CA1111626A - Process for manufacturing imitation stone used for decoration - Google Patents
Process for manufacturing imitation stone used for decorationInfo
- Publication number
- CA1111626A CA1111626A CA318,020A CA318020A CA1111626A CA 1111626 A CA1111626 A CA 1111626A CA 318020 A CA318020 A CA 318020A CA 1111626 A CA1111626 A CA 1111626A
- Authority
- CA
- Canada
- Prior art keywords
- mix
- cords
- sand
- stone
- cement
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Abstract
CANADIAN PATENT APPLICATION
TITLE: PROCESS FOR MANUFACTURING IMITATION
STONE USED FOR DECORATION
INVENTOR: MITCHELL DARRELL WRIGHT
Fox Bay Road Loris, South Carolina 29569 U.S.A.
ABSTRACT OF THE DISCLOSURE OF THE INVENTION
A new, improved and inexpensive method and mixture of cements for the manufacture of imitation stone used for the purpose of decorating the object or surface upon which it is applied for giving it the appearance of being made of real stone.
The present application is the same invention of United States Patent No. 4,133,692, filed July 21, 1977 and issued January 9, 1979.
TITLE: PROCESS FOR MANUFACTURING IMITATION
STONE USED FOR DECORATION
INVENTOR: MITCHELL DARRELL WRIGHT
Fox Bay Road Loris, South Carolina 29569 U.S.A.
ABSTRACT OF THE DISCLOSURE OF THE INVENTION
A new, improved and inexpensive method and mixture of cements for the manufacture of imitation stone used for the purpose of decorating the object or surface upon which it is applied for giving it the appearance of being made of real stone.
The present application is the same invention of United States Patent No. 4,133,692, filed July 21, 1977 and issued January 9, 1979.
Description
DETAILED DESCRIPTION OF THE PR~FERRE~ EMBODIMENT
OF THE Ir~ENTIoN
The first stcp in my process is to obtain the neces~ary ingredlents to prepare the stone mlxture.
There is a wide variety of ingredients that can be employed to obtain essentially the same end ~esult.
Howeverg there are only ~our absolutely necessary in-gredients, namely: (1) sand, (2) dry cement, (3~ water and (4) paint. An infinite number of chemicals~
minerals or other materials can be employed, along with th~ aforementioned four lngredients, to obtain various chemical reactions~ ~exturesg strengths, colors~
shapes and slzes. m e tlme required for the stones to harden can be varied by the addition of catalysts or retarders, or any other tlme varying chemical which iæ compatable with the basic mixture The texture and ~inished appearance of the stones can be varied ko sult the maker by the addition of rocks, stones, coquina~ shells, cinders, or any other mineral or ob-ject that will give the maker the texture and finish he wishes. me color possibilitiPs are endless, and can include the use of different colored sand of any type, the application o~ any type o~ paint or stain on the sur~ace after the stones have dried or the introduction into the mlxing process o~ any type of coloring agent that is compatable with the four basic ingre~ients. The sand used in my process can be o~ any available type of natural sand Mowever~ the ldeal type is the common build0rs type o~ sand used in the laying of brick. The cement used in my proce~s can be any type or color o~ natural cement, such as port-land cement, or any ona of the di~ferent types of mortarmixes that are sold commercially under dl~erent brand names, or any type cement that will harden sufficiently when mixed with a quantity o~ water.
For the sake o~ br~vity, I will limit the 1~ mixture for discus~ion, to the b~sic ~our ingredi~nts of sand, portland cement, water and paint.
In making the inltial mixture~ I incorporate three of the four basic ingr~dients~ namely æand~
portland cement, and water. The ratio of sand to cement can range ~rom one part cement to eight parts sand, to all cement and no sand. However, the ideal mixture for the best tex~ure and hardness is one part cement to three parts sand The amount of water added to the cement and sand mixture can vary from just enough water to dampen all the mixture, to sifficient water to give the mixture the consistency o~ cream.
However, the ideal amount of water is enough to obtain a consistency comparable to that of mortar mix when used to lay bricks, yet slightly dryer so that the mixture 25 wlll hold a shape when it is shaped by hand.
My process uses no molds to shape the stones, though they can be used if a particular shape is de-sirable by the maker. My process yields stones o~
random shape and size ~ust as ~atural ætones are.
