Note: Descriptions are shown in the official language in which they were submitted.
DRY COMPOSITION FOR AN INTERIOR WALL COVERING
Field
Embodiments of the invention relate to wall coverings and more
particularly to dry compositions that can be dissolved in water for forming a
paste to
apply to a surface of an interior wall in the construction industry.
Background
Walls can be decorated in a myriad of different ways, but most often are
decorated using one of the three common methodologies of using paint,
wallpaper or
plaster. All three known methods have distinct drawbacks of being messy,
requiring
additional preparation of the walls, producing noxious fumes, and are not
readily
repairable.
Painting a wall is probably the most common form of decorating a wall.
Paint is any pigmented liquid, liquefiable, or mastic composition that, after
application to
a wall or substrate in a thin layer, converts to a solid film. It is most
commonly used to
protect, color, or provide texture to objects. Paint can be made or purchased
in many
colors ¨ and in many different types, such as watercolor or synthetic. Paint
is typically
stored, sold, and applied as a liquid, but most types dry into a solid. Most
paints are
either oil-based or water-based, each having distinct characteristics with
advantages
and disadvantages. For example, due to environmental concerns, many
municipalities
have ordinance regulating or even prohibiting the discarding of oil-based
paint down
household drains or sewers. Solvents for cleaning up are also different for
water-based
paint than they are for oil-based paint. Water-based paints and oil-based
paints will
cure differently based on the outside ambient temperature of the object being
painted,
such as a house. While water-based paints are more often than not, less
odorless than
oil-based paints, they still, nonetheless, produce fumes that may be noxious
to
individuals.
Painted walls can chip, can fade, and are not easily repairable if damage
occurs. Often, when there is a damaged section of a painted wall, an entire
wall has to
be repainted, and not just a section of the wall, due to fading of the paint
over time.
Further to apply a coat of paint to a surface of a wall, the surface must be
treated prior
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to the application of the paint, substantially increasing time, effort and
costs associated
with painting a wall.
The technique of applying a wallpaper to decorate a wall is an alternative
to painting a well. Wallpaper is a material used in interior decoration to
decorate the
interior walls of buildings. It is usually sold in rolls and applied onto a
wall using
chemical adhesives. Wallpapers can come plain as "lining paper" (so that it
can be
painted or used to help cover uneven surfaces and minor wall defects thus
giving a
better surface), textured, with a regular repeating pattern design, or, much
less
commonly today, with a single non-repeating large design carried over a set of
sheets.
Wallpaper printing techniques include surface printing, gravure printing,
silk screen-printing, rotary printing, and digital printing. Wallpaper is made
in long rolls
which are hung vertically on a wall. Patterned wallpapers are designed so that
the
pattern "repeats", and thus pieces cut from the same roll can be hung next to
each other
so as to continue the pattern without it being easy to see where the join
between two
adjacent pieces occurs. In the case of large complex patterns of images, this
is
normally achieved by starting the second piece halfway into the length of the
repeat, so
that if the pattern going down the roll repeats after 24 inches, the next
piece sideways is
cut from the roll to begin 12 inches down the pattern from the first.
Applying a wallpaper to decorate a wall is labor intensive. An adhesive,
often a chemical compound having noxious fumes is applied to a surface of a
wall, and
then the wallpaper is layered on top of the adhesive chemical compound,
sandwiching
the adhesive chemical compound between the wallpaper and the surface of the
wall.
This adhesive chemical compound is then trapped behind the wallpaper until the
wallpaper and adhesive is removed at a future date. The adhesive chemical
compound
can leach into the wall, or even worse, leach into and through the wallpaper.
Furthermore, if wallpaper is damaged, the damaged section cannot be simply
replaced,
and entire sections of walls must be replaced. Finally, wallpaper can only be
applied to
surfaces that are relatively smooth, and cannot be applied to surfaces such as
rock,
brick, stucco, and plaster.
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Date Recue/Received date 2020-04-09
Plaster is a building material used for the protective or decorative coating
of walls and ceilings and for molding and casting decorative elements. Plaster
is often
used interchangeably with the term stucco.
The most common types of plaster mainly contain either gypsum, lime, or
cement, but all work in a similar way. The plaster is manufactured as a dry
powder and
is mixed with water to form a stiff but workable paste immediately before it
is applied to
the surface. The reaction with water liberates heat through crystallization
and the
hydrated plaster then hardens after it is applied to a wall.
