/or microencapsulated decor product particles may have
multiple
distinct regions of equal and/or differing sizes containing the same and/or
differing
substances, such as, for example, one or more solids, one or more liquids, one
or more gases,
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and/or combinations thereof As an example, microencapsulation technologies
useful in the
present disclosure are provided by Microtek Laboratories, Inc.
[0058] In a further embodiment, the decor product may include a removable
paint and/or
surface coating. In this regard, the decor product may be removable via wet-
chemistries,
such as ammonia-based, acid-based, and/or water-based chemistries.
Illustratively, the decor
product may be a liquid with one or more surfactants, zinc oxide, and/or one
or more colored
pigments. The decor product of the present embodiment may be removed by, for
example, a
weak acid, a buffering agent, a mildly alkaline solution, a polar or non-polar
solution, a
detergent, a soap, an alcohol, and/or a solid compound, and/or combinations
thereof.
[0059] Illustrative ammonia-based chemistries useful in the present disclosure
include
those supplied by Missouri Turf Paint (for example, TITANTM Removable), or by
Pioneer, or
by Sports Coatings, or by Specialist Group. Acid-based chemistries useful in
the decor
product of the present disclosure include those supplied by Remarkable Paint
Company, and
include, for example, those found in RE-MARKABLE Paint. Additional remarkable
field
paints useful in the present disclosure include those disclosed in, for
example, U.S. Patent
No. 7,253,140. Other useful examples of remarkable field paints in the present
disclosure
include those disclosed in, for example, U.S. Patent No. 6,653,265. Additional
examples of
strippable ammonia formulations useful in a decor product of the present
disclosure include
those disclosed in U.S. Patent No. 5,041,488 and those that include
susceptible
styrene/acrylic compounds. Other useful water-based dyes and compositions
include those
disclosed in, for example, U.S. Patent No. 6,834,589.
[0060] Water-based chemistries useful in the present disclosure include those
supplied by
Magic Colors Company (for example, Remove It Permanent Paint System). It is
further
contemplated that aqueous fabric paints and/or paint systems may be useful in
the decor
product embodiments of the present disclosure. Examples of aqueous fabric
paints useful in
the present disclosure include, for example, Jacquard Products including
Jacquard Textile
Colors, DYE-NA-FLOWTM, and NEOPAGUETM, Marabu-Textil made by Marabuwerke
GmbH & Co. KG, and SIMPLY SPRAYTM available from Sunshine Joy Distributing.
Wet-
erase inks removable by solvents after short or extended periods of time that
can be used on
multiple surfaces are also useful in the present disclosure. Such wet-erase
inks may
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incorporate water-soluble binders, cellulose derivatives, and/or polyvinyl
pyrrolidone.
Polyvinyl pyrrolidone (also known as polyvinyl pyrrolidinone) available from
ISP
Technologies, Inc. may improve the setting properties of compositions of the
present
disclosure.
[0061] Additional embodiments may incorporate dry erase inks, peelable and/or
strippable coatings, alkali soluble resins, and various value adding
chemistries disclosed
herein. Examples of dry-erase inks, compositions, and applicators thereof may
include those
provided by ITW Dymon, Pilot Pen Corp., Sanford Corp., Avery Dennison Corp.,
Binney &
Smith Inc., and Dainippon Ink and Chemicals, Inc. Other dry erase inks,
compositions, and
applicators that may be useful in the present disclosure include those
disclosed in, for
example, U.S. Patent No. 6,031,023.
[0062] Additional useful formulations of the present disclosure include
peelable and/or
strippable coatings made by Spraylat International, LTD. In addition, it is
contemplated that
the decor product may include a thermally releasable coating and/or blowing
agent to aid in
the removal of the affixed decor product. An example of thermally releasable
coatings and
blowing agents useful in the present disclosure includes those disclosed in,
for example, U.S.
Patent No. 5,010,131. Other coatings useful in the present disclosure include
nanoparticle
coating compositions disclosed in, for example, U.S. Patent No. 6,872,444.
[0063] In another embodiment, the decor product incorporates alkali soluble
resin
systems. Examples alkali resin systems include styrene/maleic anhydride,
styrene/acrylic and
methacrylic acid, isobutylene/maleic anhydride copolymers, and proprionic acid-
modified
urethanes. Alkali resin systems useful in the present disclosure are available
from companies
such as BASF Corp., Kuraray Co., LTD, Johnson Polymer, Rohm and Haas Co.,
Interpolymer Corp., Scott Bader Co., LTD, Sartomer Co., and DSM NeoResins,
among
others. Examples of useful additives for alkali soluble resin systems include
divalent zinc
salts. Other useful alkali soluble resin systems are further disclosed in U.S.
Patent No.
6,147,041. Additional alkali soluble resin systems include, for example, those
disclosed in
U.S. Patent No. 5,453,459.
[0064] Further embodiments of the present disclosure may incorporate value
adding
chemistries including powder coatings, toner and/or ink chemistries, carpet
stain removers
CA 02665976 2011-07-13
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and/or maskers, odor eliminators and/or absorbers, bleaching agents.
Compositions, methods
of carpet stain removing and/or masking, methods of composition affixation,
design aids,
including stencils, and dispensing devices useful in the present disclosure
include those
disclosed in U.S. Patent Application Nos. 2007/0014921, 2007/0089621,
2006/02288499,
and 2006-0276367, each filed on June 6, 2006. Further, technologies used in
aftermarket
carpet dyeing in the automotive industry may be useful in the present
disclosure, including,
for example, the "Pro Dye System" available from Top of the Line. An
additional
contemplated chemistry includes ultraviolet radiation cross-linking agents
that crosslink
decor product particles in preparation for affixation of the decor product to
a surface or
removal therefrom.
[0065] In other embodiments, a decor product contemplated in the present
disclosure may
include one or more additives that may be incorporated, for example, during
formulation,
added post-formulation prior to application of the decor product to a surface,
and/or after the
decor product has been applied to the surface. Illustrative additives useful
in the present
disclosure include, for example, a filler, a metallic particle, an adhesive, a
binder, a toner, a
resin such as an acrylic, an acrylic latex, a polyester, a urethane, and/or an
epoxy resin, a
carrier, a wax, a charge additive, a protein, an overcoating lacquer such as
an ultraviolet
initiator, an ultraviolet light absorber, an ultraviolet stabilizer, an
ultraviolet blocker, a
stabilizer, a thickening agent, anti-wicking additives, a dry powder, a
surfactant, a wetting
agent, an emulsifier, a coating, a dispersing agent, a perfume, a fragrance, a
pigment, a dye, a
preservative, a solvent, a lubricant, a fluidity improver, a flow additive, a
humectant, a
propellant (for example, a pressurized gas such as nitrogen gas, or similar
gas, or a
hydrocarbon based propellant such as butane and propane), an inorganic
particulate additive,
magnetically responsive microparticles, temporal emission agents, additives
providing a
safety benefit, additives providing a surface protection benefit, electrical
additives, interactive
sensory additives, a degassing agent, an antioxidant, a heat stabilizer, a
wax, a silicone
additive, a catalyst, a texturing agent, an electrical charge control agent,
an electrical
conductivity agent, a processing aid, a dry powder of a metal salt, a metal
salt of a fatty acid,
a colloidal silica, an inductive ingredient, and/or a metal oxide, and
combinations thereof.
Illustratively, a decor product composition contains an additive in an amount
of greater than
CA 02665976 2009-05-13
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about 0.1%, or less than about 75%, or between about 0% to about 50%, or
between about
0.001% to about 30%, or between about 0.01% to about 10%, or between about
0.1% to
about 5%, of the total weight of the decor product.
[0066] Humectants may be used to stabilize decor product compositions,
including
suspensions and/or emulsions and further modify flow properties of such
formulations.
Examples of humectants contemplated herein include propylene glycols, ethylene
glycols,
glycerines, ureas, and the like. Suitable propylene glycols considered for use
herein are
available from BASF.
[0067] An adhesive or binder may include resin particles chosen to exhibit a
glass
transition temperature that is lower than the glass transition temperature of
resins employed
in the color toners. Adhesives and/or binders with lower glass transition
temperatures may
positively affect the aesthetic feel of the decor after affixation. In
addition, such adhesives
and/or binders may augment the stability of a composition prepared as an
emulsion and
provide greater mechanical bonding of the decor product to carpet fibers
including, for
example, elastomeric materials including styrene/isoprene, styrene/butadiene,
and
isobutylene. Adhesives and binders may also be selected based on the
reversibility on a soft
surface, including, for example, nylon and polyester carpets, before and/or
after a curing step,
such as, for example, Alcoprint PTU (Ciba Geigy Corp.). Adhesives and
binders may
further be selected based on their ability to stabilize decor product
compositions, acting as
thickeners, as well as their ability to promote adhesion between decor
particles and a soft
surface. For example, an acrylic acid copolymer, such as is commercially
available as
Lyoprint PTU-US from Huntsman International, LLC may be used as a thickener in
the
present disclosure.
[0068] A high level of retention after curing may also be desirable in certain
applications. Examples of adhesives useful in the present disclosure include
polymeric resins
and may provide a laminating adhesive between a polymeric resin particle
and/or between a
soft surface and the polymeric resin particle. In one embodiment, the
polymeric resin, for
example, a toner such as a clear toner, may also act as an adhesive. Examples
of adhesives
and binders useful in the present disclosure include STYRONAL ND 656, a
styrene
butadiene copolymer latex from BASF Corp., and INCOREZ W2450, a
urethane/acrylic
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emulsion from Industrial Copolymers Unlimited in the UK. Other resins useful
in the present
disclosure include, for example, crosslinked terpolymers of styrene, acrylate
ester, and
acrylonitrile available from Zeon Chemical L.P., which include toner resins S-
103C and S-
111, and styrene-acrylic resins available from Sekisui Chemicals Co. LTD,
including S-LEC
resin that is based on a styrene and acrylic copolymer. Other resins useful in
the present
disclosure include, for example, styrene/butadiene, styrene/butyl acrylate,
styrene/2-
ethylhexyl acrylate, and styrene/butylacrylate resins available from Elikem,
including those
under the PLIOTONETM trade name. Polyester resins may offer lower temperature
fusing
than styrene/acrylates or styrene/butadiene resins permitting the application
of less heat to the
decor product and/or the soft surface. Illustrative polyester resins include
thermoset
polyesters, unsaturated polyester resins, such as, orthophthalic, isophthalic,
dicyclopentadiene, and bisphenol A fumarate resins, and those available from,
for example,
Kao Specialties Americas, LLC. Polyurethane resins, including those based on
an
exothermic reaction of an organic polyisocyanate with a polyol, are also
useful in the present
disclosure. Illustratively, a decor product composition contains an adhesive
in an amount of
greater than about 0.1 %, or less than about 75%, or between about 0% to about
50%, or
between about 0.001% to about 30%, or between about 0.01% to about 10%, or
between
about 0.1% to about 5%, of the total weight of the decor product.
[0069] Illustrative stabilizers include a benzophenone, a benzotriazole, a
salicylate, a
nickel organic, a monobenzoate, a formamidene, an oxalanilide and/or a phenol.
Examples
of an ultraviolet stabilizer that provides enhanced protection against
ultraviolet light includes
those disclosed in, for example, U.S. Patent No. 6,152,038. Examples of
thickening agents
useful in the present disclosure include those disclosed in, for example, U.S.
Patent No.
6,752,841. Examples of anti-wicking additives useful in the present disclosure
can be found
in U.S. Patent No. 5,116,682.
[0070] Another embodiment contemplated in the present disclosure may
incorporate one
or more surface-active (surfactant) agents, for example, emulsifiers. The use
of surfactants in
the decor product may promote colorant and/or filler wetting, as well as
improve flow and
leveling of the powder finish. In addition, surfactants promote substrate wet-
out during the
cure reaction, which improves adhesion and corrosion resistance of the decor
product. The
addition of surfactants may increase the gloss and distinctness of images of
the cured decor
CA 02665976 2009-05-13
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product, as well. The addition of one or more surfactants may act to stabilize
the decor
product formulation, as well as to assist in suspending the particles of a
decor product
formulation and attaching the decor product to a surface. Surfactants useful
in the present
disclosure include ionic, nonionic, and/or cationic surfactants. Emulsifiers
and/or
emulsifying agents useful herein include ALCOPRINTTM PTU from Ciba Geigy
Corp., the
JONCRYLTM series of emulsifying agents available from Johnson Polymer, and
others
known to those skilled in the art including, for example, adhesive
formulations and latex
formulations. Other examples of suitable emulsifiers include sodium
laurylsulfate, potassium
laurylsulfate, or ammonium laurylsulfate, including, for example TRITONTM 100
(octylphenoxypolyethoxy-ethanol-polyethylene glycol). Illustrative examples of
cationic
surfactants include dodecyl ammonium chloride, dodecyl ammonium bromide,
dodecyl
trimethyl ammonium bromide, dodecyl pyridinium chloride, dodecyl pyridinium
bromide,
and hexadecyl trimethyl ammonium bromide. Illustrative examples of anionic
surfactants
include aliphatic soap such as sodium stearate, sodium dodecanate, sodium
dodecyl sulfate,
sodium dodecylbenzenesulfonate, and sodium laurylsulfate. Illustrative
examples of
nonionic surfactants include poly-oxyethylenedodecyl ether,
polyoxyethylenehexadecyl
ether, polyoxyethylenenonylphenyl ether, polyoxyethylenelauryl ether,
polyoxyethylene
sorbitan monoleate ether, and monodecanoyl sucrose. Illustratively, a decor
product
composition contains a surfactant in an amount of greater than about 0.001%,
or less than
about 75%, or between about 0.001% to about 50%, or between about 0.1% to
about 30%, or
between about 0.01% to about 10%, or between about 0.1% to about 5% of the
total weight
of the decor product.
[0071] A fluidity improver useful herein includes, for example, styrene resin,
acrylic
resin, finely divided hydrophobic silica powder, finely divided titanium oxide
powder and
finely divided aluminum oxide powder. Further additives may serve as fiber
wetting
promoters, fiber drying promoters, fiber cleaners, and fiber cleaning
promoters. A
formulation of the present disclosure may also contain an inorganic
particulate material such
as, for example, magnetite, ferrite, cerium oxide, strontium titanate and/or
electrically
conductive titania.
[0072] The decor product may include magnetically responsive microparticles
with or
without colorant. In this embodiment, the decor product may be applied using a
static charge
CA 02665976 2009-05-13
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and/or magnetically directed force. As an example, iron oxide and/or other
magnetic
particles known to those in the art form a part of the formulation rendering
the decor product
magnetically responsive. The magnetically responsive property may be used for
further
placement onto the fiber and/or for enhanced removal from the fiber and/or to
aid with
aesthetic considerations such as creating designs and/or patterns.
[0073] Further, the decor product envisioned in the present disclosure may
have additives
designed to impart additional non-visual benefits such as fragrancing and
aromatherapy.
Further additives may include temporal emission) agents, for example, short-
or long-term
emission agents, such as spot cleaners and odor eliminators, and the like,
and/or bioactive
agent additives such as bactericides, miticides, insecticides, pesticides,
and/or fungicides,
which are released over periods of seconds to minutes to hours to days to
weeks to months to
years. An example of a bioactive agent, such as a biocide, contemplated for
use in
compositions of the present disclosure includes isothiazolinone-based
biocides, such as
Acticide MBL 5515, available from Acti-Chem Specialties, Inc. (Trumbull, CT).
[0074] Further, the decor product may incorporate additives such as fire
retardants and
anti-slip agents. Further, the applied decor product may serve to protect the
surface areas to
which it is affixed from stains, chips, dents, rips, blemishes, bums,
splintering, abrasion, cuts,
rust, oxidation, water damage, mold, and/or dirt. Further, the applied decor
product may
serve as an electrical insulator, for example, to reduce static electrical
charges.
[0075] In another embodiment, a decor product of the present disclosure may
incorporate
interactive sensory elements that interact with one or more senses of the
user. Examples of
interactive elements include mood lighting, sound (for example, music,
indicative sound, or
instructive sound), and scent (for example, fragrance emitters, deodorizers,
and/or odiferous
pet barriers only detectable by animals).
[0076] Illustratively, a formulation of a decor product, for example, an
emulsion, contains
on a weight to weight basis, at least one of. 1) a surface-active agent in an
amount of greater
than about 0.1%, or less than about 75%, or between about 0% to about 50%, or
between
about 0.001 % to about 30%, or between about 0.01 % to about 10%; or between
about 0.1 %
to about 5%; 2) an adhesive agent in an amount of greater than about 0.1 % or
less than about
75%, or between about 0% to about 50%, or between about 0.00 1% to about 30%,
or between
CA 02665976 2009-05-13
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about 0.01% to about 10%; or between about 0.1% to about 5%; 3) a colorant in
an amount of
greater than about 0.01% or less than about 95%, or between about 0.01% to
about 70%, or
between about 0.03% to about 15%, or about 0.05% to about 10%; or between
about 0.1% to
about 5%; 4) an additive in an amount of greater than about 0.1%, or less than
about 75%, or
between about 0% to about 50%, or between about 0.001% to about 30%, or
between about
0.01% to about 10%; or between about 0.1% to about 5%; and 5) the balance
water.
[0077] Further, a formulation of a decor product, for example, a rheology
modifier-
containing composition contains on a weight to weight basis, at least one of.
1) a thickener in
an amount of from about 0.01% to about 1%, or from about 0.05% to about 0.7%,
or from
about 0.1% to about 0.5%, or from about 0.12% to about 0.3%; or about 0.7%, or
about 0.5%,
or about 0.3%, or about 0.15%, or about 0.1%; 2) a gum in an amount of from
about 0.01% to
about 1%, or from about 0.03% to about 0.3%, or from about 0.05% to about
0.1%, or about
0.5%, or about 0.3%, or about 0.15%, or about 0.07%, or about 0.05%; 3) a clay
in an amount
of from about 0.01% to about 5%, or from about 0.05% to about 3%, or from
about 0.5% to
about 2%, or from about 1% to about 1.5%; or about 3.5%, or about 2.5%, or
about 1.75%, or
about 1.16%, or about 1%; 4) a surfactant in an amount of from about 0.01% to
about 5%, or
from about 0.05% to about 4%, or from about 0.15% to about 3.5%, from about
0.07% to
about 1.5%, or from about 0.1% to about 0.75%; or about 5%, or about 4%, or
about 3%, or
about 1.5%, or about 1%, or about 0.5%, or about 0.3%, or about 0.15%, or
about 0.1%; 5) a
humectant in an amount of from about 0% to about 2%, or from about 0.1% to
about 1.75%,
or from about 0.25% to about 1.5%, or from about 0.75% to about 1.25%; or
about 1.75%, or
about 1.5%, or about 1.25%, or about 1%, or about 0.75%; 6) one or more
anticorrosive
agents in an amount of from about 0.01% to about 3%, or from about 0.05% to
about 2%, or
from about 0.1% to about 1%, or from about 0.15% to about 0.5%; or about
0.35%, or about
0.15%, or about 0.1%; 7) a biocide in an amount of from about 0.01% to about
2%, or from
about 0.02% to about 1%, or from about 0.1% to about 0.5%, or about 1.5%, or
about 1.25%,
or about 1%, or about 0.75%, or about 0.5%, or about 0.3%, or about 0.2%, or
about 0.1%; 8)
a colorant in an amount of from about 1% to about 50%, or from about 2% to
about 25%, or
from about 3% to about 10%, or about 50%, or about 30%, or about 25%, or about
15%, or
about 8%, or about 6%, or about 5% or about 3%; or about 1%; and 9) the
balance water.
