Note: Descriptions are shown in the official language in which they were submitted.
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WOOD STAINING AND FINISHING WIPES AND METHOD OF
MANUFACTURING SAME
FIELD OF INVENTION
[0001] The present disclosure relates to staining and finishing wood. More
specifically, the present disclosure relates to disposable wipes that are
saturated with
wood staining and finishing compositions.
BACKGROUND
[0002] Wood, such as furniture for example, is commonly stained to achieve
a new
tone or color while preserving the natural wood appearance. The wood can be
stained by
applying a stain product onto a wood surface. Staining can be achieved by
applying a
solution including a stain to a wood surface using a brush or cloth. However,
removing
the stain solution from a can or other container using a brush or cloth before
applying the
stain solution to the wood surface can be inefficient and time consuming. In
addition, the
brush or cloth may require cleanup, which may be time consuming.
[0003] Wood is also commonly finished after being stained in order to
protect the
wood surface. Wood can be finished by applying a finishing solution using a
brush or a
cloth to the wood surface. However, extracting the finishing solution from a
can or other
container using a brush or cloth before applying the finishing solution to the
wood
surface can be inefficient and time consuming. In addition, the brush or cloth
may
require cleanup, which may be time consuming.
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SUMMARY OF THE INVENTION
100041 In one embodiment, a pre-treated wipe is disclosed. The pre-treated
wipe
includes an absorbent substrate impregnated with a solution. The solution
includes a
colorant capable of imparting a change in color to a wood surface. The
solution further
includes a finishing composition. The solution further includes a thickening
agent. The
solution has a finished viscosity that is greater than an original viscosity
of the solution
when prepared without the thickening agent. The absorbent substrate is
impregnated
with the solution before being disposed in a package.
[0005] In one embodiment, a wood surface staining and finishing kit is
disclosed.
The kit includes a plurality of wipes having an absorbent substrate
impregnated with a
solution. The solution includes a colorant capable of imparting a change in
color to a
wood surface. The solution further includes a finishing composition. The
solution
further includes a thickening agent. The solution has a finished viscosity
that is greater
than an original viscosity of the solution when prepared without the
thickening agent.
The kit further includes a tray capable of supporting the plurality of wipes.
The kit
further includes outer packaging disposed about the plurality of wipes and the
tray,
wherein the plurality of wipes are disposed within the tray before the outer
packaging is
applied. The kit further includes at least one plastic glove, wherein the
plastic glove is
removably affixed to the outer packaging.
[0006] In one embodiment, a method of manufacturing a wood surface staining
and
finishing kit is disclosed. The method includes the step of impregnating an
absorbent
substrate with a solution having a viscosity of about 3000 to 4000 centipoise
to form a
plurality of pre-treated wipes. The method further includes the step of
disposing the
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plurality of pre-treated wipes in a support tray. The method further includes
the step of
sealing the plurality of pre-treated wipes and the support tray within an
outer packaging.
The method further includes the step of adhering at least one plastic glove to
the outer
packaging.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the accompanying drawings, structures are illustrated that,
together with the
detailed description provided below, describe exemplary embodiments of the
claimed
invention. It should be understood that elements shown as a single component
may be
replaced with multiple components, and elements shown as multiple components
may be
replaced with a single component. The drawings are not to scale and the
proportion of
certain elements may be exaggerated for the purpose of illustration.
[0008] FIG. 1 is a perspective view of a flatpack including wood staining
and
finishing wipes.
[0009] FIG. 2 is a perspective view of a flatpack including wood staining
and
finishing wipes.
[0010] FIG. 3 is a perspective view of an embodiment of a wood staining and
finishing wipe.
100111 FIG. 4 is a perspective view of one embodiment of a stack of wood
staining
and finishing wipes.
[0012] FIG. 5 is a rear perspective view of a flatpack including wood
staining and
finishing wipes.
[0013] FIG. 6 is a perspective view of an embodiment of a plastic glove.
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[0014] FIG. 7 is a
flow chart illustrating one embodiment of a method for
manufacturing wood staining and finishing wipes.
[0015] FIG. 8 is an embodiment of a wetting station.
[0016] FIG. 9 is a
flow chart illustrating one embodiment of a method for staining
and finishing a wood surface using wood finishing and staining wipes.
