APPLICATOR FOR FLOOR COATINGS, AND METHODS

Field of the Disclosure

The present invention relates to an applicator system, particularly an application head, configured for applying a coating or film to a substrate surface such as a floor.

Background

Long have coatings been applied to horizontal surfaces to protect the surfaces and/or prolong their finish. Floors, in particular, which are abused by foot traffic, wheeled carts, and other objects, are especially difficult to protect. Generally, a coating composition is applied to the floor to protect it from scuff marks, scratches, dirt, grease, and other contaminants. The coating is preferably applied as a smooth, uniform layer over the floor.

To facilitate leveling the coating composition over the floor, various applicator devices are known, both hand-held systems and automatic systems (such as wheeled scrubbing and coating machines). Various designs and configurations are known for the applicator head used to spread and smooth the coating composition.

There is always room for improved designs.

Summary

The present disclosure provides an applicator system, particularly an application head, useful for applying a chemical coating composition onto a surface, such as a floor. The application head of the present disclosure is particularly suited for applying a consistent thin coating, such as less than 5 mil thick, on the surface, following the gross contours of the surface. Various embodiments of application heads are also provided, as are methods of using the application heads.

The application heads of this disclosure are particularly suited for applying two- component or two-part coating compositions, such as a coating composition that includes a water dispersible polyisocyanate component combined with a cyclic diol hard segment component. For some compositions, cyclohexanedimethanol is the preferred cyclic diol hard segment, and which could be 1,4-cyclohexanedimethanol.

Further, some embodiments of the application heads are particularly suited for applying coating compositions with high solids levels, such as greater than 40 wt-%.

In addition, some embodiments of the application heads are, additionally or alternatively, suited for applying a coating composition with an applicator system that includes a multi-compartment plastic bag or pouch, to separate individual components of the coating composition prior to reacting the individual components together to form the coating composition, the pouch having internal seals that are readily and controllably rupturable.

These and other embodiments and aspects are within the scope of this disclosure.

Brief Description of the Drawings

FIG. 1 is a perspective view of a user using an applicator system of the present disclosure;

FIG. 2 is a perspective view of a portion of the applicator system of FIG. 1, particularly, an applicator device; FIG. 3 is a perspective view of a portion of the applicator device of FIG. 2, particularly, an application head;

FIG. 4 is an end view of the application head of FIG. 3;

FIG. 5 is a front view of a second embodiment of an application head suitable for use with the system of FIG. 1; FIG. 6 is an end view of the application head of FIG. 5;

FIG. 7 is an enlarged view of a portion of the application head of FIG. 5;

FIG. 8 is a perspective view of a third embodiment of an applicator of the present disclosure;

FIG. 9 is a side view of the applicator of FIG. 8; FIG. 10 is a front view of the applicator of FIG. 8;

FIG. 11 is an enlarged view of a portion of FIG 10;

FIG. 12 is an enlarged view of an alternative embodiment of FIG. 11;

FIG. 13 is an enlarged view of an alternative embodiment of FIG. 11;

FIG. 14 is an enlarged view of an alternative embodiment of FIG. 11; FIGS. 15A-E are end views of alternative embodiments of a portion of the applicator; and

FIGS. 16A-C are diagrammatic views of the applicators in various orientations relative to a horizontal surface.

Detailed Description

The present disclosure provides an application head suitable for spreading and smoothing a coating composition on a surface, such as a floor. The application head can be part of an applicator device, which typically includes a handle or other connection which allows proper positioning of the application head in relation to the surface being coated. The applicator device, with the application head, can be part of a larger applicator system, which includes a source of the coating composition. Referring to the figures, a system for applying the coating composition to a surface, such as a floor, is illustrated. Illustrated in FIG. 1 is a user with an exemplary coating applicator system 10 applying a liquid coating composition onto floor 15. Applicator system 10 includes a liquid retainer 20 for storing the liquid coating composition prior to application to floor 15 and an applicator device 30 that applies the liquid coating to floor 15. Liquid retainer 20 may have two separate compartments (not seen) for separating the two components of the coating composition until ready to be dispensed and applied. A hose or other connecting passage 25 provides liquid coating composition from retainer 20 to applicator device 30. Applicator device 30, also seen in FIG. 2, has a handle 32 connected to an application head 35, which is shown in more detail in FIGS. 3 and 4. Application head 35, in some embodiments, is releaseably connected to handle 32.