CA 02665976 2009-05-13
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[0078] A clear toner may also be included in a decor product composition of
the present
disclosure in an amount equivalent to, for example, the amount of the
colorant. For example,
in a toner formulation having 10% by weight a colorant, an additional 10% by
weight of the
toner formulation contains a clear toner. Illustratively, in a toner
formulation with about
0.5% w/w yellow colorant, about 0.4% w/w magenta colorant, and about 0.2% blue
colorant,
the toner formulation also contains about 1.1 % clear toner. In another
example, an emulsifier
contains about 100 grams of water, about I gram of yellow NATURATM toner,
about 0.4
grams of blue NATURATM toner, about 0.8 grams of magenta NATURATM toner, about
2.2
grams of clear NATURATM toner, and about 0.33 gams of ALCOPRINTTM PTU
(LYOPRINT , available from Huntsman International LLC). An emulsion of the
present
disclosure may be made by mixing the various components of the emulsion for a
period of
time until the particles of the emulsion are coated with the emulsifying agent
or agents. The
coating of the particles may enhance the stability of the formulation. The
mixing time
depends on the particular components utilized in a formulation and can range
from, for
example, from about 1 minute or less to about 48 hours, or longer.
[0079] In another embodiment, the decor product may be formulated as a stain-
removing
and masking agent containing a base color such as a white and/or neutral color
and/or other
color onto which additional desired colors may be overlain. Illustratively,
the decor product
may contain a pH neutralizing and/or adjusting pretreatment compound such as,
for example,
a peroxide and/or a bleach, and/or a titanium dioxide-type neutral color
application. The
decor product may further include a stain-masking agent and/or coloring agent
as disclosed
herein. Another embodiment contemplates the application of a highly pigmented
coating that
has a white and/or neutral color that provides a mask and/or hides a color
difference (for
example, a stain) on a surface. Further, another material with a color
matching the bulk fiber
of the surface (for example, a carpet or textile) may be applied subsequent to
the masking of
the stain.
[0080] In yet another embodiment, a decor product composition may have a glass
transition temperature (Tg) from below about 25 C up to the melting
temperature (Tm) of the
surface substrate to which it is to be applied. In a further embodiment, the
Tg ranges from
about 45 C to about 75 C, or from about 45 C to about 60 C, or from about 45 C
to about
70 C, or about 55 C. The Tg and Tin of a composition or a surface substrate
may be
CA 02665976 2009-05-13
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measured by methods known to those skilled in the art including, for example,
dynamic
mechanical analysis, thermomechanical analysis, and differential scanning
calorimetry.
Illustratively, Tg and Tm values of decor products and surface substrates may
be determined
using a Model Q100 Differential Scanning Calorimeter (TA Instruments, Inc.) at
a heating
rate of 20 C/min.
[0081] In still another embodiment, the decor product composition has an
Imperial
Chemical Industries (ICI) cone and plate viscosity of equal to or less than
about 2,000
centipoises, or about 5 centipoises to about 100 centipoises, or about 15
centipoises to about
50 centipoises, or about 25 centipoises, or about 35 centipoises at about 150
C to about
200 C. The viscosity of a composition may by measured by methods known to
those skilled
in the art, including for example, using a Wells-Brookfield Cone/Plate
viscometer distributed
by Can-Am Instruments LTD and following methods as set forth in D4287-00(2005)
"Standard Test Method for High-Shear Viscosity Using a Cone/Plate Viscometer,"
ASTM
International. Further, a Brookfield CAP 2000H Cone and Plate Viscometer
(available from
Brookfield Engineering Laboratories, Inc.) set at 750 rpm for 25 seconds using
a size six
spindle may be used to measure the ICI Cone and Plate viscosity of the decor
product
composition.
[0082] Application of the decor product contemplated in the present disclosure
may occur
by any appropriate way that is compatible with the decor product formulation
utilized.
Illustrative ways to apply the decor product to a surface include the use of
an ink jet printer, a
jet dye process, silk screening, and/or rotary printing. Further, the decor
product may be
applied and/or dispensed with and/or by a spray gun, a sheet, a film, a
matrix, a roller, a
brush, a marker, a pen, a stamp such as a self-inking stamp, a pump sprayer, a
trigger sprayer,
a pressurized spraying device, a sponge, a squeegee, an airbrush, a fiber
separator, a dye
applicator, a roller, piezoelectric or heat driven delivery, a manual or
electronic sifter, a
powder "puff', a felted/flocked brush, and/or a powder paint dispenser. The
decor product
may be applied in a wet form, such as, for example, as a suspension or
emulsion including,
for example, a liquid-based solvent, a foam, a spray, a wet aerosol, or in a
dry form, such as,
for example, as a powder, a dry aerosol, and/or a powder with a gentle mist.
CA 02665976 2009-05-13
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[0083] By way of example, one possible method of applying a decor product to a
selected
surface is generally depicted in FIG. 1. Here, a finger pump sprayer 12
including a reservoir
14 for holding the decor product and finger pump 16 is used to apply a
generally cone-shaped
dispersion 18 of decor product to a surface 20 such as a carpet. In this
embodiment, by
varying the distance of the finger pump sprayer 12 from the surface 20 and
angle of the finger
pump sprayer relative to the surface, the size and shape of the pattern 22
imparted to the
surface may be varied. In this way, a preselected pattern may be imparted to a
surface using
a "free-hand" technique without a design device.
[0084] Additional examples of applicators and/or dispensers of the decor
product of the
present disclosure include, for example, an intermittent pressurized sprayer
(such as PULL `N
SPRAY liquid applicator marketed by The Scotts and Miracle-Gro Company), an
actuator
spray bottle, a trigger sprayer, a mechanical spray bottle, a pump and/or pump
system, a
liquid refill containing the decor product for a pressurized air chamber, an
aerosol barrier
pack containing the decor product with a driving chamber (with a propellant,
for example,
carbon dioxide or a hydrocarbon), and a liquid or gel chamber for containing
the decor
product where use would allow pressurized spraying with reduced propellant
release to the
atmosphere or room being decorated by the user. Other useful sprayers include
those
disclosed in, for example, U.S. Patent No. 6,872,444.
[0085] For example, FIG. la illustrates an aerosol container 3020 in an
inverted position
with a solid container body 3021 that terminates at a lower rim 3022 (a
dispensing end) that
is sealably connected to a mounting cup 3023, which accommodates a valve stem
3024 the
forms part of an overall aerosol valve 3025 that further includes a valve body
3026. Valve
stems contemplated in the present disclosure may further include means for
dispensing a
decor product, such as, for example, an actuator button affixed to the valve
stem, an aerosol
over cap, a trigger actuator, a tiltable valve, a rotary valve, an automated
valve, such as a
solenoid driven valve, and others known in the art.
[0086] The container 3021 may accommodate a decor product 3031 and propellant
3032,
as described herein, for application to a surface. A conically-shaped mesh
filter element 3040
may be attached to an inlet end 3041 of the valve body 3026 and includes a
plurality of pores
or holes shown schematically at 3063. Pore sizes of the filter element 3040
may be at least as
CA 02665976 2009-05-13
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large as the average diameter of the substantially homogeneous particles
contained within the
container 3021, and illustratively may range from about 100 to about 500
microns, or from
about 80 to about 500 microns in diameter. The number of pores 3063 in the
filter element
3040 may range from about 100 to about 500 per area. The mesh filter element
3040
includes a flange portion 3064 that rests or engages the rim or wall 3065 of
the lower valve
body 3026 to prevent decor product from bypassing the mesh filter element and
potentially
clogging the valve stem. Filter geometries other than conical shapes are
contemplated that
could be attached or otherwise integrally molded into the valve body 3026
[0087] Still further other ways to distribute the decor product include, for
example, a
decor product impregnated sheet that contains entrapped dry or wet decor
product particles
that when wetted or otherwise activated, releases the decor product onto the
surface. Another
example includes a decor product impregnated sheet containing entrapped liquid
that releases
the decor product onto the surface upon pressure application or controlled
puncture. A
further example includes a decor product impregnated sheet with liquid rolled
or stamped
thereon that promotes even distribution of the decor product. Still another
example includes
an apertured or perforated decor product impregnated film that collects and/or
directs a
releasing substance that once applied to the film releases the decor product
onto a surface.
Yet another example includes a decor product impregnated matrix containing
therein and/or
thereon entrapped decor product formulation that releases the decor product
onto a surface
upon pressure, vibration, liquid transfer, heat application, and/or chemical
means and/or by
an electrostatic deposition device that meters an amount of decor product to
be applied to a
surface and precisely lays the decor product on the surface.
[0088] Still further ways for application of the decor product include a
multiple chamber
system that mixes the decor product upon dispensing to give the desired decor
product color
or other characteristic, such as are exemplified in part by trigger release
systems (for
example, DLS 100, DLS 200, or Versitech systems manufactured by Take 5,
Anaheim,
California (www.take5net.com)), pump systems (for example, VERSADIAL
manufactured
by Versadial, New York, New York, a company under the Sea Change Group)
(www.versadialworld.com)), or a multichamber mixer/dispenser that is combined
with a
decor product applicator (for example, a brush, a spray bottle, or other
applicator). Further,
CA 02665976 2009-05-13
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premixed ready-to-use bottles and/or spray cans may be used to distribute and
apply the decor
product.
[0089] Additional technologies contemplated for application and/or dispersion
of the
decor product include multifunctional devices, such as, for example, a device
that combines
packaging, design positioning, decor product application, and/or removal of a
design device
from a surface. For example, in one embodiment, a design device, for example,
a stencil
contains the decor product, which can be released onto a surface by applying a
releasing
agent, such as water, to the stencil. As an example, the use of a dry decor
product may be
reversibly attached to a stencil by means of a water-soluble adhesive or the
decor product
may be attached to a sticky side of a water-soluble transparent film. Further
technologies
contemplated include sprayers that impart charges to colorant droplets and/or
stencils (similar
to powder painting), sponging, and felt tip pens and liners.
[0090] The decor product in one embodiment may be applied using heat transfer
technology including, for example, that used by color copying machines such as
a Xerox
DOCUCOLORTM 12 printing onto Xerox 3R5811 or another similar transfer paper
and/or
similar combinations of materials provided by Hewlett Packard, Canon, Geo
Knight & Co,
Avery Dennison, and 3M.
[0091] Differing application factors are contemplated for encapsulated decor
product
particles including control release, temperature release, concentration
release, and any other
release mechanism known to those skilled in the art. For example, release of
the contents of
a microencapsulated decor product particle contents may be triggered by
changes in pH, such
as by applying a common solvent such as, for example, an ammonia-containing
solution.
Examples of a temperature release mechanism include exposure of the
microencapsulated
decor product particles to a temperature above a release threshold, where the
release of the
microencapsulated decor product particle contents only occurs above the
predetermined
threshold temperature. A concentration release application may apply a portion
of a colorant
to the surface over an extended period of time to render a more evenly
distributed and/or
more thoroughly distributed appearance of the colorant to a surface.
Illustratively, a
microencapsulated decor product particle with a polymer resin particle shell
and containing
trapped colorant particles and/or other compounds disclosed herein may be
activated by
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thermal activation and/or specific chemistry-related activation (including,
for example pH
modulation using, for example, ammonia). As such, the outer polymer shell
would melt
and/or dissolve, and the colorant particles and/or other microparticle
contents may be allowed
to flow and thus be applied to the surface. Nonexclusive examples of release
mechanisms
useful in the present disclosure include those found in U.S. Patent No.
6,893,662. Additional
release mechanisms contemplated for treating of the microencapsulated decor
particle result
in at least one of breaking, heating, weakening, and/or dissolving one or more
shells of a
decor particle.
[0092] A decor product once applied and/or affixed to the surface may be
temporary,
permanent, and/or semi-permanent. An example of a semi-permanent decor product
includes
a decor product with a temporary adhesive that adheres and/or attaches a decor
particle to the
surface. Such a formulation may provide short term durability, for example,
hours to weeks,
of the decor product on a surface by substantially adhering and/or attaching
the decor product
thereon. In one embodiment, short term durability allows the decor product to
be applied to a
surface for an occasion, special event, and/or holiday without the decor
product needing to be
affixed to the surface and at the same time being easily removable therefrom.
An example of
decor product attachment to a surface is seen in FIG. 2, which is a scanning
electron
micrograph showing dry decor particles 32 attached to an individual nylon
carpet fiber 34.
[0093] Removal of the decor product from the surface may be either through dry
removal
methods or wet removal methods such as through using various devices and
methods
including, for example, a vacuum, a vacuum combined with mechanical action
such as
agitation, wet extraction, steam cleaning, chemical application (for example,
applying an
organic or inorganic solvent), using an ultrasound process, using detergents,
using dilute
ammonia solutions, and/or using an abrasive eraser. Some or all of the
aforementioned
processes may be employed to remove the decor product prior to and/or after
setting,
affixing, and/or curing of the decor product on or to the surface.
[0094] Examples of solvents useful in the present disclosure include polar
and/or
nonpolar solvents, including those disclosed in the Handbook of Organic
Solvent Properties,
Smallwood, I.M. 1996, Elsevier. Such solvents include, for example, water,
hydrocarbons,
aromatic hydrocarbons, aliphatic hydrocarbon solvents such as aliphatic
alcohols, other
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alcohols, glycol ethers, nitrated and chlorinated solvents such as chlorinated
hydrocarbons,
ketones, ethers, and/or esters. Other useful solvents include acetone, amines,
benzyl acetate,
phenols, and/or the organic sulfone or sulfoxide families including dimethyl
sulfoxide.
Detergents and soaps may also be used to remove a decor product from the
surface.
Combinations of the above may also be used.
[0095] By way of example, reversibility of a decor product applied to a
surface may be
determined in the following manner. Initially, a test surface, such as, for
example, a two-foot
by two-foot square piece of nylon and/or polyester carpet is thoroughly
cleaned using an
upright vacuum cleaner (for example, a Bissell CLEANVIEW II vacuum cleaner,
manufactured by Bissell Homecare, Inc.) to remove loose fibers and/or dirt.
The baseline
color of each of three spots over which the decor product is applied is
determined using a
colorimeter such as a Minolta data processor model DP-301 combined with a
Minolta model
CR-3 10 chroma meter (both manufactured by Konica Minolta Sensing Americas,
Inc.) set to
the "L - a - b" setting to allow determination of AE (color change) and
calibrated according
to the manufacturer's instructions.
[0096] The decor product is applied using, for example, a finger pump (output
60 micron
particle size) onto the surface of the three spots until the test area is
completely saturated.
The decor product is allowed to substantially dry to the touch, which is
typically overnight to
assure complete drying, though shorter or longer periods may be used depending
on, for
example, the relative humidity and/or temperature of the ambient environment.
After the
decor product is dry, the color of each of the three spots is determined using
the colorimeter
as mentioned above. Subsequently, the three spots are vacuumed using a wet/dry
vacuum
with a hose attachment and brushless triangular tool, such as, for example, a
Shop-Vac 1x1
portable wet/dry vacuum 12 V 60Hz, 5.5A, model 2101A (manufactured by Shop-
Vac, Inc.).
The three spots are vacuumed in one direction several times and repeated in
the other
direction for a period of to ensure adequate removal. After vacuuming, a
colorimeter
measurement is taken to determine the change in color. Change in color (A E)
was
determined using the following formula:
AE _ i((L, - L2)2 + (a, - a2)2 + (b, - b2)2)
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where "L" refers to "lightness" with values of 0 = black to 100 = white;
increasing "a" values
indicate more red color and decreasing "a" values indicate more green color;
and increasing
"b" values indicate more yellow color and decreasing "b" values indicate more
blue color.
[0097] Illustratively, a substantially removable decor product has a AE value
as compared
to the initial reading of an untreated carpet of less than about 20, or less
than about 10, or less
than about 7.5, or in the range of about 0 to about 15.
[0098] Factors that may affect reversibility of the decor product from a
surface may
include, for example, decor product specific factors, application specific
factors, and/or
surface specific factors. Examples of decor product specific factors may
include the type
and/or concentration of emulsifier included in the decor product formulation,
which may
affect adherent interactions between the decor product and the surface to
which the decor
product is applied thereto. Further, when the decor product composition
includes a
particulate component, for example, a decor particle, the reversibility of the
decor product
may be affected by the size of the particle. Although not wishing to be bound
by theory, it is
believed that smaller particle size may affect reversibility due to possible
greater penetration
of the particles into recesses and interstices of a non-smooth surface such as
carpet, thus
reducing access to the smaller particles for the subsequent removal process.
[0099] Application specific factors that may affect reversibility include the
extent of
surface saturation when applying the decor product to the surface and the
method and/or
device used to apply the decor product to the surface. Surface saturation
includes, for
example, the density of applied decor product on the surface. Greater surface
saturation may
lead to an increased likelihood of residual decor product remaining after
removing the major
portion of decor product applied to the surface, and/or greater penetration of
the decor
product into the recesses and interstices of the surface thereby reducing
accessibility of the
removal process to the decor products. Further, the method and/or application
device used to
apply the decor product may affect reversibility. Illustratively, the decor
product may be
applied to a surface in a fashion to coat the surface with little to no
surface penetration. For
example, an applicator that applies the decor product in a mist, such as by a
finger pump with
a 60 micron or less spray nozzle, may be used to coat the surface with little
or no penetration
of the interstices of the surface. In this example, decor product
reversibility may be improved
owing to the minimal surface penetration of the decor product. However, if it
is desired to
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apply the decor product with an aerosol and/or non-aerosol spray container, or
other such
applicator that expels the decor product from the container with a greater
velocity than, for
example, a hand pump, deeper penetration of the surface may result, which may
affect
removal of the decor product from the surface by, for example, limiting or
inhibiting access
of the removal process to the decor product.
[00100] Surface specific factors that may influence decor product
reversibility include, for
example, surface structure and/or texture, the electrostatic charge held by
the surface, and/or
surface pretreatments affecting, for example, surface tension. Surface
structure factors such
as fiber density, in the case of carpets and the like, may influence decor
product reversibility.
