US20130230655A1 - Particulate Materials for Acoustic Texture Material - Google Patents
Particulate Materials for Acoustic Texture Material Download PDFInfo
- Publication number
- US20130230655A1 US20130230655A1 US13/864,104 US201313864104A US2013230655A1 US 20130230655 A1 US20130230655 A1 US 20130230655A1 US 201313864104 A US201313864104 A US 201313864104A US 2013230655 A1 US2013230655 A1 US 2013230655A1
- Authority
- US
- United States
- Prior art keywords
- base portion
- acoustic texture
- texture material
- particulate
- acoustic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000463 material Substances 0.000 title claims abstract description 121
- 239000011236 particulate material Substances 0.000 title description 13
- 239000003380 propellant Substances 0.000 claims abstract description 37
- 239000000443 aerosol Substances 0.000 claims abstract description 25
- 239000002245 particle Substances 0.000 claims abstract description 17
- 239000011248 coating agent Substances 0.000 claims abstract description 15
- 238000000576 coating method Methods 0.000 claims abstract description 15
- 230000009969 flowable effect Effects 0.000 claims abstract description 12
- 239000006260 foam Substances 0.000 claims abstract description 12
- 229920000877 Melamine resin Polymers 0.000 claims abstract description 10
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 claims abstract description 10
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000012071 phase Substances 0.000 claims description 20
- 238000000034 method Methods 0.000 claims description 5
- 239000007791 liquid phase Substances 0.000 claims description 4
- 230000001788 irregular Effects 0.000 claims description 3
- 239000004793 Polystyrene Substances 0.000 description 8
- 229920002223 polystyrene Polymers 0.000 description 8
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 6
- 239000012530 fluid Substances 0.000 description 6
- 239000011261 inert gas Substances 0.000 description 5
- 239000004215 Carbon black (E152) Substances 0.000 description 4
- 238000013459 approach Methods 0.000 description 4
- 239000006261 foam material Substances 0.000 description 4
- 229930195733 hydrocarbon Natural products 0.000 description 4
- 150000002430 hydrocarbons Chemical class 0.000 description 4
- 239000007788 liquid Substances 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 230000000881 depressing effect Effects 0.000 description 2
- 239000007792 gaseous phase Substances 0.000 description 2
- 229920006327 polystyrene foam Polymers 0.000 description 2
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- 241000482268 Zea mays subsp. mays Species 0.000 description 1
- 239000004479 aerosol dispenser Substances 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- IAQRGUVFOMOMEM-UHFFFAOYSA-N but-2-ene Chemical group CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 235000013305 food Nutrition 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 238000009432 framing Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
- E04B1/84—Sound-absorbing elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D83/00—Containers or packages with special means for dispensing contents
- B65D83/14—Containers or packages with special means for dispensing contents for delivery of liquid or semi-liquid contents by internal gaseous pressure, i.e. aerosol containers comprising propellant for a product delivered by a propellant
- B65D83/28—Nozzles, nozzle fittings or accessories specially adapted therefor
- B65D83/30—Nozzles, nozzle fittings or accessories specially adapted therefor for guiding the flow of spray, e.g. funnels, hoods
- B65D83/306—Actuators formed as a rigid elongate spout
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
- B05D1/12—Applying particulate materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D83/00—Containers or packages with special means for dispensing contents
- B65D83/14—Containers or packages with special means for dispensing contents for delivery of liquid or semi-liquid contents by internal gaseous pressure, i.e. aerosol containers comprising propellant for a product delivered by a propellant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D83/00—Containers or packages with special means for dispensing contents
- B65D83/14—Containers or packages with special means for dispensing contents for delivery of liquid or semi-liquid contents by internal gaseous pressure, i.e. aerosol containers comprising propellant for a product delivered by a propellant
- B65D83/44—Valves specially adapted therefor; Regulating devices
- B65D83/48—Lift valves, e.g. operated by push action
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D83/00—Containers or packages with special means for dispensing contents
- B65D83/14—Containers or packages with special means for dispensing contents for delivery of liquid or semi-liquid contents by internal gaseous pressure, i.e. aerosol containers comprising propellant for a product delivered by a propellant
- B65D83/75—Aerosol containers not provided for in groups B65D83/16 - B65D83/74
- B65D83/752—Aerosol containers not provided for in groups B65D83/16 - B65D83/74 characterised by the use of specific products or propellants
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/02—Coverings or linings, e.g. for walls or ceilings of plastic materials hardening after applying, e.g. plaster
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F21/00—Implements for finishing work on buildings
- E04F21/02—Implements for finishing work on buildings for applying plasticised masses to surfaces, e.g. plastering walls
- E04F21/06—Implements for applying plaster, insulating material, or the like
- E04F21/08—Mechanical implements
- E04F21/12—Mechanical implements acting by gas pressure, e.g. steam pressure
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- Y10T428/24372—Particulate matter
- Y10T428/24405—Polymer or resin [e.g., natural or synthetic rubber, etc.]