In this embodiment, application head 35 has a body 40 with a first end 4OA and an opposite second end 4OB, and a width therebetween. In the depicted embodiment the width of application head 35 typically is at least 9 inches (about 23 cm) and is usually no more than about 36 inches (about 91 cm). In an alternative embodiment, the width of application head 35 is about 12 inches (about 30.5 cm) to about 24 inches (about 61 cm). It should be appreciated that in other alternative embodiments the size of the application head can vary even outside of dimensions provided above.

Body 40, in this embodiment, can be described as having been formed from a sheet of material that has been formed as desired; body 40 can be generally described as having an open construction. Body 40 includes a first portion 43 for connecting to handle 32 and

a second portion 45 which is configured for application of the liquid composition onto floor 15. Present between first portion 43 and second portion 45 is a transition portion 44. Depending on the thickness and material of body 40, body 40 is deformable or flexible, as will be further discussed below. Referring to FIG. 4, the second portion 45 is shown with an outer surface 50 and an inner surface 52, and an arcuate shape terminating at tip 55. The length of the arcuate shape may be defined by one radius or may have a different definition. In one particular embodiment, second portion 45 has a continuous arcuate shape with a radius of 2.5 inches (about 6.25 cm). The overall length of second portion 45, from tip 55 to where second portion 45 meets with transition portion 44, designated as "X", which could also be referred to as the length of application head 35. In one embodiment X is at least about 2 inches (about 5 cm) and is no more than about 12 inches (about 30.5 cm). In other embodiments, length X is about 4 inches (about 10 cm) to about 6 inches (about 15 cm), and in one embodiment, is 4.45 inches (about 11 cm). It should be appreciated that in other alternative embodiments the size of the device can vary even outside of dimensions of the example embodiments provided above.

The overall height of application head 35, in this embodiment the distance between the farthest-most-point on first portion 43 and second portion 45, designated as "Y", is at least about 2 inches (about 5 cm) and is no more than about 12 inches (about 30.5 cm). In some embodiments, height Y is about 3 inches (about 7.5 cm) to about 6 inches (about 15 cm), and in one embodiment, is 3.26 inches (about 8.3 cm).

Second portion 45 includes a contact area 60 on outer surface 50. Contact area 60 extends from first end 4OA to second end 4OB in the longitudinal direction of second portion 45, which is the direction between tip 55 and where second portion 45 meets with transition portion 44. Stated another way, in this embodiment, the longitudinal direction is orthogonal to the width of application head 35. In some embodiments, including the illustrated application head 35, contact area 60 includes the area that is the farthest-most- point from first portion 43.

In some embodiments, contact area 60 is fairly narrow in the longitudinal direction, merely being a tangential line across body from first end 4OA to second end 4OB. In some embodiments, however, body 40 and particularly second portion 45, is deformable and/or flexible when a force is applied to body 40 at first portion 43. As

second portion 45 flexes and/or deforms, contact area 60 increases, due to the flattening of second portion 45 against floor 15 or other surface.

In some embodiments, body 40 is sufficiently flexible so that the length of contact area 60, in the longitudinal direction, is at least about 0.25 inch (about 0.6 cm) and is no more than about 2 inches (about 5 cm). In some designs of application head 35, contact area 60 has a length in the longitudinal direction of about 0.75 inch (about 2 cm) to about 1.25 inches (about 3 cm), with a contact area 60 length of about 1 inch (about 2.5 cm) being particularly preferred for some embodiments.

