Method of applying a design to a surface

• US 7,556,841 B2
• Filed: 06/06/2006
• Issued: 07/07/2009
• Est. Priority Date: 06/07/2005
• Status: Expired due to Fees

• Current Assignee: SC Johnson & Son Incorporated
• Original Assignee: SC Johnson & Son Incorporated
• Inventors: Bullis, Daniel R. Jr., Santaga, Marcia L., Shah, Ketan N., Kimball, James F., Rodenkirch, Douglas S., Minor, Eric J., Zainiev, Gafur
• Primary Examiner(s): CULBERT, ROBERTS P
• Application Number:
  US11/447,817
• Publication Number:
  US 20070014921A1
• Time in Patent Office: 1,127 Days
• Field of Search: 427/292, 427/501, 427/513, 427/514, 510/278
• US Class Current: 427/292
• CPC Class Codes: B05C 17/06 Stencils B05C17/04 takes precedence; stencils used in connection with printing plates or foils B41N1/24; drawing accessories B43L13/00
• CPC Class Codes: B41M 7/0072 using mechanical wave energy, e.g. ultrasonics; using magnetic or electric fields, e.g. electric discharge, plasma
• CPC Class Codes: B41M 7/009 using thermal means, e.g. infrared radiation, heat
• CPC Class Codes: B41N 1/242 Backing sheets; Top sheets; Intercalated sheets, e.g. cushion sheets; Release layers or coatings; Means to obtain a contrasting image, e.g. with a carbon sheet or coating
• CPC Class Codes: B41N 1/248 Mechanical details, e.g. fixation holes, reinforcement or guiding means; Perforation lines; Ink holding means; Visually or otherwise detectable marking means; Stencil units
• CPC Class Codes: B44C 1/105 comprising an adhesive layer decalcomania B44C1/16; adhesive tapes C09J7/20
• CPC Class Codes: B44C 1/18 Applying ornamental structures, e.g. shaped bodies consisting of plastic material
• CPC Class Codes: B44C 1/20 Applying plastic materials and superficially modelling the surface of these materials
• CPC Class Codes: B44C 3/02 Superimposing layers B44C3/005 takes precedence
• CPC Class Codes: B44D 2/007 using stencils in artistic drawing or painting operations
• CPC Class Codes: B44D 5/00 Surface treatment to obtain special artistic surface effects or finishes pretreatment or after-treatment of surface coated by applying liquids B05D3/00; obtaining special surface effects by applying liquids or other fluent materials to surfaces B05D5/00; surface shaping of plastics, e.g. embossing, B29C59/00
• CPC Class Codes: C09D 11/0235 Duplicating inks, e.g. for stencil printing
• CPC Class Codes: C09D 5/008 Temporary coatings C09D5/20 takes precedence
• CPC Class Codes: C11D 2111/42 Application of foam or a temporary coating on the surface to be cleaned
• CPC Class Codes: C11D 2111/46 applying energy, e.g. irradiation
• CPC Class Codes: C11D 3/37 Polymers polymeric surface-active agents C11D1/008; polysaccharides C11D3/222
• CPC Class Codes: C11D 3/3715 Polyesters or polycarbonates
• CPC Class Codes: C11D 3/3726 Polyurethanes
• CPC Class Codes: C11D 3/3749 Polyolefins; Halogenated polyolefins; Natural or synthetic rubber; Polyarylolefins or halogenated polyarylolefins
• CPC Class Codes: D06P 1/0012 Effecting dyeing to obtain luminescent or phosphorescent dyeings
• CPC Class Codes: D06P 1/0016 : Dye baths containing a dyeing agent in a special form such as for instance in melted or solid form, as a floating film or gel, spray or aerosol, or atomised dyes
• CPC Class Codes: D06P 1/44 : using insoluble pigments or auxiliary substances, e.g. binders
• CPC Class Codes: D06P 1/52 : using compositions containing synthetic macromolecular substances D06P1/60 takes precedence
• CPC Class Codes: D06P 1/5264 : Macromolecular compounds obtained otherwise than by reactions involving only unsaturated carbon-to-carbon bonds
• CPC Class Codes: D06P 1/5271 : Polyesters; Polycarbonates; Alkyd resins
• CPC Class Codes: D06P 1/54 : Substances with reactive groups together with crosslinking agents
• CPC Class Codes: D06P 1/613 : Polyethers without nitrogen
• CPC Class Codes: D06P 5/001 : Special chemical aspects of printing textile materials
• CPC Class Codes: D06Q 1/00 : Decorating textiles
• CPC Class Codes: D06Q 1/06 : by local treatment of pile fabrics with chemical means
• CPC Class Codes: D06Q 1/10 : by treatment with, or fixation of, a particulate material, e.g. mica, glass beads by metallising D06Q1/04; by transferring D06Q1/12
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/249921 : Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/253 : Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/254 : Polymeric or resinous material
• CPC Class Codes: Y10T 428/28 : Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]