Definitions
- the present invention relates to particulate materials for use in acoustic texture material and, more particularly, to particulate materials that may be used in acoustic texture material formulated to be dispensed from aerosol dispensers.
- Interior walls are formed by sheets of drywall material that are secured to the framing of a building.
- the seams between adjacent sheets of drywall material are taped, mudded, and sanded to obtain a substantially flat, smooth drywall surface.
- the drywall surface is coated with primer and paint to obtain a finished surface.
- a separate texture layer is applied to the drywall surface prior to painting.
- the texture layer is formed by spraying texture material onto the drywall surface.
- Texture material is a coating material that, when sprayed, does not form a smooth, thin coating. Instead, texture material is applied in discrete drops or globs that dry to form a bumpy, irregular textured surface.
- Texture materials can be applied using any one of a number of application systems. During new construction, texture materials are commonly applied in a stream of compressed air using commercial hopper gun systems. For touch up or repair, texture material is commonly applied using hand operated pneumatic pumps or aerosol dispensing systems. Varying the parameters of the application system varies the size and spacing of the bumps to vary the look of the textured surface.
- acoustic texture material is commonly referred to as “acoustic” or “popcorn” texture material.
- acoustic texture material further comprises an aggregate material.
- the aggregate material is conventionally formed by polystyrene chips.
- chips made of polystyrene foam are dissolved by hydrocarbon aerosol propellant materials.
- aerosol dispensing systems for dispensing small amounts of acoustic texture material for repair or touch-up purposes use one of two approaches.
- the first approach is to mix a liquid hydrocarbon aerosol propellant material with chips made from materials other than polystyrene.
- chips made of materials other than polystyrene foam are used, the appearance and function of the texture surface may be different from that of the surrounding surface.
- the second approach is to combine polystyrene chips with a propellant material formed by a pressurized inert gas such as nitrogen or air.
- a pressurized inert gas such as nitrogen or air.
- This second approach allows the use of a conventional acoustic texture material including polystyrene chips.
- a pressurized inert gas causes the acoustic texture material to be dispensed very quickly.
- the use of pressurized inert gas as a propellant can make it difficult for a non-professional to control the application of the acoustic texture material.
- the present invention may be embodied as an acoustic texture material adapted to be dispensed from an aerosol assembly using bi-phase propellant materials to form a textured coating on drywall material such that the textured coating substantially matches a pre-existing acoustic texture material on the drywall material.
- the acoustic texture material has a base portion capable of existing in a flowable state and a hardened state and a particulate portion comprising discrete particles that are visible to an unaided eye.
- the particulate portion is comprised of at least one of urethane foam and melamine foam.
- the base portion is capable of securing the particles to the drywall material when the base portion is in the hardened state.
- the present invention may also be embodied as a method of using an aerosol assembly to form a textured coating on a drywall material such that the textured coating substantially matches a pre-existing acoustic coating on the drywall material comprising the following steps.
- a base portion is provided in a flowable state.
- a particulate portion comprising discrete particles of at least one of urethane foam and melamine foam is provided. The discrete particles are visible to the unaided eye.
- a bi-phase propellant material formulated not to dissolve the discrete particles is provided. The base portion in the flowable state, the particulate portion, and the bi-phase propellant are arranged within the aerosol assembly.
- the aerosol assembly is operated such that a portion of the bi-phase propellant material forces the base portion in the flowable state and the particulate portion out of the aerosol assembly and onto the drywall material.
- the base portion is allowed to form a hardened state in which the base portion secures the discrete particles to the drywall material.
- FIG. 1 is a section view of a first embodiment of an aerosol dispensing system containing acoustic texture material incorporating particulate material of the present invention
- FIG. 2 is a section view of a second embodiment of an aerosol dispensing system containing acoustic texture material incorporating particulate material of the present invention
- FIG. 3 is an elevation view depicting the use of one or both of the first and second aerosol dispensing systems of FIGS. 1 and 2 being used to deposit acoustic texture material to a surface;
- FIG. 4 is a section view of the acoustic texture material after it has been deposited on the surface.
- FIGS. 5 and 6 are bottom plan views of the surface before and after the acoustic texture material has been deposited thereon.
- FIG. 1 of the drawing depicted at 20 a therein is a first embodiment of an aerosol system for depositing on a surface 22 ( FIGS. 3-6 ) acoustic texture material 24 incorporating particulate material 26 of the present invention.
- FIG. 5 illustrates a target portion 28 of the surface 22 on which acoustic texture material 24 is to be deposited.
- the example aerosol system 20 a comprises a container assembly 30 , a valve assembly 32 , a collection assembly 34 , and an outlet assembly 36 .
