USOO8336742B2

(12) United States Patent (10) Patent No.: US 8,336,742 B2

Greer, Jr. et al. (45) Date of Patent: *Dec. 25, 2012
(54) AEROSOL SYSTEMIS AND METHODS FOR 222/402.24, 402.25; 239/337,340,592,
DISPENSING TEXTURE MATERAL 239/597
See application file for complete search history.
(75) Lester R. Greer, Jr., Sandpoint, ID
Inventors:
(US); Floyd R. French, Manchester, MO (56) References Cited
(US)
U.S. PATENT DOCUMENTS
(73) Assignee: Homax Products, Inc., Bellingham, WA 208,330 A 9, 1878 Palmer
(US)
(Continued)
(*) Notice: Subject to any disclaimer, the term of this FOREIGN PATENT DOCUMENTS
patent is extended or adjusted under 35
U.S.C. 154(b) by 0 days. CA 77O467 10, 1967

This patent is Subject to a terminal dis (Continued)

claimer.
OTHER PUBLICATIONS
(21) Appl. No.: 13/280,924 Homax Products, Inc., “Easy Touch Spray Texture Brochure', Mar.
1992, 1 page.
(22) Filed: Oct. 25, 2011
(Continued)
(65) Prior Publication Data
US 2012/OO977O3 A1 Apr. 26, 2012 Primary Examiner — Frederick C. Nicolas
(74) Attorney, Agent, or Firm — Michael R. Schacht;
Related U.S. Application Data Schacht Law Office, Inc.
(63) Continuation of application No. 12/859,195, filed on (57) ABSTRACT
Aug. 18, 2010, now Pat. No. 8,042,713, which is a
continuation of application No. 1 1/982,133, filed on Aerosol material for applying a repair coat to an uncoated
Oct. 31, 2007, now abandoned, which is a continuation portion of a substrate substantially to match a coated portion
of application No. 11/413,659, filed on Apr. 27, 2006, of the Substrate using an aerosol assembly comprises a con
OW Pat. No. 7,487,893, which is a tainer defining a product chamber and a valve assembly oper
continuation-in-part of application No. 1 1/027.219, able in open and closed modes, the aerosol material com
filed on Dec. 29, 2004, now Pat. No. 7,374,068. prises a base portion, a particulate portion, and a propellant
portion. The particulate portion is made of at least one of
(60) Provisional application No. 60/675,697, filed on Apr. urethane foam and melamine foam. With the valve assembly
27, 2005, provisional application No. 60/617,236, in the open mode, the propellant portion in the gas state gas
filed on Oct. 8, 2004. state forces at least part of the base portion, the particulate
portion, and the propellant portion in the liquid state out of the
(51) Int. C. product chamber and onto the uncoated portion of the Sub
B65D 83/00 (2006.01) strate to form the repair coat such that the repair coat Substan
(52) U.S. C. .......... 222/402.1; 222/1; 222/394: 239/337 tially matches the coated portion of the substrate.
(58) Field of Classification Search ........... 222/1, 402.1,
222/394, 402.18, 402.21, 402.22, 402.23, 15 Claims, 6 Drawing Sheets

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 US 8,336,742 B2
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CH 680849 11, 1992 * cited by examiner
U.S. Patent Dec. 25, 2012 Sheet 1 of 6 US 8,336,742 B2
U.S. Patent Dec. 25, 2012 Sheet 2 of 6 US 8,336,742 B2

FIG. 2

22
32
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282
274
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292
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U.S. Patent Dec. 25, 2012 Sheet 3 of 6 US 8,336,742 B2

FIG. 3
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324
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U.S. Patent Dec. 25, 2012 Sheet 4 of 6 US 8,336,742 B2
U.S. Patent Dec. 25, 2012 Sheet 5 of 6 US 8,336,742 B2
U.S. Patent Dec. 25, 2012 Sheet 6 of 6 US 8,336,742 B2

FIG. 9 24 Aca-A4 Ace A4AC < A4

N428
 US 8,336,742 B2
1. 2
AEROSOL SYSTEMIS AND METHODS FOR to mix a liquid hydrocarbon aerosol propellant material with
DISPENSING TEXTURE MATERIAL chips made from materials other than polystyrene. However,
when chips made of materials other than polystyrene foam
RELATED APPLICATIONS are used, the appearance and function of the texture Surface
may be different from that of the surrounding surface.
This U.S. patent application Ser. No. 13/280,924 filed on The second approach is to combine polystyrene chips with
Oct. 25, 2011 is a continuation of U.S. patent application Ser. a propellant material formed by a pressurized inert gas such as
No. 12/859,195 filed on Aug. 18, 2010, now U.S. Pat. No. nitrogen or air. This second approach allows the use of a
8,042,713, which issued on Oct. 25, 2011. conventional acoustic texture material including polystyrene
U.S. patent application Ser. No. 12/859,195 is a continua 10 chips. However, the use of a pressurized inert gas causes the
tion of U.S. patent application Ser. No. 1 1/982,133 filed on acoustic texture material to be dispensed very quickly. The
Oct. 31, 2007, now abandoned. use of pressurized inert gas as a propellant can make it diffi
U.S. patent application Ser. No. 1 1/982,133 is a continua cult for a non-professional to control the application of the
tion of U.S. patent application Ser. No. 1 1/413,659 filed on acoustic texture material.
Apr. 27, 2006, now U.S. Pat. No. 7,487,893, which issued on 15 A second form of texture material is commonly referred to
Feb. 10, 2009. as “stucco. Conventionally, stucco is a plaster material made
U.S. patent application Ser. No. 11/413,659 claims benefit of Portland cement, sand, and lime. Conventional stucco is
of U.S. Provisional Patent Application Ser. No. 60/675,697 applied while soft to vertical walls or surfaces and then
filed on Apr. 27, 2005. allowed to dry to form a decorative and protective coating.