Plaster can be relatively easily worked with metal tools or even
sandpaper, and can be molded, either on site or to make pre-formed sections in
advance, which are put in place with adhesive. Plaster is not a strong
material, and is
more suitable for finishing, rather than load-bearing, and when thickly
applied for
decoration may require a hidden supporting framework, usually in metal.
As the different forms of plaster are usually cementitious, and forms lots of
dust after is it applied, plaster is more often used for outdoor applications.
For indoor,
use, plaster is rather formed into pre-formed sections in advance, dried, and
then
placed on a surface of an interior wall using chemical adhesives. This is
advantageous
over wallpaper in that the chemical adhesives cannot leach through plaster.
However,
cracks, holes, scratches and other forms of damage formed on the per-formed
plaster
requires a replacement of entire sections of the wall in order to maintain
consistency.
Summary
Embodiments of this invention generally relate to a dry composition for an
interior wall covering, and more particularly to a dry composition for an
interior wall
covering comprising a food additive. Embodiments of the invention do not
require
preparation of a surface of an interior wall prior to the application of the
wall covering,
and allow damages, such as cracks, holes, scratches, and other forms of
surface
damage to be repaired relatively easily and quickly.
Embodiments of the invention are composed of natural and
environmentally friendly materials, are recyclable and allow interior walls to
breathe,
reducing moisture and the likelihood of the growth of mold. Embodiments are
odorless,
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and provide thermal and sound insulation. In embodiments, waste or scrap
cotton from
the textile industry, and/or waste cotton yarn can be used and recycled.
In a broad aspect of the invention, a dry composition for an interior wall
covering consists of a food additive which can be mixed with water to form a
paste and
applied to a surface of an interior wall.
Detailed Description
Generally, embodiments of the present invention relate to a dry
composition for an interior wall covering which can be mixed in an appropriate
amount
of water to form an emulsion or paste. The paste can then be applied to an
interior wall
surface and allowed to be cured. Once cured, the paste forms a solid layer of
decorative wall covering that provides various aesthetic appreciations.
Depending on
the nature of the ingredients of the dry composition, embodiments of the
present
invention consists of natural ingredients and is environmentally friendly,
easy to work
with, easy to clean up, and children safe. In embodiments, the resulting
decorative wall
covering provides increased thermal and sound insulation and reduces the
buildup of
moisture therein, thereby reducing the likelihood of the growth of mold.
In use, embodiments of the dry composition can be mixed with an
appropriate amount of water to create a paste. The paste, once it achieves a
desired
consistency, can be applied to any surface of a wall (such as an interior
wall, ceiling,
painted wall, metal wall, glass walls, cement walls, brick walls, tile walls,
stone wall,
wood walls, and rough textured walls like popcorn ceilings, plaster ceilings
an stucco)
using various means. In an embodiment, the use of a trowel was found to be
most
effective. In other embodiments, a roller can also be used to apply the wet
composition
onto the surface of the interior wall. In embodiments, a combination of the
roller to
apply the wet composition onto the surface of the wall can be employed,
followed by the
use of the trowel to evenly distribute and stretch the wet composition on the
surface of
the interior wall.
Once the paste is applied to the surface of the wall, the paste is allowed to
cure or dry to form a solid decorative layer on the surface of the interior
wall. Once the
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paste is fully cured, the decorative layer forms a solid wall coating that is
odorless, non-
corrosive, and provides additional sound and thermal insulation.
Advantageously, Applicant notes that the final dried decorative wall
covering is also non-flammable. Applicant conducted experiments to determine
flammability and noted that when exposed to direct fire and flames, the area
of the
decorative wall covering that is exposed turned black but did not ignite and
spread the
fire.
In an embodiment, 3 to 6 liters of water can be mixed with 1 kilogram of
the dry composition and allowed to set for about 25 minutes. Although the wet
composition can be allowed to set longer, Applicant has found that allowing
the dry
composition to set in water for about 25 minutes provides the best consistency
and
fluidity of the paste to allow for easier application of the paste onto a
surface of an
interior wall. The paste can be applied using a plastic trowel commonly used
in the
application of dry wall mud. As the paste is applied to the surface, a person
can use the
trowel to evenly distribute the paste across the entire surface of the wall.