Preferably, second portion 45 has a smooth radius in the longitudinal direction on outer surface 50. To facilitate using of application head 35, it is preferred that the surface 50 along the longitudinal length is uniform. Along its width, outer surface 50 of second portion 45, in this embodiment, has a smooth surface, with no angles, ribs, grooves, or other surface features. It should be appreciated that other embodiments may include angles, ribs, grooves, flats, or other features. In some embodiments, body 40 is additionally or alternately sufficiently flexible along its width, from end 4OA to end 4OB, to allow application head 35 to follow the gross contours of the surface being coated. For example, head 35 is sufficiently flexible along its width to follow undulations, dips, grooves, or other features in the surface that remove the surface from being planar. As a particular example, application head 35 could be used on a surface that has a large dip, for example, a dip that is 0.5 inch (about 1.25 cm) deep and 10 inches (about 25 cm) wide. A 12 inch (about 30 cm) wide head 35 could be sufficiently flexible so that second portion 45 maintains contact with that surface along the width of head 35. Of course, the amount of flexibility and deformation of application head 35 depends on the material of body 40, the configuration of body 40, and the shape and size of the surface feature.

Application head 35 can be used in conjunction with an applicator pad positioned on the second portion 45. Examples of suitable pads, which are generally well known for applicator systems, include microfϊber pads, fleece, and foam. Preferably, application head 35, with or without a pad, provides a smooth surface appearance and avoids an Orange peel' look in the applied coating.

In the depicted embodiment, the specific configuration of first portion 43 and transition portion 44, other than their ability to deform second portion 45, generally does

not affect the functioning of second portion 45. The specific configuration of the regions of transition between the various portions, i.e., first portion 43 to transition portion 44, transition portion 44 to second portion 45, also does not affect the functioning of application head 35. First portion 43 and transition portion 44 are configured so that when in use, contact area 60 contacts the surface being coated. In one particular example, first portion 43 has a length of about 0.73 inch (about 1.85 cm), and the transition regions are arcuate with a radius of about 0.25 inch (about 0.6 cm).

A second embodiment of an application head for use with an applicator device and optionally an applicator system is illustrated in FIGS. 5 through 7 as application head 75. In this embodiment, application head 75 has a body 80 with a first end 80A and an opposite second end 80B, and a width therebetween. In this embodiment the width of application head 75 is typically similar to the width of application head 35, described above.

Body 80 includes a first portion 83, e.g., for connecting to handle 32, and a second portion 85 which is configured for application of the liquid composition onto floor 15. In this embodiment of application head 75, first portion 83 meets second portion 85 without a transition portion therebetween.

Body 80, at least from the end view of FIG. 6, is a solid construction. Body 80 may, in some instances, be sufficiently flexible in the longitudinal direction to follow contours of floor 15. In some embodiments, body 80 is solid throughout from end 80A to end 80B.

Second portion 85 has an arcuate shape that terminates at both ends at first portion 83. In this embodiment, second portion 85 is 180 degrees and is defined by a single radius. In one particular embodiment, second portion 85 has a diameter of about 0.5 inch (about 1.25 cm), which also is the overall height of application head 75.

Second portion 85, in the longitudinal direction, is smooth, with no angles or flat portions. Along its width, however, second portion 85, in this embodiment, is toothed or serrated in a regular pattern by a plurality of spaced protrusions 90, to provide a row of spaced gaps therebetween. Protrusion 90 may be integral with second portion 85, or may be attached thereto.

For example, protrusion 90 could be molded simultaneously with second portion 85. In an alternate example protrusion 90 could be a wire or other filament that is applied (e.g.,

wrapped) onto second portion 85. Each protrusion 90 has a tip 95 that is furthest-most portion from the surface of second portion 85. See FIG. 7, which is an enlargement of a portion of FIG. 5. Tip 95 may be a rounded tip, be a point, or have a flat surface. Protrusion 90 may be tapered from tip 95 to the surface of second portion 85. Protrusions 90 are preferably spaced across second portion 85 from end 8OA to end 80B, preferably have a uniform size, and are preferably uniformly spaced.