- the container 30 defines a product chamber 40 in which the acoustic texture material 24 comprising the particulate material 26 is contained.
- a first portion 42 of the chamber 40 is occupied by the acoustic texture material 24
- a second portion 44 of the chamber 40 is occupied by a pressurized propellant material 46 .
- the example container assembly 30 comprises a can member 50 and a cup member 52 .
- the valve assembly 32 is mounted in a cup opening 34 define by the cup member 52 and operates in a closed configuration (shown) and an open configuration. In the open configuration, the valve assembly 32 defines a dispensing passageway that allows fluid communication between the interior and the exterior of the container assembly 30 .
- the outlet assembly 36 comprises an actuator member 60 that causes acoustic texture material 24 to be dispensed by the system 20 in a fan shaped spray as will be described in further detail below.
- the actuator member 60 is mounted on the valve assembly 32 such that displacing the outlet member 60 towards the valve assembly 32 places the valve assembly in the open configuration.
- the example valve assembly 32 comprises a valve seat 70 , a valve stem 72 , a valve housing 74 , a dip tube 76 , and a valve spring 78 .
- the valve seat 70 defines a seat opening 70 a and is supported by the cup member 52 .
- the valve stem 72 defines a valve stem opening 72 a and a valve surface 72 b .
- the valve stem 72 is supported by the valve seat 70 such that the valve stem moves within the valve stem opening 72 a between first and second positions, with the first position being shown in FIG. 1 .
- the valve housing 74 is supported by the valve seat 70 within the product chamber 40 .
- the valve housing 74 further supports the dip tube 76 such that the acoustic texture material 24 within can flow into the valve housing 74 when the can is upright.
- the valve spring 78 is supported by the valve housing 74 such that the spring 78 biases the valve stem 72 into the first position.
- the valve stem 72 supports the outlet assembly 36 such that depressing the actuator member 60 towards the cup member 52 forces the valve stem 72 into the second position (not shown) against the force of the valve spring 78 .
- the valve assembly 32 thus operates in the closed configuration and the open configuration as follows.
- the valve spring 78 forces the valve surface 72 b against the valve seat 70 to prevent fluid from flowing through the valve stem opening 72 a .
- the valve surface 72 b is forced away from the valve seat 70 such that fluid can flow from the interior of the valve housing 74 through the valve stem opening 72 a and thus out of the product chamber 40 .
- FIG. 2 of the drawing depicted at 20 b therein is a first embodiment of an aerosol system that may also be used to deposit the acoustic texture material 24 incorporating particulate material 26 of the present invention on the target portion 28 of the surface 22 .
- the example aerosol system 20 b comprises a container assembly 130 , a valve assembly 132 , a collection assembly 134 , and an outlet assembly 136 .
- the container 130 defines a product chamber 140 in which the acoustic texture material 24 comprising the particulate material 26 is contained.
- a first portion 142 of the chamber 140 is occupied by the acoustic texture material 24
- a second portion 144 of the chamber 140 is occupied by a pressurized propellant material 146 .
- the example container assembly 130 comprises a can member 150 and a cup member 152 .
- the valve assembly 132 is mounted in a cup opening 134 define by the cup member 152 and operates in a closed configuration (shown) and an open configuration. In the open configuration, the valve assembly 132 defines a dispensing passageway that allows fluid communication between the interior and the exterior of the container assembly 130 .
- the outlet assembly 136 comprises an actuator member 160 that causes acoustic texture material 24 to be dispensed by the system 20 in a fan shaped spray as will be described in further detail below.
- the actuator member 160 is mounted on the valve assembly 132 such that displacing the outlet member 160 towards the valve assembly 132 places the valve assembly in the open configuration.
- the example valve assembly 132 comprises a valve seat 170 , a valve stem 172 , a valve housing 174 , a dip tube 176 , and a valve spring 178 .
- the valve seat 170 defines a seat opening 170 a and is supported by the cup member 152 .
- the valve stem 172 defines a valve stem opening 172 a and a valve surface 172 b .
- the valve stem 172 is supported by the valve seat 170 such that the valve stem moves within the valve stem opening 172 a between first and second positions, with the first position being shown in FIG. 1 .
- the valve housing 174 is supported by the valve seat 170 within the product chamber 140 .
- the valve housing 174 further supports the dip tube 176 such that the acoustic texture material 124 within can flow into the valve housing 174 when the can is upright.
- the valve spring 178 is supported by the valve housing 174 such that the spring 178 biases the valve stem 172 into the first position.
- the valve stem 172 supports the outlet assembly 136 such that depressing the actuator member 160 towards the cup member 152 forces the valve stem 172 into the second position (not shown) against the force of the valve spring 178 .
- the valve assembly 132 thus operates in the closed configuration and the open configuration as follows.