In situations
where the paste is found to be too viscous to apply evenly, additional water
can be
added to reduce the overall viscosity of the paste. If the paste is too fluid,
additional dry
composition can be added to the paste to increase the viscosity of the paste.
In
embodiments, if the wet composition is not applied to the surface of the
interior wall,
and there remains unused or non-applied portions of the wet composition which
has
thickened or even hardened, additional water can be added to the unused
portions of
the wet composition to decrease the viscosity of the unused portions and then
applied
to the surface of the wall.
In embodiments, unused portions of the wet composition can be stored
indefinitely and can then be reused by simply adding water. For example, after
an
application of the wet composition is completed, the unused portion or any
left over wet
composition can be stored in a suitable container. In embodiments, this left
over portion
can even be allowed to completely dry. If there is a need to use some of the
unused
portion at a future date, the dried unused portion can be reused by simply
adding
additional water to make it fluid.
Date Recue/Received date 2020-04-09
In embodiments, the Applicant has found that applying a 1 to 3 mm thick
coat of the paste provides optimal coverage and use of the paste. Applicant
notes that
the time to dry the wet composition depends on the thickness of the wet
composition
applied, such that a thinner layer of wet composition requires less time to
dry and
conversely, a thicker layer of wet composition requires more time to dry.
After the paste has been applied to the wall surface, it can be allowed to
cure or dry until the paste forms a solid decorative coating. In embodiments,
the
Applicant has found that allowing the paste to cure for about 48 hours at a
temperature
of between 20 C to 30 C with adequate air circulation resulted in optimal
performance.
Applicant notes that increase in the ambient or room temperature increases the
fluidity
(i.e. reduces the viscosity) of the wet composition, making it more difficult
to apply the
wet composition to the surface of the interior wall. Similarly, applying the
wet
composition at lower ambient temperatures increases the viscosity such that
application
of the wet composition is hindered.
In embodiments, if a need to remove portions of the decorative wall
covering arises, such as due to damage, Applicant has found that simply
wetting the
decorative wall covering with water allows the wetted portions to be removed.
Once the
damaged portions are removed, fresh wet composition can be applied to repair
the
damaged portions of the decorative wall covering. In embodiments, the removed
wet
composition can be recycled and reused at a later date. For example, Applicant
has
found that spraying a localized area having damage with water and allowing the
water
to soak into the decorative wall covering between 15 to 20 minutes allows that
particular
portion to be scrapped off. This portion can then be repaired by reapplying a
new layer
of the wet composition, which can be freshly made, or a dried unused portion
that has
water added to it.
Accordingly, Applicant notes that embodiments of the present invention
should not be applied to areas or surfaces of walls that are near areas with
high
moisture content, such as showers, or exterior walls.
Embodiments of the dry composition consists of several ingredients, each
ingredient serving a different purpose. In an embodiment, there are three
ingredients
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which the dry composition consists of: 1) cotton; 2) paper; and 3) a food
ingredient for
binding the cotton onto the surface of an interior wall.
In embodiments, cotton is included in the composition to give texture,
aesthetic and visual decorative properties, and provide insulative properties
(ie. Thermal
and sound insulation). In embodiments, depending on the desired aesthetic
properties,
the cotton can be shredded of various sizes and color. In embodiments, the
shredded
cotton can be of a unitary size, a unitary color, or can be a variation
thereof. Further
still, in other embodiments, while polyester can be used, in order to reduce
the
environmental footprint, waste cotton from the fabric industry and/or cotton
yarn can be
used. In other embodiments, spun silk, or tram silk yarn are alternatives to
using cotton.
The second ingredient of paper, although optional, can be included to
serve as a binder for the shredded pieces of cotton. In embodiments, the paper
should
break down to serve as a binder, and accordingly, the paper is shredded paper.
In
embodiments, paper can be substituted with paper towels, which results in a
final
decorative wall covering having a different texture.
The final required ingredient is an adhesive for binding the cotton to the
surface of the interior wall. Applicant understands and is aware of prior art
that uses
chemical adhesives. For example, Applicant can use wallpaper paste, a common
chemical adhesive, but this is not the goal of the Applicant in providing an
all-natural
and environmentally friendly wall covering.
From Applicant's previous experience as an interior designer, the
Applicant recalled working on various projects creating and designing home
accessories
made from environmentally friendly products. The Applicant sought to find a
dry
composition, made from all naturally and environmentally friendly products,
that can be
used to create a wall covering for interior walls. Recalling the Applicant's
past
experiences, Applicant attempted to create embodiments of the invention using
a food
ingredient, such as flour, as the third ingredient for binding the cotton to
the wall.