In the depicted embodiment, protrusion 90 is typically at least 0.0004 inch (about 0.01 mm) tall and no more than 0.4 inch (about 10 mm) tall. In some embodiments, protrusion 90 is at least 0.004 inch (about 0.1 mm) tall and no more than about 0.2 inch (about 5 mm) tall, and in other embodiments, protrusion 90 is about 0.008 inch (about 0.2 mm) tall to about 0.08 inch (about 2 mm) tall. It should be appreciated that in other alternative embodiments the size of the protrusion can vary even outside of dimensions provided above.

In one particular example, tip 95 extends from the surface of second portion 85 about 0.004 inch (about 0.1 mm) and has a radius of about 0.001 inch (about 0.02 mm).

Adjacent protrusions 90 are spaced about 0.4 inch (about 10 mm) apart. In another particular example, tip 95 extends from the surface of second portion 85 about 0.025 inch (about 0.63 mm) and adjacent protrusions 90 are spaced about 0.05 inch (about 1.27 mm) apart. Protrusions 90 facilitate in controlling the depth or thickness of the coating being applied to a surface. In use, protrusions 90 contact the surface being coated, thus preferably allowing a coating thickness of no more than the distance between tip 95 and the surface of second portion 85. In most embodiments, the composition being coated is sufficiently flowable that it will spread over and engulf any uncoated areas left by protrusions 90. The resulting coating has a smooth surface, typically without the Orange peel' appearance.

In some embodiments, body 80 is sufficiently flexible along its width, from end 80A to end 80B, to allow application head 75 to follow and mold to the gross contours of the surface being coated and provide a constant thickness coating. For example, head 75 is sufficiently flexible along its width to follow undulations, dips, grooves, or other features in the surface that remove the surface from being planar. In some embodiments, application head 75 is sufficiently flexible within its width to accommodate uneven

surfaces, in some embodiments as much as 2-3 mm from level, such as, for example, adjacent uneven tiles. Another way, body 80 is sufficiently flexible along its width to bend at least 1 cm, from end 8OA to end 8OB, often at least 2 cm, and provide a constant thickness coating. As a particular example, application head 75 could be used on a surface that has a large dip, for example, 0.1 inch (about 2.5 mm) deep and 10 inches (about 25 cm) wide. A 12 inch (about 30 cm) wide head 75 could be sufficiently flexible so that protrusions 90 maintain contact with that surface along the width of head 75. Of course, the amount of flexibility and deformation of application head 75 depends on the material of body 80, the configuration of body 80, the height of protrusions 90, and the shape and size of the surface feature.

Examples of suitable materials for application head 35, 75, especially body 40, 80 include plastics, metals, and composite materials. The plastic is typically thermoplastic, although thermosetting materials could be used. Examples of suitable plastic materials include polyethylene (both HDPE and LDPE), polyethylene terephthalate (PET), polypropylene, and polystyrene. Materials such as polyvinyl chloride (PVC) and polyurethane may also be used.

Referring to FIGS. 8-10, an alternative embodiment of an applicator device is shown. The applicator device 100 includes an application head 102 connected to a handle 104. In the depicted embodiment the application head 102 and handle 104 comprise a one-piece construction. However, it should be appreciated that in alternative embodiments of the device the head 102 can be removable from the handle 104.

