AU745256B2 - Coating compositions - Google Patents

Description

1- P/00/011 Regulation 3.2 0 00 a00 00 00 0@OS 0 S 0. 0 COMMONWEALTH OF AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT Name of Applicant: Actual Inventor(s): Address for Service: Invention Title: GIANCARLO ANTONIO VILLANI GIANCARLO ANTONIO VILLANI

AHEARVS

Patent Trade Mark Attorneys, GPO Box 1149 Brisbane Queensland 4001 "COATING COMPOSITIONS" The following statement is a full description of this invention, including the best method of performing it known to me: "COATING COMPOSITIONS" THIS INVENTION relates to coating compositions, and it has more particular reference to coating compositions and processes for applying same, especially but not exclusively, to architectural mouldings.

For close to a decade the building industry has welcomed the use of polystyrene mouldings, coated for strength and protection purposes, in a wide variety of structures and for a wide variety of purposes. The polystyrene is obtained in o o• S" blocks of substantially rectangular form, typically about 2.4 metres long and of the same width, with a thickness of say 1.2 ooo *gig metres. The blocks are subjected to computer-controlled 15 cutting by hot-wire or a hot laser beam to provide mouldings which are eminently suitable for affixing by adhesive to a suitable background substrate, or the moulding could be

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S secured by nails or other penetrable fasteners. Preferably the mouldings are brought to the site 'after a protective @600 coating has been applied, but if penetrable fasteners are used oot S at the site, the attachment points may be patched and covered by the selected coating material subsequent to being fixed in @5 0 place.

The present invention is concerned with coating compositions and application methods particularly suitable for such architectural mouldings, and accordingly the invention will be described in relation thereto, but it is to be understood that this is illustrative only and that diverse applications can be involved in multiple industries as will be hereinafter apparent.

At the present time, conventional mouldings in the marketplace use polystyrene as the base material for creating -3the mould design which is then coated with polyurethane, for example, to create the final product. However, a number of disadvantages arise from the use of polyurethane and other coatings as currently practised. For example, all such coatings are of plastic or rubber-like form exhibiting a greater degree of softness than is thought desirable. Also, the coating compositions have characteristics which necessitate application of an etching primer prior to the final products being applied, such as paints, granosite or acrylic-based products. Then again, with the known plastic coatings, expansion and contraction of the moulding can lead e g.

to problems after a period of time, and in some cases the 0O*O coating layer may delaminate from the mould product which has S been glued to the substrate or other background material to which the moulding is affixed.

In the absence of efficient coating compositions, delamination between the polystyrene and polyurethane will become a problem when weather conditions take their toll. A further current disadvantage is that not inconsiderable materials cost and application expenses are involved with the S use of polyurethane coatings, while achieving only moderate efficiency.

The present invention has been devised to alleviate at least one of the aforementioned problems as currently encountered with known coating compositions, particularly but not exclusively in relation to architectural mouldings, and it has for its principal object the provision of a coating composition which can be applied as a desirably small thickness of coating and yet will be stronger than in the past and will be more efficient also in other respects. Another f~-l^-ui -c r-r -4object of the invention is to provide a coating composition of the character described which is eminently suitable for polystyrene mouldings, but alternatively could be applied to composite board, papier-mach6, paper pulp mass, fibreglass fabric or cotton content mass, timber strips or wooden compounds, metals, gypsum, and particulate boards of plastic, rubber or concrete, or even to brickwork. The particular characteristics of the present invention, differentiating it from the aforementioned disadvantages of the prior art, will be enumerated after the following descriptions.

With the foregoing and other objects in view, the g: invention resides broadly, according to one aspect thereof, in a coating composition in comprised iin a mixture of sand or eoe.

equivalent material, standard quality cement, water, and an acrylic, polymer-based resin comprising: by volume water based copolymer emulsion of polyvinyl acetate with versatate and/or acrylic copolymers in a water emulsion and having as one of its components 2-methyl-2,4pentanediol; ooooo 20 10% water soluble colloid protector; additives; such that the resin obtains a specific gravity in the range of 1000 50 g/l and an 8 Ford viscosity at 20'C of 7 1; the mixture having the following ratios: for every kilogram of sand: more than 20 volume per cent (vol%) cement; less than 12 vol% water; and more than 20 vol% resin; such that the ratio of resin to water is more than four uFItpone, and the ratio of resin to cement is less than two to

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0 '*FlC, -4a- For example, the acrylic polymer based resin identified by the trade mark "JOLLY FIX" as the product of Colorificio A.