U.S. patent application Ser. No. 1 1/982,133 is also a con More recently, stucco surfaces have been formed using Syn
tinuation-in-part of U.S. patent application Ser. No. 1 1/027, thetic materials designed to resemble traditional stucco. Syn
219 filed on Dec. 29, 2004, now U.S. Pat. No. 7,374,068, thetic stucco is formed by acrylic polymers that, when dry, are
which issued on May 20, 2008. flexible and water impervious. The term “stucco” will be used
U.S. patent application Ser. No. 11/027.219 claims benefit herein to refer both to traditional cement-based materials and
of U.S. Provisional Patent Application Ser. No. 60/617,236 25 to synthetic materials that resemble the traditional material.
filed on Oct. 8, 2004. Stucco material can be damaged and should be repaired for
The contents of all related applications listed above are both structural and aesthetic reasons. Non-professionals typi
incorporated herein by reference. cally do not have the tools or materials to repair a damage
stucco surface to match the look of the original stucco Surface
TECHNICAL FIELD 30 Surrounding the patch.
The need thus exists for systems and methods for dispens
The present invention relates to the art of repairing a tex ing texture materials, such as acoustic texture materials and
tured surface and, more particularly, to dispensing systems stucco materials, that facilitate the repair by non-profession
and methods for depositing texture materials. Such as acoustic als of damaged Surfaces to match the original texture material
texture material and stucco material, onto a portion of a tex 35 Surrounding the patched area.
tured surface to be repaired.
RELATED ART
BACKGROUND
Various aerosol devices for spraying a coating material
In some situations, a separate texture layer is applied to an 40 onto a wall Surface, ceiling, or the like are known. Depending
interior or external Surface, often prior to painting. The tex upon the composition of the coating material, and other fac
ture layer is typically formed by spraying texture material tors, the coating material can be sprayed onto the Surface in a
onto the Surface. Texture material is a coating material that, variety of texture patterns.
when sprayed, does not form a Smooth, thin coating. Instead, In some instances, a Somewhat roughened texture is
texture material is applied in or contains discrete drops, globs, 45 achieved by utilizing a textured composition that forms into
or particles that dry to form a bumpy, irregular textured Sur droplets when it is dispensed, with the material then harden
face. ing with these droplets providing the textured surface. In
Texture materials can be applied using any one of a number other instances, Solid particulate material is mixed with the
of application systems. During new construction, texture liquid texture material so that with the particulate material
materials are commonly applied in a stream of compressed air 50 being deposited with the hardenable liquid material on the
using commercial hopper gun systems. For touch up or repair, wall surface, these particles provide the textured surface.
texture material is commonly applied using hand operated In particular, the Applicants are aware of prior art spray
pneumatic pumps or aerosol dispensing systems. Varying the texture devices using an aerosol container which contains the
parameters of the application system varies the size and spac texture material mixed with a propellant under pressure and
ing of the bumps to vary the look of the textured surface. 55 from which the textured material is discharged onto a surface.
One specific form of texture material is commonly referred Such aerosol dispensers are commonly used when there is a
to as "acoustic' or “popcorn” texture material. In addition to relatively small surface area to be covered with the spray
a coating material, acoustic texture material further com texture material. Two Such spray texture devices are disclosed
prises an aggregate material. When the acoustic texture mate in U.S. Pat. No. 5,037,011, issued Aug. 6, 1991, and more
rial is applied using commercial hopper guns, the aggregate 60 recently U.S. Pat. No. 5,188.263, issued Feb. 23, 1993 with
material is conventionally formed by polystyrene chips. John R. Woods being named inventor of both of these patents.
However, as will be described in detail below, chips made of Additionally, the Assignee of the present invention has
polystyrene foam are dissolved by hydrocarbon aerosol pro since approximately 1983 manufactured and sold manually
pellant materials. operated devices for applying spray texture material onto
Accordingly, aerosol dispensing systems for dispensing 65 walls and ceilings. These spray texture devices are described
Small amounts of acoustic texture material for repair or touch in one or more of the following U.S. Pat. Nos. 4.41 1,387:
up purposes use one of two approaches. The first approach is 4.955,545; 5,069,390; 5,188,295. These spray texture devices
 US 8,336,742 B2
3 4
comprised a hopper containing hardenable material, a manu strate to form the repair coat such that the repair coat Substan
ally operated pump, and a nozzle. By pointing the device at tially matches the coated portion of the substrate.
the area being patched and operating the manual pump, the
hardenable material and pressurized air generated by the BRIEF DESCRIPTION OF THE DRAWING
pump were mixed in the nozzle and Subsequently sprayed
onto the area being patched. FIG. 1 is a cut-away, side elevation view of a first example
mechanical system of the present invention;
SUMMARY FIG. 2 is a cut-away, side elevation view of a second
example mechanical system of the present invention;
10
The present invention may be embodied as aerosol material FIGS. 3 and 4 are side elevation partial cut-away views
for applying a repair coat to an uncoated portion of a substrate depicting a method of use of the example dispensing systems
Substantially to match a coated portion of the Substrate using of the present invention;
an aerosol assembly comprising a container defining a prod FIGS. 5 and 6 are front plan views depicting a portion of a
uct chamber and a valve assembly operable in open and 15
wall structure under repair using the example dispensing
closed modes, the aerosol material comprising a base portion, systems of the present invention.
a particulate portion, and a propellant portion. The particulate FIG. 7 is a section view of a first embodiment of an aerosol
portion is made of at least one of urethane foam and melamine dispensing system containing acoustic texture material incor
foam. With the valve assembly in the closed mode, the prod porating particulate material of the present invention;
uct chamber is adapted to contain the base portion, the par FIG. 8 is a section view of a second embodiment of an
ticulate portion, and the propellant portion Such that the pro aerosol dispensing system containing acoustic texture mate
pellant portion exists in a gas state and a liquid state and the rial incorporating particulate material of the present inven
propellant portion in the gas state pressurizes the base por tion;
tion, the particulate portion, and the propellant portion in the FIG.9 is an elevation view depicting the use of one or both
liquid state. With the valve assembly in the open mode, the 25 of the first and second aerosol dispensing systems of FIGS. 7
propellant portion in the gas state gas state forces at least part and 8 being used to deposit acoustic texture material to a
of the base portion, the particulate portion, and the propellant Surface;
portion in the liquid state out of the product chamber and onto FIG. 10 is a section view of the acoustic texture material
the uncoated portion of the substrate to form the repair coat after it has been deposited on the surface; and
Such that the repair coat Substantially matches the coated 30 FIGS. 11 and 12 are bottom plan views of the surface
portion of the substrate. before and after the acoustic texture material has been depos
The present invention may also be embodied as a method of ited thereon.