The application head 102 of the device 100 includes an applicator 106 having a curved end profile and a support member 108. The support member 108 connects the application head 102 to the handle 104. In the depicted embodiment, the support member

108 tapers from application head 102 towards the handle 104 and includes a generally triangular webbed support structure. The overall length Liof the device is about 18-inches and the overall width Wi of the head 102 is about 2-6 inches. In should be appreciated that many other sizes and geometric configurations are also possible. Referring to FIGS. 10-14, the surface features of the application head 102 are shown and described in greater detail. In the depicted embodiment the curved end profile of the applicator 106 is convex relative to a surface to be coated. The applicator includes

a grooved contact surface 110 that is configured to contact the surface to be coated. The grooves in the depicted embodiment are parallel to each other and perpendicular to the width Wi of the applicator head 102. It should be appreciated that other groove arrangements are also possible. Referring to FIG. 11, a groove profile with triangular shaped grooves is shown.

The grooves have a height hi of between about 0.0004 to 0.4 inches and the groove has a width of Si of about 0.02-0.07 inches. FIG. 12 depicts an alternative groove arrangement where the grooves have a rectangular profile and includes flats. It should be appreciated that the raised portions between the grooves can also includes flats and/or they can be discontinuous. The rectangular grooves have a height h ₂ of between about 0.01-0.05 inches and the groove has a width of t ₂ of between about 0.02-0.03 inches. The width ti of the raised portion is between about 0.02-0.03 inches and the distance S ₂ from the center of one raised portion to the next is about 0.01-0.1 inches. Referring to FIG. 13, another embodiment of the grooved contact surface is shown. In the depicted embodiment the grooves are U-shaped and the raised portions are domed shaped. The U-shaped grooves have a height h ₃ of between about .01-.05 inches and the groove has a width t ₆ of between about 0.02-0.03 inches. The width ts of the raised portion is between about 0.02-0.03 and the distance S ₃ from the center of one raised portion to the next is between about 0.01-0.1 inches. FIG. 14 shows an embodiment of the grooved contact surface that is similar to the embodiment shown in FIG. 12 and FIG. 13. The grooves have a height h ₄ of between about .01-.05 inches and the groove has a width of U of between about 0.02-0.03 inches. The width t ₃ of the raised portion is between about 0.02-0.03 inches and the distance S ₄ from the center of one raised portion to the next is between about .01-0.1 inches. It should be appreciated that many other alternative embodiments of the grooved contact surface are possible including combinations of the above depicted groove arrangements as well as non-depicted groove contact surface arrangements.

Referring to FIGS. 15A-15E, a number of end profiles are shown. Each of the depicted end profiles are curved and are convex when viewed from below. The embodiment shown in FIG. 15A includes a generally consistent curve wherein the curve can be described as having a radius of curvature Ri of about .1875 inches. The embodiment shown in FIG. 15B includes end portions that have similar curvatures, but a middle portion that is less curved than either end portion. The embodiment shown in FIG.

15C includes end portions and a middle portion that each have different curvatures. In the depicted embodiment the portion of one of the ends and the middle is almost straight, but the overall shape of the end profile is convex. Referring to FIG. 15D, the middle and one of the end portions have a similar curvature R ₂ which is less than the curvature R3 of the other end portion. Referring to FIG 15E, the entire end profile has a similar curvature R ₄ which is relatively large. In the depicted embodiment the curvature R ₄ is about 3-5 inches. It should be appreciated that in alternative embodiments many other end profiles are possible.

Referring to FIGS. 16A-16C, schematic views of the device are shown to illustrate that the applicator head 102 is configured such that the tool can be effectively used, even when the handle 104 is at a variety of different angles relative to the horizontal. FIG. 16A discloses the handle 104 being at an angle G ₁ about 45 degrees from the horizontal. FIG. 16B discloses the handle 104 being at an angle θ ₂ about 80 degrees from the horizontal. FIG. 16C discloses the handle 104 being at an angle θ3 about -5 degrees from the horizontal. The device in the depicted embodiment is configured such that about the same portion of the grooved surface of the applicator head is in contact with the horizontal surface, even when the angle of the handle pivots through more than 90 degrees. In alternative embodiments the embodiment can be configured such that about the same portion of the grooved surface of the applicator head is in contact with the horizontal surface, even when the angle of the handle pivots through between about 30-60 degrees.

