Wood-like coating method for substrate

Abstract

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.

What is claimed is: 
     
         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.