applying a repair coat to an uncoated portion of a substrate DETAILED DESCRIPTION
Substantially to match a coated portion of the Substrate com 35
prising the following steps. An aerosol assembly comprising I. Aerosol Stucco Dispensing Systems
a container defining a product chamber and a valve assembly
operable in open and closed modes is provided. A base por Depicted in FIGS. 1 and 2 of the drawing are first and
tion, a particulate portion, and a propellant portion are pro second examples of anaerosol stucco dispensing systems 20a
vided. The particulate portion is made of at least one of 40 and 20b constructed in accordance with, and embodying, the
urethane foam and melamine foam. The base portion, the principles of the present invention. In the following discus
particulate portion, and the propellant portion are combined sion and the drawing, the appendices “a” and “b’ will be used
to form aerosol material. The aerosol material is arranged to refer to features unique to the first and second example
within the product chamber such that with the valve assembly texturing systems 20a and 20b, respectively.
in the closed mode, the propellant portion exists in a gas state 45 The example aerosol stucco dispensing systems 20a and
and a liquid state and the propellant portion in the gas state 20b comprise a fluid system 22 and a mechanical system 24a.
pressurizes the base portion, the particulate portion, and the 24b. The fluid system 22 comprises a stucco material 30 to be
propellant portion in the liquid state. With the valve assembly dispensed and a propellant material 32. The mechanical sys
in the open mode, the propellant portion in the gas state gas tems 24a and 24b comprise a container assembly 440, an
state forces at least part of the base portion, the particulate 50 actuator 44, and a valve assembly 42a and 42b, respectively.
portion, and the propellant portion in the liquid state out of the For clarity in FIGS. 1 and 2, the stucco material 30 is shown
product chamber and onto the uncoated portion of the Sub only in the container assembly 440; as will be described in
strate to form the repair coat such that the repair coat Substan further detail below, the texture material will also forced into
tially matches the coated portion of the substrate. the valve assembly 42a, 42b and, in some situations, through
The present invention may also be embodied as aerosol 55 and out the actuator 44.
material for applying a repair coat to an uncoated portion of a The container assemblies 440 and actuator 44 of the
substrate substantially to match a coated portion of the sub example mechanical systems 24a and 24b are or may be the
strate comprising a base portion, a particulate portion, and a substantially the same and will be described only once below.
propellant portion. The particulate portion made of at least The valve assemblies 42a and 42b differ and will each be
one of urethane foam and melamine foam. When the aerosol 60 described separately below.
material is confined, the propellant portion exists in a gas state In use, the stucco material 30 and propellant material 32 are
and a liquid state, the base portion, the particulate portion, and stored within the container assembly 440. The propellant
the propellant portion in the liquid state formaliquid mixture, material 32 pressurizes the stucco material 30. The valve
and the propellant portion in the gas state pressurizes liquid assembly 42a, 42b is normally in a closed state, and depress
mixture. When the aerosol material is not confined, the pro 65 ing the actuator 44 causes the valve assembly 42a, 42b to be
pellant portion in the gas state gas state displaces at least part placed into an open state. When the valve assembly 42a, 42b
of the liquid mixture onto the uncoated portion of the sub is in the open state, the pressurized propellant material 32
 US 8,336,742 B2
5 6
forces the stucco material 30 out of the container assembly The container 60 is a metal body that comprises a side wall
440 and onto a target Surface to be coated. 70, lower wall 72, and upper wall 74. The upper wall 74
The example stucco material 30 comprises a coating por defines a cap opening 76 and an inner lip 78. The inner lip 78
tion 50 and a particulate portion 52. The coating portion 50 extends around the cap opening 76. The cap 62 is also a metal
exists in a liquid state when stored in the air-tight container 5 body that comprises an extension wall 80, a base wall 82, and
assembly 440 but hardens when exposed to the air. The coat an outer lip 84. The base wall 82 defines a mounting opening
ing portion 50 is not perse important to any particular imple 86 and a mounting wall 88. The mounting wall 88 extends
mentation of the present invention. around the mounting opening 86.
The particulate portion 52 is formed by small chips or
particles of irregular shape but relatively consistent Volume. 10 capTo62form the container assembly 40, the outer lip 84 of the
is arranged over the inner lip 78 of the container 60.
The example particulate portion 52 is formed by sand, perlite, The outer lip 84 is crimped such that the outer lip 84 engages,
Vermiculite, polypropylene, polyethylene. directly or indirectly, the inner lip 78. The resulting container
As mentioned above, the propellant material 32 must be assembly 40 defines a relatively rigid structure. In addition,
compatible with the material or materials forming the par
the outer lip 84 and inner lip 78 engage each other, directly or
ticulate portion 52 of the stucco material 30. As used herein, 15 indirectly, to form
the term “compatible” refers to the lack of chemical or bio a substantially fluid-tight seal; once the
logical interaction between the propellant material 32 and the container assembly 40 is formed, fluid may flow into and out
particulate portion 52 that would substantially permanently of the main chamber 64 only through the mounting opening
alter the physical structure or appearance of the particulate 86. In the example system 20a, the outer lip 84 directly
portion 52. 2O engages the inner lip 78. As will be described in further detail
Referring now to the composition of the propellant mate below, the outer lip 84 indirectly engages the inner lip 78 in
rial 32, one or more of the following materials may be used to the example system 20b.
form the example propellant material 32: di-methyl ethylene The container assembly 40 as described is relatively con
(DME); hydrocarbons such as propane and butane and any ventional, and container assemblies of different construction
combinations of propane and butane; compressed air, and 25 may be used in place of the example container assembly 40
compressed nitrogen. depicted in FIGS. 1 and 2.
