Spray texture material compositions, systems, and methods with anti-corrosion characteristics

1. A system for dispensing texture material in a desired spray pattern that substantially matches an existing texture pattern on a target surface, comprising:

an aerosol dispenser comprising

a container assembly defining an inner surface, where the inner surface defines a main chamber; and

is at least in part a tin-plated steel,

an actuator assembly defining an outlet opening having a cross-sectional area, where the cross-sectional area of the outlet opening is adjustable;

a concentrate comprising

a solvent/carrier comprising water, where the solvent/carrier comprises approximately 25-65% of by weight of the concentrate,

a resin/binder, where the resin/binder comprises approximately 3-7% by weight of the concentrate,

filler material, where the filler material comprises approximately 20-70% by weight of the concentrate,

a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester and comprises approximately 0.5-2.0% by weight of the concentrate, and

a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite and comprises approximately 0.05-1.00% by weight of the concentrate; and

a propellant material; wherein

the concentrate and propellant material are disposed within the container assembly such that the water is exposed to the inner surface of the container assembly;

at least one of the first and second anti-corrosion materials forms a film on the inner surface of the container assembly;

the film inhibits corrosion of the inner surface of the container assembly; and

the cross-sectional area of the outlet opening is adjusted such that the propellant material forces the concentrate out of the outlet opening in a spray pattern that forms the desired texture pattern on the target surface.

2. A system as recited in claim 1 , in which the concentrate further comprises a biocide.

3. A system as recited in claim 1 , in which the concentrate further comprises a defoamer.

4. A system as recited in claim 1 , in which the concentrate further comprises a dispersant.

5. A system as recited in claim 1 , in which the concentrate further comprises a color change material.

6. A system as recited in claim 1 , in which the concentrate further comprises at least one additive selected from the group of additives consisting of a biocide, a defoamer, and a dispersant.

7. A system as recited in claim 6 , in which the concentrate further comprises a color change material.

8. A system as recited in claim 1 , in which the concentrate further comprises a particulate material.

9. A system as recited in claim 1 , in which:

at least a portion of the container assembly is formed by tin-plated steel; and

the first and second anti-corrosion materials form a protective film on any portion of the container assembly that is formed by tin-plated steel exposed to the concentrate.

10. A method of dispensing texture material onto a target surface comprising the steps of:

providing an aerosol dispenser comprising a container assembly defining an inner surface, where at least a portion of the inner surface is made of tin-plated steel;

forming a concentrate by mixing

a solvent/carrier comprising water, where the solvent/carrier comprises approximately 25-65% of by weight of the concentrate,

a resin/binder, where the resin/binder comprises approximately 3-7% by weight of the concentrate,

filler material, where the filler material comprises approximately 20-70% by weight of the concentrate,

a first anti-corrosion material, where the first anti-corrosion material is a phosphate ester and comprises approximately 0.5-2.0% by weight of the concentrate, and

a second anti-corrosion material, where the second anti-corrosion material is sodium nitrite and comprises approximately 0.05-1.00% by weight of the concentrate;

arranging the concentrate and a propellant material within the container assembly such that at least one of the first and second anti-corrosion materials forms a thin protective film on the inner surface; and

operating the aerosol dispenser such that the propellant material forces the concentrate in a spray pattern that forms the desired texture pattern on the target surface.

11. A method as recited in claim 10 , further comprising the step of mixing a biocide into the concentrate.

12. A method as recited in claim 10 , further comprising the step of mixing a defoamer into the concentrate.

13. A method as recited in claim 10 , further comprising the step of mixing a dispersant into the concentrate.

14. A method as recited in claim 10 , further comprising the step of mixing a color change material into the concentrate.

15. A method as recited in claim 10 , further comprising the step of mixing into the concentrate at least one additive selected from the group of additives consisting of a biocide, a defoamer, and a dispersant.

16. A method as recited in claim 15 , further comprising the step of mixing a color change material into the concentrate.

17. A method as recited in claim 10 , further comprising the step of mixing a particulate material into the concentrate.

18. A system as recited in claim 1 , in which the concentrate comprises:

approximately 30-60% of the solvent/carrier by weight of the concentrate;

approximately 4.5-5.5% of the resin/binder by weight of the concentrate; and

approximately 40-60% of the filler material by weight of the concentrate.

19. A method as recited in claim 10 , in which the step of forming the concentrate comprises the steps of mixing:

approximately 30-60% of the solvent/carrier by weight of the concentrate;

approximately 4.5-5.5% of the resin/binder by weight of the concentrate; and

approximately 40-60% of the filler material by weight of the concentrate.