This is done by simply pouring the prepared mixture on any flat sur~ace that the mlxture will not adhere to. However, be~ore pouring the mixtureg the ~lat sur-~ace, which can be o~ any size according to what quan-tity of stones is desired, ls first prepared by laylng several cords or ropes across ito These cords can be o~ ~n~ s~ze or composition that will allow the stones to be lifted ~rom the flat surface. The cords should 10 be lai~ out parallel to each other approximately six inches apart~ and extend past the intended area where the mixt~re is to be poured ~ar enough to allow ac-cess to them a~ter the mix is pouredO Furthermore, they should be attached firmly to the flat pouring sur-face at one end~ Enough cords should be used to coverthe entire width o~ the proposed pouring surfaceO
The mixture o~ one part cement~ four parts sand, and a quantity of water is now agitated suf~icient-ly to obtaln a thorough mixing of the three ingredients This mixture ls then poured or otherwise placed on the flat surface covering the cords~ as inidicated, and then flattened into a solid sheet of any thickness desired by the maker. The ideal thickness is from one to three inches~ Su~ficient care ls ~aken here to in-sure that the m1xture is now in one solid sheet, cover-ing all o~ the cordæ, yet leaving both ends exposed su~iciently to allow the maker to hold the cords firmly with his hands.
The solid sheet of stone mixture is now shaped lnto the deslred texture, either by hands~ or by using any type of mechanical device~ or any other method, the object of which is to make ~he entire top surface of the mixture take on the rough appearance Of natur~l stone textures.
The stone mix is now allowed to dry and begln to set up until a precise moment in the drying time is reached. In order to clearly exemplify when thls pre-cise time is reached, it i8 ~irst necessary to fully ex-plain the object of determining this time.
The solid sheet of mix is converted to stones of random shapes and siæes by simply p~lling the loose ends of all the cords a~ the same time up and away ~rom the solid sheet at an angle o~ approximately forty-~ive degrees. When the cords are pulled up and away at this angle, the~ attempt to li~t the entire sheet of mix up from the ~lat sur~ace. However, since the stone mix has not yet completely hardened, the re~ult is the breaking up of the solid sheet in~o several smaller pieces. There~ore~ the more drying time allowPd, the harder the sheet will be~ and the larger the result-ing broken pieces will beO Conversely, the sooner the cords are pulled the smaller the pieces. These pieces will hereafter be referred to as stones The amount of dryin~ time, or setting up time, is determined by either the introduction in the mixing stage of any type o~ compatable catalyst or retardent, or by ~he e~fect o~ the prevailing weather condltlons.
me ideal method is that of natural air drying on a warm day with low relative humidity~ ~rnder these con-ditions, a test should be made after approximately three hours o~ drying time has elapsed, This .is done by slowly pulling on the cords in the indicated way until one or two stones break o~ the stones are o~ the desired size~ they are then removed ~rom the cords by gently lifting straight ~p. The cords have now performed a second ~unc~ion, by creating a groove in the back side o~ the stones ThiS groove will be filled with mortar mix when the stones are put on the surface to be decorated, ~hus giving additional ad~
herence to the surface of the stones~
When the stone~ are removed rrom the pouring sur~ace and from the cords, they are then ready to be ~mooth~d over ~o attain ~helr ~inal appearance. ThiS
is accomplished by using water to wet the stonej ~ollow-ed by rubbing gently over the sur~ace and edges with either one~s hands, a spongeg a cloth, or an~ suitable device to get the desir~d e~ect This is followed by a thorough rinsing o~ the stone to remove all the loose particles o~ sand and cement, The stones are then allowed to dry c ompletely The stones can be colored by the addition of any type o~ cement colorant in the mixing stage, or by the use o~ paints or stains a~ter they are smoothed and drled. ~or all practical purposes~ the latter wl~l L6~ Eii yield the most flexible and realistic results, limited only by the ability of the maker. Any type of avail-able paint, dye, stain or other compatible coloring pigments may be used.
When the coloring agent has dried, the stones are installed on the surface to be decorated by simply applying prepared mortar mix to the surface, applying mortar mix to the back side of the finished stone, and then pressing the stone to the surface. When the mortar mix dries, the stone will be bonded to the surface securely.
This composition, when manufactured as indi-cated, can be used on any solid surface that will hold the weight of the stones, and the mortar mix used when laid in the normal manner of laying such stones. It can be used indoors or outdoors to decorate the surface on which it is affixed, and give it the appearance of being made of real stone.
. ~
OF THE Ir~ENTIoN
The first stcp in my process is to obtain the neces~ary ingredlents to prepare the stone mlxture.
There is a wide variety of ingredients that can be employed to obtain essentially the same end ~esult.