The propellant material 32 used by the example aerosol The example actuator 44 is a plastic body defining an
system 20 is formed by DME. When DME is used as the actuator passageway 90. The actuator passageway 90 com
propellant material 32, the propellant material32 exists partly prises a threaded portion 92 and an outlet portion 94. As will
in a liquid phase that is mixed with the stucco material 30 and 30 be described in further detail below, the threaded portion 92 is
partly in a gas phase that pressurizes the stucco material 30. adapted to engage the valve assemblies 42a and 42b. The
As the stucco material 30 is forced out of the container example outlet portion 94 is frustoconical, but other shapes
assembly 440, the pressure within the container assembly 440 may be used instead or in addition. The example actuator
drops. This pressure drop causes more of the liquid phase passageway 90 turns along an angle of approximately 90
propellant material 32 to gasify. Once the actuator 44 is 35 degrees, but the actuator passageway 90 may be straight or
released and the valve assembly 42 returns to its closed state, turn along an angle other than 90 degrees.
the gas phase propellant material 32 continues to gasify until The actuator 44 as described is also relatively conven
the stucco material 30 within the container assembly 440 is tional, and actuators of different construction may be used in
again pressurized. The use of DME as the propellant material place of the example actuator 44 depicted in FIGS. 1 and 2.
32 pressurizes the stucco material 30 at a relatively constant, 40 C. First Example Valve Assembly
relatively low level that allows the controlled dispensing of Referring now specifically to FIG. 1, the first example
the stucco material 30. valve assembly 42a will now be described in further detail.
Inert, compressed gasses, such as air or nitrogen, may be The valve assembly 42a comprises a valve seat 120, a valve
used as the propellant material 32. A propellant 32 formed of stem 122, a valve housing 124, a valve spring 126, and a
compressed inertgasses pressurizes the container to force the 45 collection tube 128.
stucco material 30 out of the container assembly 440. To The example valve seat 120 comprises a Support portion
accommodate expansion of the compressed inert gasses, the 130, a seat portion 132, and a wall portion 134. Extending
system 20 is typically charged to a relatively high initial from the support portion 130 is a retaining projection 136, and
pressure. formed in the wall portion 134 is a retaining recess 138. In
Given the foregoing basic understanding of the example 50 addition, the valve seat 120 defines a stem opening 140 that
aerosol stucco dispensing systems 20a and 20b, the details of extends from the seat portion 132 and through the support
the systems 20a and 20b will now be described below in portion 130. Extending from the support portion 130 into the
further detail. stem opening 140 are a plurality of support projections 142. A
A. Coating Portion seat surface 144 is formed in the seat portion 132 around the
The coating portion 50 of the stucco material 30 forming 55 stem opening 140.
part of the fluid system 22 may be conventional and typically The valve stem 122 comprises a threaded portion 150, a
includes the following components: binder Such as acrylic guide portion 152, an inlet portion 154, and a stop portion
polymer, emulsifier Such as esther alcohol, filler Such as cal 156. A spring cavity 158 is formed in the stop portion 156.
cium carbonate, water, biocide, fungicide, anti-freeze Such as The valve stem 122 further comprises a stem passageway 160
propylene glycol. 60 defining a stem inlet 162 and a stem outlet 164. The stem inlet
B. Container Assembly and Actuator 162 is formed in the inlet portion 154 of the valve stem 122,
Referring now to FIGS. 1 and 2, the container assembly 40 and the stem outlet 164 is formed adjacent to the threaded
and actuator 44 of the example mechanical systems 24a and portion 150 of the stem 122.
24b will now be described in detail. The example container The valve housing 124 comprises a side wall 170, a bottom
assemblies 40 each comprises a container 60 and a cap 62. 65 wall 172, a tube projection 174, and a spring projection 176.
The cap 62 is attached to the container 60 to define a main A mounting projection 178 extends from the side wall 170.
chamber 64. The valve housing 124 defines a valve chamber 180, and a
 US 8,336,742 B2
7 8
housing inlet passageway 182 extends through the tube pro seat surface 144 is annular and curved. The stop portion 156
jection 174 to allow fluid to flow into the valve chamber 180. is sized and configured to conform to the shape of the seat
The housing inlet passageway 182 defines a housing inlet surface 144.
axis B. In the example valve assembly 42, the housing inlet Accordingly, when the stop portion 156 of the valve stem
axis B is parallel to and offset from the valve axis A. Other engages the seat surface 144, fluid flow between the valve
configurations may be used, but offsetting the housing inlet chamber 180 and the stem passageway 160 is substantially
axis B from the valve axis A allows the spring projection 176 prevented, and the valve assembly 42a is in its closed posi
to be aligned with the valve axis A. The spring 126 itself thus tion. However, by applying a force on the actuator 44 Suffi
may be aligned with the valve axis A. cient to compress the valve spring 126, the stop portion 156 is
The collection tube 128 comprises a side wall 190 and 10
displaced away from the seat surface 144 to place the valve
defines a tube passageway 192. The tube passageway 192 assembly 42a into its open configuration. When the valve
defines a tube inlet 194 and a tube outlet 196.