It should be understood that although only several specific embodiments have been illustrated in the figures, variations of each of these embodiments are within the scope of this disclosure. Additionally, it is understood that elements or features described in respect to one embodiment could be incorporated into or with other embodiments and variations thereof.

The application head of some embodiments is suited for applying a composition, such as a reactive composition, onto a surface, such as floor 15 of FIG. 1. Some embodiments of the application head are suited for application of compositions having high solids levels, such as at least 40 wt-% solids. Some embodiments of the application head are suited for application of compositions having a dynamic viscosity of less or equal to about 25,000 centipoise. Application head 35, 75, 106 can be used in system 10, which includes composition retainer 20 and applicator device 30. It should be appreciated that in

other alternative embodiments, the application heads can be configured to be suited for compositions having less solid by weight and/or greater dynamic viscosity.

A preferred coating applicator system 10 for use with heads 35, 75, 106 includes a multi-compartment plastic bag or pouch, to separate individual components, which has internal seals that are readily and controllably rupturable. To mix the individual components, the internal divider between the pouches is ruptured and the individual components are mixed, for example, by kneading. The mixed components are dispensed from the pouch as a reactive composition.

One preferred retainer 20, which also functions as a dispensing unit, is described in PCT publication WO 2004/108404, the entire disclosure of which is incorporated by reference. This publication discloses various embodiments of multi-compartment plastic bags or pouches.

Upon dispensing from retainer 20, the composition is easy to apply to a surface, such as a floor. The surface can be generally any material, such as vinyl, linoleum, ceramic, wood, marble, and the like. Application head 35, 75, 106 provides suitable coatings on smooth surfaces as well as porous or other surfaces having a texture.

With application head 35, 75, 106, the reactive coating is easy to apply and forms a thin, easily managed coating with minimal streaks, grooves, or other surface imperfections. In some situations only one pass with application head 35, 75, 106 is needed to obtain a smooth and even coating. Application head 35, 75, 106 is especially suited for applying a coating at a thickness of usually no more than about 5 mil (about 127 micrometers). In some embodiments, depending on the composition and the surface being coating, the applied coating is about 2 mil (about 51 micrometers), or even about 1 mil

(about 25 micrometers) thick. Compositions having high solids levels, such as greater than 40 wt-%, or even greater than 50 wt-%, can be readily applied with application head

35, 75, 106. Application head 35, 75, 106 is able to provide a thin, consistent coating, with high solids levels, over uneven surfaces.

In some instances the surface to be coated must be prepared, for example, by cleaning, stripping to remove previous coatings, and/or priming. Although the discussion has been directed to using application head 35, 75, 106 on a floor, a variety of other surfaces such as, for example, walls, counter tops and shelving, furniture, and bathroom surfaces, could be coated.

An example of a reactive coating composition for spreading and/or coating with application head 35, 75, 106 is a waterbased two-part polyurethane finish composition formed from a two-part or two-component system. Such a reactive composition can include a water dispersible polyisocyanate component combined with a cyclic diol hard segment component, such as cyclohexanedimethanol. A preferred cyclohexanedimethanol, for some compositions, is 1,4-cyclohexanedimethanol. Additional details regarding such composition formed from a water dispersible polyisocyanate component and a cyclic diol hard segment are disclosed in co-pending patent application having attorney docket no. 62026US002 (application number 11/423061) the entire disclosure of which is incorporated by reference.

It should be understood that the waterbased two-part polyurethane finish composition and the various features thereof that have been described herein and in co- pending patent application having attorney docket no. 62026US002 (application number 11/423061) are only examples of suitable compositions for application by the application head, applicator devices and applicator systems of the present disclosure. Other compositions can also be applied.

The invention has been described with reference to various embodiments and techniques. However, it will be apparent to one of ordinarily skill in the art that many variations and modifications may be made while remaining within the spirit and scope of the invention.