DETAILED DESCRIPTION
[0017] A pre-treated
wood staining and finishing cloth or wipe, and method for
manufacturing and using the same, is disclosed and described in detail by way
of
examples and with reference to the figures. It will be appreciated that
modifications to
the disclosed and described examples can be made and may be desired for a
specific
application. In this
disclosure, any identification of specific shapes, materials,
techniques, arrangements, etc., are either related to a specific example
presented or are
merely a general description of such a shape, material, technique,
arrangement, etc.
Identifications of specific details or examples are not intended to be, and
should not be,
construed as mandatory or limiting unless specifically designated as such.
Selected
examples are hereinafter disclosed and described in detail with reference made
to FIGS.
1-9.
100181 A wipe
generally includes an absorbent substrate that is pre-treated with a
solution including wood stain, a wood finishing composition, and/or a
thickening agent,
or a combination thereof, before being disposed in a package. In one
embodiment, the
wipe may be impregnated with a solution that both stains a wood surface and
also
finishes the wood surface to protect the surface (hereinafter referred to as
"the solution").
The pre-treated wipe eliminates the need for extracting a staining solution or
finishing
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solution from a container with a brush or a cloth before applying it to a wood
surface,
thereby allowing for a cleaner and more efficient wood staining and finishing
process.
Additionally, the pre-treated wipe enables more efficient staining and
finishing of a wood
surface by eliminating a step and enabling the staining and finishing of a
wood surface in
one combined step. In addition, because the wipes are disposable, cleaning up
after the
project is simplified.
[00191 In one
embodiment, the absorbent substrate may be made of any suitable
material or combination of materials that are capable of absorbing the
solution and
applying the solution to a wood surface. In one example, the absorbent
substrate is made
of a nonwoven fabric. In another example, the absorbent substrate may be made
of a
70% viscose fabric and 30% polyethylene terephthalate (PET) fiber blend. In
another
example, the absorbent substrate may include a spunlace material. In yet
another
example, the absorbent substrate may include a material with a fine apertured
pattern.
Generally, the absorbent substrate may have an absorption capacity of about
700% to
about 1250%, and desirably about 950%. An example of a suitable absorbent
substrate is
commercially available from Jacob Holm Industries, located in Candler, NC.
[0020] In one
embodiment, the solution to be absorbed by the absorbent substrate
may include a colorant, or stain, that imparts color to a wood surface. The
colorant may
be non-soluble in solution, such as a pigment. In another example, the
colorant may be
soluble, such as a dye. In one embodiment, the colorant may impart a natural
oak color, a
maple color, a chestnut color, a dark mahogany color, or a walnut color to the
surface on
which it is applied. It should be appreciated that the colorant may include
other suitable
colors of pigment or dye, or a combination of pigment and dye.
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100211 The solution
may further include a base solvent for carrying the colorant and
for aiding in applying thc colorant to a wood surface. In one example, the
solvent is
water-based or aqueous-based. In other example, the solvent may be oil-based
or non-
aqueous-based. It should be understood that the solvent may be any solvent
suitable for
aiding in applying the colorant to a wood surface.
[0022] The solution
may further include a finishing composition for adding a
protective coating to a wood surface. In one example, the finishing
composition is a
polyurethane composition with acrylic resin. It should be understood that the
solution
may include other types of finishing compositions, suitable for protecting a
wood surface.
[0023] The solution
may further include a thickening agent for increasing the
viscosity of the solution. An increased viscosity allows for the solution to
stay
impregnated in the absorbent substrate for longer periods of time without
separating due
to gravitational forces. For example, by adding the thickening agent to the
solution, the
finished wipe may be capable of retaining the solution for a minimum of at
least two
years.
100241 In one
example, the thickening agent includes an alkali soluble, non cellulosic
anionic emulsion, which includes approximately 4.5% of the total formula by
weight. It
should be understood that other thickening agents may be used, suitable for
increasing the
viscosity of the solution. In one example, the viscosity of the solution after
the addition
of the thickening agent may be from about 3000 to about 4000 centipoise.