The valve assembly 42a is formed generally as follows. assembly 42a is in its open configuration, fluid may flow
The following assembly steps may be performed in different between the valve chamber 180 and the stem passageway
160.
sequences, and the following discussion does not indicate a 15
preferred or necessary sequence of assembly steps. When fitted with the first example valve assembly 42a, the
The valve stem 122 is arranged such that the guide portion aerosol stucco dispensing system 20a is used to dispense
152 thereof is received within the stem opening 140. The stucco material 30 as follows. The actuator 44 is aimed
geometry of the example valve stem 122 requires a two-piece towards a target Surface and depressed towards the cap mem
construction that would allow the relatively wide threaded ber 62 to place the valve assembly 42a in its open configura
portion 150 to be attached to the relatively wide stop portion tion. The propellant material 32 forces the stucco material 30
156 after the guide portion 152 has been arranged within the through the tube inlet 194, the tube passageway 192, the tube
stem opening 140. If the threaded portion 150 is relatively outlet 196, and the housing inlet 182 and into the valve cham
narrow and can be inserted through the stem opening 140, the ber 180.
valve stem 122 may be made of a single-piece construction. 25 From the valve chamber 180, the stucco material 30 flows
As another alternative, the threaded portion 150 may be elimi between the stop portion 156 and the seat surface 144 and into
nated; in this case, the actuator 44 is secured to the valve stem the stem inlet 162. The stucco material 30 then flows through
122 by other means such as friction and/or the use of an the stem passageway 160 and out of the stem outlet 164. The
adhesive. stucco material 30 then flows along the actuator passageway
The valve spring 126 is arranged such that one end thereof 30 90 and out of the outlet portion 94 thereof. The stucco mate
is retained by the spring projection 176 on the bottom wall rial 30 discharged through the outlet portion 94 forms a spray
172 of the valve housing 124. The valve housing 124 is and ultimately lands on the target surface.
displaced until the mounting projection 178 on the housing When sufficient stucco material 30 has been deposited onto
side wall 170 is received by the retaining recess 138 on the the target surface, the force on the actuator 44 is released. The
wall portion 134 of the valve seat 120. The other end of the 35 valve spring 126 displaces the valve stem 122 to place the
spring 126 is received by the spring cavity 158 in the valve valve assembly 42a back into its closed configuration. The
Seat 120. stucco material 30 thus no longer flows out of the valve
The support projections 142 on the support portion 130 of chamber 180 through the stem passageway 160.
the valve seat 120 engage the guide portion 152 of the valve D. Second Example Valve Assembly
stem 122 to restrict movement of the valve stem 122 within a 40 Referring now specifically to FIG. 2, the second example
predetermined range along a valve axis A. The valve spring valve assembly 42b will now be described in further detail.
126 resiliently opposes movement of the valve stem 122 The valve assembly 42b comprises a valve seat 220, a valve
towards the bottom wall 172 of the valve housing 124. stem 222, a valve housing 224, a valve spring 226, and a
The valve seat 120 is displaced such that the support por collection tube 228.
tion 130 extends through the mounting opening 86 in the cap 45 The example valve seat 220 comprises a Support portion
62. Further displacement of the valve seat 120 forces the 230, a seat portion 232, and a wall portion 234. Extending
retaining projection 136 on the valve seat 120 past the mount from the support portion 230 is a retaining projection 236. In
ing wall 88 on the cap 62. The retaining projection 136 addition, the valve seat 220 defines a stem opening 240 that
engages the mounting wall 88 to mechanically attach the extends from the seat portion 232 and through the support
valve seat 120 onto the cap 62. The overlap of the mounting 50 portion 230. A seat edge 242 is formed in the seat portion 232
wall 88 and base wall 82 with the valve seat 120 forms a around the stem opening 240.
Substantially fluid-tight seal around the mounting opening 86. The valve stem 222 comprises a threaded portion 250, a
The collection tube 128 is secured to the valve housing 124 guide portion 252, an inlet portion 254, and a stop portion
by inserting the tube 128 into the housing inlet passageway 256. The valve stem 222 further comprises a stem passageway
182 or, as shown in FIG. 1, inserting the tube projection 174 55 260 defining a stem inlet 262 and a stem outlet 264. The stem
into the tube passageway 192. inlet 262 is formed in the inlet portion 254 of the valve stem
The actuator 44 is attached to the valve stem 122. In par 222, and the stem outlet 264 is formed adjacent to the
ticular, in the example mechanical system 24a, the threaded threaded portion 250 of the stem 222.
portions 92 and 150 engage each other to detachably attach The valve housing 224 comprises a side wall 270, a bottom
the actuator 44 to the valve stem 122. As generally discussed 60 wall 272, and a tube projection 274. A mounting portion 276
above, other attachment systems may be used to attach the extends from the side wall 270. The valve housing 224 defines
actuator 44 to the valve stem 122. a valve chamber 280, and a housing inlet passageway 282
The valve assembly 42a operates basically as follows. The extends through the tube projection 274 to allow fluid to flow
valve spring 126 biases the valve stem 122 into an extended into the valve chamber 280.
position as shown in FIG.1. When the valve stem 122 is in the 65 The collection tube 228 comprises a side wall 290 and
extended position, the stop portion 156 thereof engages the defines a tube passageway 292. The tube passageway 292
seat surface 144 formed on the valve seat 120. The example defines a tube inlet 294 and a tube outlet 296.
 US 8,336,742 B2
9 10
The valve assembly 42b is formed generally as follows. ber 62 to place the valve assembly 42b in its open configura
The following assembly steps may be performed in different tion. The propellant material 32 forces the stucco material 30
sequences, and the following discussion does not indicate a through the tube inlet 294, the tube passageway 292, the tube
preferred or necessary sequence of assembly steps. outlet 296, and the housing inlet 282 and into the housing
The valve stem 222 is arranged such that the guide portion chamber 280.
252 thereof is received within the stem opening 240. The From the valve chamber 280, the stucco material 30 flows
geometry of the example valve stem 222 requires a two-piece between the stop portion 256 and the seat edge 242 and into
construction that would allow the relatively wide threaded the stem inlet 262. The stucco material 30 then flows through
portion 250 to be attached to the relatively wide stop portion the stem passageway 260 and out of the stem outlet 264. The
256 after the guide portion 252 has been arranged within the 10 stucco material 30 then flows along the actuator passageway
stem opening 240. If the threaded portion 250 is relatively 90 and out of the outlet portion 94 thereof. The stucco mate
narrow and can be inserted through the stem opening 240, the rial 30 discharged through the outlet portion 94 forms a spray
valve stem 222 may be made of a single-piece construction. and ultimately lands on the target Surface.