B. Casati S.p.A. of Verona, Italy, having their Product Code 109001, and having as one of its components 2-methyl-2,4pentanediol, is one example of the resin described.

In one embodiment, the coating composition may be formulated without the water, but it is preferred that the water is more than 4 vol% of the sand.

In one practical example, the aforementioned ingredients are used in the proportions by volume of 5 litres of resin r r ,U .S -rOFFp~ V.- ("JOLLY FIX" as hereinbefore described); 4 litres of cement, kg (12 litres) of sand and 400 mis of water. However, in other Examples, the material formulation by volume ranges within the following: Resin: 5 litres (plus 300% down to less Cement: 4 litres (plus 100% down to less or further down to none at all) Sand: 12 litres (plus 100% down to less and Water: 300-500 mis (plus or minus 100%), all .depending on the temperature as described.

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**go The ingredients may be mixed in any suitable container, *6S@ such as of metal or plastics material, the easiest procedure being to place the resin and water in the container and cause these to be mixed by stirring steadily, adding the cement and S sand progressively, such as in a standard concrete mixer.

However, provided thorough mixing is ensured, all ingredients e g.

could be added simultaneously to the container. The mixed 20 product should be used without being stored since it contains o oo Sa cement component and will set in a reasonably short period ioo S of time, such as 12 hours when in mixed bulk form. However, if a film of water is placed over the product in a container, it may be stored overnight for example, being able to be remixed manually and used without loss of efficiency.

The mixed product can be applied to the mouldings as later described, and thus in most cases the already-coated mouldings are brought to the building site and applied to the substrate material. However, if desired, the coating could be applied at the site after the moulding has been affixed. It will thus be apparent that the product can be used also as a patching compound, covering marks left by penetrable fasteners when such procedures are called for, and also usable for repair purposes in the event of damage to a moulding or the unlikely event of delamination occurring. The composition may be used as a filler if repairs are needed to existing mouldings, even if such existing mouldings were manufactured in accordance with the prior art.

The cement used may be any type of standard quality cement, but it has been found that standard Portland cement, *ivory or white, is effective. The sand used is preferably beach sand which is quite fine, but any sand-like substitute ***could be used, provided it has a generally comparable grain Xe*:size. It will be apparent that the key component is the resin 1 5 product, and this may be used in the commercial form in which it may be purchased from the Italian company, Colorificio A. S:B. Casati S. p. A. of Verona, Italy, put out under the trade mark "JOLLY FIX" and identified by the Product Cods 109001. The .:.:product information identifies the product further as containing "2-metil-2,4-pentandiolo" (that is 2-methyl-2,4pentanediol, or hexylene glycol). This product is an acrylic, :polymer-based liquid resin (or powdered form if desired) currently sold in 16 litre containers, designed for use as a masonry sealer, the normal instructions being to dilute the product with water and then paint it over the masonry for sealing purposes. Its use in the present invention, with unexpected results, and in novel proportions, is considered both novel and inventive in meeting a new demand with most desirable characteristics. It will of course be appreciated that a further feature of the invention lies in the use of any -7chemically equivalent substitute in lieu of the "JOLLY FIX" resin as will be apparent to persons skilled in the art.

The coating technique will now be described as applied to a polystyrene moulding, and in f act manual spraying may be employed, or mechanical spraying, or the mouldings may be dipped, or the coating material could be trowelled on, or brushed on or sponged on. Preferably there is used a manual spray action employing a hand-held, standard domestic or industrial hopper gun, spraying being arranged at various 10 degrees and angles depending upon the size and shape of the moulding. This can be achieved by forward and backward movement alternately in the longitudinal direction of the 0*earticle or by circular rotation progressively in a spiral or equivalent circular-type motion until the desired thickness of coating has been attained. The operator may incorporate airflow pressure and hand-trigger adjustment of the hopper gun to *:create the desired steady flow and ensure evenness of coating to the polystyrene, the pressure in the compressor for *:.:spraying purposes being about 2.8 1.4 MPa (400 200 psi).