For example, dense carpet structures may be more likely to minimize particle
penetration as
opposed to open structures such as, for example, nylon shag carpets and older
carpets with
damaged braids. Thus, less dense surfaces may influence decor product
reversibility by, for
example, reducing the access of the decor product to the removal process as
compared to
more dense surfaces.
[00101] Further, surface electrostatic charge and/or surface tension may
influence
reversibility. Illustratively, a surface treatment may be used to lower the
electrostatic charge
and/or surface tension to improve the reversibility characteristics of the
decor products.
Examples of surface treatments that may be used include 3M SCOTCHGUARDTM
Carpet
and Upholstery Protector (manufactured by 3M) and/or Advanced TEFLON Carpet
protector (manufactured by E. I. du Pont de Nemours and Company). Further,
such
pretreatments may promote decor product coverage and/or dispersion on the
surface with
smaller volumes of the decor product thus indirectly promoting decor product
reversibility
through minimizing the risk of oversaturation.
[00102] In some instances, the decor product may be formulated to have a
larger particle
size to improve or enhance reversibility by reducing the amount of particles
based on size
that can penetrate the smaller interstices of the surface. Further, and not
wishing to be bound
by theory, it is believed that smaller sized particles, for example, particles
less than about 5 to
about 10 microns in size, may be held relatively more tightly to the surface
by an electrostatic
charge and/or surface tension as compared to larger particles, for example,
particles greater
than about 20 microns in size, making the smaller sized particles relatively
more difficult to
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remove from the surface as compared to larger sized particles. Thus, in some
embodiments,
surface pretreatment, additional effort and/or additional methods may be
needed to achieve
the same reversibility characteristics for decor products formulated with
smaller particles as
compared to decor products formulated with larger particles.
[00103] Once a decor product of the present disclosure has been applied to a
surface and
the user has decided to keep the decor product on the surface, the decor
product may be cured
and/or affixed by chemical curing and/or mechanical bonding to the surface
temporarily,
permanently, and/or semi-permanently according to the formulation of the decor
product.
Any curing or affixing technique compatible with the decor product and the
surface is
contemplated in the methods disclosed herein including, for example, the
application of
energy and/or a chemical to the decor product. Examples of curing or affixing
techniques
include, for example, heat curing, steam curing, pressure curing, exposure to
an
electromagnetic field, including for example, ultraviolet radiation, radio
frequency curing, a
magnetic field, and the like, ultrasound curing, induction heat curing, solar
heat curing,
exothermic reaction heat curing, convective heat curing, and/or radiant heat
curing. Further,
curing or affixation of the decor product may be accomplished by exposure of
the decor
product to the ambient environment.
[00104] The decor product in one embodiment may be affixed to a surface using
heat in a
range from about -7 C to about 650 C, or about 4 C to about 400 C, or at a
temperature less
than about 260 C, or about 20 C to about 180 C, or about 65 C to about 120 C,
or higher and
lower temperatures depending on the surface in which the decor product is
applied. Further,
the duration of the curing or affixing step is generally decor product- and/or
surface-specific,
and illustratively, ranges from less than 1 second to about 15 minutes, or
from about 15
minutes to about 1 hour, or from about 1 hour to about 4 hours, or from about
5 hours to
about 8 hours, or from about 8 to about 12 hours, or longer for curing of the
decor product.
[00105] Tools that may be used to cure and/or affix the decor product to a
surface include,
for example, a hot iron, an enclosure or frame containing a CALRODTM heating
element
suspended over the surface being heated, an enclosure or frame with one or
more
incandescent light bulbs, a heat gun, an enclosure or frame with a heater and
a blower to
infuse hot air onto the substrate, an enclosure or frame with an infrared
heating element, an
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enclosure or frame with an ultraviolet light source, a steam-making device, a
heated tool (for
example, a household iron, an electric griddle, or a hair dryer or objects
similar in function
but specifically designed for the application), or a microwave emitting device
or a radio
frequency emitting device. The devices contemplated herein to be used for
decor product
affixation may incorporate heat sensors and timers to facilitate the
affixation process and
further protect the surface to which the decor product is being applied from
damage from
overheating.
[00106] Additional ways to affix the decor product to a surface include
inductive heating
of a decor product containing metal nano- or microparticles, moisture curing
systems, adding
magnetic enhancements to a deposited decor product, and treatment of additives
within the
decor product to induce affixation. Further ways to affix the decor product to
a surface
include those disclosed in the U.S. patents provided in Table No. 1 above.
[00107] An illustration of affixation is shown in FIG. 3. Here, the decor
product has been
applied to a surface 44, such as a nylon carpet described herein and has
substantially dried to
the surface to form substantially dry decor particles 42 attached thereto. An
affixation device
46 emitting energy 48, for example, an electromagnetic field, is being passed
over the applied
decor particles 42 in a direction A. Upon contact of the emitted energy 48,
the decor particles
begin to melt and flow and upon removal of the emitted energy begin to cool
and bond to the
surface 44 to become substantially affixed to the surface. A further example
of fixation is
seen in FIG. 4, which is a scanning electron micrograph showing a resultant
decor particle
film formed on individual fibers of a carpet.
[00108] Protective coverings may also be applied to a deposited decor product
for the
purpose of affixing the decor product and/or to add to the resiliency of the
decor product to
wear. Useful protective coverings include, for example, nanoparticle coating
compositions
disclosed in, for example, U.S. Patent No. 6,872,444. Further, fixatives
useful in the present
disclosure include those used in artistry to fix and/or seal, for example,
pastels, pencil,
charcoal, crayon, ink, gouache, or watercolor. Such fixatives include those
available under
the trade names Blue Label Reworkable FIXATIF (Martin F. Webber Co.), GOLDEN
Archival Spray Varnish (Golden Artist Colors Inc.), KRYLON Workable Fixative
(Krylon
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Products Group, The Sherwin-Williams Company), and LASCAUX Fine Art Fixative
(Lascaux Colours & Restauro, Switzerland).
[00109] It is further contemplated that the surface to which a decor product
is to be applied
and/or affixed thereto may be conditioned prior to the application of the
decor product.
Examples of such conditioning include, but are not limited to cleaning,
vacuuming, steam
cleaning, bleaching, pH balancing, reducing the pH, increasing the pH,
sweeping, painting,
scrubbing, wetting, texturing, leveling, tilting, drying, heating, cooling,
sanding, buffing,
coating, removing coatings therefrom, reducing the electrostatic charge of the
surface, and/or
applying a surface treatment, such as an upholstery and carpet protector
including, for
example, 3M SCOTCHGAURDTM Carpet and Upholstery Protector (manufactured by 3M)
and/or Advanced TEFLON Carpet protector (manufactured by E. I. du Pont de
Nemours
and Company).
[00110] Illustratively, the durability of a substantially affixed decor
product can be
expressed in terms of a AE value by determining the ratio of the AE measured
between an
untreated surface and a decor product affixed on the surface and the AE
measured between
the untreated surface and the decor product affixed and subsequently vacuumed
as described
herein and subtracting this ratio from 100. Illustratively, the percentage
change in AE for a
substantially affixed decor product has a range of about 0% to about 20%
change in AE.
[00111] A further embodiment of the present disclosure includes the use of a
design device
that a user may use to control the application of the decor product to a
surface for the purpose
of creating, for example, a pattern on the surface to enhance the aesthetic
effect of the decor
product. Possible decor product patterns on surfaces contemplated in the
present disclosure
include any and all images, patterns, shapes, and/or designs. Preselected or
random patterns
may also be imparted to a surface using an inherent dispersal pattern from a
decor product
applicator with or without movement of the applicator over a selected surface
during
application of the decor product. For example, by using a spray applicator
with a cone-
shaped dispersal pattern, a user may choose to apply discrete spots and/or
circles having
diameters that are varied by varying the distance from which the applicator is
held from the
surface during application of the decor product. Further, a user may move the
applicator
during application of the decor product over the surface in a predetermined or
random pattern
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to achieve a predetermined or random pattern on the surface. As such,
preselected patterns
and/or random patterns may be imparted to a surface with or without a design
device.
[00112] Design devices contemplated in the present disclosure may limit,
direct, focus,
concentrate, guide, dilute, and/or disperse an amount of decor product applied
to certain
predetermined areas of a selected surface. The design device may include, for
example, a
stencil, a template, an array, a guide, a frame, a pattern imparting device, a
device imparting
graphics in a random manner, a manual device, an automatic device, a computer
guided
device, a programmed device, and/or any combination thereof. The design device
contemplated for use herein including, for example, a stencil, may be
constructed totally or in
part with a material such as, for example, paper, wood, stone, plastic,
cardboard, metal,
and/or any combination thereof.
[00113] Stencils or other design devices contemplated for use in the present
disclosure
may be designed, constructed, shaped, and/or reshaped, in a predetermined,
ordered,
disorganized, and/or random manner by means of laser, knife, die cutting,
and/or any other
appropriate means as determined by the nature of the stencil material (for
example, hardness
or softness of the stencil materials) to render a predetermined, ordered,
disorganized, and/or
random shape that allows a predetermined, ordered, disorganized, and/or random
deposition
of at least a visual design by introducing a decor product on a surface. The
stencils may
further be laminated and have additional layers applied thereto post-
construction and/or post-
designing.
[00114] An exemplary stencil 60 useful in the present disclosure is shown in
FIG. 5 and
includes a material containment layer 62 (for example, for the absorption of
liquids and/or
entrapping of dry materials and/or solids) that includes a paper tissue, a
synthetic woven or
non-woven material that may or may not be coated with an absorbent hydrophilic
material,
and/or a solid and/or liquid entrapping substance. The material containment
layer may have a
thickness of about 0.01 mil to about 1000 mils, or about 0.1 mil to about 500
mils, or about
0.5 mil to about 150 mils, or about 1.25 mils to about 50 mils, or about 2
mils to about 15
mils, or a lesser or greater thicknesses depending on the application. The
stencil may also
incorporate a liquid barrier layer 64 to protect a selected surface from
unintended colorant
exposure that may comprise a liquid barrier made of any hydrophobic material,
including a
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polyolefin such as polyethylene. The liquid barrier layer 64 may also be
comprised of a
coating applied to one surface of the absorbent material to hinder liquid
transport through the
absorbent material. Such a coating may be polymeric in composition such as an
acrylic
polymer. The liquid barrier may have a thickness in the range of about 0.01 to
about 1000
mils, or about 0.1 mil to about 500 mils, or about 0.5 mil to about 150 mils,
or about 1.25
mils to about 50 mils, or about 2 mils to about 15 mils, or lesser or greater
thicknesses
depending on the application. An example of a material containment layer and
barrier layer
combined together useful in the present disclosure, includes the commercially
available
GOTCHA COVERED drop cloth by Kimberly-Clark Corp. The stencil 60 further
includes
a first support layer 66 that helps to secure the edges of one or more cutout
portions 68 that
provides a passage through at least the material containment layer 62 and the
liquid barrier
layer 64 of the stencil 60. In this embodiment, the first support layer 66
comprises threads,
but other materials may be used, in addition to or in place of threads as
described below.
Further, the stencil 60 includes a second support layer 70 that helps to
secure the stencil 60 to
a surface (not shown), such as a carpet. The second support layer 70 may
consist of adherent
materials including, for example, adherent mesh-like materials as described
below.
[00115] A cross-sectional view of the stencil 60 is shown in FIG. 6. Here, the
cutout
portions 68 are shown through the material containment layer 62, the liquid
barrier layer 64,
and the second support layer 70. However, the second support layer 70 need not
have the
cutout portion 68 pass therethrough to allow a decor product to be deposited
on a surface due
to its mesh-like structure.
[00116] In another embodiment, the material containment layer and the barrier
layer may
be made of the same material. For example, a dual purpose material (for
example, a paper
material) that has densities that differ by layers. In this example, the top
layer of the dual
purpose material corresponds to the material containment layer and has a
density that absorbs
liquids and/or entraps dry material and/or solids and the bottom layer
corresponds to the
barrier layer and has a density that prevents passage of liquids therethrough.
Further, varying
thicknesses may contribute to the functionality of the dual purpose material
previously
described in addition to or in lieu of varying material densities. Such a dual
purpose material
may be advantageous over using multiple materials to create a stencil
envisioned in the
current disclosure by facilitating manufacture of the stencil.
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[00117] Another stencil that may be used in the present disclosure may also
include a
fibrous support layer that has securement and/or attachment properties, such
as tulle, scrim,
VELCRO , VERSA HOOK from Avery Dennison, and the like. Illustratively, when
the
support layer is laid upon a surface, the support layer comes in contact with
the surface to
which the stencil is to be releasably secured in such a way as to adequately
secure the stencil
to the surface to allow deposition of the decor product upon the surface and
render the
intended result. The support layer may also comprise other adherent
mechanisms, properties,
and/or devices such as, adhesive strips, pressure-sensitive adhesive, and/or
any standard
bonding mechanism known to those skilled in the art. An additional support
layer including,
for example, a loose grid, web, or mesh-like material including, for example,
thread, is
envisioned that may be placed adjacent the barrier layer of the stencil. In
this embodiment,
the cutout portion may extend through the material containment layer, the
barrier layer, and
the support layer. An exemplary stencil useful in the present disclosure in
which the support
layer is a pressure-sensitive adhesive includes that disclosed in, for
example, U.S. Patent No.
6,779,443. The support layer may be of sufficient area to minimize unintended
exposure of a
surface, as well as function to maintain the structural integrity of the
stencil.
[00118] Stencils that may be used in this application may be substantially
resilient to decor
product removing means and/or affixation means. The stencil may be used to
protect
underlying surfaces from the decor product removing means disclosed herein.
Further,
stencils contemplated within the context of the present disclosure when
disposed upon a
surface may protect portions of the selected surface from at least one of
application, removal,
or affixation of the decor product by means of at least one of the material
containment layer
or the barrier layer. Further, a design device may protect an area adjacent to
the preselected
pattern from receipt of the decor product.
[00119] Stencils contemplated in the present disclosure may have cutout
portions and/or
peripheral edges substantially shaped into a desired pattern, shape, and/or
design.
Illustratively, as seen in FIG. 7, a stencil 80 has star-shaped peripheral
edge 82 and an
internal cutout 84 having a similar shape as the peripheral edge. This
exemplary stencil may
be used, for example, when a decor product is being applied to a large area of
a surface such
that the stencil base 86 between the peripheral edge 82 and the internal
cutout 84 blocks
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application of the decor product to the surface to leave a decor product-free
pattern on the
surface.
[00120] The stencil may also have one or more cut-out portions and/or pre-cut
punch-out
portions that may be selectively removed by a user. Reverse image stencils
contemplated in
one embodiment may be used to impart a reverse visual image upon a surface by
first being
placed upon the surface to which a decor product is intended to be applied. In
this
embodiment, the peripheral edge of the stencil is cut and/or constructed to
impart a pattern,
shape, and/or design to a surface when a decor product is applied to the
stencil and
underlying surface. It is envisioned, that the reverse image stencil may or
may not have a
cutout portion therethrough. After the placing of the stencil or stencils, the
decor product is
applied to both the surface and the stencils. The stencil or stencils function
to protect the
underlying surface in the shape of the desired image resulting in a decor
product-free area in
the shape of the desired image surrounded by a decor product covered area
outlining the
desired shape. Further, conventional stencils contemplated in the present
disclosure may be
used to impart a visual image upon an intended surface by first being placed
upon the surface
to which a decor product is intended to be applied, after the placing of the
stencil or stencils
the decor product is applied to both the surface and the stencils, and the
stencil or stencils
function to protect the surface surrounding the shape of the desired image
resulting in a decor
product covered area in the shape of the desired image surrounded by a decor
product-free
area outlining the desired shape.
[00121] Another illustrative stencil imparts an image to a surface when used
in
conjunction with the decor product removal means, such as, for example, a
vacuum, after the
decor product has been applied to the surface. In this example, the decor
product is first
applied to the surface and the stencil is placed on the surface where the
decor product had
been applied. After the stencil has been applied to the treated area, a user
may apply a second
decor product to the treated area and stencil to impart multiple patterns of
different decor
products a surface. This process may be repeated until a desired affect is
achieved.
Alternatively, after applying the stencil to the treated area, the decor
product that remains
exposed within cutout portions of the stencil and/or in areas surrounding the
peripheral edges
of the stencil may be removed by decor product removing means disclosed
herein. The
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removal of the decor product results in images similar to those with the
reverse image stencils
and/or the conventional stencils disclosed above.
[00122] One or more stencils may be used simultaneously to apply a visual
design to a
surface. When desired, one or more stencils may be used in combination with
any number of
other stencils contemplated in the present disclosure and/or auxiliary devices
that aid in
design formation and/or stencil communication. A multiplicity of stencils
intended to be
used together to impart a design or other graphic representation on a selected
surface may be
coordinated with relation to one another and the room or volume of choice by
coordinating,
aligning, interfacing, connecting, and/or guiding systems that secure the
stencils either
together or apart from each other or from predetermined or random positions
within a room
or other volume either on the surface on which the decor is intended to be
applied or any
other point in the room or other volume. Examples of coordinating, aligning,
interfacing,
connecting, and/or guiding means useful herein include reusable or disposable
pegs that
anchor stencils and/or additional auxiliary devices that aid in design
formation and/or stencil
communication together via peg securement locations, color strips disposed
along a surface
of the stencils, letters, symbols, notches, and/or other indicia that guide
assembly of the
stencil organization. An example of a stencil coordinating mechanism is
illustrated in FIGS.
8-11.
[00123] FIG. 8 depicts a disposable and/or reusable peg 90 that can be affixed
to a surface
to form an anchor point on the surface for coordinating stencil placement on
the surface. In
this example, the peg 90 has multiple layers of adhesive strips 92 to adhere
the peg to the
surface, however, a single strip may be included or some other adherent
mechanism such as
VELCRO dots and/or other adhesive agents known to those skilled in the art.
[00124] FIG. 9 shows a transparent layout tool 102 that may be placed on a
surface 104 to
be decorated. The layout tool 102 includes one or more spacing portions 106,
for example,
an array, sized to permit one or more pegs 90 to be inserted (as shown by
arrow B) into the
spacing portion and attached to the surface 104. The layout tool may also
include a colored
pattern that may serve as a preview for a selected decor design that may be
achieved using a
corresponding set of stencils. To determine placement of the layout tool 102
on the surface
104 in order to, for example, center the layout tool on the surface, the user
may measure a
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distance from a feature on the surface, for example, a floor vent, or may
measure a distance
from a wall or other room feature to determine desired placement of the layout
tool.
[00125] By using of a plurality of pegs 90 along with the layout tool 102, a
user may
construct an array 112 of pegs attached to the surface 104 as is seen in FIG.