Absent a
thickening agent, the solution may have a lower viscosity, between 50 to 70
centipoise
for example. It should be understood that if the viscosity of the solution
without
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thickening agent is from about 3000 to about 4000 centipoise, then a
thickening agent
may not be needed.
[0025] In one embodiment,
the finished solution used to impregnate the absorbent
substrate may be Minwax Water Based WoodSheen Rubbing Stain and Finish,
commercially available from The Sherwin-Williams Company, or other similar
products.
However, it should be appreciated that other suitable formulations may be
used.
[0026] After the
absorbent substrate is impregnated with the solution, it is cut to form
the finished wipe. In another embodiment, the substrate may be cut before the
solution is
applied. Once saturated and cut, the wipes are then folded, placed in a tray,
and disposed
in a resealable package. Packaging the wipes after they are impregnated with
the solution
helps ensure that the solution is evenly distributed throughout the substrate
and
sufficiently absorbed.
[0027] In one embodiment,
a plurality of wipes may be packaged in a flatpack 100, as
illustrated in FIG. 1. The flatpack 100 may be made of plastic or any material
suitable
for packaging and maintaining the integrity of the wipes. The flatpack 100 may
include
an opening (not shown) for providing access to the wipes inside and a peel-and-
reseal
sticker 102 disposed over the opening to seal to the opening and prevent the
wipes from
drying. The peel-and-reseal sticker 102 may be configured to peel back to an
open
position, exposing the opening 104, and allowing access to the wipes 106, as
illustrated in
FIG. 2. It should be appreciated that other methods of opening and closing the
flatpack
100 may be used to provide access to the wipes 106, while preventing the wipes
106 from
drying. For example, a re-sealable plastic door or lid may be disposed over
the opening.
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100281 Any suitable
number of wipes 106 may be included in a single flatpack 100.
In one example, a flatpack 100 includes eight wipes 106 stacked on top of each
other.
The width or length of the wipes 106 may be greater than the width or length
of the
flatpack. Accordingly, the wipes 106 may be folded in a 'z' configuration, as
illustrated
in FIG. 3, inside the flatpack 100 and can be unfolded to a full width or
length when
extracted from the flatpack 100 in order to cover a greater surface area of
wood. It
should be appreciated that the wipes 106 may be folded in other suitable
configurations in
order to fit inside the flatpack 100. For example, the wipes 106 may be folded
in a "z"
configuration from left-to-right or right-to-left, as illustrated. Or, in one
example, the
wipes 106 may be folded in a "z" configuration from top-to-bottom or bottom-to-
top (not
shown).
(0029] Each wipe 106
may comprise any suitable amount of solution. In one
example, each finished wipe 106 in an eight count flatpack 100 may include
about 27
grams of solution and be configured to provide stain and finish coverage for
about 50
square feet of wood surface. In one example, each wipe 106 may include between
about
27-32 grams of solution.
[0030] A tray 302, as
illustrated in FIG. 4, may be used to provide support for the
wipes 106 inside the flatpack 100. In particular, the tray 302 may provide a
more rigid
form to the flatpack 100, thereby allowing the flatpack 100 to stand upright
in a store
display such as a stadium tray display (not shown) and may provide for a
cleaner and
more efficient packaging process.
[0031] In one
embodiment, the tray 302 may support the stack of wipes 106 on a
conveyor belt during a packaging process such that the tray 302 prevents the
wipes 106
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from making contact with the conveyor belt. This helps prevent the solution
from
staining the conveyor belt, thus preventing potential damage to the conveyor
belt and also
reducing the amount of time which may be needed to clean the conveyor belt.
The tray
302 may include an outer perimeter lip 304 extending upward which further
provides for
a cleaner and more efficient packaging process by containing excess solution
inside the
tray 302. The tray 302 may comprise any suitable material. In one example, the
tray 302
is plastic. In another example, the tray 302 is paper. A tray 302 is
commercially
available from Reliant Group in Paterson, New Jersey, for example.