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 décor 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.

Claims

1. A method of applying a composition to a surface, the method comprising:

applying an effective amount of a composition in a preselected pattern to a selected surface to affect a color change thereon, the composition comprises a colorant, a surface-active agent, at least one of a polymer or a resin, and at least about 70 wt % of a liquid;

allowing the composition to substantially dry on the surface to form substantially dry particles greater than about 1 micron in size attached to the surface; and

applying energy to the substantially dry particles to achieve a film greater than about 0.1 micron in thickness on the surface.

2. The method of claim 1, wherein the substantially dry particles are characterized by the ability to be removable from a nylon test carpet by vacuuming that results in a Δ

E on the nylon test carpet of about 20 or less.

3. The method of claim 1, wherein the polymer comprises at least one of a thermoset polymer or a thermoplastic polymer.

4. The method of claim 1, wherein the dry particles have a first energy level and the film has a second energy level.

5. The method of claim 1, wherein the composition is formulated to be substantially removed from the selected surface before the step of applying energy to the substantially dry particles.

6. The method of claim 5, wherein the composition further comprises at least one substantially homogeneous dé

cor particle, a first additive, and a liquid carrier, and wherein the dé

cor particle comprises a second additive, the colorant, and at least one of;

an epoxy resin and a curative,

an epoxy resin, an acid-terminated polyester resin, and an accelerant, or

an acid-terminated polyester resin and a curative.

7. The method of claim 1, wherein the selected surface comprises a soft surface.

8. The method of claim 1, wherein the composition further comprises an additive.

9. The method of claim 8, wherein the additive comprises at least one of a stabilizer, an induction agent, a susceptor, a magnetic responsive agent, a metallic particle, an anti-wicking agent, a thickening agent, an adhesive, a binder, a surfactant, a lubricant, a viscosity modifier, a humectant, a propellant, an inorganic particulate material, or a pH neutralizing agent.

10. The method of claim 1, wherein the energy is applied by at least one of heat, steam, an electromagnetic field, or a chemical.

11. The method of claim 1, wherein the composition further comprises at least one of an ammonia-based chemistry, a water-based chemistry, an acid-based chemistry, an aqueous fabric paint, a thermally releasable coating, a peelable coating agent, a strippable coating agent, or an alkali soluble resin.

12. A method of applying a colorant to a surface, the method comprising:

applying an effective amount of a liquid-based composition containing a colorant in a preselected pattern to a selected surface to affect a color change thereon, the liquid-based composition formulated to be applied in the effective amount to a nylon test carpet and to substantially dry to form particles greater than about 1 micron in size attached thereto, and upon vacuuming of the nylon test carpet resulting in a Δ

E of about 20 or less.