10. To
coordinate one or more stencils on the surface 104 using the coordinating
mechanism of the
current embodiment, the user may place a stencil 122 or a layout tool having a
hollow peg
124 centered over a hole in the stencil (not shown) on top of one of the pegs
90 adhered to the
surface 104 (as shown by arrow C) to anchor the stencil on the surface.
Alternatively, the
hole in the stencil 122 may serve to receive the peg 90 and orient the stencil
on the surface. It
is also envisioned that a stencil 122 may include more than one hole and/or
hollow peg 124,
for example, a hollow peg at each corner of a square stencil, to securely
position the stencil
on the surface. Further, in a similar fashion, additional layout tools 102
that include holes
and/or hollow pegs 124 may be positioned on the surface 104 in a predictable
and
symmetrical manner by starting with a minimal number of measurements for the
first layout
tool position. In this way, an array of pegs 90 may be placed on a large
surface using one
layout tool 102 to allow a large number of stencils to be placed on the
surface 104 to permit
an entire surface to be decorated with at one time.
[00126] Use of coordinating, interfacing, and/or guiding means may allow the
consumer to
impart a decor product in predetermined or random patterns, designs, images,
lines,
geometric shapes, discrete images, and/or repetitive images and the like, in a
visually
perceived organized manner or a visually perceived disorganized and/or random
manner.
[00127] Any and all images, patterns, shapes, and/or designs may be imparted
on a surface
using the design devices of the present disclosure. For example, images,
patterns, shapes,
and/or designs contemplated in the present disclosure may be regular or non-
regular, linear or
non-linear, and repeatable or non-repeatable patterns, including, for example,
ornamental,
tracery, or geometric forms, simplified primitive and symbolic images and
patterns,
compositional multi-object landscapes, images depicting real or imaginary
stories or plots,
images with text, art images, standard and/or reproducible images, real or
imaginary letters,
real or imaginary numbers, cartoons, real or imaginary typographical symbols,
illustrations,
patterns, designs, indicia, and/or shapes, and combinations thereof.
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[00128] Further, images, patterns, shapes, and/or designs useful in the
present disclosure
may be varied by palette, combination of standard or random images, size,
positioning on a
surface and/or customized by combination of multiple parameters, for example,
pictures,
patterns, palette, size, positioning, among others. The images, patterns,
shapes, and/or
designs useful in the present disclosure may also be varied by coloring with
reflective and/or
refractive elements, optical effects provided by an overcoat, the use of
optical properties of
static or dynamic flat images, and/or use of tactile properties imparted to a
surface by
additives and/or by affixation of the decor product.
[00129] It is further contemplated that images, patterns, shapes, and/or
designs useful in
the present disclosure may also be chosen by the consumer based on like or
dislike, visual
evaluation by comparing an image with a standard set of images, colors, and/or
templates.
The images, patterns, shapes, and/or designs useful in the present disclosure
may also be
chosen based on an interactive digital library with changeable parameters for
adjustment to
specific room or other volume environments, and may also be based on computer
modeling
for a specific room or other volume.
[00130] Further still, the images, patterns, shapes, and/or designs
contemplated may be, for
example, the result of freestyle design, the creation of single color images
using varied forms
of stencils, the creation of multiple color images using several stencils, the
creation of
multiple color images using compound stencils where with a sequential and
possibly repeated
manner one color is applied to a surface and stencil, then a layer of stencil
removed and a
protective layer added to protect the first color and/or a second color is
immediately applied
creating a color mixture on the dual exposed areas and a single color area on
the single
exposure areas, transfer of prefabricated images from a carrier, and/or
sequential image
fabrication from standard elements such as lines, dots, and/or pixels.
[00131] Additional images, patterns, shapes, and/or designs contemplated may
be unique
art work, single independent images, one or more systems of connected,
potentially
interrelated images coordinated with the immediate environment (with a room or
objects
within or characteristic of a room), and/or a two way coordination of
decorative images on
one or more surfaces and immediate surroundings. Further, images, patterns,
shapes, and/or
designs contemplated may serve purposes beyond visual ornamentation, such as
teaching,
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directing, and/or instructing, including prompts, reminders, messages,
alphabets, maps,
equations, phrases, poems, warnings, language tools, or indexing means (for
example, bar
codes).
[00132] It is also contemplated that combining one or more decor products with
at least
one stencil allows a user to create images that may be monochromatic with
constant or varied
intensity and with or without shadow effects. Further, images possible using
the present
disclosure may also be polychromatic with constant or varied intensity and
with or without
shadow effects, or may be two or more color contrast images achieved via
multiple patches of
colors and shapes. Polychromatic images may have mixed or intermediate colors
and may or
may not provide complete and natural palette. Any number of variations to the
appearance of
a treated surface may be achieved using the compositions of the decor product
envisioned in
this disclosure along with or more design devices.
[00133] An example of using the decor product with a design device is
described
hereafter. As seen in FIG. 12, a method of applying a design to a soft surface
such as a carpet
is shown generally at 200. In one embodiment, the carpet is already been
installed in a room
and may be substantially dry, although the method may be undertaken on a wet
or humid
surface as well. To apply the design to the carpet, according to one method of
the present
disclosure, a user first selects one or more design devices at step 212.
[00134] In addition to selecting one or more design devices, a user may select
one or more
decor products to be incorporated into the design that may differ, for
example, by color. One
or more consumer aids may be used to assist the user in making these
selections. The design
mechanisms may include, for example, a user making a simple decorating
decision, such as
determining an arrangement of design devices and colors to sophisticated
computer design
aids, such as CD-ROM training programs that teach color application or provide
creative
suggestions. Additional consumer aid design mechanisms include color analysis,
matching,
and blending, and may include the use of colorimeters, color scanners, and/or
software
algorithms. Further examples of consumer aids, are disclosed herein.
[00135] Once the user has selected one or more design devices, the user then
places the
design device adjacent the carpet (step 214). The one or more design devices
may be placed
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in any arrangement on the carpet and may cover a small portion of the surface,
such as a
center, edge, or corner, or substantially the entire carpet, or any amount
therebetween.
[00136] After the one or more design devices have been placed in a desired
arrangement
on the carpet, the user applies a decor product to a cutout portion of the
design device at step
216. Alternatively, or in addition to, the decor product may be placed on
portions of the
design device that directly contact (for example, a non-cutout portion of the
design device)
the soft surface. Upon contacting the surface, the user may allow the decor
product to
substantially dry on the surface at step 218. After application of the decor
product the design
device may be left in place while the decor product dries or may be removed
from the surface
immediately after application at step 220. If the used decides not to keep the
design on the
surface, the user may substantially remove the decor product from the surface
as described
herein at step 222. Otherwise, if the user decides to keep the design, the
user may
substantially affix the decor product to the surface as described herein at
step 224. Further,
the design device may be removed from the surface before or after the decor
product is
removed from or affixed to the surface.
[00137] An example of a stencil 230 useful in the present disclosure is shown
in FIG. 13.
The stencil 230 consists of a stencil base 232 and a cutout portion 234. The
stencil base 232,
including the material containment layer (not shown), barrier layer (not
shown), and a
support layer 236, is made out of any appropriate material including, for
example, paper,
plastic, cardboard, cloth, synthetic fabric, natural fabric, cellulose, and/or
metal, or any other
desired material. The cutout portion 234 consists of any pattern, shape, or
design desired. A
support layer 236, as is visible through the cutout portion 234, is provided
adjacent a bottom
surface of the stencil base 232. The stencil 230 is used to create an image on
a surface by
applying the decor product to the cutout portion 234 of the stencil, wherein
upon removal of
the stencil, the design is left on the surface of the carpet. The decor
product can then be
removed or affixed.
[00138] A bottom view of the stencil 230 is shown in FIG. 13A, further
depicting the
support layer 236. The support layer 236 extends across a small portion of a
bottom surface
of the stencil base 232, but may extend to and/or beyond edges of the stencil
base. The
support layer 236 assists in securing the stencil 230 to a soft surface,
securing the edges of the
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stencil, keeping the stencil flat, and securing and/or facilitating the
transfer of a decor
product.
[00139] A cross section of a stencil useful in the present disclosure and
similar to the
stencil 230 of FIGS. 13 and 13A is shown at 240 in FIG. 14. The stencil 240
includes an
absorbent top layer 242, a liquid barrier layer 244, and cutout portions 246
representing a
cutout portion of a design, such as the cutout portion 234 (FIGS. 13 and 13A).
In addition,
the stencil 240 may be disposed adjacent a carpet 248. The absorbent top layer
242 inhibits
or prevents dripping and/or bleeding of a decor product while on the carpet
248, as well as
when the stencil 240 is removed from the carpet, and may consist of, for
example, paper
tissue and/or a synthetic non-woven material coated with an absorbent,
hydrophilic material.
The liquid barrier layer 244 is disposed adjacent the absorbent top layer 242
and inhibits or
prevents the decor product from seeping through to the carpet 248 and may
consist of any
hydrophobic material, including, for example, a polyolefin such as
polyethylene.
[00140] A cross sectional view of the stencil 230 is shown in FIG. 15. The
stencil 230
includes an absorbent top layer 252, a liquid barrier layer 254, and cutout
portions 234, and
may be disposed adjacent a carpet 259. The stencil 250 further includes a
support layer 236
that may consist of a woven and/or non-woven mesh material, such as, for
example, tulle,
scrim, and/or cheesecloth spanning the cutout portion and that allows the
decor product to
substantially pass therethrough.
[00141] FIG. 16 illustrates an additional stencil that may be provided, for
example, in a kit,
shown generally at 270. The stencil 270 may be used at a border of a carpet
and includes a
stencil base 272 and a cutout portion 274. The stencil 270 also includes color
strips 276 and
278 having a specific color thereon, for the purpose of aligning the stencil
270 with one or
more additional stencils having corresponding and/or complementary color
strips.
[00142] A stencil 280 that may be used at a corner of a carpet is shown in
FIG. 17. The
stencil 280 includes a stencil base 282 and a cutout portion 284. The stencil
280 further
includes color strips 286 and 288 and an arrow 290 used for aligning the
stencil 280 with
internal surfaces of a corner of the carpet.
[00143] Two additional stencils are shown in FIG. 18 and FIG. 19. A stencil
1000 of FIG.
18 may be used at a first end of a carpet and includes a stencil base 1020, a
cutout portion
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1040, and a color strip 1060. A stencil 1100 of FIG. 19 may be used at a
second end of a
carpet and includes a stencil base 1120, a cutout portion 1140, and a color
strip 1160.
[00144] FIGS. 20-22 illustrate an exemplary application of the respective
stencils 270,
280, 1000, 1100 of FIGS. 16-19 to a carpet 1260 according to a sample set of
instructions that
may be provided in a kit along with the stencils. As shown in FIG. 20, a room
1200 is
provided for illustrative purposes. The room 1200 includes a first wall 1220,
a second wall
1240, and the carpet 1260. Following the instructions provided, the user is
instructed to place
the corner stencil 280 of FIG. 17 into a corner formed by walls 1220 and 1240,
wherein the
arrow 290 is pointing to the corner.
[00145] The user is further instructed to place first and second border
stencils 270 of FIG.
16, adjacent the corner stencil 280 of FIG. 17, as shown in FIG. 21. The color
strip 276 of
the first border stencil 270 is placed on top of or adjacent the color strip
(not shown) of the
corner stencil 280 having the same color thereon. Likewise, the color strip
278 of the second
border stencil 270 is placed on top of or adjacent the color strip (not shown)
of the corner
stencil 280 having the same color thereon.
[00146] Further, and as shown in FIG. 22, the user is instructed to place the
first and
second end stencils 1000 and 1100 of FIGS. 18 and 19, respectively, adjacent
the first and
second border stencils 270. The color strip 1060 of the first end stencil 1000
is placed on top
of the color strip (not shown) of the first border stencil 270 having the same
color thereon.
Likewise, the color strip 1160 of the second end stencil 1100 is placed on top
of the color
strip (not shown) of the second border stencil 270 having the same color
thereon.
[00147] The user may then apply (for example, by spraying) the decor product
on the
cutout portions of the stencils 270, 280, 1000, 1100. After applying the decor
product, the
user may remove the stencils to view the design produced on the carpet by the
remaining
decor product 1520. A sample design created by the remaining decor product
1520 is shown
generally at 1500 in FIG. 23.
[00148] In yet an alternative embodiment, a room 1600 is shown in FIG. 24.
Four walls
1620, 1640, 1660, and 1680 define outer portions of a carpet 1700. A design
device, such as
a grid pattern 1720, may be used in conjunction with one or more design
devices, such as a
stencil 1740. The grid pattern 1720 may be designed to cover all or a portion
of the carpet
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1700. Once the grid pattern 1720 is placed adjacent the carpet 1700, one or
more stencils,
such as the stencil 1740 having a cutout portion 1760 therethrough, may be
used to create a
design. The stencil 1740 and the grid pattern 1720 may include color strips,
such as the color
strips illustrated in FIGS. 16-19 to assist the user in arranging the design
devices.
Alternatively, letters, symbols, notches, indicia and/or other unique
identifiers may be used to
assist in arrangement of the stencil 1740 with the grid pattern 1720.
[00149] In addition to creating discrete images and the like as disclosed
above, the present
disclosure may be used as a resource for large area interior design in a
commercial and/or
non-commercial setting. In this capacity, the present disclosure may be used,
for example, to
create a border on a surface that would be monochromatic (solid, discrete
design, random
design) or polychromatic (solid, discrete design, random design) or to create
a whole room
change such as discrete shapes, images, design, random shapes by applying a
monochromatic
solid or non-solid or a polychromatic solid or non-solid decor product (full
coverage) from
wall to wall or that would account for complex room peripheries, such as
fireplace stoops,
door/entryways, jogs in walls, carpet to non-carpet thresholds, sunken or
raised portions in
rooms, floor vents, outlets, other built in items disruptive of surfaces in
general.
[00150] Still further, the present disclosure may be used for creating a
discrete image in a
selected area of interest as determined by the user such as, for example, a
wall, a ceiling, a
doorway, an entryway, a walkway, a hallway, a stair, or a flight of stairs, or
at the top of a
flight of stairs, or in front of or over a hearth or fireplace.
(00151] The present disclosure also provides kits that contain one or more
components
herein described, including, for example, a design device and/or a decor
product that may be
substantially removed from a surface prior to being affixed thereon. A set of
instructions
may also be included in the kit instructing the user how to apply the design
to a soft surface
such as a carpet. The kit may further comprise one or more application devices
for
transferring the decor product to the carpet and/or one or more fixative
devices for affixing
the decor product to the surface. In addition, the kit may include a
protective covering for
protecting the decor product after it has been applied to the carpet,
especially while it is
drying. The kit may further include an iron screen that is used to provide a
user with an
indication of what areas of the decor product have already been ironed or
affixed.
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[00152] As an example, the kit may be provided having one or more stencils,
for example,
five stencils, a decor product, an application device such as a sprayer, an
affixing device such
as a heating device (for example, an iron or a radio frequency emitting
device), and/or a set of
instructions. The kit may also include a system to identify, choose, make,
modify, and/or
prepare the surface on which the decor product is to be applied.
[00153] In another example, a suspension of the present disclosure may be a
component of
a kit that includes an aerosol container (for example, the aerosol container
3020 shown in
FIG. la) that has a dispensing end connected to an aerosol valve. The aerosol
valve may
include a valve stem including means for discharging the aerosol product
downward through
the valve body when the dispensing end of the container is directed downward.
The valve
stem may include an inlet end connected to a mesh filter element having a pore
size at least as
large as an average diameter of the substantially homogeneous particles.
[00154] Numerous options for customization of the present disclosure may be
utilized with
the assistance of one or more consumer aids. Consumer aids contemplated in the
present
disclosure, which may be provided in a kit, individually and/or in any
suitable fashion,
include any and all design mechanisms and/or aids and devices that enable the
consumer to
use the present disclosure including instructions, color predicting aids,
design templates
showing the look prior to and/or after decorating possibly using a software
algorithm to
present a retrospective view of a surface treated with the decor product,
instructional videos,
CD-ROMs, internet web pages to select and predict designs, colors, and overall
looks,
interactive computers terminals, in store displays, customer service,
advertising, training
courses, recorded messages, text messages, mailings, books, literature,
lectures, training
courses, correspondence courses, and any combination thereof, as well as,
other
communicating means. Through the aforementioned communicating means, a user
may be
taught, for example, how to use a kit including the present disclosure.
Further, the user may
be instructed how to employ the disclosure for commercial applications such
as, for example,
interior design applications.
[00155] Additional consumer aids include devices to be employed by persons
such as a
user, an agent of the user, a trainer, a displayer, a salesman, a teacher, or
a technician to
enable the user to use the present disclosure such as color carpet chips, for
example, pieces of
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carpet with differing decor product formulations of differing coverage affixed
thereon to
demonstrate how different decor product formulations appear on different types
and/or colors
of carpet. Further consumer aids include color templates, for example, sheets
of opaque or
clear material of different colors with different colors of decor product
affixed thereon with
instructional ratios of the base colorants used to make each decor product
color to allow the
user to make each decor product color from the separate base colorants and
other additives.
[00156] Illustratively, in FIG. 25 an exemplary consumer aid 2000 is shown
that enables a
user to preview how a pattern will appear in a certain color (or shade or tint
or texture, and
any other variation) on a surface when the consumer aid is placed on the
surface. The
consumer aid 2000 may enable the user to make or mix the decor product and/or
assist the
user in selecting the color of the decor product that would be an appropriate
and/or
aesthetically pleasing color and/or contrast when compared to the base color
of the surface.
The consumer aid 2000, in this case, is included in a kit having two decor
products of
differing colors, such as dark gray and white. Further, the consumer aid 2000
includes
instructions on how to achieve each variation in pattern displayed on the
consumer aid, in this
case varying shades of gray. The consumer aid 2000 of the current embodiment
includes a
transparent sheet 2002 upon which is disposed a pattern 2004 that is repeated
a number of
times, such as six times. Each repeat has a different shade of gray becoming
more white
progressing from upper left to lower right, as is seen by comparing, for
example, pattern 2004
and pattern 2006. Beneath each pattern repeat is a ratio printed on the
transparent sheet 2002
that indicates a mixture percentage, such as is seen at 2008 where a mixture
of 100 percent
dark gray and 0 percent white is indicated or as is seen at 2010 where a
mixture of 20 percent
dark gray and 80 percent white is indicated. In this way, a user may achieve
each of the
shades of gray associated with each pattern repeat by mixing the dark gray and
white decor
products included in the kit at the percentages indicated. Further, any color
may be created in
this manner by mixing appropriate amounts of differing colored decor products.