As another alternative, the threaded portion 250 may be elimi When sufficient stucco material 30 has been deposited onto
nated; in this case, the actuator 44 is secured to the valve stem 15
the target surface, the force on the actuator 44 is released. The
222 by other means such as friction and/or the use of an valve spring 226 displaces the valve stem 222 to place the
adhesive. valve assembly 42b back into its closed configuration. The
The valve spring 226 is arranged such that one end thereof stucco material 30 thus no longer flows out of the valve
is supported by the base wall 82 of the cap 62. The other end chamber 280 through the stem passageway 260.
of the spring 226 is arranged below the actuator 44 such that E. Method of Use
depressing the actuator 44 towards the container assembly 40 Referring now to FIGS. 3-6, the method of using the
compresses the spring 226. example aerosol stucco dispensing systems 20a and 20h will
The support portion 230 of the valve seat 220 engages the now be described in further detail. In FIG. 3, reference char
guide portion 252 of the valve stem 222 to restrict movement acter 20 is used to refer to either of the dispensing systems 20a
of the valve stem 222 within a predetermined range along a 25 and 20b as described above.
valve axis A. The valve spring 226 resiliently opposes move As shown in FIGS. 3 and 5, a wall structure 320 defines a
ment of the valve stem 222 towards the bottom wall 272 of the wall surface 322 at least partly coated with a layer of pre
valve housing 224. existing stucco material 324. The example wall surface 322
The valve seat 220 is displaced such that the support por defines a coated portion330 and an uncoated portion332. The
tion 230 extends through the mounting opening 86 in the cap 30 uncoated portion 332 may be formed where a patch 334 has
62. Further displacement of the valve seat 220 forces the been made in the wall structure, but the dispensing system 20
retaining projection 236 on the valve seat 220 past the mount of the present invention can be used to dispense stucco mate
ing wall 88 on the cap 62. The retaining projection 236 rial 30 in other environments.
engages the mounting wall 88 to mechanically attach the The dispensing system 20 is arranged such that the outlet
valve seat 220 onto the cap 62. The overlap of the mounting 35 portion 94 of the actuator passageway 90 defined by the
wall 88 and base wall 82 with the valve seat 220 forms a actuator 44 is generally directed towards the uncoated portion
Substantially fluid-tight seal around the mounting opening 86. 320 as shown in FIG. 3. The actuator 44 is then depressed to
The collection tube 228 is secured to the valve housing 224 cause the dispensing system 20 to dispense the stucco mate
by inserting the tube projection 274 into the tube passageway rial 30 in a spray 340. The stucco material 30 is then allowed
292 or, as shown in FIG. 2, inserting the collection tube 228 at 40
to dry and harden.
least partly into the housing inlet passageway 282. The spray340 causes the stucco material 30 to be deposited
The actuator 44 is attached to the valve stem 222. In par onto the uncoated portion 332 in a thin layer 342 (FIG. 4) that
ticular, in the example mechanical system 24b, the threaded substantially matches the pre-existing layer 324. A broken
portions 92 and 250 engage each other to detachably attach line 344 in FIG. 6 illustrates where the uncoated portion 332
the actuator 44 to the valve stem 222. As generally discussed 45 was located prior to application of the stucco material 30.
above, other attachment systems may be used to attach the
actuator 44 to the valve stem 222. II. Aerosol Acoustic Texture Dispensing Systems
The valve assembly 42b operates basically as follows. The
valve spring 226 biases the valve stem 222 into an extended Depicted in FIGS. 7 and 8 of the drawing are first and
position as shown in FIG. 2. When the valve stem 222 is in the 50 second examples of an aerosol acoustic texture dispensing
extended position, the stop portion 256 thereof engages the systems 420a and 420b constructed in accordance with, and
seat edge 242 formed on the valve seat 220. When the stop embodying, the principles of the present invention.
portion 256 of the valve stem engages the seat edge 242, fluid
flow between the valve chamber 280 and the stem passage A. First Example
way 260 is substantially prevented, and the valve assembly 55
42b is in its closed position. Referring now to FIG. 7 of the drawing, depicted at 420a
However, by applying a force on the actuator 44 Sufficient therein is a first embodiment of an aerosol system for depos
to compress the valve spring 226, the stop portion 256 is iting on a surface 422 (FIGS. 9-12) acoustic texture material
displaced away from the seat edge 242 to place the valve 424 incorporating particulate material 426 of the present
assembly 42b into its open configuration. When the valve 60 invention. FIG. 11 illustrates a target portion 428 of the sur
assembly 42b is in its open configuration, fluid may flow face 422 on which acoustic texture material 424 is to be
between the housing chamber 280 and the stem passageway deposited.
260. The example aerosol system 420a comprises a container
When fitted with the first example valve assembly 42b, the assembly 430, a valve assembly 432, a collection assembly
aerosol stucco dispensing system 20b is used to dispense 65 434, and an outlet assembly 436. The container 430 defines a
stucco material 30 as follows. The actuator 44 is aimed product chamber 440 in which the acoustic texture material
towards a target Surface and depressed towards the cap mem 424 comprising the particulate material 426 is contained. A
 US 8,336,742 B2
11 12
first portion 442 of the chamber 440 is occupied by the acous The valve assembly 532 is mounted in a cup opening 554
tic texture material 424, while a second portion 444 of the define by the cup member 552 and operates in a closed con
chamber 440 is occupied by a pressurized propellant material figuration (shown) and an open configuration. In the open
446. The example container assembly 430 comprises a can configuration, the valve assembly 532 defines a dispensing
member 450 and a cup member 452. passageway that allows fluid communication between the
The valve assembly 432 is mounted in a cup opening 454 interior and the exterior of the container assembly 530.
defined by the cup member 452 and operates in a closed The outlet assembly 536 comprises an actuator member
configuration (shown) and an open configuration. In the open 560 that causes acoustic texture material 424 to be dispensed
configuration, the valve assembly 432 defines a dispensing by the system 420 in a fan shaped spray as will be described
10 in further detail below. The actuator member 560 is mounted
passageway that allows fluid communication between the
interior and the exterior of the container assembly 430. on the valve assembly 532 such that displacing the actuator
The outlet assembly 436 comprises an actuator member member 560 towards the valve assembly 532 places the valve
assembly in the open configuration.