13. The method of claim 12, wherein the liquid-based composition comprises a dé

cor product and the method further comprises;

selecting a design device that includes the dé

cor product;

placing the design device adjacent a surface;

applying a release mechanism to the design device, wherein the step of applying of the release mechanism releases the dé

cor product from the design device onto the surface;

removing the design device from the surface;

allowing the dé

cor product to substantially dry on the surface to form a substantially dry dé

cor product attached thereto; and

at least one of substantially removing the dry dé

cor product from the surface or substantially affixing the dry dé

cor product thereon;

wherein the dry dé

cor product is formulated to be substantially affixed to the surface and can be substantially removed from the surface before the dry dé

cor product is affixed thereto.

14. The method of claim 12 further comprising:

applying to the surface a consumer aid comprising a color predicting aid and a pattern;

selecting a design device and the liquid-based composition, the liquid-based composition comprising a dé

cor product that is formulated to be substantially affixed to the surface by at least one of chemical curing or mechanical bonding; and

applying the dé

cor product to the surface using the design device;

wherein the dé

cor product substantially dries on the surface to form a substantially dry dé

cor product attached thereto and wherein the substantially dry dé

cor particle can be substantially removed from the surface before it is substantially affixed thereto.

15. The method of claim 14, wherein the consumer aid further comprises at least one of a design template, a color matching aid, a color blending sheet, a colorimeter, a color scanner, a color carpet chip, a color chart, or a color graph.

16. The method of claim 12, wherein the step of applying the effective amount of the liquid-based composition to the selected surface further comprises:

selecting a design device;

placing the design device adjacent a soft surface;

applying to a cutout portion of the design device the liquid-based composition that comprises a dé

cor product that is formulated to be substantially affixed to the soft surface upon application of energy thereto;

removing the design device from the soft surface;

allowing the dé

cor product to substantially dry on the soft surface to form a substantially dry dé

cor product attached thereto; and

at least one of substantially removing the dry dé

cor product from the soft surface or substantially affixing the dry dé

cor product thereon;

wherein the dry dé

cor product can be substantially removed from the soft surface before application of energy thereto.

17. The method of claim 16, wherein the step of removing of the dé

cor product from the surface comprises a vacuuming process.

18. The method of claim 16, wherein the step of affixing of the dé

cor product to the soft surface comprises exposing the dé

cor product to at least one of heat, steam, an electromagnetic field, or a chemical.

19. The method of claim 18, wherein dé

cor product is affixed over a predetermined period of about 1 microsecond to about 12 hours.

20. The method of claim 18, wherein the dé

cor product is affixed using at least one of chemical curing, mechanical bonding, a heat-emitting tool, an induction field-emitting tool, or a radiation emitting source.

21. The method of claim 16, wherein the dé

cor product is affixed to the soft surface at a temperature less than about 260°

C. and has a viscosity of equal to or less than about 2000 centipoises prior to application to the surface.

22. The method of claim 16, wherein the dé

cor product, once applied to the soft surface, is substantially attached to the surface until the dé

cor product is substantially removed or substantially affixed thereto.

23. The method of claim 16, wherein the dé

cor product comprises at least one of a colorant, a particle, or a coating.

24. The method of claim 16, wherein the soft surface is pretreated prior to application of the dé

cor product by at least one of cleaning, vacuuming, steam cleaning, bleaching, pH balancing, adjusting the pH, sweeping, painting, scrubbing, wetting, drying, heating, cooling, sanding, buffing, coating, or removing a coating therefrom.

25. The method of claim 16, wherein the removal of the dé

cor product from the soft surface is facilitated by at least one of a surfactant, a zinc oxide, an alcohol, a blowing agent, a buffering agent, a mildly alkaline solution, a polar solution, a non-polar solution, a detergent, or a soap.

26. The method of claim 16, wherein the dé

cor product is determined to be substantially affixed to the soft surface by using a consumer aid that indicates by a change in color that the dé

cor product is substantially affixed to the surface.