Further, any
sort of instructions is contemplated to instruct a user to achieve a given
color and/or pattern
appearance. Further, the kit may also include a combined mixing and
application device that
contains the decor product(s) and corresponds with the consumer aid, such that
the
percentages given the example above for mixing dark gray and white decor
products may
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indicate how to adjust the settings on the mixing and application device to
achieve the
indicated color or shade or texture shown on the consumer aid 2000.
[00157] Additional consumer aids include carpet templates, stencil templates,
for example,
templates illustrative of different images and image characteristics that are
possible or
desirable to a user, as well as how different stencils can be used together,
positional
templates, for example, templates that indicate to a user how a decor product
image can be
incorporated on a surface in a given space, tester samples (similar to the
tester samples
supplied by Benjamin Moore & Co.), trial periods, color matching sheets, for
example,
similar to color matching sheets used in make-up matching to skin tones, used
to match
colors, or to predict color look and contrast, color blending sheets, for
example, similar to
color matching sheets that further allow a user to preview combined colors on
a surface, color
charts, color graphs, color analysis devices, colorimeters, color scanners,
software algorithms
for color assessment and formulating colors, and other means for determining
proportions
and types of decor product to be used for a specified or unspecified surface
in a room,
hallway, house, building, or other area.
[00158] In addition, by mixing differently colored decor products, any number
of
additional colors may be formed. As an example, a user may purchase one or
more pre-
formulated decor products including colored toners and/or other decor
particles or may mix
various colored toners to achieve any desired color. Design mechanisms such as
color charts,
color analysis devices, or other ways for determining the proportion and type
of colored toner
to achieve a particular color can also be provided to a user. Additionally, a
user may directly
apply the toners to the surface or the toners may be incorporated into the
decor product such
as by mixing the toner with water or another solvent, or a predetermined
formulation of more
than one part to make a liquid suspension or emulsion, for example, and then
applied to the
surface.
[00159] Additional consumer aids include devices to be employed by the user to
help the
user identify, (for example, tools and/or kits used to identify the type or
composition of carpet
fibers to help direct the user toward a particular decor product formulation),
choose, make,
modify (for example, kits or compounds that can be included in kits to alter
the physical
appearance of a surface, such as an embossing compound), combine, and prepare
surfaces on
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which a decor product may be applied and/or affixed. These consumer aids
enable the user to
choose the correct decor product formulation for a given surface to have a
given intended
effect, for example, a textured look on a soft surface or a smooth look on a
hard surface, or
any combination thereof.
[00160] Further, the consumer aids will help users in choosing, making,
modifying,
combining and/or preparing design devices, such as a stencil, to render
images, patterns,
shapes, and/or designs to be imparted to the surface when applying the stencil
and/or a decor
product to the intended surface. Still further, the consumer aids contemplated
help or assist
the user in choosing, using, making, modifying, and/or preparing decor product
formulations
that may be ready-to-use or require preparation prior to application to a
surface.
[00161] In addition to selecting one or more design devices, a user may select
one or more
colors to incorporate into the design. One or more design mechanisms may be
used to assist
the user in making these selections. The design mechanisms may include, for
example, a user
making a simple decorating decision, such as determining an arrangement of
design devices
and colors to sophisticated computer design aids, such as CD-ROM training
programs that
teach color application or provide creative suggestions. Additional design
mechanisms
include color analysis, matching, and blending, and may include the use of
colorimeters,
color scanners, and/or software algorithms.
[00162] Additional consumer aids may take the form of store displays and/or
presentations
of the disclosure, including, for example, the decor product packaged in
liquid form or
powder form to be suspended in liquid immediately before use, and/or one or
multiple decor
product colors and decor product additives to be mixed before use, and/or a
kit comprising
elements of the present disclosure such as multiple or single colors, one or
more designs,
instructions, an application device, a fixative device, a protective covering,
and/or an iron
screen or other indicator, such as, for example, a color changing additive, to
differentiate
between fixed and unfixed areas of the applied decor product.
[00163] Illustrative chemistries useful in a decor product composition
includes a low
temperature cure epoxy decor particle, a low temperature cure epoxy-polyester
hybrid decor
particle, and/or a low temperature cure polyester-triglycidyl isocyanurate
(TGIC) decor
particle. Typical ranges of constituents of the aforementioned decor particles
contemplated
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in the present disclosure include an amount of binder, which includes at least
a polymer or
resin and one or more curatives, based on weight percentages of about 50% or
greater of the
total weight of the decor particle. Further, other components of the decor
particle, including,
for example, additives, fillers, pigments, degassing agents, flow additives,
and the like, may
be included in amounts ranging from about 50% or less of the total weight of
the decor
particle. Such ranges may be adjusted to attain the desired characteristics of
the decor
particle as appropriate as is known to those skilled in the art. Further, to
assure full
stoichiometry of reactions between polymers and/or resins and curatives,
amounts of
polymers and/or resins and curatives used may range from about 50% to about
150% based
on relative equivalent weights of the compounds and/or as recommended by the
manufacturer.
[00164] A low temperature cure epoxy decor particle may include a binder
system that
has an epoxy resin and a curative. An example of an epoxy resin is a bisphenol
A resin
having the following general chemical structure of Formula 1:
Formula I:
0 yCidyteth.r of Bisphonol A (001613A)
Ftexlbifity
C o
O
cafi, ON cw'
.,~ ets Good Thormal PrOptit!![se
k Adtn
wherein n is an integer from 2 to 20.
[00165] Bisphenol A epoxy resins useful in a decor particle include those
resins having an
epoxy equivalent weight of about 650 to about 900, or about 700 to about 750;
a Tg of about
45 C to about 75 C, or about 55 C; and/or an ICI cone and plate viscosity of
about 5 poise to
about 100 poise, or about 35 poise at 150 C.
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[00166] Another example of an epoxy resin useful in a decor product
formulation is a
novolac epoxy resin. Examples of novolac epoxy resins include the following
general
chemical structures of Formulas II and III:
Formula II:
Epoxy Phenol NOVOtoo
/0\ /O /
O-CH -CH-CHa O-CHI CF-CH, 0-CH2-+CH-C112
CHe CH,
t
Formula III:
Epoxy cresol Novolac
CJ-CH2-C~HH 4-Clams-CH CHI
12
In
wherein n is an integer from I to 4.
[00167] The glass transition temperatures and viscosities of the novolac epoxy
resins are
similar to those provided above for the bisphenol A epoxy resins. A curative
agent useful in
a binder system that has an epoxy resin includes, for example, a phenolic
curative. An
example of a phenolic curative agent is Huntsman Hardener XB 3086 supplied by
Huntsman
Advanced Materials (Switzerland) GmbH, which is compatible with bisphenol-A-
based
epoxy resins and novolac-epoxy-based resins. The Huntsman Hardener XB 3086
contains
phenol, 4,4'-(1-methylethylidene)bis-, polymer with 2,2'-[(1-
methylethylidene)bis(4,1-
phenyleneoxym ethylene)]bis[oxirane] (commonly described as a polymer of epoxy
resin and
bisphenol A), a Huntsman Advanced Materials confidential accelerator, and
Phenol, 4,4'-(1-
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methylethylidene)bis- (commonly known as Bisphenol A). The Huntsman Hardener
XB
3086 has the following properties: amine value of 0.83-0.93 eq/kg, recommended
combining
weight of about 135, and a softening point of 84 C to 94 C.
[00168] Stoichiometric ratios of the epoxy resin and the curative are
calculated based on
the combining weights, or equivalent values, of resins and curatives. Values
of the
combining weights may be determined by chemical structure (for example,
average
molecular weight divided by the number of reactive groups, amine values, acid
or hydroxyl
numbers, etc.) or empirically based on laboratory experiments. For example,
using a lower
molecular type 3 bisphenol A epoxy resin with an epoxy equivalent weight (EEW)
of 700
and Huntsman Hardener XB 3086 with a manufacturer recommended equivalent
weight of
135, the calculation for a full (100%) stoichiometry is shown below in Table
No. 2.
[00169] Table No. 2. Full Stoichiometry of an Epoxy Resin and Curative Agent
Decor Particle.
Constituent Epoxy Equivalent Weight Approx.
Percent
Type 3 Bisphenol A Epoxy Resin 700 84.2%
Huntsman Hardener XB 3086 135 15.2%
Total 835 100.0%
In other embodiments, the epoxy resin and curative agent ratio may range from,
for example,
about 84% to about 85% epoxy resin to about 16% to about 15% curative agent.
To lower
the cure temperature of an epoxy decor particle, accelerants and/or catalysts
such as, for
example, a phenolic curative may be incorporated into the composition. An
illustrative
phenolic curative has a combining weight of about 100 to about 500. Other
accelerants
and/or catalysts compatible with epoxy resins known to those skilled in the
art may also be
used. An illustrative cure condition for an epoxy-polyester hybrid decor
particle includes a
bake time of about 15 minutes at about 150 C, or less.
[00170] The low temperature cure epoxy decor particle composition may include
any
desired colorant and/or additive. Illustratively, a low temperature cure epoxy
decor particle
composition may include the following constituents as shown below in Table No.
3.
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[00171] Table No. 3. Low Temperature Cure Epoxy Decor Particle
Compositions.
Approx.
Constituent Weight %
Bisphenol A Epoxy 48 - 58
Bisphenol A Curative 9 - 11
Flow Additive 0.2 - 3
Degassing Agent 0.2 - 5
Colorant 0.3 - 40
Filler 10 - 30
[00172] Another illustrative chemistry useful in a decor product is a low
temperature cure
epoxy-polyester hybrid decor particle that has a binder system having a low
temperature cure
epoxy and a polyester resin. Illustrative epoxy resins include the bisphenol A
epoxy resins or
Novolac epoxy resins described above. An illustrative polyester resin includes
an acid
terminated saturated polyester resin. The polyester resin may have an acid
number of
between about 75 and about 85. Example includes acid terminated saturated
polyesters used
as a co-reactant in epoxy-polyester hybrid coating powder formulations. The
polyester may
be synthesized from neopentyl glycol, terephthalic acid, trimellitic
anhydride, and other types
of glycols and dibasic organic acids. The branched polyesters may have resin
functionalities
of about 2 to about 4, or of about 2.5 to about 3.5 (indicating, that about
2.5 to about 3.5
carboxyl groups per polyester molecule). Resin acid numbers may range from
about 35 to
about 90 with hydroxyl numbers of about 5 to about 10 (residual hydroxyl).
Acid terminated,
saturated polyester resins suitable for combination with epoxy resins may have
an acid
number of about 70 to about 90, or about 80; a calculated combining weight
(combining
weight equals 56,100/acid number) of about 625 to about 800, or about 700; a
glass transition
temperature about 45 C to about 60 C, or about 55 C; and/or an ICI cone and
plate viscosity
of about 15 poise to about 50 poise, or about 25 poise, at about 200 C.
[00173] To lower the cure temperature of an epoxy-polyester hybrid decor
particle, an
accelerant and/or catalyst such as, for example, a stannous-organic and/or
imidazole-type
compound may be incorporated into the composition. Other accelerants and/or
catalysts
CA 02665976 2009-05-13
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known to those skilled in the art may also be used. An illustrative cure
condition for an
epoxy-polyester hybrid decor particle includes a bake time of about 15 minutes
at about
150 C, or less.
[00174] Stoichiometric ratios for an epoxy-polyester hybrid decor particle may
be
calculated based on the combining weights of resins and curatives. However, as
known in
the art, molecular structure and chemical functionalities may differ and
fluctuate for organic
polymer products, making the depiction and calculation of chemical reactions
more difficult
and ambiguous than for inorganic chemical reactions. Illustratively,
stoichiometric ratios
may be calculated based on combining weights (also referred to as equivalent
values) of
epoxy and acid-terminated polyester resins. The values of the combining
weights may be
determined by chemical structure (for example, average molecular weight
divided by the
number of reactive groups, amine values, acid numbers, etc.). For example, a
lower
molecular weight type 3 bisphenol A epoxy resin with an epoxy equivalent
weight of 700 and
an acid terminated saturated polyester resin with an average number of 80
(combining weight
of polyester equals 56,100 divided by 80, which equals approximately 700),
provides a full
(100%) stoichiometric calculation as shown below in Table No. 4.
[00175] Table No. 4. Full Stoichiometry of an Epoxy-Polyester Hybrid Decor
Particle.
Constituent Epoxy Equivalent Weight Approx.
Percent
Type 3 Bisphenol A Epoxy Resin 700 50%
Acid Terminated Polyester 700 50%
Total 1400 100.0%
[00176] The low temperature epoxy-polyester hybrid decor particle composition
may
include any desired colorant and/or additive. Illustratively, a low
temperature cure epoxy-
polyester hybrid decor particle composition may include the following
constituents as shown
below in Table No. 5.
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[00177] Table No. 5. Low Temperature Cure Epoxy-Polyester Hybrid Decor
Particle Compositions.
Approx.
Constituent Weight %
Bisphenol A Epoxy 29 - 34
SP3320 Hybrid Polyester 29 - 34
Flow Additive 0.2 - 3
2-PI (Catalyst) 0.2-0.8
Degassing Agent 0.2 - 5
Colorant 0.3 - 40
Filler 10 - 30
[00178] Another illustrative chemistry useful in a decor product is a low
temperature cure
polyester-triglycidyl isocyanurate (TGIC) decor particle. Illustratively, a
polyester includes
an acid terminated saturated polyesters synthesized using, for example, a
monomer such as
trimethylolpropane, terephthalic acid, neopentyl glycol, adipic acid,
hexanediol, 1,4-
cyclohexyldimethanol, and isophthalic acid, and pentanediol. The polyesters in
one
embodiment have resin functionalities of about 2.05 to about 2.2 (that is,
about 2.05 to about
2.2 carboxyl groups per polyester molecule). The resin acid numbers may range
from about
20 to about 60, or range on average from about 28 to about 38. The hydroxyl
numbers may
range from about 5 to about 10 (residual hydroxyl). TGIC is a trifunctional
epoxide resin that
is used as a hardener in polyester-based powder formulations. The combining
weight of
TGIC is 106. Illustratively, an acid terminated, saturated polyester resins
suitable for
combination with TGIC in a low temperature cure polyester-TGIC decor particle
possess, for
example, an acid number about 30 to about 40, or about 35; a calculated
combining weight
(combining weight equals 56,100 divided by acid number) of about 1,400 to
about 1,870, or
about 1,600; a glass transition temperature about 45 C to about 70 C, or about
55 C; and/or
an ICI cone and plate viscosity of about 15 poise to about 50 poise, or about
25 poise, at
200 C.
[00179] To lower the cure temperature of a polyester-TGIC decor particle, an
accelerant
and/or catalyst such as, for example, triphenylethyl phosphonium bromide
and/or imidazole-
type compounds may be incorporated into the composition. Other accelerants
and/or
catalysts known to those skilled in the art may also be used. For example, a
glycidyl curative
chemistries such as aliphatic, cycloaliphatic, aromatic, and methacrylate
based glycidyl
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compounds with equivalent weights of about 50 to about 1,000 and melt
temperatures below
about 125 C may by utilized in the low temperature cure polyester-TGIC decor
particle. An
illustrative cure condition for a polyester-TGIC decor particle includes a
bake time of about
15 minutes at about 135 C.
[00180] As mentioned above, molecular structures and chemical functionalities
may differ
and fluctuate for organic polymer products. Illustratively, stoichiometric
ratios are calculated
based on the combining weights of epoxy and acid terminated polyester resins.
Values of the
combining weights may be determined from the chemical structure of the
respective
compounds. For example, an acid terminated saturated polyester with an average
acid
number of 35 (combining weight of polyester equals 56,100 divided by 35, which
equals
approximately 1,600) combined with TGIC, provides a full (100%) stoichiometric
calculation
as shown below in Table No. 6.
[00181] Table No. 6. Full Stoichiometry of a Polyester-TGIC Decor Particle.
Constituent Epoxy Equivalent Weight Approx.
Percent
Acid Terminated Polyester 1600 93.8%
TGIC 106 6.2%
Total 1706 100.0%
[00182] Due to the large molecular size of the polyester resin and the small
molecular size
and spherical shape of TGIC, a about 10% to about 15% stoichiometric surplus
of TGIC may
be utilized to achieve, for example, a polyester resin/TGIC ratio of 93/7.
[00183] The low temperature polyester-TGIC decor particle composition may
include any
desired colorant and/or additive. Illustratively, a low temperature polyester-
TGIC decor
particle composition may include the following constituents as shown below in
Table No. 7.
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[00184] Table No. 7. Low Temperature Cure Polyester-TGIC Decor Particle
Compositions.
Approx.
Constituents Weight %
RUCOTE 921 Polyester 54 - 63
TGIC 4 - 5
Flow Additive 0.2 - 3
Degassing Agent 0.2 - 5
Colorant 0.3 - 40
Filler 10 - 30
[00185] An alternative carboxyl polyester resin curative to TGIC includes, for
example,
PRIMID (EMS-PRIMID, a unit of EMS-Chemie AG). PRIMID is a beta-hydroxyl
alkyl
amide curative. However, PRIMID may require longer cure times than a TGIC-
based
chemistry, as well as a PRIMID based coating may appear slightly more orange
than a
TGIC-based coating. Pinholes and blistering may also be an issue with the use
of a
PRIMID based decor particle where a coating thickness exceeds 4.0 mils.
[00186] For example, a low temperature polyester-PRIMID decor particle
composition
may include any desired colorant and/or additive. Illustratively, a low
temperature polyester-
TGIC decor particle composition may include the following constituents as
shown below in
Table No. 7a.
[00187] Table No. 7a. Low Temperature Cure Polyester-PRIMID Decor Particle
Compositions.
Approx.
Constituents Weight %
Crylcoat 2671-3 Polyester 70 - 83
PRIMID XL-552 5-7
Flow Additive 0.5 - 3
Degassing Agent 1 - 3
Colorant 0.3 - 25
Filler 0-20
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[00188] Polyurethane based decor particles may be arrived at by combining a
hydroxyl
polyester resin with a triazole blocked polyisocyanate cross-linking agent,
and may further
include any desired colorant and/or additive. Illustratively, a low
temperature polyurethane
decor particle composition may include the following constituents as shown
below in Table
No. 7b.
[00189] Table No. 7b. Low Temperature Cure Polyurethane Decor Particle
Compositions.
Approx.
Constituents Weight %
Albester 3160 65 - 77
Alcure 4470 11-14
Flow Additive 0.5 -3
Degassing Agent 1 - 3
Colorant 0.3 - 25
Filler 0-24
[00190] As mentioned above, a decor product, which includes a decor particle,
may
include any desired colorant and/or additive. Illustratively, the decor
particle composition
may include, for example, a flow additive, a degassing agent, a surfactant or
wetting agent, an
antioxidant, a heat stabilizer, a ultraviolet light absorber, a wax, a
silicone additive, a catalyst,
a texturing agent, an electrical charge control agent, an electrical
conductivity agent, a
processing aid, a filler, and combinations thereof.