460 that causes acoustic texture material 424 to be dispensed The example valve assembly 532 comprises a valve seat
by the system 420 in a fan shaped spray as will be described 15 570, a valve stem 572, a valve housing 574, a dip tube 576,
in further detail below. The actuator member 460 is mounted
on the valve assembly 432 such that displacing the to actuator and a valve spring 578. The valve seat 570 defines a seat
opening 570a and is supported by the cup member 552. The
member 460 towards the valve assembly 432 places the valve valve stem 572 defines a valve stem opening 572a and a valve
assembly in the open configuration. surface 572b. The valve stem 572 is supported by the valve
The example valve assembly 432 comprises a valve seat seat 570 such that the valve stem moves within the valve stem
470, a valve stem 472, a valve housing 474, a dip tube 476, opening 572a between first and second positions, with the
and a valve spring 478. The valve seat 470 defines a seat first position being shown in FIG. 8.
opening 470a and is supported by the cup member 452. The The valve housing 574 is supported by the valve seat 570
valve stem 472 defines a valve stem opening 472a and a valve within the product chamber 540. The valve housing 574 fur
surface 472b. The valve stem 472 is supported by the valve 25 ther supports the dip tube 576 Such that the acoustic texture
seat 470 such that the valve stem moves within the valve stem material 424 within can flow into the valve housing 574 when
opening 472a between first and second positions, with the the can is upright. The valve spring 578 is supported by the
first position being shown in FIG. 7. valve housing 574 such that the spring 578 biases the valve
The valve housing 474 is supported by the valve seat 470 stem 572 into the first position. The valve stem 572 supports
within the product chamber 440. The valve housing 474 fur 30 the outlet assembly 536 such that depressing the actuator
ther supports the dip tube 476 Such that the acoustic texture member 560 towards the cup member 552 forces the valve
material 424 within can flow into the valve housing 474 when stem 572 into the second position (not shown) against the
the can is upright. The valve spring 478 is supported by the force of the valve spring 578.
valve housing 474 such that the spring 478 biases the valve The valve assembly 532 thus operates in the closed con
stem 472 into the first position. The valve stem 472 supports 35 figuration and the open configuration as follows. When no
the outlet assembly 436 Such that depressing the actuator force is applied to the actuator member 560, the valve spring
member 460 towards the cup member 452 forces the valve 578 forces the valve surface572b against the valve seat 570 to
stem 472 into the second position (not shown) against the prevent fluid from flowing through the valve stem opening
force of the valve spring 478. 572a. When a force is applied to the actuator member 560, the
The valve assembly 432 thus operates in the closed con 40 valve surface 572b is forced away from the valve seat 570
figuration and the open configuration as follows. When no such that fluid can flow from the interior of the valve housing
force is applied to the actuator member 460, the valve spring 574 through the valve stem opening 572a and thus out of the
478 forces the valve surface 472b against the valve seat 470 to product chamber 540.
prevent fluid from flowing through the valve stem opening
472a. When a force is applied to the actuator member 460, the 45 C. Method of Use
valve surface 472b is forced away from the valve seat 470
such that fluid can flow from the interior of the valve housing Turning now to FIGS. 9-12, the use of the aerosol dispens
474 through the valve stem opening 472a and thus out of the ing systems 420a and 420b will now be described in further
product chamber 440. detail. These dispensing systems 420a and 420b are used in
50 the same manner and are both identified by reference charac
B. Second Example ter 420 in FIGS. 9-12.
As shown in FIG. 9, the dispensing system 420 deposits a
Referring now to FIG. 8 of the drawing, depicted at 420b fan-shaped spray of acoustic texture material 424 on the
therein is a first embodiment of an aerosol system that may target portion 428 of the surface 422. As shown in FIGS. 10
also be used to deposit the acoustic texture material 424 55 and 12, the acoustic texture material 424 covers the target
incorporating particulate material 426 of the present inven portion 428 to match the pre-existing acoustic texture mate
tion on the target portion 428 of the surface 422. rial on the Surface 422 Surrounding the target portion 428.
The example aerosol system 420b comprises a container Referring for a moment back to FIGS. 7 and 8, it can be
assembly 530, a valve assembly 532, a collection assembly seen that, in addition to the particulate material 426, the
534, and an outlet assembly 536. The container 530 defines a 60 acoustic texture material comprises a base portion 620 in the
product chamber 540 in which the acoustic texture material form of a flowable liquid. The base portion 620 of the par
424 comprising the particulate material 426 is contained. A ticulate material conventionally comprises a carrier, a filler,
first portion 542 of the chamber 540 is occupied by the acous and a binder.
