EP1604837A1

EP1604837A1 - Procedure for the realization of visible surfaces which reproduce various forms, said surfaces being obtained on cement mortar

Info

Publication number: EP1604837A1
Application number: EP04076686A
Authority: EP
Inventors: Giacomo Zanette
Original assignee: M C Z SpA
Current assignee: M C Z SpA
Priority date: 2004-06-09
Filing date: 2004-06-09
Publication date: 2005-12-14

Abstract

Procedure for the realization of surfaces which reproduce various types of forms, said surfaces being obtained on elements in cement mortar, said procedure being realized on a panel (1) of cement mortar realized in a known way and specifically on a visible or external surface (11) of it (1) and applying with known means such as a brush or equivalent a film (P) of a suitable colouring material; when the application of the film (P) is complete, there will be the partial and irregular removal of the most protruding parts of it (P), by means of a chosen method such as a spongy and/or abrasive material, leaving in the recessed parts of the external surface (12) some areas (12) which are more or less coloured;

Description

This invention has as its object a rapid and fast method of execution which, starting from a casting of suitable cement mortar in a special mould with an appropriate shape, allows, after opportune working, the realization of visible surfaces which reproduce various shapes such as surfaces which replicate the so-called visible bricks or stones, also visible, of an aged type which is completely similar to that which exists in homes made of the same material and in other types of the most varies surfaces.
Commonly known and realized are the so-called cement panels on which, by means of the traditional moulding procedure, which is the casting of a suitable type of cement mix, that is with well-defined characteristics in order to realize homogeneous and continuous surfaces, various types of surfaces are obtained, in particular those which reproduce the most varied kinds of surfaces. These surfaces may reproduce the effect of visible brick or visible stone or other.
These procedures, per se already known, and the means used for them, consist mainly of a mould which is in fact known whose matrix, usually obtained from a silicon material similar to rubber, has a negative of decorative patterns and/or whatever else may be required.
Said mould in silicon material shall be housed in bracketing and containing devices which are also known; then, the negative part or surface which includes the decorative pattern desired shall be, as is known, covered with a suitable colouring substance. When the colouring of the aforementioned part, which can be defined as the negative of the mould is complete, cement will be cast into it, covering the entire worked surface (in negative image) for a certain pre-established and preferred thickness. A waiting period then follows, for the cement to harden, and when the cement is hardened, the panels are removed from the moulds thus realizing the desired piece.
The aforementioned system obviously involves substantial objective limits in its realization. In fact, it is not always possible for the operator to cover the entire "negative" part, that is, the shaped part, of the mould with the products that make up the coloured layer of superficial finish of the panel, thus leading to a real irregularity of the final desired surface, clearly with poor aesthetics and finishing.
What is more, with the casting of the cement in the mould, even if it were perfectly covered with the products for creating the desired coloured surface finish and so forth, it may occur that the cast cement itself removes them partially.
This irregular removal (during cement casting) of products to create the surface finish is in some cases plausible and acceptable, for example if it is desired to realize an irregular service such as the one which may be defined as aged. But in other cases, such as those to create the effect of visible bricks, it may create a scarcely uniform colouring effect and hence non-uniformity of the final surface to be obtained.
These defects would substantially compromise the value of the product from an aesthetic and/or qualitative point of view, limiting its use to areas which are not directly visible. Therefore, the panels thus obtained will have a poor aesthetic effect and will not be applicable to the front and aesthetic parts, that is, the parts which distinguish the final product in which the panels thus realized are to be used.
To better understand the characteristics and the advantages which can be obtained with the procedure described herein, completely as an example and in no way limiting, in a chosen form of realization, hereunder follows a description with reference to the attached drawing in which:

figure 1 is a prospect representation of the panel in its initial state;
figure 2 represents the panel in figure 1 in a chosen transversal section;
figure 3 represents the panel in figure 2 during an initial working phase;
figure 4 again represents the panel in figure 2 and 3 at the end of the procedure.