[0032] The flatpack
100 may also include at least one plastic glove 502 for handling
the wipes 106, as illustrated in FIG. 5. The plastic glove 502 may be provided
in a
folded configuration and disposed on the back side 504 of flatpack 100. In one
example,
the flatpack 100 includes two plastic gloves 502, provided in a folded
configuration and
disposed on the backside 504, that are secured to the backside 504 of the
flatpack 100
using glue or other suitable adhesive. The folded plastic gloves 502 may be
disposed at
least partially underneath a back fin seal 506 such that it is at least
partially concealed by
the back fin seal 506. This placement provides for at least some protection
and helps
prevent the folded plastic gloves 502 from being knocked off or displaced from
the
flatpack 100 during packaging, shipping, or display. FIG. 6 illustrates one
plastic glove
502 when unfolded. Plastic gloves 502 are commercially available from Brand
Builders
in New Jersey.
[00331 FIG. 7 is a
flow chart illustrating an example method 700 for manufacturing
wood staining and finishing wipes. In one example, the method includes
impregnating
the absorbent substrate with a solution 702. Specifically, in order to
impregnate the
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substrate with solution, a wetting station, or other suitable applicator, is
used to coat the
substrate with the solution. As illustrated in FIG. 8, a first or bottom
wetting station 802
is configured to impregnate a first side of a substrate 804 with the solution
and a second
or top wetting station 806 is configured to impregnate an opposite side of the
substrate
804 with the solution. . In one example, the wetting stations may be
cylindrical or tube ¨
shaped.
[0034] A hose 810
facilitates transfer of solution from a supply station 812 to the
wetting stations 802 and 806. The solution flows through the wetting stations
802 and
806, onto the substrate 804 through one or more openings 814 and 816 as the
substrate
804 passes. In one example, the one or more openings 814 and 816 are slits
that span the
length of the stations 802 and 806, ensuring that the substrate 804 is
impregnated with
sufficient solution. It should be appreciated that the openings 814 and 816
can be any
size or shape, suitable for ensuring delivery of sufficient solution to the
substrate 804
given the viscosity of the solution.
[0035] A folding
station 818 is configured to fold the substrate 804 after the substrate
804 is impregnated with solution and to pass the folded substrate 804 onto a
conveyor
belt 820, where it travels towards a cutting station 822. It should be
understood that a
folding station 818 may fold the substrate 804 using any known suitable
folding
techniques. It should also be understood that the cutting station 822 may cut
the substrate
804 using any known suitable cutting technique.
[0036] In one
example, a second bottom wetting station 824, a top wetting station
826, and a folding station 828 are provided to impregnate and fold a second
substrate
830. The second folding station 828 is configured to pass the second substrate
830 onto
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the conveyor belt 820 simultaneous to the first folding station 818 passing
the first
substrate 804 onto the conveyor belt such that the second folded substrate 830
is stacked
on top of the first folded substrate 804.
[0037] It should be
understood that although two wetting stations, bottom wetting
stations, and folding stations are illustrated, any suitable number may be
provided in
order to facilitate impregnating, folding, and stacking a plurality of
substrates. In one
example, eight sets of top and bottom wetting stations and folding stations
may be
provided in order to impregnate, fold, and stack eight substrates onto the
conveyor belt
820.
[0038] In one
example, a post-dose station 836 is disposed above the conveyor belt
820, between the folding stations 818 and 828 and the cutting station 822.
Although not
illustrated, the hose 810 facilitates transfer of solution from the supply
station 812 to the
post-dose station 836. The post-dose station 836 is configured to ensure
consistent
impregnation of the substrates 804 and 830 and to prevent under filling by
providing an
extra dose of solution, or to drip extra solution, onto to the substrates 804
and 830 before
the substrates proceed to cutting station 822.
[0039] A toothed
roller 832 may be provided to pull the stack of impregnated
substrates towards the cutting station 822. The toothed roller 832 includes
one or more
teeth 834 to grip the stack of folded substrates without compressing solution
out from the
stack of substrates. Specifically,
the teeth 834 alleviate the need for applying
compression to the stack of substrates by the roller 832. The toothed roller
832 pulls the
stack of folded substrates uniformly at a consistent rate in order to prevent
the stack of
substrates from hydroplaning as the stack travels along the conveyor belt 820
towards the
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cutting station 822. This helps ensure that the cutting station 822 makes cuts
of
consistent length.