Experimentation using flour was somewhat successful in that the final
dried decorative wall covering this adhere to the surface of the wall.
However, the
Applicant noted that the wall covering was easily removed from the wall upon
drying.
Continuing along the lines of using a food ingredient for adhesion, the
Applicant
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experimented with corn starch, another food ingredient. The results were
similar in that
the final dried wall covering was easily removed from the surface of the wall.
Other food
ingredients that were used in obtaining a final formulation included calcium
citrate
malate, and ingredient used in fortifying calcium in dairy products, namely
ice cream,
and cellulose gum, another ingredient used in the ice cream manufacturing
industry.
Applicant found that the cellulose gum provided the best results with respect
to
consistency of the wet composition for application onto a surface of an
interior wall,
softness of the final product after application and hardness and resiliency of
the final
decorative wall covering.
Advantageously, Applicant noticed that cellulose gum also does not
promote bacterial growth, whereas flour and corn starch did. As described
above,
Applicant used food ingredients that were readily available and found in the
Applicant's
pantry. Applicant notices that mold and moths were found in the flour and the
corn
starch, after long term storage, however, no such growth was found in the
stored
cellulose gum.
Upon determining an appropriate food ingredient to act as the adhesive,
Applicant experimented with various concentrations or ratios of each
ingredient to
provide the most desirable final decorative wall covering. The table below
illustrates the
various amounts of each ingredient used and the resulting subjective test
results.
Formulation Used Relative Texture
(cotton ¨ paper ¨ cellulose gum wt:wt:wt)
80% ¨ 10% ¨ 10% Softest
70% ¨ 10%¨ 20% About the same softness as 70% cotton
with
20% paper
70% ¨ 20% ¨ 10% Softer than 60% cotton
60% ¨ 20% ¨ 20% Softer than 45% cotton
45% ¨ 45% ¨ 10% Softer than 0% cotton
0% ¨ 90% ¨ 10% Hard
0% ¨ 80% ¨ 20% Hard
90% ¨ 0% ¨ 10% Not as soft as 80% cotton paper and 10%
paper
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Importantly, the Applicant did not notice any difference in the ability of the
wet composition to adhere to the surface of the interior wall when 20%
cellulose gum
was used when compared with 10% cellulose gum used. Thus, the experimental
data
suggests that using about 10% cellulose gum is just as effective as using 20%
cellulose
gum. However, Applicant noted that an increase in the cellulose gum used
resulted in a
final decorative wall covering that was not as soft as the final decorative
wall covering
when 10% of cellulose gum was used.
Furthermore, as one can see from the data above, generally, the resulting
decorative wall covering increases in softness as more cotton is used in the
formulation.
However, when 90% of cotton without paper is used, the final decorative wall
covering
is not as soft as compared to the 80% of cotton and 10% paper. Similarly,
Applicant
noted that the softness of the final decorative wall covering decreased as
more paper
was used in the dry composition.
Although further experiments are required, Applicant postulates that
beyond 80% cotton, paper is required to increase the softness of the final
decorative
wall covering.
In embodiments a method for manufacturing the dry composition consists
of providing shredded cotton by shredding cotton in a shredding machine. In an
embodiment, the shredding machine for the cotton can have two steel blades
rotating
concurrently in a clockwise direction. The distance of the blades can be
varied to
produce different sizes of the shredded cotton. In an embodiment, the cotton
shredding
machine can operate to shred at least 1,000 kg per day. In embodiments, a
variation of
the cotton shredder can be adapted and used to shred paper.
In embodiments, the method for manufacturing the dry composition further
consists of providing shredded paper and mixing the shredded cotton, shredded
paper
and the food additive in an appropriately sized container. In one embodiment,
the
shredded cotton, shredded paper, and the dry food ingredient can be mixed in a
mixing
machine for about 30 minutes, and then packaged for storage or transportation.
Applicant notes that the use of a mixing machine is recommended as the
ingredients of
the dry composition must be thoroughly mixed as to form a uniform consistency
or
homogeneity.
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In embodiments, to assist with maintaining consistency of the desired
color of the final decorative wall covering, white cotton can be dyed with
various colored
pigments using technology and methodology known in the art.
Date Recue/Received date 2020-04-09