27. The method of claim 16, wherein the design device comprises a stencil having a first layer, a second layer, and a support layer, wherein at least one of the first layer or the second layer comprises at least one of a peripheral edge or a cutout portion, the peripheral edge or cutout portion defining at least one of an indicium, a pattern, a shape, or a design, wherein the cutout portion provides a passage through at least the first layer and the second layer;

wherein the support layer comprises an optional adherent mechanism.

28. The method of claim 16, wherein the dé

cor product comprises on a weight to weight basis;

about 0.1% to about 5% of a surfactant;

about 0% to about 10% of an adhesive;

about 1.1% to about 40% of a powder; and

about 0.1% to about 5% of an additive.

29. The method of claim 12, wherein the liquid-based composition comprises a dé

cor product that includes an encapsulated dé

cor particle, wherein the dé

cor particle further comprises a shell, a colorant, and an additive.

30. The method of claim 29, wherein the dé

cor product is allowed to substantially dry on the selected surface to form a substantially dry dé

cor product attached thereto.

31. The method of claim 29 further comprising at least one of removing the substantially dry dé

cor product from the surface or treating the substantially dry dé

cor product to release the colorant and additive from the encapsulated dé

cor particle;

wherein the substantially dry dé

cor product is formulated to be substantially removable from the surface prior to being treated.

32. The method of claim 29, wherein the step of treating of the microencapsulated dé

cor particle at least one of breaks, heats, weakens, or dissolves the shell.

33. The method of claim 12, wherein the pattern is applied using a design device that protects a portion of the selected surface from at least one of application, removal, or substantial affixation of the composition.

34. The method of claim 33, wherein the design device is disposed between the selected surface and the liquid-based composition and protects an area adjacent to the preselected pattern from receipt of the liquid-based composition.

35. The method of claim 33, wherein the liquid-based composition is applied to the design device and to the selected surface substantially simultaneously.

36. The method of claim 12, wherein the liquid-based composition comprises an additive and a liquid carrier;

wherein the liquid-based composition is formulated to be substantially removable from the surface after being substantially attached thereto.

37. A method of applying a colorant to a surface, the method comprising:

applying to a selected surface in a preselected pattern an effective amount of a liquid-based composition comprising a colorant and a particle having a thermoset polymer to affect a color change thereon, the liquid-based composition formulated to be applied to a nylon test carpet in the effective amount to substantially dry to form particulates greater than about 1 micron in size attached thereto and to result in a Δ

E of about 20 or less upon vacuuming of the nylon test carpet.

38. A method of applying a colorant to a surface, the method comprising:

applying to a selected surface in a preselected pattern an effective amount of a water-based composition comprising a colorant and a particle to affect a color change thereon, the water-based composition formulated to be applied to a nylon test carpet in the effective amount to substantially dry to form particulates having a mean particle size of greater than about 1 micron attached thereto and to result in a Δ

E of about 20 or less upon vacuuming of the nylon test carpet.

39. A method of affecting a color change on a surface, the method comprising:

applying to a selected surface in a preselected pattern an effective amount of a liquid-based composition comprising a particle having a colorant and a polymer to affect a color change on the surface, the liquid-based composition formulated to be applied to the surface in the effective amount to substantially dry to form particulates greater than about 1 micron in size attached thereto, and to be substantially removable from a textile prior to application of energy to the particulates; and

forming a film greater than about 0.1 micron in thickness on the surface by melting the particulates.

40. A method of affecting a color change on a surface, the method comprising:

applying an effective amount of a composition comprising a water-based carrier and at least one of a polymer or a resin to a selected surface to affect a color change thereon, the composition formulated to form substantially dry particles greater than about 1 micron in size upon substantial removal of the water-based carrier; and

forming a film greater than about 0.1 micron in thickness on the surface by application of energy sufficient to melt the at least one polymer or resin;

wherein the composition is formulated to result in a Δ

E of about 20 or less upon vacuuming of the surface prior to formation of the film.