- the valve spring 178 forces the valve surface 172 b against the valve seat 170 to prevent fluid from flowing through the valve stem opening 172 a .
- the valve surface 172 b is forced away from the valve seat 170 such that fluid can flow from the interior of the valve housing 174 through the valve stem opening 172 a and thus out of the product chamber 140 .
- FIGS. 3-6 the use of the aerosol dispensing systems 20 a and 20 b will now be described in further detail. These dispensing systems 20 a and 20 b are used in the same manner and are both identified by reference character 20 in FIGS. 3-6 .
- the dispensing system 20 deposits a fan-shaped spray of acoustic texture material 24 on the target portion 28 of the wall 22 .
- the acoustic texture material 24 covers the target portion 28 to match the pre-existing acoustic texture material on the surface 22 surrounding the target portion 28 .
- the acoustic texture material comprises a base portion 220 in the form of a flowable liquid.
- the base portion 220 of the particulate material conventionally comprises a carrier, a filler, and a binder.
- the propellant material 46 , 146 is simply an inert pressurized gas such as air or nitrogen.
- the propellant material 46 , 146 is a material, referred to herein as bi-phase propellant material, that exists in both gaseous and liquid phases within the container assembly 30 , 130 .
- the liquid phase of the propellant material 46 , 146 forms a part of the base portion 220 , while the gaseous phase propellant material 46 , 146 occupies the pressurized portion 44 of the container assembly 30 , 130 .
- the pressure within the pressurized portion 44 , 144 of the container assemblies 30 , 130 drops. Under these conditions, a portion of the bi-phase propellant material 46 , 146 in the liquid phase gasifies to re-pressurize the pressurized portion 44 , 144 of the container assembly 30 , 130 .
- the pressure within the pressurized portion 44 , 144 is thus under most conditions sufficient to force the acoustic texture material 24 out of the container assembly 30 , 130 along the dispensing passageway when the valve assembly 32 , 132 is in the open configuration.
- the propellant material 46 , 146 may thus be a pressurized inert gas such as air or nitrogen.
- the present invention is of particular significance when the propellant material is a bi-phase propellant material such as di-methyl ethylene (DME) or any one of a number of hydrocarbon propellants such as those available in the industry as A-40 and A-70.
- the advantage of using bi-phase propellant materials is that the pressure within the pressurized portion 44 , 144 of the container assembly 30 , 130 is kept at a relatively constant, relatively low level as the level of acoustic texture material 24 drops. This constant, low level pressure allows the texture material 24 to be dispensed in many small bursts instead of in a few large bursts, as is the case when pressurized inert gases are used as the propellant material 46 , 146 .
- particulate materials 26 suitable for use in acoustic texture materials are incompatible with bi-phase propellant materials.
- polystyrene chips are commonly used in acoustic texture materials dispensed using commercial hopper guns.
- polystyrene chips dissolve in the bi-phase propellant materials of which the Applicant is aware.
- urethane foam materials and melamine foam materials may be used as the particulate material 26 with bi-phase propellant materials such as DME and hydrocarbon propellants such as A-40 and A-70.
- Melamine foam materials in particular are easily chopped up using conventional material processors (e.g., a food blender) into irregular shapes that match the appearance and function of polystyrene chips.
- material processors e.g., a food blender
- Melamine foam materials are already commonly used in building applications and have desirable fire retardant, thermal, and acoustic properties.
- the base portion 220 may be the same as a conventional base used in commercially available acoustic texture materials. Instead of polystyrene chips, however, urethane and/or melamine foam is chopped up into particles of an appropriate size and use as the particulate. In addition, a bi-phase propellant material is used to form part of the carrier portion of the base portion 220 .
Abstract
An acoustic texture material adapted to be dispensed from an aerosol assembly using bi-phase propellant materials to form a textured coating on drywall material such that the textured coating substantially matches a pre-existing acoustic texture material on the drywall material. The acoustic texture material has a base portion capable of existing in a flowable state and a hardened state and a particulate portion comprising discrete particles that are visible to an unaided eye. The particulate portion is comprised of at least one of urethane foam and melamine foam. The base portion is capable of securing the particles to the drywall material when the base portion is in the hardened state.
Description
- This application, (Attorney's Ref. No. P217346) is a continuation of U.S. patent application Ser. No.13/114,954 filed May 24, 2011.
- U.S. patent application Ser. No. 13/114,954 is a continuation of U.S. patent application Ser. No. 11/982,134 filed Oct. 31, 2007, now U.S. Pat. No. 7,947,753 which issued May 24, 2011.
- U.S. patent application Ser. No. 11/982,134 is a continuation of U.S. patent application Ser. No. 11/027,219 filed Dec. 29, 2004, now U.S. Pat. No. 7,374,068 which issued May 20, 2008.