tic texture material 424, while a second portion 544 of the In some aerosol systems, the propellant material 446,546 is
chamber 540 is occupied by a pressurized propellant material 65 simply an inert pressurized gas such as air or nitrogen. In
546. The example container assembly 530 comprises a can other aerosol systems, the propellant material 446,546 is a
member 550 and a cup member 552. material, referred to herein as bi-phase propellant material,
 US 8,336,742 B2
13 14
that exists in both gaseous and liquid phases within the con What is claimed is:
tainer assembly 430,530. The liquid phase of the propellant 1. Aerosol material for applying a repair coat to an
material 446,546 forms a part of the base portion 620, while uncoated portion of a Substrate Substantially to match a
the gaseous phase propellant material 446,546 occupies the coated portion of the Substrate using an aerosol assembly
pressurized portion 444 of the container assembly 430,530. comprising a container defining a product chamber and a
As the acoustic texture material 424 is dispensed, the pres valve assembly operable in open and closed modes, the aero
sure within the pressurized portion 444,544 of the container Sol material comprising:
assemblies 430,530 drops. Under these conditions, a portion a base portion;
of the bi-phase propellant material 446,546 in the liquid phase 10
a particulate portion made of at least one of urethane foam
gasifies to re-pressurize the pressurized portion 444,544 of and melamine foam; and
the container assembly 430,530. The pressure within the a propellant portion; whereby
pressurized portion 444,544 is thus under most conditions with the valve assembly in the closed mode, the product
sufficient to force the acoustic texture material 424 out of the chamber is adapted to contain the base portion, the par
container assembly 430,530 along the dispensing passage 15 ticulate portion, and the propellant portion such that
way when the valve assembly 432,532 is in the open configu the propellant portion exists in a gas state and a liquid
ration. The propellant material 446,546 may thus be a pres state, and
Surized inert gas Such as air or nitrogen. the propellant portion in the gas state pressurizes the
However, the present invention is of particular significance base portion, the particulate portion, and the propel
when the propellant material is a bi-phase propellant material lant portion in the liquid State; and
such as di-methyl ethylene (DME) or any one of a number of with the valve assembly in the open mode, the propellant
hydrocarbon propellants such as those available in the indus portion in the gas state gas state forces at least part of the
try as A-40 and A-70. The advantage of using bi-phase pro base portion, the particulate portion, and the propellant
pellant materials is that the pressure within the pressurized portion in the liquid state out of the product chamber and
portion 444,544 of the container assembly 430,530 is kept at 25 onto the uncoated portion of the substrate to form the
a relatively constant, relatively low level as the level of acous repair coat such that the repair coat Substantially
tic texture material 424 drops. This constant, low level pres matches the coated portion of the substrate.
sure allows the texture material 424 to be dispensed in many 2. Aerosol material as recited in claim 1, in which the
Small bursts instead of in a few large bursts, as is the case propellant portion comprises a hydrocarbon propellant.
when pressurized inert gases are used as the propellant mate 30 3. Aerosol material as recited in claim 1, in which the
rial 446,546. propellant portion comprises DME.
Many particulate materials 426 suitable for use in acoustic 4. Aerosol material as recited in claim 1, in which the
texture materials are incompatible with bi-phase propellant propellant portion comprises A-40.
materials. For example, as described above polystyrene chips 5. Aerosol material as recited in claim 1, in which the
35 propellant portion comprises A-70.
are commonly used in acoustic texture materials dispensed 6. A method of applying a repair coat to an uncoated
using commercial hopper guns. However, polystyrene chips portion of a Substrate Substantially to match a coated portion
dissolve in the bi-phase propellant materials of which the of the Substrate, the method comprising the steps of:
Applicant is aware. providing an aerosol assembly comprising a container
The Applicant has discovered that urethane foam materials 40 defining a product chamber and a valve assembly oper
and melamine foam materials may be used as the particulate able in open and closed modes;
material 426 with bi-phase propellant materials such as DME providing a base portion;
and hydrocarbon propellants such as A-40 and A-70. providing a particulate portion made of at least one of
Melamine foam materials in particular are easily chopped up urethane foam and melamine foam;
using conventional material processors (e.g., a food blender) 45 providing a propellant portion;
into irregular shapes that match the appearance and function combining the base portion, the particulate portion, and the
of polystyrene chips. Melamine foam materials are already propellant portion to form aerosol material;
commonly used in building applications and have desirable arranging the aerosol material within the product chamber
fire retardant, thermal, and acoustic properties. such that with the valve assembly in the closed mode,
To manufacture the acoustic texture material 424, the base 50 the propellant portion exists in a gas state and a liquid
portion 620 may be the same as a conventional base used in state, and
commercially available acoustic texture materials. Instead of the propellant portion in the gas state pressurizes the
polystyrene chips, however, urethane and/or melamine foam base portion, the particulate portion, and the propel
is chopped up into particles of an appropriate size and use as lant portion in the liquid State; and
the particulate. In addition, a bi-phase propellant material is 55 with the valve assembly in the open mode, the propellant
used to form part of the carrierportion of the base portion 620. portion in the gas state gas state forces at least part of the
The Applicanthas thus determined that a conventional base base portion, the particulate portion, and the propellant
portion using melamine foam chips and DME as a propellant portion in the liquid state out of the product chamber and
is commercially practical and obtains acceptable aesthetic onto the uncoated portion of the substrate to form the
and functional results. Appropriate adjustments in the liquids 60 repair coat such that the repair coat Substantially
used as the carrier in a conventional acoustic texture material matches the coated portion of the substrate.
formulation may be required to obtain a desired consistency 7. A method as recited in claim 6, in which the propellant
of the acoustic texture material 424 as it is deposited on the portion comprises a hydrocarbon propellant.
surface 422. 8. A method as recited in claim 6, in which the propellant
Various modifications can be made to the embodiments 65 portion comprises DME.
described above without departing from the principles of the 9. A method as recited in claim 6, in which the propellant
present invention. portion comprises A-40.
 US 8,336,742 B2
15 16
10. A method as recited in claim 6, in which the propellant when the aerosol material is not confined, the propellant
portion comprises A-70. portion in the gas state gas state displaces at least part of
11. Aerosol material for applying a repair coat to an the liquid mixture onto the uncoated portion of the sub
uncoated portion of a Substrate Substantially to match a strate to form the repair coat Such that the repair coat
coated portion of the Substrate comprising: 5 substantially matches the coated portion of the substrate.
a base portion; 12. Aerosol material as recited in claim 11, in which the
a particulate portion made of at least one of urethane foam propellant portion comprises a hydrocarbon propellant.
and melamine foam; and 13. Aerosol material as recited in claim 11, in which the
a propellant portion; whereby propellant portion comprises DME.
when the aerosol material is confined, 14. Aerosol material as recited in claim 11, in which the
the propellant portion exists in a gas state and a liquid 10 propellant portion comprises A-40.
State,
15. Aerosol
the base portion, the particulate portion, and the propel propellant portion material as recited in claim 11, in which the
lant portion in the liquid state form a liquid mixture, comprises A-70.
and
the propellant portion in the gas state pressurizes liquid
mixture; and