[0040] Referring back
to FIG. 7, once the solution has been applied to the substrate
and formed into pre-treated individual wipes, one or more pre-treated wipes
are stacked
or disposed into a tray 704. In one example, eight wipes arc stacked into a
tray. In one
example, the wipes are folded in a 'z' pattern before being stacked into a
tray. It should
be understood that the wipes may be folded in any suitable pattern. In one
example, the
wipes may not be folded.
[0041] Once stacked
in the tray, the tray of wipes is sealed with flow wrap to create a
flatpack or an outer packaging 708. Flow wrap is commercially available from
Prime
Label located in Pewaukee, Wisconsin. In one example, sealing the tray of
wipes
includes creating a back fin seal, a top seal, and a bottom seal. In one
example, the
flatpack created with the flow wrap includes an opening to allow for access to
the wipes.
In another example, the step of sealing the wipes with flow wrap also includes
creating an
opening to allow for access to the wipes. A peel-and-reseal sticker, also
commercially
available from Prime Label, is disposed on the flow wrap 706 prior to sealing
the tray
inside the flow wrap in order to cover the opening. At least one glove packet
is then
adhered thereto 710. It should be appreciated that other suitable re-sealable
lids or labels
may be used. In one example, the glove packet is adhered to the back of the
flatpack, at
least partially concealed by the back fin seal.
[0042] Once packaged,
the individual flatpacks of pre-treated wipes may be used to
stain and finish a wood surface, as illustrated by the flow chart in Fig 9.
First, a wood
surface is cleaned in preparation for being stained and finished 902. In one
example,
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cleaning the wood surface includes sanding the wood surface. The glove packet
is then
removed from the flatpack 904. The glove packet is opened and used to prevent
a user's
skin from making contact with the solution. The peel-and-reseal sticker is
then pulled
back to an open position and a wipe is removed from the flatpack 906. The peel-
and-
reseal sticker is then returned to the closed position to prevent remaining
wipes in the
flatpack from drying out.
[0043] The solution
is then applied to a wood surface by moving the impregnated
wipe across the wood surface 908. In one example, the wipe is moved along the
wood
surface in the direction of the grain of the wood, working the solution into
the wood.
Excess solution is then removed from the wood surface 910 using a clean rag.
In one
example, after allowing for time to dry, a second coat of stain and finish may
be applied
by repeating steps 906, 908, and 910 one or more times in order to achieve a
deeper color
and sheen. In one example, a second coat may be applied after waiting for the
wood
surface to dry for about one hour. In one example, the wood surface may be
subjected to
normal use after waiting for the wood surface to dry for about 24 hours.
[00441 It should be
appreciated that although the examples described herein are
directed to a wipe that is presoaked with a solution for staining and
finishing a wood
surface, a wipe may similarly be presoaked with alternative suitable solutions
for staining
and finishing other types of surfaces.
[0045] To the extent
that the term "includes" or "including" is used in the
specification or the claims, it is intended to be inclusive in a manner
similar to the term
"comprising" as that term is interpreted when employed as a transitional word
in a claim.
Furthermore, to the extent that the term "or" is employed (e.g., A or B) it is
intended to
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mean "A or B or both." When the applicants intend to indicate "only A or B but
not both"
then the term "only A or B but not both" will be employed. Thus, use of the
term "or"
herein is the inclusive, and not the exclusive use. See, Bryan A. Garner, A
Dictionary of
Modern Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms "in"
or "into"
are used in the specification or the claims, it is intended to additionally
mean "on" or
"onto." Additionally, to the extent that the terms "on" or "onto" are used in
the
specification or the claims, it is intended to additionally mean "in," "into,"
or "near."
Furthermore, to the extent the term "connect" is used in the specification or
claims, it is
intended to mean not only "directly connected to," but also "indirectly
connected to" such
as connected through another component or components.
[0046] The foregoing description of examples has been presented for
purposes of
illustration and description. It is not intended to be exhaustive or limiting
to the forms
described. Numerous modifications are possible in light of the above
teachings. Some of
those modifications have been discussed, and others will be understood by
those skilled
in the art. The examples were chosen and described in order to best illustrate
principles
of various examples as are suited to particular uses contemplated. The scope
is, of
course, not limited to the examples set forth herein, but can be employed in
any number
of applications and equivalent devices by those of ordinary skill in the art.
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