- U.S. patent application Ser. No. 11/027,219 claims benefit of U.S. Provisional Patent Application Ser. No. 60/617,236 filed Oct. 8, 2004.
- All related applications cited in this Related Applications section, including the subject matter thereof, are incorporated herein by reference.
- The present invention relates to particulate materials for use in acoustic texture material and, more particularly, to particulate materials that may be used in acoustic texture material formulated to be dispensed from aerosol dispensers.
- Interior walls are formed by sheets of drywall material that are secured to the framing of a building. The seams between adjacent sheets of drywall material are taped, mudded, and sanded to obtain a substantially flat, smooth drywall surface. The drywall surface is coated with primer and paint to obtain a finished surface.
- In some situations, a separate texture layer is applied to the drywall surface prior to painting. The texture layer is formed by spraying texture material onto the drywall surface. Texture material is a coating material that, when sprayed, does not form a smooth, thin coating. Instead, texture material is applied in discrete drops or globs that dry to form a bumpy, irregular textured surface.
- Texture materials can be applied using any one of a number of application systems. During new construction, texture materials are commonly applied in a stream of compressed air using commercial hopper gun systems. For touch up or repair, texture material is commonly applied using hand operated pneumatic pumps or aerosol dispensing systems. Varying the parameters of the application system varies the size and spacing of the bumps to vary the look of the textured surface.
- One specific form of texture material is commonly referred to as “acoustic” or “popcorn” texture material. In addition to a coating material, acoustic texture material further comprises an aggregate material. When the acoustic texture material is applied using commercial hopper guns, the aggregate material is conventionally formed by polystyrene chips. However, as will be described in detail below, chips made of polystyrene foam are dissolved by hydrocarbon aerosol propellant materials.
- Accordingly, aerosol dispensing systems for dispensing small amounts of acoustic texture material for repair or touch-up purposes use one of two approaches. The first approach is to mix a liquid hydrocarbon aerosol propellant material with chips made from materials other than polystyrene. However, when chips made of materials other than polystyrene foam are used, the appearance and function of the texture surface may be different from that of the surrounding surface.
- The second approach is to combine polystyrene chips with a propellant material formed by a pressurized inert gas such as nitrogen or air. This second approach allows the use of a conventional acoustic texture material including polystyrene chips. However, the use of a pressurized inert gas causes the acoustic texture material to be dispensed very quickly. The use of pressurized inert gas as a propellant can make it difficult for a non-professional to control the application of the acoustic texture material.
- The need thus exists for improved systems and methods for dispensing small quantities of acoustic texture material for the purpose of touch-up or repair.
- The present invention may be embodied as an acoustic texture material adapted to be dispensed from an aerosol assembly using bi-phase propellant materials to form a textured coating on drywall material such that the textured coating substantially matches a pre-existing acoustic texture material on the drywall material. The acoustic texture material has a base portion capable of existing in a flowable state and a hardened state and a particulate portion comprising discrete particles that are visible to an unaided eye. The particulate portion is comprised of at least one of urethane foam and melamine foam. The base portion is capable of securing the particles to the drywall material when the base portion is in the hardened state.
- The present invention may also be embodied as a method of using an aerosol assembly to form a textured coating on a drywall material such that the textured coating substantially matches a pre-existing acoustic coating on the drywall material comprising the following steps. A base portion is provided in a flowable state. A particulate portion comprising discrete particles of at least one of urethane foam and melamine foam is provided. The discrete particles are visible to the unaided eye. A bi-phase propellant material formulated not to dissolve the discrete particles is provided. The base portion in the flowable state, the particulate portion, and the bi-phase propellant are arranged within the aerosol assembly. The aerosol assembly is operated such that a portion of the bi-phase propellant material forces the base portion in the flowable state and the particulate portion out of the aerosol assembly and onto the drywall material. The base portion is allowed to form a hardened state in which the base portion secures the discrete particles to the drywall material.