With reference to the figures, it is noted that the common particulars shall be mentioned with the same references.
With particular reference to figures 1 and 2, it is noted that the panel will have a surface which can be defined as the visible surface, which for simplicity will be defined as external surface 11, which shall be used for aesthetic purposes. It will be shaped in various manners; in this particular case it will be moulded like visible stone.
Said external surface 11 of panel 1 will be crude, meaning it still has to be worked so as to obtain on it (11) the desired effect of the requested finish.
Then, as shown in figure 3, this surface 11 will be covered, with a suitable tool such as an appropriate brush or similar means, with the colouring products which are commonly used and known in the building sector which form a covering film P which will be nearly homogeneous for the entire external surface 11 of the panel 1.
Said film P will be nearly homogeneous and of a constant thickness for the entire external surface 11 of the panel 1.
When the phase of covering external surface 11 is finished, there will be obtained upon it (11) the aforementioned film P which will cause a homogeneous colouring of it (11).
Next is the removal of excessive colouring which makes up the film applied to it (11).
Removal of the colouring must first of all take place preferably before drying or hardening of the film P and can be performed, as shown, with a tool equipped with absorbent materials of a known type such as a sponge or equivalent means. If instead the film hardens it can be removed by brushing, preferably with an abrasive brush.
The removal of excess colouring shall take place by means of rubbing with the aforementioned absorbent and/or abrasive materials on the external surface 11 which supports the film P.
When the removal of excesses of film P on the protruding part of the external surface 11 of panel 1, as shown in figure 4, there may be noted some zones 12 which are more or less coloured or even without any colour, but this surface will be heterogeneous and will almost perfectly reproduce a desired surface type such as a portion which imitates a wall with antique visible stones or bricks which are also referred to as visible, and anything else desired by the operator or required for the final use of the panel 1 concerned. Essentially, the removal of the film P from the raised parts of the external surface 11 of the panel will leave zones 12 on it (11) where part of the film P will remain almost unaltered thus generating chromatic effects which are aesthetically required and desired by the operator for the specific purposes.
Clearly it is possible to make variations both in the formation of the film P as well as on the external surface 11 of the panel. Variations may also be made to the method of application of the colours, operating with machines or manual tools different than a brush as indicated in the description. Also, it is possible to realize layers of different colours in order to obtain the most widely varied and imaginative colour effects. Furhermore, it is possible to vary the thickness of the films P applied to the panel 1 in order to obtain further special aesthetic effects.
Also, for the removal of excessive parts of said film P, it is possible to use automatic mechanical means which reproduce in all manners the manual device as described in this form of realization.
In fact, it is possible to realize and match with one another a substantial number of panels with small surfaces, or panels with large surfaces can be realized which then for convenience and manufacturing rationality are worked with automatic machinery, for example, equipment provided with devices such as brushes and/or sponges or any other automated device to work quickly the substantial surfaces thus realized.
Obviously the uses of these panels worked in this manner may be many. In fact, they can be used to cover external and or internal walls of buildings, to realize decorative surfaces walls of fireplaces for outdoor barbecue grills, and in general for all construction uses where they may be suitable and necessary.
It is well understood that different variations may be made to the described procedure and are subsequently claimed with reference to the drawing.

Claims

Procedure for the realization of surfaces which reproduce various types of forms, said surfaces being obtained on elements in cement mortar, said procedure being characterized by the fact that on a panel (1) of cement mortar realized in a known way and specifically on a visible or external surface (11) of it (1) and applying with known means such as a brush or equivalent a film (P) of a suitable colouring material; when the application of the film (P) is complete, there will be the partial and irregular removal of the most protruding parts of it (P), by means of a chosen method such as a spongy and/or abrasive material, leaving in the recessed parts of the external surface (12) some areas (12) which are more or less coloured;
Procedure according to claim 1 characterized by the fact that two or more layers of film (P) may be applied having the same and/or different colour and/or thickness;
Procedure in accordance with claim 1 characterized by the fact that the film (P) may be removed from the external surface (11) of the panel (1) when it (P) still must harden or after it has hardened;
Procedure in accordance with claim 1 characterized by the fact that the operations of laying and removing the film (P) on the external surface (11) of the panel (1) may be performed by manual and/or mechanical procedures.