[00191] Flow additives may be utilized in formulating a decor particle
composition to, for
example, reduce or prevent cratering of a finished cured product and/or to
improve flow and
leveling. Illustratively, the flow additives may be low molecular acrylic
polymers, either in
liquid form (for example, a liquid containing about 100% active substance), or
in solid form
(for example, a solid with about 65% active substance). Examples of flow
additives include
Acronal 4F (about 100% active, BASF), Byk 363 P (about 65% active, BYK-
Chemie),
RESIFLOW P-67 (manufactured by Estron Chemical), RESIFLOW PF-67 (about 65%
active, Estron Chemical), MODAFLOWTM 3 (about 65% active, Monsanto), and
POWDERMATETM 486 CFL (about 65% active, Troy Corp.). Illustratively, a flow
additive
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may be added to a decor particle composition in a range of between about 0.3%
to about 1%
of 100% active flow additive per total formula weight of the decor particle.
[00192] A degassing agent may be added to a decor particle composition to, for
example,
aid in the evaporation of volatile products within the composition during the
heating and/or
curing cycle to reduce and/or prevent pinholing (volatile bubbles being
trapped at the surface
boundary between the finish and the air). Some degassing agents, such as
Benzoin (Velsicol
Chemical Corp.), may solvate the resin/curative mix during the liquid phase of
the cure
process. Other degassing agents are surfactant-like and other are wax-like and
affect the
surface tension of the film surface to promote degassing. Illustratively, a
decor particle
composition may contain from about 0.2% to about 2% of active degassing agent
per total
formula weight of the decor particle. For example, a decor particle that is
curable between
about 135'C and about 149'C (for example a polyester-PRIMID chemistry), may
contain a
combination of about 1% to about 1.8% OXYMELT A-2 or A-4 (Estron Chemical)
and
about 0.2% Benzoin per total formula weight of the decor particle.
[00193] A surfactant or wetting agent that may be used in a decor product or
decor particle
composition may, for example, promote colorant and/or filler wetting, and/or
improve the
flow and/or leveling of a finished cured product. In addition, a surfactant or
wetting agent
may promote substrate wet-out during the cure reaction, which may improve
adhesion and/or
corrosion resistance. The addition of surfactants may also increase gloss and
distinctness of
image of the cured film as well. Illustratively, surfactant levels can range
from 0.1% to about
0.5% of active substance per total formula weight of the decor particle.
Examples of
surfactants or wetting agents include cationic, anionic functional organic
compounds, silane,
and polysiloxane, including, for example, NUOSPERSETM 657 (manufactured by
Elementis
Specialties) and SURFYNOLTM 104 S (Air Products and Chemicals, Inc.). Further,
surfactants contemplated for use herein may also be used to aid in suspension
stabilization.
For example, a sodium dioctyl sulfosuccinate sold as AEROSOL OT-SE available
from
Cytec Industries, Inc. (West Paterson, NJ) is contemplated for use herein.
Further suitable
examples include the Tergitol line of products from Dow Chemical, sodium
lauryl sulfate, the
Pluronic product line from BASF, and the Tween and Span series of
surfactants from
Croda International.
CA 02665976 2009-05-13
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[00194] An antioxidant or heat stabilizer may be used in a decor particle
composition to,
for example, inhibit or prevent heat induced yellowing during the curing
and/or heating cycle.
Illustratively, an antioxidant or heat stabilizer may be used in a white or
relatively light
colored decor particle composition in an amount from about 0.2% to about 0.5%
of active
substance per total formula weight of the decor particle. More or less
antioxidant or heat
stabilizer may be used with other colored decor particles. Examples of
antioxidants include
Irganox 1076 (Ciba Specialty Chemicals Corp.) and Irganox(& B-225 Ciba
Specialty
Chemicals Corp.). An example of a heat stabilizer is Sandostab P-EPQ
(Clariant).
[00195] Anticorrosive agents may be used in compositions contemplated herein.
Examples of suitable anticorrosive agents include potassium hydrogen phosphate
(CAS No.
7758-11-4) available from Rhodia (Cranbury, NJ), potassium dihydrogen
phosphate (CAS
No. 7778-77-0), sodium nitrate, benzoic acid, and amino alcohols, such as one
of the AMP
series, for example AMP-95, available from Angus Chemical Company (Buffalo
Grove, IL).
[00196] An ultraviolet light absorber can be added to a decor particle
composition to, for
example, improve ultraviolet resistance (for example, weatherability) of a
cured finished
product. Used in combination with antioxidants and/or heat stabilizers, the
performance of
ultraviolet absorbers can be further enhanced.
[00197] A wax may be added to a decor particle composition to, for example,
control the
gloss and/or flow of a cured decor product. A wax may also be used to add
texturing to a
cured decor product. Additionally, some wax additives may improve mar and
scratch
resistance of a cured decor product. Illustratively, a wax from a natural
product, such as
Carnauba wax, beeswax, hydrocarbon compounds, halogenated hydrocarbons, and
PTFE
comprise a large percentage of waxes and may be used in the decor product
and/or decor
particle composition. Examples of wax additives include DT3329-1 (Ciba Geigy),
Castor
Wax, Powder Tex 61 (Shamrock Technologies, Inc.), Lanco TF-1778 (available
from
Noveon Inc.), and Lanco PP-1362D (available from Noveon, Inc.).
[00198] A silicone additive may also be added to a decor particle composition
to improve,
for example, mar and scratch resistance of a cured decor product. Although not
wishing to be
held by theory, it is believed that the silicone additives reduce the
coefficient of friction that
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may affect, for example, intercoat adhesion in a two-coat system. Examples of
silicone
additives include polysiloxane and silicone oil.
[00199] Catalysts such as 2-Propyl imidazole may be added to a decor particle
composition to, for example, accelerate cure speed, lower cure temperature,
and/or improve
physical and/or chemical properties of the cured product.
[00200] Texturing agents may be added to a decor particle composition to, for
example,
alter and/or manipulate the viscosity of the composition.
[00201] Electrical charge control additives may be added to a decor particle
composition
to, for example, control transfer efficiency. Examples include TINUVIN 144
(Ciba
Specialty Chemicals), barium titanate, and quaternary ammonium salts.
[00202] Electrical conductivity additives may be added to a decor particle
composition to,
for example, dissipate electrical charge in the composition and/or finished
product. The
electrical conductivity additives may be, for example, filler-like, pigment-
like, or wax-like in
nature.
[00203] Processing aids may be added to a decor particle composition to, for
example,
facilitate processing of the composition. Processing aids are well known to
those skilled in
the art.
[00204] Colorants may be added to a decor particle composition to, for
example, obtain a
desired color. Illustrative pigments include organic and inorganic pigments,
including, for
example, titanium dioxide, iron oxide red, iron oxide yellow, iron oxide
black, heat stabilized
iron oxide, calcinated mixed metal oxide, diarylide, condensed disazo, and
phthalo blue.
Illustrative colorants and amounts that may be used individually or in
combination in the
decor product and/or decor particle composition are provided below in Table
No. 8.
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[00205] Table No. 8. Pigments.
Approx.
Colorant Weight %
Titanium Dioxide 1-40
Iron Oxide Yellow (C.I. Yellow 14) 2-20
HR-70 Yellow (Organic Pigment) 1.5 - 2
274-0033 (Organic Pigment) 0.3 - 2
RT-172-D (Organic Pigment) 0.5 - 5
F5RK-A (Organic Pigment) 0.05 - 3
15-1101 AR (Organic Pigment) 0.5 - 5
15-1101 PV Fast Blue A4R (Organic Pigment) 0.3 - 2
BK 5099 Iron Oxide Black (C.I. Black 11) 0.5 - 2
Iron Oxide Red (C.I. Red 101) 1.5 - 20
Lansco 3136 Green (Phthalo Green) 0.1 - 1
RO 8097 (Iron Oxide Red) 0.5-10.
Hostaperm Pink E-WD (Blue quinacridone pigment) 0.5 - 2
201 Y Red (Iron oxide red) 0.1 - 12
Engelhard 6118 0.1 - 1
Ultra Marine Blue (C.I. Blue 29) 15 - 25
Numerous other organic and inorganic colorants known to those skilled in the
art may be
utilized in the compositions herein described.
[00206] A filler may also be added to a decor particle composition. Two
illustrative fillers
include calcium carbonate and barium sulfate (CaCO3 and BaSO4, respectively,
both
manufactured by Fisher Chemicals). The calcium carbonate fillers added to the
decor
product and/or decor particle compositions may, for example, reduce gloss, as
well as the
flow of an applied finish at higher concentrations. Wollastonite-type fillers
may also be
utilized as fillers in the decor product and/or decor particle compositions.
Talcum, clay,
dolomite, and magnesium-aluminum-silicate in powder form, usually ground to 1-
10 microns
average particle size, or micron sized glass beads, may also be used as
fillers to obtain
specific properties, such as, for example, corrosion resistance, gloss
control, and/or film
texture.
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[00207] Further, fillers, clays, and gums may serve as rheology modifiers by
aiding in the
stabilization of particle suspensions, as well as in the flow properties of
such suspension, as is
known in the art. Examples of clays contemplated include, for example, those
described in
U.S. Patent No. 7,288,585. Additional examples include Veegum granules,
Bentone clays,
and silica thickeners. One possible example of suitable Veegum granules is
Veegum D
granules available from R. T. Vanderbilt Company, Inc. (Norwalk, CT).
Additional
examples contemplated for use herein include smectite clays, for example, the
Laponite
series, available from Southern Clay Products, Inc. (Gonzales, TX). Suitable
Laponite grades
include Laponite B, D, DF, J, RS, RDS, S, S482, XLG, XLS, and XL21.
[00208] Illustrative gums and appropriate substitutes contemplated for use
herein include
xanthan gum, guar gum, carboxy methyl cellulose, hydroxyl ethyl cellulose,
Acrysol
thickener products available from Rohm & Haas (Philadelphia, PA), polyacrylic
polymers,
and polyvinyl alcohol, and the like. An example of a suitable xanthan gum
contemplated for
use herein is Kelzan HP, available from CP Kelco (San Diego, CA).
[00209] Additional rheology modifiers contemplated herein include cellulosics,
hydrophobically modified ethoxylated urethanes (huers), surfactant gels,
polyesters, and
polysaccharides, such as chitins.
[00210] Illustratively, a decor product is applied to a surface to achieve a
film thickness of
about 0.004 mils to about 2.2 mils (about 0.01 microns to about 56 microns)
upon curing of
the decor product, or to achieve coverage of about 0.02 to about 0.1 g dry
decor product per
square inch of surface, such as a carpet.
[00211] A decor particle formulation such as those embracing low temperature
cure epoxy
chemistry, low temperature cure epoxy-polyester hybrid chemistry, low
temperature cure
polyester-TGIC chemistry, low temperature cure PRIMID chemistry, and low
temperature
cure polyurethane chemistry may be prepared in accordance with the following
general
processing procedure.
[00212] Formulation constituents are dry mixed either through low-intensity
tumble-
mixing or through high-intensity dry-blending performed in a mixer containing
a vertical or
horizontal mixing shaft with blades rotating at 50-1,000 rpm. Formulations are
low-intensity
tumble-mixed for about 5 to about 20 minutes, for example, or high-intensity
dry-mixed for
CA 02665976 2009-05-13
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about 1 to about 5 minutes, for example, depending on batch size. Mixing
serves to
homogenize the active chemical ingredients and to disperse inert ingredients
for enhanced
color consistency and to avoid protrusions in applied films. Batch sizes may
range from
quarts to kiloliters in size. After dry-blending, the temperature of the
mixture is maintained
at or below about 40 C to prevent lumping or meltdown.
[00213] The mixtures are extruded within minutes to hours after dry-mixing.
Single screw
extruders with reciprocating screw shaft movements, also called co-kneaders,
and twin screw
extruders with co-rotating screw shafts are suitable extruders, as well as
planetary extruders,
counter-rotating twin screw extruders, or single screw extruders. Illustrative
extruder size
ranges from table-top laboratory models with 10-30 mm screw diameters and 1-5
kg per hour
theoretical outputs to production models with 30 to over 300 mm screw
diameters and 100 kg
to over 2,000 kg per hour theoretical outputs.
[00214] The extruders for processing may be heated via water, oil, or
electrical heat jacket
located on the outside of the extruder barrels. Extruder barrel processing
temperatures may
range from about 70 C to about 125 C, though temperatures outside this range
may be used
to achieve desired properties in some applications. Some extruder barrel
heaters utilized in
the powder processing may be segmented, in which case, the premix intake zone
of the
extruder may be run cold or at a minimal heat of about 40 C to about 50 C.
Depending on
extruder and screw design, a barrel heat of about 100 C 15 C is adequate for
processing
highly-reactive, low temperature cure powder coating formulas. The screws may
have a
helical section in the premix intake area and "paddle" sections for dispersing
and melt-mixing
the extrudate. Residence time of the extrudate within the extruder typically
does not exceed
about 60 seconds. The production extruders used for processing the powder
coatings are run
between about 50 and about 750 rpm screw speed. Screw speeds and extruder
barrel
temperatures are selected to obtain between about 50% to about 90% torque.
Extrudate
temperatures range from about 100 C to about 125 C as a result of extruder
barrel heat and
frictional heat from the rotating screws. The extrudate is immediately cooled
after exiting the
extruder to solidify the material for further processing and to arrest
chemical reactions. The
extrudate is gravity-fed into counter-rotating chill rolls set about 1.5 to
about 3 mm apart.
The resulting extrudate sheet is transported on a cooling belt to a flaker or
crusher unit where
the sheet is broken into flakes under about 1 inch square in size. Cooling
belt temperatures
CA 02665976 2009-05-13
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from about 5 C to about 35 C are maintained during processing. The resulting
flakes are
milled and characterized using air classifying mills (ACM), cyclones, and
sieves, to
determine particle size distributions and mean particle sizes. Illustratively,
a particle size
distribution for a decor particle ranges from about 90% by volume or more of
the particles
having a size less than about 100 microns, or less than about 25 microns, or
less than about
microns, or from about 0.1 to about 50 microns, or from about I to about 20
microns, or
from about 3 to about 10 microns, or from greater than about 750 nm to about
100 microns.
Further examples of particle sizes include particles from about 20 to about 80
microns, or
from about 25 to about 75 microns, or from about 30 to about 70 microns, or
from about 35
to about 75, or from about 40 to about 60 microns, or from about 40 to about
80 microns, or
about 40 to about 50 microns, or from about 50 to about 60 microns in size, or
about 40
microns, or about 45 microns, or about 50 microns, or about 55 microns, or
about 60 microns,
or larger or smaller particle sizes depending on the desired application. All
equipment is
purged after processing different formulas or colors to avoid chemical or
color cross-
contamination.
[00215] An emulsified decor product may be prepared in accordance with the
following
general processing procedure. In a one-gallon glass container, initially an
emulsifier is added
to a powder, such as a NATURATM toner and/or a decor particle and mixed to
thoroughly
coat the powder with the emulsifier. Water is then added to the powder and
emulsifier
mixture and is blended using an IKA-Werke Eurostar power basic mixer at a
speed of about
750 rpm for about 4 hours. Additional additives may be added if so desired at
any point
during preparation of the decor product. After the 4 hour blending period, the
mixture is
further mixed by continuously mixing at room temperature on a magnetic
stir/heat plate
(Isotemp #409N0063 available from Fisher-Scientific) with a 2-inch magnetic
stir bar at 100
rpm for an additional 24 hours. Illustratively, an emulsified decor product
composition may
include the following constituents as shown below in Table No. 9.
CA 02665976 2009-05-13
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[00216] Table No. 9. Emulsified Decor Product Composition.
Approx.
Constituents Weight %
Water 70 - 97
Surfactant 0.1 - 5
Powder 1.1 - 40
Adhesive 0-10
Additive 0.1 - 5
[00217] Similarly, a rheology modifier-containing composition may be
formulated using a
procedure similar to that described below.
[00218] A rheology modifier-containing composition may include the following
constituents as shown below in Table No. 9a.
[00219] Table No. 9a. Rheology Modifier-containing Composition.
Approx.
Constituents Weight %
Rheology Modifier 0.1 - 4
Thickener 0.1-0.5
Surfactant 0.05-3.0
Humectant 0.0-2.0
Water soluble polymer 0.0-2.0
Biocide 0.02-1.0
Anticorrosive agent 0.05-2.0
Colorant particles 3-10
Water 76 - 97
[00220] For example, a rheology modifier-containing composition may include,
for
example, about 0.12 to about 0.3% by weight of a thickener, about 0.05 to
about 0.1% by
weight of a gum, about 1.0 to about 1.5% by weight of a clay, about 0.1 to
about 0.75% by
weight of a sodium dioctyl sulfosuccinate, about 0.75 to about 1.25% by weight
of propylene
glycol, about 0.1 to about I% by weight of an anticorrosive agent, about 0.1
to about 0.5% by
CA 02665976 2009-05-13
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weight of a biocide, substantially homogeneous particles including a colorant
and a resin, and
a liquid carrier.
[00221] The present disclosure is further illustrated by the following
examples, which
should not be construed as limiting in any way. Unless otherwise stated, all
percentages
recited in these examples are weight percents based on total specified
composition weight.
EXAMPLES
[00222] The decor particle compositions of examples 1-24 were prepared using
the general
processing procedure described above by blending (mixing) and processing the
constituents
on a 19 mm APV laboratory twin screw extruder (Model No. MPI9TC-25,
manufactured by
Baker Perkins) with co-rotating screws at 100 C barrel temperature, 400 rpm
screw speed,
and 50% to 90% torque. The extrudate was cooled on chill rolls that resulted
in 3/32 inch
(about 3 mm) thick solid extrudate sheets. The sheets were broken into flakes
no larger than
I square inch (6.45 cm2) in size. The flakes may be ground on air-cooled jet
mills and
classified to a particle size range of about 0 microns to about 80 microns, or
larger.
[00223] The following steps are taken to achieve a specific size range, such
as, for
example from about 40 to about 60 microns. The resulting particle powder from
the above
procedure is first dry sieved through a 60 micron sieve, and the pass through
is collected, thus
removing anything above 60 microns. The second step is to dry sieve the pass
through using
a 40 micron sieve, and discarding the pass through, to eliminate relatively
large particles that
are smaller than 40 microns in size. In the final step, a slurry of the
remaining particles is
made in water and then strained through a 40 micron filter cloth to remove any
small particles
attached to large particles. The particles may then be used to prepare decor
product
compositions, such as those described herein.
[00224] The decor products of examples 25-28 were prepared using the general
processing
procedure described above by mixing the decor particle or toner and emulsifier
for a period
of time until the decor particles or toner were coated with the emulsifying
agent or agents.