-
FIG. 1 is a section view of a first embodiment of an aerosol dispensing system containing acoustic texture material incorporating particulate material of the present invention; -
FIG. 2 is a section view of a second embodiment of an aerosol dispensing system containing acoustic texture material incorporating particulate material of the present invention; -
FIG. 3 is an elevation view depicting the use of one or both of the first and second aerosol dispensing systems ofFIGS. 1 and 2 being used to deposit acoustic texture material to a surface; -
FIG. 4 is a section view of the acoustic texture material after it has been deposited on the surface; and -
FIGS. 5 and 6 are bottom plan views of the surface before and after the acoustic texture material has been deposited thereon. - Referring initially to
FIG. 1 of the drawing, depicted at 20 a therein is a first embodiment of an aerosol system for depositing on a surface 22 (FIGS. 3-6 )acoustic texture material 24 incorporatingparticulate material 26 of the present invention.FIG. 5 illustrates atarget portion 28 of thesurface 22 on whichacoustic texture material 24 is to be deposited. - The
example aerosol system 20 a comprises acontainer assembly 30, avalve assembly 32, acollection assembly 34, and anoutlet assembly 36. Thecontainer 30 defines aproduct chamber 40 in which theacoustic texture material 24 comprising theparticulate material 26 is contained. Afirst portion 42 of thechamber 40 is occupied by theacoustic texture material 24, while asecond portion 44 of thechamber 40 is occupied by apressurized propellant material 46. Theexample container assembly 30 comprises acan member 50 and acup member 52. - The
valve assembly 32 is mounted in acup opening 34 define by thecup member 52 and operates in a closed configuration (shown) and an open configuration. In the open configuration, thevalve assembly 32 defines a dispensing passageway that allows fluid communication between the interior and the exterior of thecontainer assembly 30. - The
outlet assembly 36 comprises anactuator member 60 that causesacoustic texture material 24 to be dispensed by thesystem 20 in a fan shaped spray as will be described in further detail below. Theactuator member 60 is mounted on thevalve assembly 32 such that displacing theoutlet member 60 towards thevalve assembly 32 places the valve assembly in the open configuration. - The
example valve assembly 32 comprises avalve seat 70, avalve stem 72, avalve housing 74, adip tube 76, and avalve spring 78. Thevalve seat 70 defines aseat opening 70 a and is supported by thecup member 52. The valve stem 72 defines a valve stem opening 72 a and avalve surface 72 b. The valve stem 72 is supported by thevalve seat 70 such that the valve stem moves within the valve stem opening 72 a between first and second positions, with the first position being shown inFIG. 1 . - The
valve housing 74 is supported by thevalve seat 70 within theproduct chamber 40. Thevalve housing 74 further supports thedip tube 76 such that theacoustic texture material 24 within can flow into thevalve housing 74 when the can is upright. Thevalve spring 78 is supported by thevalve housing 74 such that thespring 78 biases thevalve stem 72 into the first position. The valve stem 72 supports theoutlet assembly 36 such that depressing theactuator member 60 towards thecup member 52 forces thevalve stem 72 into the second position (not shown) against the force of thevalve spring 78. - The
valve assembly 32 thus operates in the closed configuration and the open configuration as follows. When no force is applied to theactuator member 60, thevalve spring 78 forces thevalve surface 72 b against thevalve seat 70 to prevent fluid from flowing through the valve stem opening 72 a. When a force is applied to theactuator member 60, thevalve surface 72 b is forced away from thevalve seat 70 such that fluid can flow from the interior of thevalve housing 74 through the valve stem opening 72 a and thus out of theproduct chamber 40. - Referring now to
FIG. 2 of the drawing, depicted at 20 b therein is a first embodiment of an aerosol system that may also be used to deposit theacoustic texture material 24 incorporatingparticulate material 26 of the present invention on thetarget portion 28 of thesurface 22. - The
example aerosol system 20 b comprises acontainer assembly 130, avalve assembly 132, acollection assembly 134, and anoutlet assembly 136. Thecontainer 130 defines aproduct chamber 140 in which theacoustic texture material 24 comprising theparticulate material 26 is contained. Afirst portion 142 of thechamber 140 is occupied by theacoustic texture material 24, while asecond portion 144 of thechamber 140 is occupied by apressurized propellant material 146. Theexample container assembly 130 comprises acan member 150 and acup member 152. - The
valve assembly 132 is mounted in acup opening 134 define by thecup member 152 and operates in a closed configuration (shown) and an open configuration. In the open configuration, thevalve assembly 132 defines a dispensing passageway that allows fluid communication between the interior and the exterior of thecontainer assembly 130. - The
outlet assembly 136 comprises anactuator member 160 that causesacoustic texture material 24 to be dispensed by thesystem 20 in a fan shaped spray as will be described in further detail below. Theactuator member 160 is mounted on thevalve assembly 132 such that displacing theoutlet member 160 towards thevalve assembly 132 places the valve assembly in the open configuration. - The
example valve assembly 132 comprises avalve seat 170, avalve stem 172, avalve housing 174, adip tube 176, and avalve spring 178. Thevalve seat 170 defines aseat opening 170 a and is supported by thecup member 152. Thevalve stem 172 defines a valve stem opening 172 a and avalve surface 172 b. Thevalve stem 172 is supported by thevalve seat 170 such that the valve stem moves within the valve stem opening 172 a between first and second positions, with the first position being shown inFIG. 1 . - The