Howeverg there are only ~our absolutely necessary in-gredients, namely: (1) sand, (2) dry cement, (3~ water and (4) paint. An infinite number of chemicals~
minerals or other materials can be employed, along with th~ aforementioned four lngredients, to obtain various chemical reactions~ ~exturesg strengths, colors~
shapes and slzes. m e tlme required for the stones to harden can be varied by the addition of catalysts or retarders, or any other tlme varying chemical which iæ compatable with the basic mixture The texture and ~inished appearance of the stones can be varied ko sult the maker by the addition of rocks, stones, coquina~ shells, cinders, or any other mineral or ob-ject that will give the maker the texture and finish he wishes. me color possibilitiPs are endless, and can include the use of different colored sand of any type, the application o~ any type o~ paint or stain on the sur~ace after the stones have dried or the introduction into the mlxing process o~ any type of coloring agent that is compatable with the four basic ingre~ients. The sand used in my process can be o~ any available type of natural sand Mowever~ the ldeal type is the common build0rs type o~ sand used in the laying of brick. The cement used in my proce~s can be any type or color o~ natural cement, such as port-land cement, or any ona of the di~ferent types of mortarmixes that are sold commercially under dl~erent brand names, or any type cement that will harden sufficiently when mixed with a quantity o~ water.
For the sake o~ br~vity, I will limit the 1~ mixture for discus~ion, to the b~sic ~our ingredi~nts of sand, portland cement, water and paint.
In making the inltial mixture~ I incorporate three of the four basic ingr~dients~ namely æand~
portland cement, and water. The ratio of sand to cement can range ~rom one part cement to eight parts sand, to all cement and no sand. However, the ideal mixture for the best tex~ure and hardness is one part cement to three parts sand The amount of water added to the cement and sand mixture can vary from just enough water to dampen all the mixture, to sifficient water to give the mixture the consistency o~ cream.
However, the ideal amount of water is enough to obtain a consistency comparable to that of mortar mix when used to lay bricks, yet slightly dryer so that the mixture 25 wlll hold a shape when it is shaped by hand.
My process uses no molds to shape the stones, though they can be used if a particular shape is de-sirable by the maker. My process yields stones o~
random shape and size ~ust as ~atural ætones are.
This is done by simply pouring the prepared mixture on any flat sur~ace that the mlxture will not adhere to. However, be~ore pouring the mixtureg the ~lat sur-~ace, which can be o~ any size according to what quan-tity of stones is desired, ls first prepared by laylng several cords or ropes across ito These cords can be o~ ~n~ s~ze or composition that will allow the stones to be lifted ~rom the flat surface. The cords should 10 be lai~ out parallel to each other approximately six inches apart~ and extend past the intended area where the mixt~re is to be poured ~ar enough to allow ac-cess to them a~ter the mix is pouredO Furthermore, they should be attached firmly to the flat pouring sur-face at one end~ Enough cords should be used to coverthe entire width o~ the proposed pouring surfaceO
The mixture o~ one part cement~ four parts sand, and a quantity of water is now agitated suf~icient-ly to obtaln a thorough mixing of the three ingredients This mixture ls then poured or otherwise placed on the flat surface covering the cords~ as inidicated, and then flattened into a solid sheet of any thickness desired by the maker. The ideal thickness is from one to three inches~ Su~ficient care ls ~aken here to in-sure that the m1xture is now in one solid sheet, cover-ing all o~ the cordæ, yet leaving both ends exposed su~iciently to allow the maker to hold the cords firmly with his hands.
The solid sheet of stone mixture is now shaped lnto the deslred texture, either by hands~ or by using any type of mechanical device~ or any other method, the object of which is to make ~he entire top surface of the mixture take on the rough appearance Of natur~l stone textures.
The stone mix is now allowed to dry and begln to set up until a precise moment in the drying time is reached. In order to clearly exemplify when thls pre-cise time is reached, it i8 ~irst necessary to fully ex-plain the object of determining this time.
