Objects containing coatings

Abstract

A method for coating an object with waist material or recycled material, comprising: a. grinding the material to obtain ground material having a particle size of less than 2.5 mm; b. coating the object with an aqueous binder to obtain a coated object; c. applying the ground material to the coated object by electrostatic spraying to obtain an object having a wet coating; d. optionally repeating steps b and c; and e. drying the object having the wet coating to obtain an object having a coating.

Description

[Technical Field]

[0001] The present invention relates to a method of coating an object with a material, an object including the coating, and uses of the object. [Background technology]

[0002] The reuse of materials and the use of waste materials will become increasingly important in the coming years. Also, the restoration of objects will become increasingly common in an era of raw material scarcity. However, challenges exist in the reuse of various materials that are currently deposited in landfills or burned for disposal. Summary of the Invention [Problem to be solved by the invention]

[0003] There is a need for improved methods of coating objects for use or reuse, and for the use of materials in coating objects. [Means for solving the problem]

[0004] The inventors have discovered a method for coating an object with a material, which is the subject of the present invention.

[0005] The present invention provides a method for coating an object with recycled or waist material, comprising the steps of: a. grinding the waist material or recycled material to obtain ground material having a particle size of less than 2.5 mm; b. coating the object with an aqueous binder to obtain a coated object; c. applying the ground material to a coated object by electrostatic spraying to obtain an object having a wet coating; d. optionally repeating steps b and c; e. drying the object having the wet coating to obtain an article including the coating; The present invention relates to a method comprising:

[0006] Advantages of the method according to the invention include the efficient use of waste or recycled materials as a coating on an object, the provision of a simple method that can be used for many different objects, the resulting durable object that can be useful for many years, the flexibility in changing the material used to coat the object, and the extension of the object's lifespan in an economically sustainable manner. Furthermore, the method provides a highly efficient coating method that uses less energy than known methods: for example, energy consumption is reduced by at least 90% compared to conventional coating methods. DETAILED DESCRIPTION OF THE INVENTION

[0007] Detailed Description object The object to be coated can in principle be any object with any type of surface, which may be made of, for example, metal, wood, rubber, or any other material that can be bonded with the aqueous binder used according to the invention.

[0008] material The material can in principle be any material that can be pulverized to a small particle size. Preferably, the material is recycled or waste material. Examples of materials suitable for coating objects are leather, cork, cloth, wood materials such as walnuts, peach kernels, acorns, chestnuts, oak, and beach, rubbery materials such as tires, shoe soles, and mattresses, and hard materials such as pearl glass, metal powder, sand, and gravel.

[0009] Covering Coating is defined as bonding a thin layer of material to the surface of an object, for example as a decorative, protective or hiding layer.

[0010] Different terms can be used for covering, such as repairing, covering, forming a skin on an object, etc. Covering can also be defined as coating or covering the surface of an object with ground material.

[0011] crushing Comminution of the recycled material can be accomplished by any known method, examples of which include milling, sanding, chopping, using a hammer mill, etc. Comminution can also be defined as size reduction or pulverization.

[0012] An example of a suitable grinding system is the Retsch SM 300, which includes a metal sieve to measure the particle size of the ground recycled material.

[0013] particle size The particle size of the material before grinding can be anywhere between 1 mm and several decimeters. Preferably, the particle size of the material before grinding ranges between 1 millimeter and 1 cm. After grinding, the particle size of the ground recycled material is typically less than 2.5 mm, preferably less than 1.5 mm or less than 1 mm. Preferably, the particle size is less than 0.84 mm and greater than 0.1 mm.

[0014] Particle size is determined by sieving particles through a mesh filter with an appropriate mesh size. For example, a material with a particle size of less than 0.84 mm is understood to be the sieve fraction that can pass through a mesh 20 filter (with 0.841 mm holes). The amount of fines is preferably limited, for example, less than 20% by weight of the total particles, more preferably less than 10% by weight. Fines are particles with a size of less than 0.1 mm.