It will be appreciated that the coating composition can *be applied to any of the objects previously mentioned, but it is eminently suitable for polystyrene mouldings or equivalent articles such as composite board or timber products. The coating will be found to have greatly increased strength because of its formulation, and thus it meets the present demand for coated polystyrene mouldings which will present harder surfaces and be more resistant to denting. The durability of the coating will be less affected by weather conditions than in the past, for a similar period of time.

Because the coating composition is light in weight yet strong in durability, the coating thickness can be as small as 0.05 mm, but the preferred thickness is 1 mm to 2 mm, and sometimes up to 10 mm or more where filling is required, preferably applied in successive operations spaced in time.

While the coatings are light in weight, they give a solid, more cement-like appearance in the final product. There can be a price saving to the consumer since less material is applied for comparable results, while there is the major advantage that delamination should not occur with these .'ID compositions. Most importantly, no primer will be required for adequate adhesion and the resultant product will be found o to offer good water-resistance characteristics.

In an alternative embodiment, the coating composition of S: the present invention may be as formulated as first defined above, but without sand.

In order that the present invention may be more readily *00g understood and put into practical effect, reference will now be made to a working example which illustrates one preferred embodiment of the invention.

20 EXAMPLE: O•6o eO The best performing composition in accordance with the present invention, known at the time of filing this application is as follows. 2 bags of sand, each of 25 kg, were poured into a revolving cement mixer. To the sand was added an amount of approximately 10 litres of Portland cement, followed by 2 litres of water. After mixing these components thoroughly, 11 litres of "JOLLY FIX" resin as hereinbefore described were added, and mixed thoroughly to form a coating composition.

The coating composition was applied to architectural

Claims (5)

1. A coating composition in comprised in a mixture of sand or equivalent material, standard quality cement, water, and an acrylic, polymer-based resin comprising: by volume water based copolymer emulsion of polyvinyl acetate with versatate and/or acrylic copolymers in a water emulsion and having as one of its components 2-methyl-2,4- pentanediol; 10% water soluble colloid protector; 5% additives; such that the resin obtains a specific gravity in the range of 1000 50 g/l and an 8 Ford viscosity at 20°C of 7 1; said mixture having the following ratios: for every kilogram of sand: more than 20 volume per cent (vol%) cement; less than 12 vol% water; and more than 20 vol% resin; such that the ratio of resin to water is more than four to one, and the ratio of resin to cement is less than two to one.

2. A coating composition according to claim 1, but without water added to said mixture.

3. A coating composition according to claim 1, wherein the water added to said mixture is at least 4 vol% of the sand.

4. A coating composition according to claim 1, wherein the jmixture comprises 2 bags of sand, each of 25 kg, added to a evolving cement mixer; approximately 0 litres of Portland Pevolving cement mixer; approximately 10 litres of Portland r i-l-~i i lr~- ~j~LIII~-Cl~i~:jl-i~ll cement added to the sand in the revolving cement mixer, followed by 2 litres of water added to the revolving cement mixer, followed after being thoroughly mixed by 11 litres of resin being added, and mixed thoroughly to form a coating composition. A coating composition having the material formulation by volume range within the following:- Resin: 5 litres (plus 300% down to less Cement: 4 litres (plus 100% down to less or further down to none at all) Sand: 12 litres (plus 100% down to less "•and ••go Water:

300-500 mls (plus or minus 100%), 85% by volume water based copolymer emulsion of polyvinyl S acetate with versatate and/or acrylic copolymers in a water emulsion and having as one of its components 2-methyl-2,4- pentanediol; eoee 10% water soluble colloid protector; 5% additives; such that the resin obtains a specific gravity in the range of 1000 50 g/l and an 8 Ford viscosity at 20 0 C of 7 i. 6. An architectural moulding when coated by a coating composition according to any one of claims 1 to 7. An architectural moulding when coated by a coating composition as substantially hereinbefore described with reference to any one of the examples. -11- 8. A coating composition according to claim 1, but without the sand. Dated this 18th day of January, 2002 GIANCARLO ANTONIO VILLANI By his Patent Attorneys AHEARN FOX