The solid sheet of mix is converted to stones of random shapes and siæes by simply p~lling the loose ends of all the cords a~ the same time up and away ~rom the solid sheet at an angle o~ approximately forty-~ive degrees. When the cords are pulled up and away at this angle, the~ attempt to li~t the entire sheet of mix up from the ~lat sur~ace. However, since the stone mix has not yet completely hardened, the re~ult is the breaking up of the solid sheet in~o several smaller pieces. There~ore~ the more drying time allowPd, the harder the sheet will be~ and the larger the result-ing broken pieces will beO Conversely, the sooner the cords are pulled the smaller the pieces. These pieces will hereafter be referred to as stones The amount of dryin~ time, or setting up time, is determined by either the introduction in the mixing stage of any type o~ compatable catalyst or retardent, or by ~he e~fect o~ the prevailing weather condltlons.
me ideal method is that of natural air drying on a warm day with low relative humidity~ ~rnder these con-ditions, a test should be made after approximately three hours o~ drying time has elapsed, This .is done by slowly pulling on the cords in the indicated way until one or two stones break o~ the stones are o~ the desired size~ they are then removed ~rom the cords by gently lifting straight ~p. The cords have now performed a second ~unc~ion, by creating a groove in the back side o~ the stones ThiS groove will be filled with mortar mix when the stones are put on the surface to be decorated, ~hus giving additional ad~
herence to the surface of the stones~
When the stone~ are removed rrom the pouring sur~ace and from the cords, they are then ready to be ~mooth~d over ~o attain ~helr ~inal appearance. ThiS
is accomplished by using water to wet the stonej ~ollow-ed by rubbing gently over the sur~ace and edges with either one~s hands, a spongeg a cloth, or an~ suitable device to get the desir~d e~ect This is followed by a thorough rinsing o~ the stone to remove all the loose particles o~ sand and cement, The stones are then allowed to dry c ompletely The stones can be colored by the addition of any type o~ cement colorant in the mixing stage, or by the use o~ paints or stains a~ter they are smoothed and drled. ~or all practical purposes~ the latter wl~l L6~ Eii yield the most flexible and realistic results, limited only by the ability of the maker. Any type of avail-able paint, dye, stain or other compatible coloring pigments may be used.
When the coloring agent has dried, the stones are installed on the surface to be decorated by simply applying prepared mortar mix to the surface, applying mortar mix to the back side of the finished stone, and then pressing the stone to the surface. When the mortar mix dries, the stone will be bonded to the surface securely.
This composition, when manufactured as indi-cated, can be used on any solid surface that will hold the weight of the stones, and the mortar mix used when laid in the normal manner of laying such stones. It can be used indoors or outdoors to decorate the surface on which it is affixed, and give it the appearance of being made of real stone.
. ~
Claims (8)
What is Claimed is:
1. Process of manufacture of imitation stone used for decorative purposes in construction cum-prising mixing cement, sand and water in amounts to form a mix to provide a consistency of mortar mix that will hold a shape when shaped, preparing a non-adher-ing surface by laying a plurality of cords across the surface in which the cords are of a size and compo-sition that may allow the mix when at least partially hardened to be lifted from the surface for forming immitation stone pieces, pouring a sheet of mortar mix into a determined random configuration shape and size by simply pouring the prepared mix onto said non-ad-hering surface, said cords being substantially disposed in parallel relation, and having ends to allow access to the cords, allowing the mix partially to dry and to set for a predetermined time, pulling loose acces-sible ends of the cords generally upward and away from the sheet of mix at approximately 45° when the cords seem to attempt to lift the entire sheet of mix up from the surface and breaking up the sheet of mix into random sized pieces caused by the continued step of pulling said cords.
2 The process of Claim 1 wherein said mix comprises one part of cement to eight parts of sand.
3. The process of Claim 1 wherein said mix in one part cement to three parts of sand.
4. The process of Claim 1 wherein paints are applied to said surface of the stone.
5. The process of Claim 1 wherein one part cement and four parts sand comprise said mix.
6. The process of Claim 1 wherein the sheet of mix extends from one to three inches in thickness.
7. The process of Claim 1 with the predeter-mined time being approximately three hours and subse-quently testing of the mix before break up of the mix into stone.
8. The process of Claim 1 wherein water is added to wet the partially hardened mix prior to com-plete curing the surface is rubbed to shape up a smooth surface, the hardened stone is rinsed to remove loose particles of sand and cement, and the resultant product is dried.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA318,020A CA1111626A (en) | 1978-12-15 | 1978-12-15 | Process for manufacturing imitation stone used for decoration |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA318,020A CA1111626A (en) | 1978-12-15 | 1978-12-15 | Process for manufacturing imitation stone used for decoration |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1111626A true CA1111626A (en) | 1981-11-03 |
Family
ID=4113146
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA318,020A Expired CA1111626A (en) | 1978-12-15 | 1978-12-15 | Process for manufacturing imitation stone used for decoration |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1111626A (en) |
-
1978
- 1978-12-15 CA CA318,020A patent/CA1111626A/en not_active Expired
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |