WOOD-LIKE COATING METHOD FOR SUBSTRATE
A protective coating method of a material such as aromatic polyurethane substrates is effected through a process that promotes coating adhesion to the substrate while providing a wood-like aesthetic. Closed cells on the surface of the aromatic polyurethane are opened via sanding techniques to promote adhesion. Once a sufficient surface is achieved, the substrate is coated using spray techniques to protect the aromatic polyurethane from ultra-violet light exposure. The wood-like appearance is achieved through embossing a wood-grain on the deformable surface and subsequently filling the grain with a contrasting agent to highlight its appearance through a reverse-roll-coating technique. Abrasion properties are achieved through a final clear top coat that allows both the contrast agent and the top coat to fully cure.
1 . A coated substrate comprising:
a substrate of aromatic polyurethane;
the substrate having an embossed surface with one or more indented portions and one or more non-indented portions, the one or more indented portions and the one or more non-indented portions have an appearance of a wood-grain pattern;
a base coat layer on the embossed surface;
a cured non-catalyzed contrast agent on the one or more indented portions of the embossed surface; and
an abrasion resistant clear coat layer having excess catalyst on the non-catalyzed contrast agent within the one or more indented portions.
2 . The coated substrate of claim 1 , wherein the abrasion resistant clear coat further comprises an excess of cross-linker, hardening agent, or both.
3 . The coated substrate of claim 1 , wherein the base coat layer is a fully pigmented, plural component coating.
4 . A coated substrate comprising:
a substrate of aromatic polyurethane;
the substrate having an embossed surface with one or more indented portions and one or more non-indented portions, the one or more indented portions and the one or more non-indented portions have an appearance of a wood-grain pattern;
a fully hiding base coat layer including a first cured base coat layer on the embossed surface, and a second cured base coat layer on the embossed surface;
a cured non-catalyzed contrast agent covering the one or more indented portions of the embossed surface and contrasting with the fully hiding base coat layer; and
an abrasion resistant clear coat layer having excess catalyst within the one or more indented portions.
5 . The coated substrate of claim 4 , wherein each of the first and second base coat layers has a mix ratio between 3-6/1/1-3 of paint/hardener/thinner.
6 . A method for coating aromatic polyurethane substrate for exterior uses, the method comprising:
sanding an aromatic polyurethane substrate to create porosity by opening closed-cells and promote mechanical adhesion;
pressure embossing a wood grain pattern into the substrate; base-coating the substrate with a plural component coating, applying under-indexed contrasting agent to the substrate;
removing excess contrasting agent using reverse roll coating; and final coating with an over-indexed abrasion resistant clear coating.
7 . The method of claim 6 wherein the step of pressure embossing is before the step of base-coating.
8 . The method of claim 6 wherein the step of pressure embossing is after the step of base-coating.
9 . The method of claim 6 , wherein the step of final coating includes using the abrasion resistant clear coat having an excess of cross-linker, hardening agent, or both.
10 . The method of claim 6 wherein, after the step of final coating, catalytically curing the contrast agent.