CA2665976C

CA2665976C - Composition for application to a surface

Info

Publication number: CA2665976C
Application number: CA 2665976
Authority: CA
Inventors: Glenn R. Frazee; Cathy A. Hinkfuss; Kameshwer Rao Yerramilli; James F. Kimball; Ketan N. Shah
Original assignee: SC Johnson and Son Inc
Current assignee: SC Johnson and Son Inc
Priority date: 2008-05-14
Filing date: 2009-05-13
Publication date: 2012-02-21
Anticipated expiration: 2029-05-13
Also published as: CA2665976A1

Abstract

Compositions, methods, apparatuses, kits, and combinations are described for permanently or temporarily re-designing, decorating, and/or re-coloring a surface. The compositions useful in the present disclosure include a decor product that is formulated to be applied and affixed to a surface. If desired, the décor product may be substantially removed from the surface before being affixed thereto. If a user desires to remove the décor product, the décor 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 décor product to the surface in a permanent or semi-permanent manner, the décor 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 décor 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 décor product to create, for example, a pattern on the surface.

Description

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.

[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 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;

[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;

[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 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 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, 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 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 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 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, 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 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 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 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 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 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 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 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.

[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 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.

[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 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 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, 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 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 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) 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 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 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 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 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 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 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.

[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 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 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 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.

[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, 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 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 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 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 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.

[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 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 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 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 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.

[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

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-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.

[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 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.

[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 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.

[00184] Table No. 7. Low Temperature Cure Polyester-TGIC Decor Particle Compositions.

Approx.
Constituents Weight %
RUCOTE 921 Polyester 54 - 63 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 Flow Additive 0.5 - 3 Degassing Agent 1 - 3 Colorant 0.3 - 25 Filler 0-20 [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 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.

[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 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.

[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.

[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 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 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.

[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 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, 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, 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-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.

[00228] Table No. 10. White Low Temperature Cure Epoxy Composition.
Constituents (wt %) KD-242G Epoxy 48 Huntsman Hardener XB 3086 10 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 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.

[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 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 Oxymelt A-2 1.05 TiO2R-960 15.
15-1101 A4R Pigment 2.5 BK 5099 0.45 BaSO4 20 [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 Oxymelt A-2 1 TiO2 RCL-6 1.18 Y IOM Iron Oxide Yellow Pigment 2.54 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.

[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 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 Oxymelt A-2 1 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.

[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 Oxymelt A-2 1 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 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.

[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 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.

[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 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.

[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 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.

[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 Actiron NXJ-60 0.5 Oxymelt A-2 1 TiO2 RCL-6 1.18 Y IOM Iron Oxide Yellow Pigment 2.54 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.

[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 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 Actiron NXJ-60 0.5 Oxymelt A-2 1 BaSO4 10 [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 Actiron NXJ-60 0.5 Oxymelt A-2 1 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 Oxymelt A-2 1 TiO2R-960 40 [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 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.

[00282] Table No. 28. Red Low Temperature Cure Polyester-TGIC Decor Particle Composition.

Constituents (wt %) Rucote 921 Polyester 54.6 TGIC 4.2 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 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 [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 Oxymelt A-2 1 Ti02 RCL-6 1.18 Y I OM Iron Oxide Yellow Pigment 2.54 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.

[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 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 Oxymelt A-2 1 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.

[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 Oxymelt A-2 1 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 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.

[00303] Table No. 35. Brown Low Temperature Cure PRIMID Decor Particle Composition.

Constituents (wt %) Crylcoat 2671-3 80.7 PRIMID XL-552 6.1 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 Oxymelt A-2 1.32 TiO2 R-960 1.2 F5RK-A Red 0.08 UMB 304 1.2 [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 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.

[00312] Table No. 38. Green Low Temperature Cure PRIMID Decor Particle Composition.

Constituents (wt %) Crylcoat 2671-3 76.5 PRIMID XL-552 5.8 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 Oxymelt A-2 1.6 TiO2 R-960 8.65 RO 8097 0.75 201Y Red 10.5 [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 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.

[00321] Table No. 41. Brown Low Temperature Cure Polyurethane Decor Particle Composition.

Constituents (wt %) Albester 3160 73.8 Alcure 4470 13 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.

[00324] Table No. 42. Burgundy Low Temperature Cure Polyurethane Decor Particle Composition.

Constituents (wt %) Albester 3160 75 Alcure 4470 13.2 Oxymelt A-2 1.33 Ti02 R-960 1 F5RK-A Red 0.07 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.

[00327] Table No. 43. Gold Low Temperature Cure Polyurethane Decor Particle Composition.

Constituents (wt %) Albester 3160 65 Alcure 4470 11.5 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 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 [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 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.

[00336] Table No. 46. Pink Low Temperature Cure Polyurethane Decor Particle Composition.

Constituents (wt %) Albester 3160 72 Alcure 4470 12.7 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 Oxymelt A-2 1.27 TiO2 R-960 5.75 BK 5099 0.5 F5RK-A Red 0.33 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 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.

[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 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.

[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.

[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 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.

Claims

1. A composition for applying a colorant to a surface, the composition comprising:
a) about 0.3 to about 13.5% by weight a fluid matrix component comprising i) about 0.1 to about 4% by weight of a rheology modifier, ii) 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, iii) about 0.05 to about 2% by weight an anticorrosive agent, iv) about 0 to about 2% by weight of a propylene glycol, and v) about 0 to about 2% by weight of a water soluble polymer;
b) about 3 to about 10% by weight substantially homogeneous particles having a mean particle size of about 35 µm to about 75 µm and comprising a colorant, an additive, and at least one of a thermoplastic or a thermoset resin; and c) a liquid carrier.