[0015] coating The coating is applied to the surface of the object by coating the surface with an aqueous binder, followed by application of the ground recycled material. Typically, the thickness of the layer of aqueous binder on the surface of the object ranges between 50 and 1000 micrometers. Optionally, more layers of aqueous binder, such as two layers, can be applied to the surface of the object.

[0016] The thickness of the layer of ground material is typically in the range of 0.2 to 3 millimeters.

[0017] It is also possible to apply more than one coating layer onto an object by sequentially applying aqueous binder and ground material, for example, by applying two or three successive layers of binder and ground material.

[0018] Water-based binder The aqueous binder used in the method of the present invention preferably comprises an acrylate binder, such as an acrylic acid ester copolymer or a styrene-acrylic acid ester copolymer. The binder preferably comprises between 40 and 80 weight percent of the styrene-acrylic acid ester copolymer, between 20 and 60 weight percent of the acrylic acid ester copolymer, and between 0 and 10 weight percent of additives such as biocides, antifoaming agents, thickeners, fillers, etc., all weight percents being based on the amount of organic components in the aqueous binder.

[0019] Preferably, the amount of styrene acrylic acid ester copolymer ranges between 50 and 70% by weight and the amount of acrylic acid ester copolymer ranges between 25 and 45% by weight, based on the amount of organic components in the binder.

[0020] The amount of organic component typically ranges between 50 and 75% by weight based on the total amount of the aqueous binder, which means that the aqueous binder contains between 30 and 50% by weight of water.

[0021] Styrene acrylate copolymers and acrylate copolymers are well known to those skilled in the art.

[0022] The amount of aqueous binder applied to the surface of an object typically ranges between 150 and 250 g / m². If more than 250 g / m² is applied, wet spots may be observed after application of the ground material. If less than 150 g / m² is applied, the ground material may not bond well to the surface of the object.

[0023] The amount of aqueous binder used also depends on the type of ground material being applied. Some materials, such as cork, do not absorb much aqueous binder. In these cases, applying 150-200 g / m² of binder may be sufficient.

[0024] Other materials, such as cotton obtained from recycled jeans, tend to absorb much more water-based binder and require more binder to be applied than cork, for example between 180 and 250 g / m².

[0025] The aqueous binder preferably contains a flexible material that functions as a thickener. One preferred flexible material used is xanthan gum. Preferably, the aqueous composition contains between 0.1 and 1.5% by weight, more preferably between 0.2 and 1% by weight, of xanthan gum based on the amount of the aqueous binder. Xanthan gum improves the thixotropic behavior of the aqueous binder.

[0026] Electrostatic coating The grinding material is preferably applied using electrostatic application techniques, where the application of the grinding material with an electrostatic charge results in a uniform distribution of the material, a uniform layer being applied, and the grinding material reaching all corners of the object surface.

[0027] Preferred electrostatic application techniques are electrostatic flocking and powder coating. Electrostatic flocking is a textile technique that uses Coulombic propulsion to project short fibers from an electrically charged source toward the object to be coated, resulting in a dense array aligned perpendicular to the surface of the object.

[0028] Powder coating is a type of coating in which ground material is applied as a free-flowing dry powder. Powder coating is typically applied electrostatically and then dried under heat. In this application, the object does not need to have an electrical charge as is the case with conventional electrostatic powder coating. It is sufficient that the ground material is charged when applied to the surface of the object.

[0029] It is preferred that a sufficient air supply be used when powder coating and / or electrostatic flocking is performed to move the charged ground material to the object to be coated.

[0030] Preferably, the amount of ground material bonded to the coated surface of the object is between 50 and 500 g / m2.

[0031] Preferably, the volume of supply air used to assist in the electrostatic application of the ground material ranges between 10 and 100 times the volume of the ground material. For example, if the volume of ground material being applied to an object is 0.1 m3 / hour, the volume of air used to apply the material to the object preferably ranges between 1 and 10 m3 / hour.