Water was then added and thoroughly mixed as described above.
[00225] In the composition of Table Nos. 10-25, the trademark KUKDO KD-242G
(manufactured by Kukdo Chemical Co., LTD) is a type 3 bisphenol-A epoxy resin
with an
epoxy equivalent weight of about 700 g/eq. In the composition of Table Nos. 10-
17,
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Huntsman Hardener XB 3086 (manufactured by Huntsman Advanced Materials) is a
proprietary phenolic curative containing phenol, 4,4'-(1-methylethylidene)bis-
, polymer with
2,2'-[(1-methylethylidene)bis(4,1-phenyleneoxymethylene)]bis[oxirane]
(commonly
described as a polymer of epoxy resin and bisphenol A), a confidential
accelerator, and
phenol, 4,4'-(1-methylethylidene)bis- (commonly known as bisphenol A). In the
composition of Table Nos. 18-25, Actiron NXJ-60 (manufactured by Advanced
Technology
& Industrial Co.) is a 2-propylimidazole catalyst. In the composition of Table
Nos. 10-13,
18-21, and 26-29, the trademark TI-PURE Ti02 R-960 (manufactured by E.I. du
Pont de
Nemours and Company) is a titanium oxide white pigment. In the composition of
Table Nos.
11-12, 14-15, 19-20, 22-23, 27, and 30-31, Y 10M (CAS. No. 51274-00-1,
manufactured by
ABCR) is an iron oxide yellow pigment. In the composition of Table Nos. 11,
19, and 27-29,
274-0033 (CAS No. 5468-75-7, manufactured by ABCR) is a yellow pigment having
the
chemical formula of 2,2'-((3,3'-dichloro(1,1'-biphenyl)-4,4'-diyl) bis(azo))
bis(N-(2-M-
ehylphenyl)-3-oxobutyramide). In the composition of Table Nos. 11, 19, and 27,
HR-70
Yellow (manufactured by Clariant) is a yellow organic pigment. In the
composition of Table
No. 46, Hostaperm Pink E-WD is a blue shade quinacridone pigment for use in
waterborne
preparations available from Clariant, and SynergyTM Orange 6118 is an orange
pigment
available from Engelhard Corporation. In the compositions of Table Nos. 26-33,
the
trademark RUCOTE 921 polyester (manufactured by Bayer Material Science, LLC)
is a
low viscosity carboxyl functional polyester having an acid value of 38 mg
KOH/g, a
hydroxyl number 6 mg KOH/g, a viscosity of 1800 ICI cone and plate at 200
C/cPs, and a Tg
of 60 C. In the compositions of Table Nos. 34-39, the trademark Crylcoat 2671-
3
polyester, a carboxyl-terminated polyester resin is manufactured by Cytec
Industries. The
trademark PRIMID XL-552 is a beta-hydroxyl alkyl amide curative, available
from EMS-
PRIMID. In the compositions of Table Nos. 40-47, Albester 3160, hydroxyl-
terminated
polyester resin, and Alcure 4470, a triazole blocked polyisocyanate are
available from Hexion
Specialty Chemicals, Columbus, OR
[00226] Example 1: Preparation of a White Low Temperature Cure Epoxy Decor
Particle.
[00227] A white low temperature cure epoxy-based decor particle having the
composition
shown in Table No. 10 below was prepared in the manner described above.
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[00228] Table No. 10. White Low Temperature Cure Epoxy Composition.
Constituents (wt %)
KD-242G Epoxy 48
Huntsman Hardener XB 3086 10
P-67 1
Oxymelt A-2 1
TiO2R-960 40
[00229] Example 2: Preparation of a Yellow Low Temperature Cure Epoxy Decor
Particle.
[00230] A yellow low temperature cure epoxy-based decor particle having the
composition
shown in Table No. 11 below was prepared in the manner described above.
[00231] Table No. 11. Yellow Low Temperature Cure Epoxy Decor Particle
Composition.
Constituents (wt %)
KD-242G Epoxy 49
Huntsman Hardener XB 3086 11
P-67 1
Oxymelt A-2 1
TiO2R-960 20
Y 10M Iron Oxide Yellow Pigment 4
274-0033 2.2
HR-70 Yellow Pigment 1.8
BaSO4 10
[00232] Example 3: Preparation of a Red Low Temperature Cure Epoxy Decor
Particle.
[00233] A red low temperature cure epoxy-based decor particle having the
composition
shown in Table No. 12 below was prepared in the manner described above.
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[00234] Table No. 12. Red Low Temperature Cure Epoxy Decor Particle
Composition.
Constituents (wt %)
KD-242G Epoxy 48.5
Huntsman Hardener XB 3086 10.3
P-67 1
Oxymelt A-2 1.04
TiO2 R-960 5.13
Y I OM Iron Oxide Yellow Pigment 0.03
RT-172-D Pigment 2.5
F5RK-A Pigment 1.5
BaSO4 30
[00235] Example 4: Preparation of a Blue Low Temperature Cure Epoxy Decor
Particle.
[00236] A blue low temperature cure epoxy-based decor particle having the
composition
shown in Table No. 13 below was prepared in the manner described above.
[00237] Table No. 13. Blue Low Temperature Cure Epoxy Decor Particle
Composition.
Constituents (wt %)
KD-242G Epoxy 49.25
Huntsman Hardener XB 3086 10.75
P-67 I
Oxymelt A-2 1.05
TiO2R-960 15.
15-1101 A4R Pigment 2.5
BK 5099 0.45
BaSO4 20
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[00238] Example 5: Preparation of a Brown Low Temperature Cure Epoxy Decor
Particle.
[00239] A brown low temperature cure epoxy-based decor particle having the
composition
shown in Table No. 14 below was prepared in the manner described above.
[00240] Table No. 14. Brown Low Temperature Cure Epoxy Decor Particle
Composition.
Constituents (wt %)
KD-242G Epoxy 51.67
Huntsman Hardener XB 3086 9.13
P-67 1
Oxymelt A-2 1
TiO2 RCL-6 1.18
Y IOM Iron Oxide Yellow Pigment 2.54
BK 5099 2
RO 8097 1.48
BaSO4 30
[00241] Example 6: Preparation of an Iron Oxide Yellow Low Temperature Cure
Epoxy
Decor Particle.
[00242] An iron oxide yellow low temperature cure epoxy-based decor particle
having the
composition shown in Table No. 15 below was prepared in the manner described
above.
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[00243] Table No. 15. Iron Oxide Yellow Low Temperature Cure Epoxy Decor
Particle Composition.
Constituents (wt %)
KD-242G Epoxy 57.8
Huntsman Hardener XB 3086 10.2
P-67 I
Oxymelt A-2 I
Y IOM Iron Oxide Yellow Pigment 20
BaSO4 10
[00244] Example 7: Preparation of a Iron Oxide Red Low Temperature Cure Epoxy
Decor
Particle.
[00245] An iron oxide red low temperature cure epoxy-based decor particle
having the
composition shown in Table No. 16 below was prepared in the manner described
above.
[00246] Table No. 16. Iron Oxide Red Low Temperature Cure Epoxy Decor
Particle Composition.
Constituents (wt %)
KD-242G Epoxy 57.8
Huntsman Hardener XB 3086 10.2
P-67 I
Oxymelt A-2 1
RO 8097 20
BaSO4 10
[00247] Example 8: Preparation of an Ultra Marine Blue Low Temperature Cure
Epoxy
Decor Particle.
[00248] An ultra marine blue low temperature cure epoxy-based decor particle
having the
composition shown in Table No. 17 below was prepared in the manner described
above.
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[00249] Table No. 17. Ultra Marine Blue Low Temperature Cure Epoxy Decor
Particle Composition.
Constituents (wt %)
KD-242G Epoxy 57.8
Huntsman Hardener XB 3086 10.2
P-67 1
Oxymelt A-2 1
UMB-304 20
BaSO4 10
[00250] Example 9: Preparation of a White Low Temperature Cure Epoxy_Pol
ey_ster
Hybrid Decor Particle.
[00251] A white low temperature cure epoxy-polyester hybrid decor particle
having the
composition shown in Table No. 18 below was prepared in the manner described
above.
[00252] Table No. 18. White Low Temperature Cure Epoxy-Polyester Hybrid
Decor Particle Composition.
Constituents (wt %)
KD-242G Epoxy 28.5
SP 3320 Hybrid Polyester 29
P-67 1
Actiron NXJ-60 0.5
Oxymelt A-2 1
TiO2 R-960 40
[00253] Example 10: Preparation of a Yellow Low Temperature Cure Epoxy-Pol e~
ster
Hybrid Decor Particle.
[00254] A yellow low temperature cure epoxy-polyester hybrid decor particle
having the
composition shown in Table No. 19 below was prepared in the manner described
above.
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[00255] Table No. 19. Yellow Low Temperature Cure Epoxy-Polyester Hybrid
Decor Particle Composition.
Constituents (wt %)
KD-242G Epoxy 29.75
SP 3320 Hybrid Polyester 29.75
P-67 1
Actiron NXJ-60 0.5
Oxymelt A-2 1
TiO2 R-960 20
Y IOM Iron Oxide Yellow Pigment 4
274-0033 Pigment 2.2
HR-70 Yellow Pigment 1.8
BaSO4 10
[00256] Example 11: Preparation of a Red Low Temperature Cure Epoxy-Pol e~
ster
Hybrid Decor Particle.
[00257] A red low temperature cure epoxy-polyester hybrid decor particle
having the
composition shown in Table No. 20 below was prepared in the manner described
above.
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[00258] Table No. 20. Red Low Temperature Cure Epoxy-Polyester Hybrid Decor
Particle Composition.
Constituents (wt %)
KD-242G Epoxy 29.15
SP 3320 Hybrid Polyester 29.15
P-67 1
Actiron NXJ-60 0.5
Oxymelt A-2 1.04
TiO2 R-960 5.13
Y IOM Iron Oxide Yellow Pigment 0.03
RT-172-D Pigment 2.5
F5RK-A Pigment 1.5
BaSO4 30
[00259] Example 12: Preparation of a Blue Low Temperature Cure Epoxy-Polyester
Hybrid Decor Particle.
[00260] A blue low temperature cure epoxy-polyester hybrid decor particle
having the
composition shown in Table No. 21 below was prepared in the manner described
above.
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[00261] Table No. 21. Blue Low Temperature Cure Epoxy-Polyester Hybrid
Decor Particle Composition.
Constituents (wt %)
KD-242G Epoxy 29.75
SP 3320 Hybrid Polyester 29.75
P-67 1
Actiron NXJ-60 0.5
Oxymelt A-2 1.05
TiO2R-960 15
15-1101 A4R Pigment 2.5
BK 5099 0.45
BaSO4 20
[00262] Example 13: Preparation of a Brown Low Temperature Cure Epoxy-
Polyester
Hybrid Decor Particle.
[00263] A brown low temperature cure epoxy-polyester hybrid decor particle
having
the composition shown in Table No. 22 below was prepared in the manner
described above.
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[00264] Table No. 22. Brown Low Temperature Cure Epoxy-Polyester Hybrid
Decor Particle Composition.
Constituents (wt %)
KD-242G Epoxy 30.1
SP 3320 Hybrid Polyester 30.2
P-67 1
Actiron NXJ-60 0.5
Oxymelt A-2 1
TiO2 RCL-6 1.18
Y IOM Iron Oxide Yellow Pigment 2.54
BK 5099 2
RO 8097 1.48
BaSO4 30
[00265] Example 14: Preparation of an Iron Oxide Yellow Low Temperature Cure
Epoxy-
Pol. esy ter Hybrid Decor Particle.
[00266] An iron oxide yellow low temperature cure epoxy-polyester hybrid decor
particle
having the composition shown in Table No. 23 below was prepared in the manner
described
above.
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[00267] Table No. 23. Iron Oxide Yellow Low Temperature Cure Epoxy-Polyester
Hybrid Decor Particle Composition.
Constituents (wt %)
KD-242G Epoxy 33.75
SP 3320 Hybrid Polyester 33.75
P-67 1
Actiron NXJ-60 0.5
Oxymelt A-2 1
Y IOM Iron Oxide Yellow Pigment 20
BaSO4 10
[00268] Example 15: Preparation of an Iron Oxide Red Low Temperature Cure
Epoxy-
Polyester Hybrid Decor Particle.
[00269] An iron oxide red low temperature cure epoxy-polyester hybrid decor
particle
having the composition shown in Table No. 24 below was prepared in the manner
described
above.
[00270] Table No. 24. Iron Oxide Red Low Temperature Cure Epoxy-Polyester
Hybrid Decor Particle Composition.
Constituents (wt %)
KD-242G Epoxy 33.75
SP 3320 Hybrid Polyester 33.75
P-67 I
Actiron NXJ-60 0.5
Oxymelt A-2 1
RO 8097 20
BaSO4 10
CA 02665976 2009-05-13
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[00271] Example 16: Preparation of an Ultra Marine Blue Low Temperature Cure
Epoxy-
Polyester Hybrid Decor Particle.
[00272] An ultra marine blue temperature cure epoxy-polyester hybrid decor
particle
having the composition shown in Table No. 25 below was prepared in the manner
described
above.
[00273] Table No. 25. Ultra Marine Blue Low Temperature Cure Epoxy-Polyester
Hybrid Decor Particle Composition.
Constituents (wt %)
KD-242G Epoxy 33.75
SP 3320 Hybrid Polyester 33.75
P-67 1
Actiron NXJ-60 0.5
Oxymelt A-2 1
UMB-304 20
BaSO4 10
[00274] Example 17. Preparation of a White Low Temperature Cure Polyester-TGIC
Decor Particle.
[00275] A white low temperature cure polyester-TGIC decor particle having the
composition shown in Table No. 26 below was prepared in the manner described
above.
[00276] Table No. 26. White Low Temperature Cure Polyester-TGIC Decor
Particle Composition.
Constituents (wt %)
Rucote 921 Polyester 54
TGIC 4
P-67 1
Oxymelt A-2 1
TiO2R-960 40
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[00277] Example 18. Preparation of a Yellow Low Temperature Cure Polyester-
TGIC
Decor Particle.
[00278] A yellow low temperature cure polyester-TGIC decor particle having the
composition shown in Table No. 27 below was prepared in the manner described
above.
[00279] Table No. 27. Yellow Low Temperature Cure Polyester-TGIC Decor
Particle Composition.
Constituents (wt %)
Rucote 921 Polyester 55.75
TGIC 4.25
P-67 1
Oxymelt A-2 1
TiO2 R-960 20
Y I OM Iron Oxide Yellow Pigment 4
274-0033 Pigment 2.2
HR-70 Yellow Pigment 1.8
BaSO4 10
[00280] Example 19. Preparation of a Red Low Temperature Cure Polyester-TGIC
Decor
Particle.
[00281] A red low temperature cure polyester-TGIC decor particle having the
composition
shown in Table No. 28 below was prepared in the manner described above.
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[00282] Table No. 28. Red Low Temperature Cure Polyester-TGIC Decor
Particle Composition.
Constituents (wt %)
Rucote 921 Polyester 54.6
TGIC 4.2
P-67 1
Oxymelt A-2 1.04
TiO2 R-960 5.13
274-0033 Pigment 0.03
RT-172-D 2.5
F5RK-A 1.5
BaSO4 30
[00283] Example 20. Preparation of a Blue Low Temperature Cure Polyester-TGIC
Decor
Particle.
[00284] A blue low temperature cure polyester-TGIC decor particle having the
composition shown in Table No. 29 below was prepared in the manner described
above.
[00285] Table No. 29. Blue Low Temperature Cure Polyester-TGIC Decor
Particle Composition.
Constituents (wt %)
Rucote 921 Polyester 55.75
TGIC 4.25
P-67 1
Oxymelt A-2 1.05
TiO2 R-960 15
274-0033 Pigment 0.03
15-1101 A4R Pigment 2.5
BK 5099 0.45
BaSO4 20
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[00286] Example 21. Preparation of a Brown Low Temperature Cure Polyester-TGIC
Decor Particle.
[00287] A brown low temperature cure polyester-TGIC decor particle having the
composition shown in Table No. 30 below was prepared in the manner described
above.
[00288] Table No. 30. Brown Low Temperature Cure Polyester-TGIC Decor
Particle Composition.
Constituents (wt %)
Rucote 921 Polyester 56.5
TGIC 4.3
P-67 I
Oxymelt A-2 1
Ti02 RCL-6 1.18
Y I OM Iron Oxide Yellow Pigment 2.54
BK 5099 2
RO 8097 1.48
BaSO4 30
[00289] Example 22. Preparation of an Iron Oxide Yellow Low Temperature Cure
Polyester-TGIC Decor Particle.
[00290] An iron oxide yellow low temperature cure polyester-TGIC decor
particle having
the composition shown in Table No. 31 below was prepared in the manner
described above.
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[00291] Table No. 31. Iron Oxide Yellow Low Temperature Cure Polyester-TGIC
Decor Particle Composition.
Constituents (wt %)
Rucote 921 Polyester 63.3
TGIC 4.7
P-67 1
Oxymelt A-2 1
Y I OM Iron Oxide Yellow Pigment 20
BaSO4 10
[00292] Example 23. Preparation of an Iron Oxide Red Low Temperature Cure
Polyester-
TGIC Decor Particle.
[00293] An iron oxide red low temperature cure polyester-TGIC decor particle
having the
composition shown in Table No. 32 below was prepared in the manner described
above.
[00294] Table No. 32. Iron Oxide Red Low Temperature Cure Polyester-TGIC
Decor Particle Composition.
Constituents (wt %)
Rucote 921 Polyester 63.3
TGIC 4.7
P-67 1
Oxymelt A-2 1
RO 8097 20
BaSO4 10
[00295] Example 24. Preparation of a Ultra Marine Blue Low Temperature Cure
Polyester-TGIC Decor Particle.
[00296] An ultra marine blue temperature cure polyester-TGIC decor particle
having the
composition shown in Table No. 33 below was prepared in the manner described
above.
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[00297] Table No. 33. Ultra Marine Blue Low Temperature Cure Polyester-TGIC
Decor Particle Composition.
Constituents (wt %)
Rucote 921 Polyester 63.3
TGIC 4.7
P-67 I
Oxymelt A-2 1
UMB-304 20
BaSO4 10
[00298] Example 25. Preparation of a Bay Blue Low Temperature Cure PRIMID
Decor
Particle.
[00299] A blue low temperature cure PRIMID -based decor particle having the
composition shown in Table No. 34 below was prepared in the manner described
above.
[00300] Table No. 34. Bay Blue Low Temperature Cure PRIMID Decor Particle
Composition.
