EP0205423B1

EP0205423B1 - Method of making simulated stone and wood

Info

Publication number: EP0205423B1
Application number: EP85900406A
Authority: EP
Inventors: Henry Schiffer
Original assignee: Individual
Current assignee: Individual
Priority date: 1984-12-07
Filing date: 1984-12-07
Publication date: 1989-03-15
Also published as: ATE41330T1; DE3477142D1; EP0205423A1; JPS62500917A; WO1986003433A1; AU565148B2; NO863180L; DK374486D0; DK374486A; BR8407372A; NO863180D0; EP0205423A4; AU3747285A

Abstract

A method fo making simulated stone, slate, wood or coral rock wall, floor or roof comprising the steps of applying a coating of polyvinyl acetate latex emulsion (I), followed after drying by application of a mortar mixture, a slurry of cement, sand, water and modified acrylic resin (II). The slurry is permitted to partially set and then indentations in a selected design and/or surface texturing are made (III). After complete setting and hardening, a seal coating containing the desired color is applied (IV). Alternately, a thin coat of the mortar mixture mixed with shading color is applied, allowed to dry and then covered with a clear seal coating (IV A). This is followed by grouting if required (V) and then a final clear coating (VI).

Description

This invention relates to a method for making a simulated natural material surface on a wall, floor or roof according to the preamble of the only claim.
In the applicant's prior patent U.S. 4,349,588 a method is described for making a simulated brick or tile wall or floor using cement, water-based adhesive and optionally water-insoluble powdered pigment. The consecutive steps in that method consist of applying a mixture of the cement, water and water-based adhesive directly to a wall or floor, permitting partial setting, scoring selected indentations, permitting complete set, applying mortar into the indentations as a grout and then applying a clear water-resistant coating to the entire surface. Where color is desired a water insoluble powdered pigment is included in the initial mixture. In one variation, a clear coating is applied before applying the grout.
The method of the prior patent, while suitable for simulating brick or tile is not suitable for simulating stone, slate, wood or coral rock.
One object of the present invention is to provide a method for making simulated stone, slate, wood or coral rock.
The object is solved by the features as laid out in the characterizing portion of the only claim.
The method of this invention comprises first applying a coating of polyvinyl acetate latex emulsion to the existing surface to be covered and allowing the coating to dry. A mortar mixture made from a mixture of cement, sand, water and modified acrylic resin is then applied by trowel or with a spray nozzle from a hopper. The applied mortar mixture is permitted to partially set. Then, indentations in a selected design and/or desired surface texturing are made with appropriate tools to the partially set slurry. Excess material is then removed and the treated surface allowed to completely set and harden. After complete hardening, a first seal coating containing desired color or stain is applied. Alternately, a thin coat of the mortar mixture with shading color is applied, allowed to dry and then covered with a first clear seal coating. After the seal coating is dry any grout that is required can then be applied. This is followed by a final clear seal coating. The seal coatings in all cases are water-resistant.
The steps of the method of this invention are shown in the drawing which illustrates the steps of the process in making a simulated stone floor.
The following examples illustrate the invention:-
The references to I, II, III, IV, IVA, V and VI are to the drawing.
Example 1. A simulated stone floor is prepared by the following steps:
A 50% solid aqueous dispersion of polyvinyl acetate is applied to the surface to be covered and then allowed to dry. (1). After drying, a cement slurry is applied (II). Such a slurry typically consists of 5 gallons of water, 50 to 75 pounds of sand, 50 pounds, of Portland cement and 1-1/2 pounds of a modified acrylic resin emulsion having a high solids content. An example of such a resin emulsion is a commercial acrylic emulsion which has a solids content of 53%, viscosity of 300 centipoises, a specific gravity of 1.18 and a pH of 8.5. The slurry can be applied by either a trowel or a spraying apparatus. The depth of the slurry coating is in the range of 1/8 to one inch.
After the slurry coating is applied it is allowed to partially set, which typically takes two to three hours. When it is partially set, appropriate indentations according to a selected design and/or surface texturing are made with appropriate tools. (III). Thereafter, the excess materials are removed and the applied slurry allowed to completely harden. After this, a water-resistant seal coat containing the desired color or colors is applied. (IV). Where desired one seal coat of one color may be applied to a seal coat of another color before complete drying of the first seal coat, thus permitting blending, streaking and other similar desired effects. After the seal coats have completely dried required grout is applied. (V). The final step comprises applying a clear water-resistant seal coat to the entire surface. (VI).
Example 2. A simulated stone floor is prepared by the steps described in Example 1, except that instead of applying water-resistant seal coats containing color to the completely hardened surface, a thin coat of slurry containing shading color is applied, allowed to dry and then covered with a clear water-resistant seal coat. (IVA).
Example 3. Simulated wood is prepared by the same method as described in Example 1. The indentations are those which simulate the thin lines between wood planks. The texturing is much less than with simulated stone and the color in the first seal coat can be wood stain. Color can also be added to the wood grout.

Claims

A method for making a simulated natural material surface on a wall, floor or roof comprising applying to the wall, floor or roof a mortar comprising a mixture of cement, water and water-based adhesive and allowing it to partially set; scoring indentations and/or surface texturing in a selected design in the partially set material and removing the excess material; allowing the mortar to completely set; applying a grout into the indentations and allowing it to set; and applying a clear water-resistant coating to the entire surface of the applied mixture, characterised in that the method is a method for making a simulated stone, slate, wood or coral rock surface; that prior to application of the mortar there is applied to the wall floor or roof a coating of a high solid aqueous emulsion of polyvinyl acetate, which coating is allowed to dry; that the mortar is an aqueous slurry of cement, sand and modified acrylic resin; and that prior to grouting either (a) a water-resistant seal coating containing desired colour is applied and allowed to dry or a thin coating of slurry containing shading colour is applied and allowed to dry and then a clear water resistant seal coating is applied.