[0032] Use of pressure / rolling One option is to apply pressure to the coating layer, for example with a roller, to force the ground material into the layer of aqueous binder.

[0033] Drying After application of the ground material, the binder is preferably dried using air, for example hot air.

[0034] After drying, the surface of the covered object can be coated with a water-repellent coating. [Example]

[0035] Example 1: Binder Composition A binder composition is prepared by mixing 65 wt% styrene acrylic ester copolymer dispersion (60% solids), 32.5 wt% acrylic ester copolymer dispersion (60% solids), 0.35 wt% xanthan gum, and additives such as biocides and defoamers.

[0036] Example 2: Grinding of materials The following materials were ground in a Retsch 300 SM grinder with a number of different mesh sieves to separate the ground material into different fractions: leather, cork, seeds, coffee, peach kernel, wood, cloth.

[0037] Example 3: Application of material to an object An object (for example a chair) is sprayed with the binder composition prepared as in Example 1. 200 g / m2 of binder composition is applied in a uniform manner.

[0038] Using a GEMA powder applicator, which uses air to move the particles, different ground materials are applied to the wet coating layer of the object. In this example using leather and cork, 30 volumes of air are used based on the volume of ground material. Optionally, after grinding, the applied layer of ground material is rolled.

[0039] After drying with hot air, the object (chair) is ready for use. [Brief explanation of the drawings]

[0040] [Figure 1] Shown is a chair that was used for 30 years before being given a new upholstery layer. [Figure 2] 2 shows the chair of FIG. 1 with a new upholstery layer. [Figure 3] Showing the Fjord chair before cladding. [Figure 4] Showing the Fjord chair after cladding.

Claims

1. 1. A method for coating an object with recycled or waist material, comprising: a. grinding a material to obtain ground material having a particle size of less than 2.5 mm; b. coating the object with an aqueous binder to obtain a coated object; c. applying the ground material to the coated object by electrostatic spraying to obtain an object having a wet coating; d. optionally repeating steps b and c; e. drying the object having the wet coating to obtain the object including the coating; A method comprising:

2. 2. The method of claim 1, wherein the ground material has a particle size of less than 1.5 mm, more preferably less than 1 mm, more preferably less than 0.84 mm, and most preferably between 0.1 mm and 0.84 mm.

3. 3. The method according to claim 1 or 2, wherein the material is selected from the group consisting of leather, cork, cloth, woody materials such as walnuts, peach kernels, acorns, chestnuts, oak, and beach, rubbery materials such as tires, shoe soles, and mattresses, and hard materials such as pearl glass, metal powder, sand, and gravel.

4. The method of any one of claims 1 to 3, wherein the coating of the object is a repair of the object.

5. 5. The method of claim 1, wherein the aqueous binder comprises between 40 and 80% by weight of styrene acrylic acid ester copolymer and between 20 and 60% by weight of acrylic acid ester copolymer, based on the amount of organic material of the aqueous binder.

6. 6. The method of any one of claims 1 to 5, wherein the binder preferably comprises between 0.1 and 1.5 wt. %, more preferably between 0.2 and 1 wt. %, of Xantar Gum, based on the weight of the binder composition.

7. The method according to any one of claims 1 to 6, wherein the amount of solids of the aqueous binder ranges between 50 and 75% by weight.

8. The method of any one of claims 1 to 7, wherein the aqueous binder is applied to the body at between 150 and 250 g / m2.

9. The method according to any one of claims 1 to 8, wherein the binder is applied in a layer thickness between 0.5 mm and 3 mm.

10. A method according to any one of claims 1 to 9, wherein during step c air is added to assist the application of the ground material.

11. The method of claim 10, wherein the volume of air ranges between 10 and 100 times the volume of ground material applied onto the coated object.

12. 12. The method according to any one of claims 1 to 11, wherein the amount of ground material applied in step c ranges between 50 and 500 g / m2 of the surface of the coated object.

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