Constituents (wt %)
Crylcoat 2671-3 82.6
PRIMID XL-552 6.2
P-67 1
Oxymelt A-2 1.29
TiO2 R-960 7.3
BK 5099 1.05
15-1101 PV Fast Blue A4R 0.56
[00301] Example 26. Preparation of a Brown Low Temperature Cure PRIMID Decor
Particle.
[00302] A brown low temperature cure PRIMID -based decor particle having the
composition shown in Table No. 35 below was prepared in the manner described
above.
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[00303] Table No. 35. Brown Low Temperature Cure PRIMID Decor Particle
Composition.
Constituents (wt %)
Crylcoat 2671-3 80.7
PRIMID XL-552 6.1
P-67 1
Oxymelt A-2 1.5
TiO2 R-960 2
BK 5099 2.7
Y 10M Iron Oxide Yellow 3.1
RO 8097 1.5
201Y Red 1.4
[00304] Example 27. Preparation of a Burgundy Low Temperature Cure PRIMID
Decor
Particle.
[00305] A burgundy low temperature cure PRIMID -based decor particle having
the
composition shown in Table No. 36 below was prepared in the manner described
above.
[00306] Table No. 36. Burgundy Low Temperature Cure PRIMID Decor
Particle Composition.
Constituents (wt %)
Crylcoat 2671-3 82
PRIMID XL-552 6.2
P-67 1
Oxymelt A-2 1.32
TiO2 R-960 1.2
F5RK-A Red 0.08
RO 8097 7
UMB 304 1.2
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[00307] Example 28, Preparation of a Gold Low Temperature Cure PRIMID Decor
Particle.
[00308] A gold low temperature cure PRIMID -based decor particle having the
composition shown in Table No. 37 below was prepared in the manner described
above.
[00309] Table No. 37. Gold Low Temperature Cure PRIMID Decor Particle
Composition.
Constituents (wt %)
Crylcoat 2671-3 71.1
PRIMID XL-552 5.4
P-67 I
Oxymelt A-2 1.31
TiO2 R-960 11.6
BK 5099 0.19
Y 10M Iron Oxide Yellow 8.9
201Y Red 0.15
UMB 304 0.35
[00310] Example 29. Preparation of a Green Low Temperature Cure PRIMID Decor
Particle.
[00311] A green low temperature cure PRIMID -based decor particle having the
composition shown in Table No. 38 below was prepared in the manner described
above.
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[00312] Table No. 38. Green Low Temperature Cure PRIMID Decor Particle
Composition.
Constituents (wt %)
Crylcoat 2671-3 76.5
PRIMID XL-552 5.8
P-67 I
Oxymelt A-2 1.29
TiO2 R-960 9.5
BK 5099 1.2
Y IOM Iron Oxide Yellow 4.5
Lansco 3136 Green 0.21
[00313] Example 30. Preparation of a Rust Low Temperature Cure PRIMID Decor
Particle.
[00314] A rust low temperature cure PRIMID -based decor particle having the
composition shown in Table No. 39 below was prepared in the manner described
above.
[00315] Table No. 39. Rust Low Temperature Cure PRIMID Decor Particle
Composition.
Constituents (wt %)
Crylcoat 2671-3 72.1
PRIMID XL-552 5.4
P-67 1
Oxymelt A-2 1.6
TiO2 R-960 8.65
RO 8097 0.75
201Y Red 10.5
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[00316] Example 31 Preparation of a Blue Low Temperature Cure Polyurethane
Decor
Particle.
[00317] A blue low temperature cure polyurethane-based decor particle having
the
composition shown in Table No. 40 below was prepared in the manner described
above.
[00318] Table No. 40. Blue Low Temperature Cure Polyurethane Decor Particle
Composition.
Constituents (wt %)
Albester 3160 75.5
Alcure 4470 13.3
P-67 1
Oxymelt A-2 1.29
TiO2 R-960 7.3
BK 5099 1.05
15-1101 PV Fast Blue A4R 0.56
[00319] Example 32. Preparation of a Brown Low Temperature Cure Polyurethane
Decor
Particle.
[00320] A brown low temperature cure polyurethane-based decor particle having
the
composition shown in Table No. 41 below was prepared in the manner described
above.
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[00321] Table No. 41. Brown Low Temperature Cure Polyurethane Decor
Particle Composition.
Constituents (wt %)
Albester 3160 73.8
Alcure 4470 13
P-67 1
Oxymelt A-2 1.5
TiO2 R-960 2
BK 5099 2.7
Y I OM Iron Oxide Yellow 3.1
RO 8097 1.5
201Y Red 1.4
[00322] Example 33. Preparation of a Burgundy Low Temperature Cure
Polyurethane
Decor Particle.
[00323] A burgundy low temperature cure polyurethane-based decor particle
having the
composition shown in Table No. 42 below was prepared in the manner described
above.
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[00324] Table No. 42. Burgundy Low Temperature Cure Polyurethane Decor
Particle Composition.
Constituents (wt %)
Albester 3160 75
Alcure 4470 13.2
P-67 1
Oxymelt A-2 1.33
Ti02 R-960 1
F5RK-A Red 0.07
RO 8097 7
UMB 304 1.4
[00325] Example 34. Preparation of a Gold Low Temperature Cure Polyurethane
Decor
Particle.
[00326] A gold low temperature cure polyurethane-based decor particle having
the
composition shown in Table No. 43 below was prepared in the manner described
above.
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[00327] Table No. 43. Gold Low Temperature Cure Polyurethane Decor Particle
Composition.
Constituents (wt %)
Albester 3160 65
Alcure 4470 11.5
P-67 1
Oxymelt A-2 1.33
TiO2 R-960 11.6
BK 5099 0.17
Y 10M Iron Oxide Yellow 8.9
201Y Red 0.15
UMB 304 0.35
[00328] Example 35. Preparation of a Green Low Temperature Cure Polyurethane
Decor
Particle.
[00329] A green low temperature cure polyurethane-based decor particle having
the
composition shown in Table No. 44 below was prepared in the manner described
above.
[00330] Table No. 44. Green Low Temperature Cure Polyurethane Decor Particle
Composition.
Constituents (wt %)
Albester 3160 70
Alcure 4470 12.3
P-67 1
Oxymelt A-2 1.29
TiO2 R-960 9.5
BK 5099 1.2
Y IOM Iron Oxide Yellow 4.5
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Lansco 3136 Green 0.21
[00331] Example 36. Preparation of a Rust Low Temperature Cure Polyurethane
Decor
Particle.
[00332] A rust low temperature cure polyurethane-based decor particle having
the
composition shown in Table No. 45 below was prepared in the manner described
above.
[00333] Table No. 45. Rust Low Temperature Cure Polyurethane Decor Particle
Composition.
Constituents (wt %)
Albester 3160 65.9
Alcure 4470 11.6
P-67 1
Oxymelt A-2 1.6
TiO2 R-960 8.65
RO 8097 0.75
201Y Red 10.5
[00334] Example 37. Preparation of a Pink Low Temperature Cure Polyurethane
Decor
Particle.
[00335] A pink low temperature cure polyurethane-based decor particle having
the
composition shown in Table No. 46 below was prepared in the manner described
above.
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[00336] Table No. 46. Pink Low Temperature Cure Polyurethane Decor Particle
Composition.
Constituents (wt %)
Albester 3160 72
Alcure 4470 12.7
P-67 1
Oxymelt A-2 1.18
TiO2 R-960 11.5
Hostaperm Pink E-WD 1.25
SynergyTM Orange 6118 0.14
BK 5099 0.1
Y IOM Iron Oxide Yellow 0.13
[00337] Example 38. Preparation of an Indigo Low Temperature Cure Polyurethane
Decor Particle.
[00338] An indigo low temperature cure polyurethane-based decor particle
having the
composition shown in Table No. 47 below was prepared in the manner described
above.
[00339] Table No. 47. Indigo Low Temperature Cure Polyurethane Decor Particle
Composition.
Constituents (wt %)
Albester 3160 77
Alcure 4470 13.6
P-67 1
Oxymelt A-2 1.27
TiO2 R-960 5.75
BK 5099 0.5
F5RK-A Red 0.33
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15-1101 PV Fast Blue A4R 0.55
[00340] Example 39. Preparation of Low Temperature Cure Rheology Modifier-
containing Decor Product Compositions.
[00341] Low temperature cure rheology modifier-containing decor product
compositions
having the formulation shown in Table No. 48 below are prepared in the manner
described
above.
[00342] Table No. 48. Low Temperature Cure Rheology Modifier-containing
Decor Product Compositions.
Constituents (wt %)
Lyoprint PTU-US 0.15
Kelzan HP 0.07
Veegum granules 1.16
Aerosol OTS 0.15
Propylene glycol 1
Potassium hydrogen phosphate 0.15
Potassium dihydrogen phosphate 0.35
Acticide MBL 5515 0.3
Deionized water 91.62
A composition from one or more of Table
Nos. 10 - 47
[00343] The decor product from Table No. 48 utilizing the PRIMID Bay Blue
particle of
Example 25 was mixed according to the following methodology. The batch size
was
adjusted to 400 g. A 600 mL beaker was loaded with about 128 g (35% of the
total water
available) of deionized water. The Veegum granules were added to the beaker
and mixed
for about 2 to about 3 hours. Propylene glycol, Aerosol OTS, Acticide MBL
5515,
potassium hydrogen phosphate, and potassium dihydrogen phosphate were added to
the
beaker and mixed for about 15 minutes. The Primid Bay Blue particle made
according to
Example 25 was added and mixed for about 15 minutes. The Kelzan HP was added
and
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mixed for about 1 to about 2 hours. The Alcoprint PTU-US was added and mixed
until it
was substantially dissolved, which was about 2 hours to about 3 hours. The
remaining about
238.68 g (65% of the total water) deionized water was added.
[00344] Example 40. Application, Affixation, Reversibility, and Durability of
the Decor
Products of Example 39 on a Soft Surface.
[00345] The decor products of Example 39 are tested for their ability to be
applied to a
nylon test carpet, removed (reversibility) from the nylon test carpet prior to
an affixation step,
affixed to the nylon test carpet using heat as the energy source, and their
durability after
affixation to the nylon test carpet. The following may be performed for each
formulation of
Example 39 to test reversibility, affixation, and durability thereof.
[00346] A decor product of Example 39 is thoroughly mixed and placed into an 8
oz. PET
bottle with finger pump fine mist sprayers having an output of 60 micron
particle size
(N2862524410WHT3, bottle neck - 24/410; available from ebottles.com, Inc.) or
other
suitable dispenser, such as an aerosol container with a mesh filter and a
propellant, described
above. A two-foot by two-foot piece of nylon test carpet is vacuumed using a
Bissell
CLEANVIEW II vacuum cleaner manufactured by Bissell Homecare, Inc. to remove
loose
fibers and dirt. The specifications of the nylon test carpet utilized are
indicated in Table 49.
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[00347] Table 49. Nylon Test Carpet and Polyester Test Carpet Specifications.
Nylon Test Carpet Polyester Test Carpet
Style 7522 Favored One SP501
Manufacturer Mohawk Industries Mohawk Industries
Pile Yarn Content Filament 100% Nylon Spun 100% Polyester
Yarn Twists per inch 4.25 x 4.25 5.0 x 4.8
Fabric Type Cut Pile Cut Pile
Fiber Treatment Ultrastrand with soil & stain Mohawk APP Polyester W/SGC
Gauge 5/32 1/8 C
Pile Height 0.485 0.440
Stitches per inch 7.83 8.50
Certified Pile Weight 25.20 oz. 39.50 oz.
Total Weight 56.29 oz. 71.03 oz.
Density 1871 3232
Dye Method Fluidye Beck
Primary Backing Woven Polypropylene Woven Polypropylene
Secondary Backing Woven Polypropylene Woven Polypropylene
Performance Appearance 3.50 3.25
Retention Rating
[00348] The baseline color of each of three spots over which the decor product
is applied
is determined using a Minolta data processor model No. DP-301 combined with a
Minolta
model No. CR-3 10 chroma meter (both manufactured by Konica Minolta Sensing
Americas,
Inc.) that is set to the "L - a - b" setting to record A E (color change) and
calibrated
according to the manufacturer's instructions.
[00349] The following tests are performed separately for each of the decor
products of
Example 39. Prior to application of the decor product, a stencil made of a
disposable
absorbent material available from Kimberly-Clark Corp. with a nylon mesh
backing is
centered on the surface of the nylon test carpet sample. Subsequently, the
decor product is
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applied as a gentle mist to the nylon test carpet from the finger sprayer at
distance of 8-10
inches from the nylon test carpet and at a rate to saturate the top surface of
the nylon test
carpet. The applied decor product is allowed to dry overnight at ambient
temperature and
humidity on the nylon test carpet. Once dried, one half of the applied decor
product pattern is
removed from the nylon test carpet using a Shop-Vac 1 x 1 wet/dry vacuum
with hose
attachment (1-1/4 inch diameter x 4 feet). The vacuum characteristics include
1 peak
horsepower, 115 cubic feet/minute of air flow, 52 inches of sealed pressure,
and electrical
ratings of 120 V, 60 Hz, and 5.5A. The pattern is vacuumed twenty times in one
direction
and then twenty times in the opposite direction over the same area. Once
vacuumed, L - a -
b measurements are taken from the vacuumed areas of the nylon test carpet with
the Minolta
data processor and Minolta chroma meter.
[00350] The un-vacuumed decor product pattern is subsequently affixed on the
nylon test
carpet by placing an absorbent paper towel (WYPALL X60 reinforced wipes from
Kimberly-Clark Corp.) over the decor product pattern and heating the decor
product pattern
using a household iron (Hamilton-Beach Model #14340) set at the highest
setting (cotton).
Heat is applied through the absorbent paper towel in a circular motion for 2
'/2 minutes per
square ft of decor product. Subsequently, the paper towel is removed from the
nylon test
carpet and L - a - b values are measured on the affixed decor product pattern
using the
Minolta data processor and Minolta chroma meter specified above.
[00351] To determine the resilience of the affixed decor product on the nylon
test carpet,
one half of the affixed decor product is vacuumed twenty times (using a back
and forth
motion) with a Shop-Vac 1x1 wet/dry vacuum with hose attachment. The L - a -
b
values of the vacuumed and affixed versus the affixed-only (unvacuumed) areas
are taken
using a Minolta data processor combined with a Minolta chroma meter as
mentioned above.
[00352] Approximate expected measures of reversibility, affixation, and
durability of
decor products of Example 39 are shown below in Table No. 50. The values
indicated in
Table No. 50 are believed to be representative of results that would be
measured for any of
the decor product compositions described herein.
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[00353] Table No. 50. Approximate Expected Measures of Reversibility,
Affixation, and Durability of Decor Product of Example 39.
L a b DE
Initial 53 - 56 4-6 11 -12 -
Application 42 - 48 1-5 -4 - -16 17 - 29
Reversibility 50 - 52 4-5 9-12 2-5
Affixation 38 - 45 -4-4 -11 - 0 14 - 29
Durability (vacuumed) 37 - 46 -3-4 -9-1 13 - 28
Durability (not vacuumed) 37 - 43 -3-4 -11 - 0 15 - 29
[00354] Example 41. Reversibility Based on Particle Size on a Test Carpet for
Decor
Products of Example 39.
[00355] The Decor Bay Blue particle of Example 25 was processed and filtered
using a
mesh screen to achieve the noted particle size distribution in Table No. 51.
The Bay Blue
particle was added to the decor product according to the methodology of
Example 39. The
resulting decor product was mixed in a trigger actuated container and applied
to the nylon test
carpet described in Example 39 above, with the below modifications. The number
of spray
strokes utilized in the application are indicated in Table No. 51. The decor
product was
substantially dried affixed and vacuumed according to the method in Example
39, and
subjectively measured for reversibility, where a rating of N/R indicated that
the decor product
was not acceptably reversible and where a rating of R indicated that the decor
product was
acceptably reversible.
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[00356] Table No. 51. Decor Product Reversibility Based on Colorant Particle
Size of
Example 39 using the Decor Particle of Example 25.
MPS = 10 m MPS = 20 m MPS = 30 m MPS = 40 m MPS = 50 m
Dist.: 0 - 20 Dist.: 10 - 30 Dist.: 20 - 40 m Dist.: 30 - 50 Dist.: 40 - 60
m m m m
A B A B A B A B A B
Carpet I N/R N/R N/R N/R R Borderline R R R R
N/R
Carpet II N/R N/R N/R N/R R Borderline R R R R
N/R
Carpet III N/R N/R N/R N/R R Borderline R R R R
N/R
Carpet IV N/R N/R N/R N/R R Borderline R R R R
N/R
Carpet V N/R N/R N/R N/R Borderline N/R R R R R
N/R
MPS = mean particle size; Dist. = distribution of particle size; A = 50
strokes of spray using a
Calmar trigger; B = 100 strokes of spray using a Calmar trigger (considered to
be
representative of consumer use); Carpet I = Nylon 2'x3' Mohawk Style: Favored
One #7522;
color = Pediment; Fiber = 100% continuous filament with Scotchguard by
Mohawk; Carpet
II = Nylon 2'x3' Mohawk Style: Gameday #7499; Yam: Filament 100% Nylon cut
pile;
Treatment: Ultrastrand with soil and stain. Carpet III = Carpet I with an
additional antistatic
treatment; Carpet IV = Carpet II with an additional antistatic treatment; and
Carpet V =
Carpet I with a high slip treatment; N/R = not acceptably reversible; and R =
acceptably
reversible.
[00357] Example 42. Determination of Glass transition temperatures (Tg) and
melting
temperatures (Tm) of Surface Substrates.
[00358] Tg and Tm of surface substrates were measured using a Model Q100
Differential
Scanning Calorimeter (TA Instruments, Inc.) at a heating rate of 20 C/min.
Specifically, in
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this way, the nylon carpet of Table No. 49 was measured to have a Tg of 40-45
C and a Tm
of 257 C. Further, a polyester carpet of Table No. 49 was measured to have a
Tg of 140-
150 C and a Tm of 247 C.
INDUSTRIAL APPLICATION
[00359] The compositions and formulations disclosed herein allow for the
application of a
decor product to a surface, and more specifically a soft surface such as a
carpet, a rug,
draperies, curtains, upholstery, and the like. By applying the decor product
to the soft
surface, perceived aesthetic quality of the soft surface is improved and may
extend the useful
life of the soft surface before need for replacement.
[00360] The disclosure has been presented in an illustrative manner in order
to enable a
person of ordinary skill in the art to make and use the disclosure, and the
terminology used is
intended to be in the nature of description rather than of limitation. It is
understood that the
disclosure may be practiced in ways other than as specifically disclosed, and
that all
modifications, equivalents, and variations of the present disclosure, which
are possible in
light of the above teachings and ascertainable to a person of ordinary skill
in the art, are
specifically included within the scope of the claims.