valve housing 174 is supported by thevalve seat 170 within theproduct chamber 140. Thevalve housing 174 further supports thedip tube 176 such that the acoustic texture material 124 within can flow into thevalve housing 174 when the can is upright. Thevalve spring 178 is supported by thevalve housing 174 such that thespring 178 biases thevalve stem 172 into the first position. Thevalve stem 172 supports theoutlet assembly 136 such that depressing theactuator member 160 towards thecup member 152 forces thevalve stem 172 into the second position (not shown) against the force of thevalve spring 178. - The
valve assembly 132 thus operates in the closed configuration and the open configuration as follows. When no force is applied to theactuator member 160, thevalve spring 178 forces thevalve surface 172 b against thevalve seat 170 to prevent fluid from flowing through the valve stem opening 172 a. When a force is applied to theactuator member 160, thevalve surface 172 b is forced away from thevalve seat 170 such that fluid can flow from the interior of thevalve housing 174 through the valve stem opening 172 a and thus out of theproduct chamber 140. - Turning now to
FIGS. 3-6 , the use of theaerosol dispensing systems systems reference character 20 inFIGS. 3-6 . - As shown in
FIG. 3 , the dispensingsystem 20 deposits a fan-shaped spray ofacoustic texture material 24 on thetarget portion 28 of thewall 22. As shown inFIGS. 4 and 6 , theacoustic texture material 24 covers thetarget portion 28 to match the pre-existing acoustic texture material on thesurface 22 surrounding thetarget portion 28. - Referring for a moment back to
FIGS. 1 and 2 , it can be seen that, in addition to theparticulate material 26, the acoustic texture material comprises abase portion 220 in the form of a flowable liquid. Thebase portion 220 of the particulate material conventionally comprises a carrier, a filler, and a binder. - In some aerosol systems, the
propellant material propellant material container assembly propellant material base portion 220, while the gaseousphase propellant material pressurized portion 44 of thecontainer assembly - As the
acoustic texture material 24 is dispensed, the pressure within thepressurized portion container assemblies bi-phase propellant material pressurized portion container assembly pressurized portion acoustic texture material 24 out of thecontainer assembly valve assembly propellant material - However, the present invention is of particular significance when the propellant material is a bi-phase propellant material such as di-methyl ethylene (DME) or any one of a number of hydrocarbon propellants such as those available in the industry as A-40 and A-70. The advantage of using bi-phase propellant materials is that the pressure within the
pressurized portion container assembly acoustic texture material 24 drops. This constant, low level pressure allows thetexture material 24 to be dispensed in many small bursts instead of in a few large bursts, as is the case when pressurized inert gases are used as thepropellant material - Many
particulate materials 26 suitable for use in acoustic texture materials are incompatible with bi-phase propellant materials. For example, as described above polystyrene chips are commonly used in acoustic texture materials dispensed using commercial hopper guns. However, polystyrene chips dissolve in the bi-phase propellant materials of which the Applicant is aware. - The Applicant has discovered that urethane foam materials and melamine foam materials may be used as the
particulate material 26 with bi-phase propellant materials such as DME and hydrocarbon propellants such as A-40 and A-70. Melamine foam materials in particular are easily chopped up using conventional material processors (e.g., a food blender) into irregular shapes that match the appearance and function of polystyrene chips. Melamine foam materials are already commonly used in building applications and have desirable fire retardant, thermal, and acoustic properties. - To manufacture the
acoustic texture material 24, thebase portion 220 may be the same as a conventional base used in commercially available acoustic texture materials. Instead of polystyrene chips, however, urethane and/or melamine foam is chopped up into particles of an appropriate size and use as the particulate. In addition, a bi-phase propellant material is used to form part of the carrier portion of thebase portion 220. - The Applicant has thus determined that a conventional base portion using melamine foam chips and DME as a propellant is commercially practical and obtains acceptable aesthetic and functional results. Appropriate adjustments in the liquids used as the carrier in a conventional acoustic texture material formulation may be required to obtain a desired consistency of the
acoustic texture material 24 as it is deposited on thesurface 22.
Claims (6)
1. An acoustic texture material adapted to be dispensed from an aerosol assembly using bi-phase propellant materials to form a textured coating on drywall material such that the textured coating substantially matches a pre-existing acoustic texture material on the drywall material, the acoustic texture material comprising:
a base portion capable of existing in a flowable state and a hardened state; and
a particulate portion comprising discrete particles that are visible to an unaided eye; wherein
the particulate portion is comprised of at least one of urethane foam and melamine foam; and
the base portion is capable of securing the particles to the drywall material when the base portion is in the hardened state.
2. An acoustic texture material as recited in claim 1 , in which the particulate portion is formulated such that the bi-phase propellant materials do not dissolve the discrete, visible, irregular particles when the acoustic texture material is mixed with a liquid phase of the bi-phase propellant materials.
3. An acoustic texture material as recited in claim 1 , in which the particulate portion is distributed throughout the base portion when the base portion is in the flowable state and the acoustic texture material is stored within the aerosol assembly.
