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 method for coating a substrate, the method comprising:
pressure embossing a pattern into the substrate to form a patterned substrate having an embossed pattern;
coating the patterned substrate with a base coating to form a coated substrate;
applying an under-indexed contrasting agent to the embossed pattern of the coated substrate and removing excess under-indexed contrasting agent to form a contrasting agent coated substrate with a portion of the under-indexed contrasting agent remaining in the embossed pattern, the under-indexed contrasting agent comprising a plural component paint that does not contain a catalyst, a cross-linker, or a hardening agent; and
coating the contrasting agent coated substrate with an over-indexed coating, the over-indexed coating comprising a plural component paint comprising an excess of a catalyst, a cross-linker, or a hardening agent.
2. The method of claim 1 , wherein the substrate is mechanically embossed after coating the patterned substrate with the base coating.
3. The method of claim 1 , wherein the substrate comprises an aromatic polyurethane.
4. The method of claim 3 , further comprising a step of sanding the substrate prior to coating the patterned substrate with the base coating to create porosity to promote mechanical adhesion.
5. The method of claim 1 , wherein the substrate is mechanically embossed prior to coating the patterned substrate with the base coating.
6. The method of claim 1 wherein the excess under-indexed contrasting agent is removed by reverse roll-coating.
7. The method of claim 1 , wherein the embossed pattern comprises a wood grain pattern.
8. The method of claim 1 , wherein the over-indexed coating comprises an abrasion-resistant clear coating.
9. The method of claim 1 , wherein the under-indexed contrasting agent is partially dried before coating the contrasting agent coated substrate with the over-indexed coating.
10. The method of claim 1 , wherein the base coating comprises a fully pigmented, plural component coating.
11. The method of claim 1 , wherein the base coating comprises a thermal cure two-component polyurethane based system.
12. A method for coating a substrate comprising an aromatic polyurethane, the method comprising:
pressure embossing a pattern into the substrate comprising the aromatic polyurethane to form a patterned substrate having an embossed pattern;
coating the patterned substrate with a base coating comprising a thermal cure two-component polyurethane based system to form a coated substrate;
applying an under-indexed contrasting agent to the embossed pattern of the coated substrate and removing excess under-indexed contrasting agent to form a contrasting agent coated substrate with a portion of the under-indexed contrasting agent remaining in the embossed pattern, the under-indexed contrasting agent comprising a plural component paint that does not contain a catalyst, a cross-linker, or a hardening agent; and
coating the contrasting agent coated substrate with an over-indexed coating, the over-indexed coating comprising a plural component paint comprising an excess of a catalyst, a cross-linker, or a hardening agent.
13. The method of claim 12 , wherein the excess under-indexed contrasting agent is removed by reverse roll-coating.
14. The method of claim 13 , wherein the under-indexed contrasting agent is partially dried before coating the contrasting agent coated substrate with the over-indexed coating.
15. The method of claim 12 , wherein the over-indexed coating comprises an abrasion-resistant clear coating.
16. The method of claim 12 , wherein the embossed pattern comprises a wood grain pattern.