2. The composition of claim 1, wherein the rheology modifier comprises at least one of a cellulosic, a gum, a hydrophobically modified ethoxylated urethanes, a surfactant gel, a clay, a polyester, or a chitin.

3. The composition of claim 2, wherein the rheology modifier comprises a gum and a clay.

4. The composition of claim 3, wherein the composition comprises about 0.03%
to about 0.2% by weight of the gum and about 0.1% to about 3.0% by weight of the clay.

5. The composition of claim 1, wherein the composition comprises about 0.10%
to about 0.5% of the acrylic acid copolymer and about 0.05% to about 3.0% by weight of the surfactant.

6. The composition of claim 1, wherein the anticorrosive agent comprises at least one of potassium hydrogen phosphate, potassium dihydrogen phosphate, sodium nitrate, benzoic acid, or an amino alcohol.

7. The composition of claim 1, wherein the water soluble polymer comprises polyvinyl pyrrolidinone.

8. An aerosol container containing the composition of claim I and a propellant.

9. The aerosol container of claim 8 having a dispensing end connected to an aerosol valve, the aerosol valve comprising a valve stem including means for discharging the aerosol product downward through the valve stem when the dispensing end of the container is directed downward, the valve stem comprising an inlet end connected to a mesh filter having a pore size at least as large as an average diameter of the substantially homogeneous particles.

10. The aerosol container of claim 9, wherein the pore size ranges from about to about 500 microns.

11. The aerosol container of claim 10, wherein the particles size of the substantially homogeneous particles range from about 40 microns to about 60 microns.

12. The composition of claim 1, wherein the at least one of the thermoplastic or thermoset resin comprises at least one of an epoxy, a polyester, a styrene-butadiene copolymer, a polyurethane, a styrene-acrylate, or an acrylic.

13. The composition of claim 12, wherein the at least one of the thermoplastic or thermoset resin has a melting point less than a melting point of the surface.

14. The composition of claim 1, wherein the substantially homogeneous particles further comprise at least one of a catalyst, a co-reactant, an accelerant, a cross-linking agent, or a curative.

15. A suspension for applying a colorant to a surface, the suspension comprising:
a) a fluid matrix comprising about 0.1 to about 4% by weight of a rheology modifier comprising at least one of a cellulosic, a gum, a hydrophobically modified ethoxylated urethanes, a surfactant gel, a clay, a polyester, and a chitin, 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;
b) about 3 to about 10% by weight substantially homogeneous particles for suspension within the matrix, the substantially homogeneous particles having a mean particle size of about 35 µm to about 75 µm and comprising 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; and c) a liquid carrier.

16. The suspension of claim 15, wherein the substantially homogeneous particles comprise at least one of:
a) the epoxy resin that comprises at least one of an epoxy equivalent weight of about 650 to about 900, a glass transition temperature from about 45°C to about 75°C, and an ICI
cone and plate viscosity at 150°C of about 5 to about 100 poises;
b) the acid-terminated polyester that comprises at least one of an acid number range of about 30 to about 90, a combining weight of about 1400 to about 1900, a glass transition temperature from about 45°C to about 70°C, and an ICI cone and plate viscosity at 200°C of about 15 to about 50 poises;
c) an epoxy resin to curative ratio that ranges from about 82-84 to about 18-16;
d) an epoxy resin to acid-terminated polyester ratio that ranges from about 45-55 to about 55-45; and e) an acid-terminated polyester resin to curative ratio that ranges from about 90-95 to about 10-5.

17. The suspension of claim 15, wherein the particle, on a weight percentage basis, coinprises at least one of:

a) about 40% to about 55% of an epoxy resin, about 5% to about 15% of a curative, about 8% to about 42% of a colorant; and about 0.5% to about 35% of an additive;
b) about 48% to about 50% of an epoxy resin, about 9% to about 12% of a curative, about 9% to about 40% of a colorant, and about 2% to about 32% of an additive;
c) about 25% to about 30% of an epoxy resin, about 25% to about 30% of a polyester resin, about 8% to about 40% of a colorant, and about 0.5% to about 35% of an additive;
d) about 28.5% to about 30% of an epoxy resin, about 29% to about 30% of a polyester resin, about 9% to about 40% of a colorant, and about 2% to about 33% of an additive;
e) about 50% to about 60% of a polyester resin, about 3% to about 5% of a curative, about 8% to about 40% of a colorant, and about 0.5% to about 35% of an additive; and f) about 54% to about 56% of a polyester resin, about 3.75% to about 4.5% of a curative, about 9% to about 40% of a colorant, and about 2% to about 33% of an additive.

18. A kit comprising the suspension of claim 15 and an aerosol container that comprises a dispensing end connected to an aerosol valve, the aerosol valve comprising a valve stem including means for discharging the aerosol product downward through the valve stem when the dispensing end of the container is directed downward, the valve body comprising an inlet end connected to a mesh filter having a pore size at least as large as an average diameter of the substantially homogeneous particles.

19. The kit of claim 18, wherein the aerosol container further comprises a propellant.

20. A composition for applying a colorant to a surface, the composition comprising:
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.