4. A method of using an aerosol assembly to form a textured coating on a drywall material such that the textured coating substantially matches a pre-existing acoustic coating on the drywall material comprising the steps of:
providing a base portion in a flowable state;
forming a particulate portion comprising discrete particles of at least one of urethane foam and melamine foam, where the discrete particles are visible to the unaided eye;
providing a bi-phase propellant material formulated not to dissolve the discrete particles;
arranging the base portion in the flowable state, the particulate portion, and the bi-phase propellant within the aerosol assembly;
operating the aerosol assembly such that a portion of the bi-phase propellant material forces the base portion in the flowable state and the particulate portion out of the aerosol assembly and onto the drywall material;
allowing the base portion to form a hardened state in which the base portion secures the discrete particles to the drywall material.
5. A method as recited in claim 4 , further comprising the step of formulating the particulate portion such that the bi-phase propellant materials do not dissolve the particles when the acoustic texture material is mixed with the bi-phase propellant materials.
6. A method as recited in claim 4 , further comprising the step of distributing the particulate portion throughout the base portion when the base portion is in the flowable state and the acoustic texture material is within the aerosol assembly.
Priority Applications (1)
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US13/864,104 US20130230655A1 (en) | 2004-10-08 | 2013-04-16 | Particulate Materials for Acoustic Texture Material |
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US11/982,134 US7947753B2 (en) | 2004-10-08 | 2007-10-31 | Particulate materials for acoustic texture material |
US13/114,954 US8420705B2 (en) | 2004-10-08 | 2011-05-24 | Particulate materials for acoustic texture material |
US13/864,104 US20130230655A1 (en) | 2004-10-08 | 2013-04-16 | Particulate Materials for Acoustic Texture Material |
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US13/114,954 Active US8420705B2 (en) | 2004-10-08 | 2011-05-24 | Particulate materials for acoustic texture material |
US13/864,104 Abandoned US20130230655A1 (en) | 2004-10-08 | 2013-04-16 | Particulate Materials for Acoustic Texture Material |
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US13/114,954 Active US8420705B2 (en) | 2004-10-08 | 2011-05-24 | Particulate materials for acoustic texture material |
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-
2004
- 2004-12-29 US US11/027,219 patent/US7374068B2/en not_active Expired - Fee Related
-
2005
- 2005-02-22 CA CA2497927A patent/CA2497927C/en not_active Expired - Fee Related
- 2005-10-06 GB GB0520370A patent/GB2418959B/en not_active Expired - Fee Related
- 2005-10-07 AU AU2005220237A patent/AU2005220237A1/en not_active Abandoned
-
2007
- 2007-10-31 US US11/982,134 patent/US7947753B2/en active Active
-
2011
- 2011-05-24 US US13/114,954 patent/US8420705B2/en active Active
-
2013
- 2013-04-16 US US13/864,104 patent/US20130230655A1/en not_active Abandoned
Cited By (6)
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US9415927B2 (en) | 2007-04-04 | 2016-08-16 | Homax Products, Inc. | Spray texture material compositions, systems, and methods with anti-corrosion characteristics |
US9580233B2 (en) | 2007-04-04 | 2017-02-28 | Ppg Architectural Finishes, Inc. | Spray texture material compositions, systems, and methods with anti-corrosion characteristics |
US9382060B1 (en) | 2007-04-05 | 2016-07-05 | Homax Products, Inc. | Spray texture material compositions, systems, and methods with accelerated dry times |
US9592527B2 (en) | 2007-04-05 | 2017-03-14 | Ppg Architectural Finishes, Inc. | Spray texture material compositions, systems, and methods with accelerated dry times |
US9776785B2 (en) | 2013-08-19 | 2017-10-03 | Ppg Architectural Finishes, Inc. | Ceiling texture materials, systems, and methods |
USD787326S1 (en) | 2014-12-09 | 2017-05-23 | Ppg Architectural Finishes, Inc. | Cap with actuator |
Also Published As
Publication number | Publication date |
---|---|
US8420705B2 (en) | 2013-04-16 |
US20110281030A1 (en) | 2011-11-17 |
US20060079588A1 (en) | 2006-04-13 |
GB2418959A (en) | 2006-04-12 |
CA2497927C (en) | 2012-05-08 |
AU2005220237A1 (en) | 2006-04-27 |
GB0520370D0 (en) | 2005-11-16 |
CA2497927A1 (en) | 2006-04-08 |
US7374068B2 (en) | 2008-05-20 |
GB2418959B (en) | 2008-06-25 |
US20080128203A1 (en) | 2008-06-05 |
US7947753B2 (en) | 2011-05-24 |
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Owner name: HOMAX PRODUCTS, INC., WASHINGTON Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:GREER, LESTER R., JR.;REEL/FRAME:030887/0607 Effective date: 20130422 |
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STCB | Information on status: application discontinuation |
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