U.S. patent application number 10/424969 was filed with the patent office on 2004-10-28 for decorative siding panel and method of manufacture.
Invention is credited to Sandy, Howard M..
Application Number | 20040211141 10/424969 |
Document ID | / |
Family ID | 33299439 |
Filed Date | 2004-10-28 |
United States Patent
Application |
20040211141 |
Kind Code |
A1 |
Sandy, Howard M. |
October 28, 2004 |
Decorative siding panel and method of manufacture
Abstract
A decorative siding panel is disclosed. The panel preferably
comprises a thermoformed unit which includes upper and lower
attachment flanges bordering a central area which is formed with a
raised profile to simulate natural stone. The panel preferably
includes means for attachment to adjacent panels forming a given
horizontal course. The panels are preferably thermoformed to a
desired shape, a textured coating in a series of coating stages, a
color is applied to the texture and the coatings fixed to the
unit.
Inventors: |
Sandy, Howard M.; (Richmond
Hill, CA) |
Correspondence
Address: |
Howard M. Sandy
Quickstone Decorative Facings, Inc.
107 Gemini Crescent
Richmond Hill
ON
L4S2K7
CA
|
Family ID: |
33299439 |
Appl. No.: |
10/424969 |
Filed: |
April 28, 2003 |
Current U.S.
Class: |
52/506.01 ;
52/518 |
Current CPC
Class: |
E04F 13/0871 20130101;
E04F 13/185 20130101; E04F 13/0864 20130101; E04F 13/0875
20130101 |
Class at
Publication: |
052/506.01 ;
052/518 |
International
Class: |
E04B 009/00 |
Claims
What is claimed is:
1. A wall panel adapted to be fastened to a mounting surface, said
panel comprising: (a) a formed, thermoplastic panel defining a back
and a front surface where said front surface is outwardly-curved
whereby said outwardly-curved surface is bounded by one or more
attachment flanges where each said flange extends to said mounting
surface, said curved surface defining a void space between said
mounting surface and said outwardly curved surface; and (b) said
front surface of said panel including: (i) one or more textured
layers; and (ii) one or more pigmented layers, where each of said
layers are thermobonded to said panel.
2. The wall panel of claim 1 further including means to attach a
given panel to adjacent, horizontally-oriented panels.
3. The wall panel of claim 2 where said panel further defines a
first and second end where each said first end includes a male
connector which is receivable in a female connector disposed on
said second end on an adjacent panel.
4. The wall panel of claim 1, wherein each said mounting flange
defines a planar surface which is adapted to contact said mounting
surface.
5. The wall panel of claim 1 wherein the thermoplastic panel is
made of acrylic.
6. The wall panel of claim 1 further including means to drain any
fluid trapped in said void space.
7. The wall panel of claim 6 wherein said drainage means includes
one or more apertures formed on a bottom-most portion of said
curved surface.
8. The wall panel of claim 1 wherein said textured layers are
partially comprised of a mixture including an aggregate, sand,
silica, quartz crystals and a binding agent.
9. The wall panel of claim 7 where said aperture includes means to
limit access into the void space through said aperture.
10. The wall panel of claim 1 where said attachment flange, when
said panel is joined to the other panels in a series of horizontal
courses, resembles a motor joint.
11. A siding assembly for an exterior wall surface made up of a
plurality of siding units, said units adapted to be affixed to the
wall surface with similar units in overlapping horizontal courses
with the units of each course lying in overlapping relation to each
other, each of said units comprising: a main body portion including
a front face and a rear face, said front face including a
substantially convex main portion bounded by one or more linear lip
portions; and said front face defining at one end a male connector
where said male connector is adapted to fit into an aperture in an
adjoining siding unit, said front face defining at the opposite end
a female connector adapted to receive a male connector disposed on
an adjoining siding unit; said lip portion adapted to contact said
wall surface such that the convex portion defines a void space
between said rear face and said wall surface; and a textured layer
thermobonded to said front face.
12. The siding assembly of claim 11 wherein said front surface
defines means to drain the void space.
13. The siding assembly of claim 12 wherein said drainage means
comprises one or more apertures disposed in the lower surface of
the convex main portion such that any moisture collecting in said
void space may pass through said aperture.
14. The siding assembly of claim 11 where said main body portion is
comprised of a thermoformable material.
15. The siding assembly of claim 14 where said thermoformable
material includes acrylic/pvc.
16. The siding assembly of claim 11 wherein said textured layer
includes alternating layers of a texturing agent and a pigment.
17. The siding assembly of claim 11 where said textured layer is
formed from a method comprising the steps of: (a) heating the main
body portion; (b) applying a base coating to the front surface of
said main body portion; (c) drying said base coat about said
main-body portion; (d) applying a primer coat to the front surface
of said main body portion; (e) heat drying said primer coat for a
selected time interval; (f) applying a textured coating; and (g)
heating the main body portion to dry each for a selected time
interval.
18. The method of claim 17 further including the steps of: (a)
applying a pigment to the textured coating; (b) heat drying the
coating for a selected time interval; and (c) applying a sealer to
the frontal surface of the main body portion.
19. The method of claim 17 wherein the textured coating is drawn
from a group consisting of one or more of an aggregate, sand,
silica, and/or quartz crystals and a binder emulsion.
20. The method of claim 17 wherein the main body portion is heated
to a temperature of 80.degree. F.
21. The method of claim 17 where the steps of heat drying occur in
a range of 120-170.degree. F.
22. The method of claim 17 where the pigmentation is applied
irregularly over the textured surface.
23. A facing panel structure for a wall comprising a plurality of
sheets whose outer surface is contoured for simulating at least one
of various construction facing materials, positioned thereon in
spaced relation with each other and with mortar line portions
simulated between said construction material, each of said sheets
having flange portions extending one or more edge portions, said
flange portions bounding a substantially convex portion, said
convex portion defining at one end a mating protrusion and at the
second end a mating aperture adapted to receive the mating portion
from an adjacent panel structure, said convex portions defining one
or more drainage apertures about their bottom surface, whereby upon
mounting said sheets of material on said wall said mating
protrusions of one sheet are received in said mating protrusion on
adjoining sheets of material, said outer surface of said panel
provided with a pigmented, textured coating which is sealed and
thermally bonded to said outer surface.
24. The facing panel structure of claim 23 wherein said
substantially convex portion of said sheet defines a void area
between the facing panel structure and the wall.
25. The facing panel of claim 23 wherein said sheets are formed of
a cellular polyethylene.
26. The facing panel of claim 23 wherein the textured coating is
applied using the sequential steps of: (a) applying a base coating
to the front surface of said sheet; (b) drying said base coat about
said sheet; (c) applying a primer coat to the front surface of said
sheet; (d) heat drying said primer coat for a selected time
interval; (e) applying a textured coating; (f) applying a pigment
to the textured coating; (g) heat drying the coating for a selected
time interval; (h) applying a sealer to the frontal surface of the
sheet; and (i) heating the sheet to dry each for a selected time
interval.
27. The method of claim 25 further including the initial step of
first heating the sheet.
28. A siding assembly for an exterior wall surface made up of at
least a first siding unit and a second siding unit where each of
said siding units defines a front and back surface, each of siding
units comprising: a body molded in a described configuration to
define a face surface bounded by one or more attachment portions,
the front surface of said body including one or more textured
layers bonded to said surface; said body including a first and a
second end where said first end includes a raised portion and said
second end defines an aperture, where said raised portion is
adapted to be received in said aperture formed in said second
siding unit to align said horizontal flange portions of the first
and second siding unit; said flange portion defining a
substantially coplanar surface adapted to contact said wall
surface; said first surface defining a void area between said back
surface and said wall; and means to allow the drainage of moisture
which may collect in said void area.
29. The siding assembly of claim 28 wherein the body is comprised
of a thermoplastic.
30. The siding assembly of claim 28 wherein the body is comprised
of a moldable material.
31. The siding assembly of claim 28 wherein said flanges are formed
horizontally.
32. A method of manufacturing a siding member which includes a base
member having a front and back surface, comprising the steps of:
(a) applying a first base coating to a front surface of the base
member; (b) applying a second, primer coating to said first surface
of the base member; (c) applying a third textured coating to said
first surface of said base member; (d) applying a fourth, pigmented
coating to said first surface of said base member; (e) applying a
fifth sealant coat to said fourth, pigmented coating; and (f)
curing said multiple layers.
33. The method of claim 31 further including the step of applying a
fifth sealant coat to said fourth, pigmented coating.
34. The method of claim 31 further including the steps of curing
the first and second layers prior to the application of a
subsequent layer.
35. The method of claim 31 where said curing step is accomplished
by circulating a hot gas across the front surface of said bound
member.
36. The method of claim 31 wherein said gas is air.
37. The method of claim 31 where the gas is heated to a temperature
in the range of 100-120.degree. F.
38. The method of claim 31 further including the step of first
forming the base member into a profile having a convex face bounded
by horizontal flange members.
39. The method of claim 31 where the textured coating comprises a
binding agent and one or more compositions drawn from the group of
aggregate, sand, silica or quartz crystals.
40. The method of claim 31 wherein the coatings are sprayed,
atomized, brushed or trowelled.
41. The method of claim 31 where in the hot gas is applied to the
front surface for approximately fifteen minutes.
42. The method of claim 31 further including a step taken prior to
the application of the sealing coating wherein the textured frontal
surface is immersed in a mixture of water over which has been
dispersed a coating of a water-insoluble pigment.
43. The method of claim 41 where the water/pigment mixture is in
the range of 100 parts water and 125 parts pigment.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to decorative wall
panels and methods for their manufacture. More specifically, the
present invention relates to a simulated stone wall covering which
is comprised of overlapping panels, and methods of fabrication.
[0003] 2. Description of the Prior Art
[0004] In the construction and finishing trades there have been
many prior attempts to simulate a brick, stone or tile surface
using materials less expensive than the genuine material. Some of
these attempts involved cutting the genuine brick, stone, etc. into
thin slabs which are then adhered to a conventional concrete wall,
etc. for support. See, for example, U.S. Pat. Nos. 3,131,514;
1,669,351; 3,660,214; 3,740,910; 3,521,418; 3,775,916; 3,646,715;
2,122,696; 2,149,784; 2,339,489; 3,426,490; and 1,902,271. The
expense, time, and care involved in cutting the brick or stone,
etc. into desired thin slabs and then adhering them to the desired
surface or substrate detract from the advantages of such
techniques.
[0005] Another attempt to simulate a brick, stone, tile, etc.
exterior involves pouring a mortar or concrete mix into a mold or
form which includes the desired relief, e.g., brick, stone, etc.
This technique is described, for example, in U.S. Pat. Nos.
3,002,322 and 3,874,140. Various limitations are inherent in this
technique. For example, in order for the concrete or mortar mix to
properly and completely fill the molds without leaving air pockets
the mix must contain a considerable amount of water. This detracts
from the strength of the cured mixture and increases the curing
time. The finished product unfortunately still has the appearance
of concrete and is all the same color, i.e., it does not have one
color for the bricks or stone relief and a different color for the
spacing between the brick or stone shapes. Moreover, it is
difficult if not impossible to obtain sharp edges on the brick or
stone shapes in these molds. As a result, the shapes are not as
realistic as desired.
[0006] Another technique simply involves making panels or sections
from plastic which has been molded to the desired relief. The
panels or sections are then used as the outer decorative facing for
the structure to be covered. See, for example, U.S. Pat. Nos.
3,882,218; 3,177,279; and 3,232,017. Of course, these products do
not provide a totally realistic appearance and would not be
adequate as a substitute for real brick, stone, tile, etc. in all
situations.
[0007] Still other techniques involve making simulated brick or
tile elements out of plastic and then bonding them to a supporting
panel or sheet with adhesive. See U.S. Pat. Nos. 3,991,529 and
4,079,554. Again, such a technique includes serious
limitations.
[0008] Yet another technique involved forming two layers of
magnesite applied to a metal lathe. The second layer is of a
different color than the first layer. Before the second layer
hardens, grooves are cut therethrough to form the shape of bricks,
for example, and to reveal the underlying layer of magnesite. See
U.S. Pat. No. 1,583,748. Disadvantages with this technique include
the lack of stone relief. Further, this process does not provide
for graduation of color. Finally, the product resultant from this
process requires a skilled installer using skim coat and
mortar.
[0009] Another technique described in U.S. Pat. No. 3,426,490
involves forming individual brick veneer blocks made of concrete or
fired clay which are adhered to a wire mesh in panel form. The
panels are then secured to a wall with nails or staples. Mortar is
then applied between the veneer blocks and forced into the wire
mesh. This technique also suffers as a result of its cumbersome
method of application which does not lend itself to quick
application.
[0010] U.S. Pat. No. 3,496,694 describes yet another method in
which molded formations made from cementitious plaster, plastic, or
other suitable decorative material are adhered to a flexible base
material. The prefabricated material may then be rolled up and
transported to the job site where it is attached to the frame of a
building. The disadvantage of this method is that it requires an
even flat surface for mounting. This product resultant from the
method requires an installation process which is
material-intensive.
[0011] U.S. Pat. No. 3,868,801 describes a building panel for a
prefabricated house. The panel includes masonry elements (such as
bricks), polyester mortar, wire mesh, polymer foam, and inner
facing layers are held together by the mortar and foam.
[0012] U.S. Pat. No. 3,344,570 describes a reinforced flooring tile
including a body of concrete with reinforcing framework embedded
therein. The network is thermoplastic synthetic resin or metallic
reinforcing.
[0013] U.S. Pat. No. 3,067,545 describes an artificial siding for
frame buildings. A brick-like block is made of standard concrete
block mixture which may include coloring pigments and
water-proofing agents. The block is molded on metal mesh in such a
manner that it extends through the mesh. The exterior surface of
the walls of the building are covered with wooden-sheathing and
then felt paper. The brick/mesh pieces are then nailed to the wall
individually as siding in such a manner that the mesh overlaps the
mesh of the piece in the row below it. Presumably the spaces
between adjacent bricks would have to be sealed in some manner.
[0014] U.S. Pat. No. 2,819,495 describes a method for making
building blocks having a molded mortar surfacing simulating a
plurality of bricks or stones. The mortar is first placed into a
mold and must be tamped into compartments; then additional
intermediate layers are added, after which concrete mix is added to
form the main portion of the block. A disadvantage of this
technique is that the facing is applied to the concrete block prior
to the required conventional steam or oven curing of the block.
Accordingly, additional care is required to handle such blocks
prior to curing.
[0015] U.S. Pat. No. 2,748,443 describes a particular technique
(involving a specially designed stencil) for applying a plastic
mix, like mortar, to the face of a building in a predetermined
pattern to simulate stone blocks. However, the wall to be faced is
first covered with lathing over which is provided a continuous
coating of plastic mix and then a brown coat. Then the mortar mix
is applied with the aid of the stencil. This technique, of course,
would not be practical for use with individual building blocks, nor
is it a convenient technique even for large building faces.
[0016] U.S. Pat. No. 1,571,849 describes a multi-step method for
making building blocks which is similar to that described in U.S.
Pat. No. 2,819,495. A grate is placed on a flat plate and a
concrete mix is then placed into the openings in the grate and must
be tamped down until it is even with the top of the grate. The
grate is then removed and the spaces between the shapes formed by
the grate are filled with cementitious compost colored differently
than the shapes left by the grate. Then another concrete mixture is
added to form another layer. The resulting structure is then
removed from the mold on the flat plate and placed in the bottom of
a mold of a cement block forming machine where the main portion of
a cement block is formed on top.
[0017] U.S. Pat. No. 2,618,815 describes a method for applying a
coating of plaster or cement to a wall to simulate the appearance
of stone, cement blocks, or similar construction units. A plastic
mold is filled with a concrete and mortar mix. The mold is then
placed against a wall until the mortar mix adheres and sets.
Alternatively, the mold may be coated with an adhesive coating such
as a mixture of paraffin and kerosene. Marble dust, quartz
particles or the like are then spread onto the coating, followed by
ground stone particles. The mold is then filled with the mortar
mix. Then the mortar mix may be pressed against the wall and the
mold removed immediately, leaving the marble dust and
paraffin-kerosene coating covering the mortar.
[0018] U.S. Pat. No. 2,130,911 describes a prefabricated building
unit in which a first layer is applied directly onto a Celotex,
fiber board, etc. The first layer may be plaster or cement (0.25 to
2 inches thick). Then facing elements made from natural stone,
cement, wood, metal, linoleum or the like are pressed onto the
surface of the first layer while either or both are in a plastic or
semi-cured condition. Alternatively, the facing elements may be
secured to the first layer by cement or adhesive. The facing
elements may be pre-formed or may be formed from a plastic material
on the base member in a continuous operation.
[0019] U.S. Pat. No. 3,304,673 describes a pre-cast panel which is
adapted to be keyed to adjacent panels with specially formed
inserts. The panel includes a base layer of cement and an embossed
outer layer which simulates brick. Before the base layer is set the
outer layer is added and then a mold is impressed against the
surface of the outer layer to emboss it and provide a simulated
brick facing. The outer layer may include pigments for coloring.
Alternatively, the outer layer may be cast in a separate mold,
hardened, and then laid in place over the first layer.
[0020] U.S. Pat. No. 3,503,165 describes a structural panel made of
concrete. A simulated brick appearance may be achieved by putting a
thin layer of wet concrete over the face of the panel and then
pressing a mold downwardly into the wet concrete to imprint a brick
appearance.
[0021] Each of the methods disclosed in these prior references
display the disadvantage of a tedious and rather involved
fabrication process and/or a labor and material intensive
installation process. In this connection, fabrication techniques
which emphasize extensive use of concrete or stone layering may be
as expensive as the materials which they were developed to replace.
Further, many of the end results of these prior processes require
an involved installation process. Finally, none of these prior
processes achieve the goal of a low cost, low weight, easily
assembleable system, where the end result closely replicates stone
or masonry.
SUMMARY OF THE INVENTION
[0022] The present invention addresses the above and other
disadvantages of prior decorative wall panels and methods for their
fabrication.
[0023] In a general embodiment, the system of the invention
includes a series of connectable panels, where each panel comprises
a one-piece substrate or base layer and a decorative layer bonded
to the frontal surface of the substrate. The base layer may be
formed from a variety of materials and may be molded into a variety
of forms and shapes. Structurally, the panel includes features
which allow for its ready-installation on a wall or other surface
via an adhesive or conventional fasteners.
[0024] In a preferred embodiment, the panel includes features which
allow it to overlap and to be structurally integrated into other
panels so as to form a continuous course. In such a fashion, a
series of courses of panels may be aligned relative to each other
to adopt the visual appearance of natural stone or masonry.
[0025] The present invention also includes a method of fabrication
of the aforedescribed panels. In one embodiment, the method of
fabrication includes the sequential steps of intermittently heating
the panel, applying a base coating about the frontal surface of the
panel, introducing a pigment on the frontal surface of the panel,
applying one or more texturing compounds to yield a desired texture
and finish, applying one or more sealer coats to the textured coat
and then thermobinding all layers to each other and to the
panel.
[0026] desired texture and finish, applying one or more sealer
coats to the textured coat and then thermobinding all layers to
each other and to the panel.
[0027] The present invention presents several advantages over prior
art structures and methods for their fabrication. A second benefit
of the invention is the design of the system which prevents
moisture from being trapped between the substrate and the facing
structure. In such a fashion, degeneration of the facing and the
system itself is significantly reduced.
[0028] Another such advantage is the ease of fabrication. Panels of
the present invention may be produced in an assembly-line process.
In such a fashion, the end product is of a consistent appearance
and quality. Further, the ability to use an assembly-line process
renders the system more economical than competitive systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIGS. 1A-1B are perspective views of one embodiment of the
panel system of the invention.
[0030] FIG. 2 is a detailed, perspective view of the embodiment of
the panel system of the invention illustrated in FIGS. 1A-1B.
[0031] FIG. 3 is a perspective view of one embodiment of the
invention as shown in its intended application in a series of rows
and courses.
[0032] FIG. 4 is a perspective, detailed view of one embodiment of
the connector tab system of the present invention.
[0033] FIG. 5 is a perspective, detailed view of a second
embodiment of a connector system of the present invention.
[0034] FIG. 6 is a side view of a drainage system operable in the
present invention.
[0035] FIG. 7 is a perceptive view of a second embodiment of a
drainage system operable with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] The system of the present invention comprises a series of
fabricated panels, each of which is adapted to be applied, in
combination with other panels, to a surface so as to replicate
alternating courses of cut stone or masonry.
[0037] In one embodiment, the panel 2 of the present invention
defines a front 4 and a back 6 surface. When viewed in
cross-section, the panel 2 defines a profile having a top 8 and a
bottom 10 flange. Each of flanges 8, 10 define planar surfaces
which are substantially coplanar to each other. These flanges 8, 10
are adapted to attach to a mounting surface 20, e.g. a wall, via
conventional fasteners or adhesives (not shown). Flanges 8 and 10
bound a convex surface 18, as will be discussed below. Flanges 8
and 10 are designed to replicate a mortar joint when appearing in a
series of horizontal courses, such as illustrated in FIG. 3.
[0038] Flanges 8, 10 bound a convex face surface 18 as shown in
FIG. 2. This convex surface 18 extends outwardly from the mounting
surface 20 in the fashion of cut stone or masonry. In such fashion,
the outward bow of surface 18 from surface 20 may be varied,
depending on the type of masonry or stone sought to be
imitated.
[0039] Panel 2 may be made from a variety of materials which can be
molded or thermoformed to a desired shape. It is contemplated that
acrylic/pvc, such as Kleerdex Vinyloy 103, may be used.
Alternately, the use of ABS and Styrene is also contemplated as
being within the scope of the invention for use as panel 2.
[0040] The profile of panel 2 may be varied depending on the "look"
sought to be replicated. In the instance of an acrylic/pvc, a flat
panel may be thermoformed into a desired shape in a manner familiar
to those skilled in the art.
[0041] Panel 2 defines a first and second end, 22 and 24
respectively, as illustrated in FIG. 2. Both first 22 and second
ends 24 are provided with means to attach each panel to each
adjacent panel comprising a given course. In one embodiment, this
attachment means may compromise one or more studs or tabs 25
disposed at the first end 22 of each panel 2 and a corresponding
aperture(s) 28 disposed in the second end 24. In such a fashion,
each panel 2 can be interconnected with adjacent panels in a manner
illustrated in FIGS. 1A-1B.
[0042] As illustrated in FIG. 4, the studs or tabs 25 may include
an elongate stem 30 which defines an outside diameter larger than
the inside diameter of aperture 28. Stem 30 may be bisected into
multiple subcomponents such that stem 30 may be compressed to fit
into protrusion 28 in a manner familiar to those skilled in the
art.
[0043] Still other means of attachment are also envisioned within
the spirit of the invention. By reference to FIG. 5, panels 2 may
be provided with a stud 40 about one end and a groove 42 about the
opposite end. Stud 40 may include along its length an area of a
reduced radial diameter which is receivable in groove 42, again in
a manner familiar to those skilled in the art.
[0044] These alternate means of interconnecting adjacent panels, in
conjunction with the natural tendency of the convex faces of
adjacent panels 2 to "nest within each other" provides a ready
means to ensure proper horizontal alignment of a course of panels
2.
[0045] It is inevitable that any surface exposed to the elements
will allow some moisture to penetrate through to the mounting
surface 20. If this moisture was not allowed some method of escape
or migration, retention of this moisture could result in
deterioration of said mounting surface 20. Alternatively, moisture
collection in the airspace 17 behind the panels 2, if not allowed
means to dry, could also result in a substantial deterioration of
the panel 2. Further, moisture collecting behind panel 2, when
frozen, could weaken or destroy the adhesive bonds between panels 2
and the mounting surface 20.
[0046] In one preferred embodiment, each panel 2 is provided with
one or more moisture outlets 60. These outlets 60 are desirably
formed on the lower portion of convex face 18, as illustrated in
FIGS. 1A-1B and 2. In such a fashion, moisture, e.g. rain, will not
be prone to enter these outlets 60 while conversely, moisture
present behind panels 2 will be disposed to exit void space 17.
[0047] Moisture outlets 60 may define a circular or semi-circular
shape. In one illustrated embodiment, outlet 60 includes a partial
cap or lid 61 which extends over aperture 62. In such a fashion,
greater resistance to moisture intrusion may be obtained.
Alternately, outlet 60 may be formed with intersecting grooves 63
such as illustrated in FIG. 7. This embodiment offers the benefit
of preventing insects, e.g. wasps, from entering said apertures and
nesting in the void space 17.
[0048] The present invention is also directed to a method of
fabricating panels 2. As set forth above, panel 2 is desirably
formed from a thermoformable material, e.g., cellular polyethylene,
which is shaped via the technique of thermo forming or plastic
injection or rotational molding in a desired shape or series of
shapes. Once formed, panel 2 is evenly heated about its front 4 and
back 6 surfaces. This heating may be accomplished via a hot air
convection. It has been discovered that, in the example of cellular
polyethylene, an even heat of 80.degree. F. is optimum to the
fabrication process of the invention. This optimum temperature
range, however, will vary depending on the material composition and
thickness of the panel. This temperature is desirably maintained
for some fifteen minutes prior to the initiation of subsequent
steps in the process.
[0049] Once heated to an optimum temperature, a base coating is
applied over the frontal surface 4 of the panel 2. This coating may
include an acrylic polymer bonding agent. The purpose of this
coating is to prepare and set up the molecular surface of the
formed substrate with a bonding agent that allows color primer coat
to make a mechanical and flexible attachment to the said surface
without direct interface with the face of panel 2. This coating may
be applied by spray, brush or atomization process in a manner
familiar to those skilled in the art. The panel 2 and the base coat
is then heat-dried. In a preferred embodiment, this drying process
may be accomplished by circulating hot air at a temperature of
168-170.degree. F. for about fifteen minutes about the frontal
surface 4 of panel 2.
[0050] A primer coating is next applied over the base coat to the
frontal surface 4. This coating may include a DryVit Color Primer
as made by Dryvit Systems Inc., or other pigmented acrylic primer,
e.g. Dryvit Color Prime This coating is then air dried, again at a
temperature of between 100-120.degree. F., for a duration of some
fifteen minutes.
[0051] A first textured coating is then applied to the coated
surface. This coating may comprise a mixture of one or more of an
aggregate, sand, silica, quartz crystals, and a binder, e.g.
DryVit, Stone Mist or DryVit Ameristone. The first textured coating
is preferably applied to a 50% coverage This mixture may again be
sprayed, atomized or brushed over the frontal surface 4 of panel 2.
Once applied, this first textured coating is allowed to remain
partially wet prior to the introduction of the next coating.
[0052] A solution of water-based or oil colored pigments and/or
dyes is next applied to the partially wet surface of the first
textured coating. In a preferred embodiment, the mixture may be
comprised of 100 parts water to 125 parts colored pigments and/or
dyes. In the example of a sand-colored texture, it has been
discovered that a mixture of 100 parts water to 125 parts
acrylic-based paint provides an optimum look and feel. The pigment
or dyes used in this step may include a number of commercially
available products, e.g. DryVit.RTM. Color Primer or Benjamin
Moore.RTM. Acrylic Paint. This pigment or dye solution is
preferably applied with a "stacato" or rapidly flinging or
irregular motion. The application of this solution is also
preferably applied under a selected pressure and at a selected
distance between the means of application and the front 4 of panel
2.
[0053] The impact of the pigment or dye solution on the wet, first
textured coating results in a wide dispersal of the pigment into a
wide variety of shapes. The size and configuration of these shapes
is determined by a number of factors including the pressure at
which the pigment is applied, the viscosity of the pigment, and the
distance of the surface 4 of panel 2 from the means of application.
The application of the pigment onto the wet surface also results in
a "bleeding" of the pigment solution into muted color tones, tints
and contrasts. Each of the variables may be altered again depending
on the pressure of application, the viscosity of the mixture and
the distance of the means of application to the front surface 4 of
panel 2.
[0054] A second textured coating is next applied to the substrate.
This second textured coating may again be comprised of a mixture of
one or more of aggregate, sand, silica, quartz crystals and a 100%
acrylic binder. This coating is preferably partial (as opposed to
complete) in order to highlight textures felt desirable for the
particular application. In this connection, it may be desirable to
use a different mixture of texturing agents, or to apply the
texture in a different manner, than the initial texture coating to
achieve optimum results.
[0055] If desired, an additional coating of a colored solution may
be added, as desired. Additionally, additional or varying textured
layers may also be applied to reach a desired color and
texture.
[0056] Once a desired texture and color is achieved, a sealer is
applied to the front surface 4 of the panel 2. This coating
preferably comprises a semi-gloss or high gloss, e.g., DryVit.RTM.
Demandit 100% clear acrylic coating, again dependent on the desired
end application. Over this coating, a second flat, semi-gloss or
high gloss coat is applied, with this procedure being repeated to
replicate the depth or field of depth of strata found in natural
stone, marble, graphite or limestone.
[0057] The coated and textured substrate is then preferably heated
to a temperature of between 168-170.degree. F. for some fifteen
minutes to complete the drying process. Each panel 2 of the system
is then ready for installation.
[0058] An example of one embodiment of the fabrication method of
the present invention is set out below.
EXAMPLE 1
[0059] A sheet of acrylic/pvc (Kleerdex Vinyloy 103, Acrylic/PVC,
P-1 haircell texture) having a thickness of 0.040 and/or 0.60 was
thermoformed into a stone or a stone molding configuration. The
sheet was evenly heated to 80.degree. F. A base coating (Quickstone
Conditioner) was sprayed over the face of the pre-heated
acrylic/pvc formed sheet. The substrate and base coating was heat
dried by circulating hot air at a temperature of 100.degree. F.,
for the duration of approximately fifteen minutes. A primer coating
(DryVit.RTM. Color Primer) was then sprayed over the surface of the
base coating. The sheet, base coating and color prime were then
heat dried by circulating hot air at a temperature of 100.degree.
F., for a duration of fifteen minutes. An initial or first and
partial coating of a mixture of aggregate, silica, sand, quartz
crystal and 100% DryVit acrylic binder emulsion was then sprayed
over the face of the pre-formed and base coated sheet. The partial
coating on the surface of the sheet was allowed to remain wet. A
solution (100 parts water to 125 parts acrylic-based paint) of
DryVit.RTM. Color Primer was applied onto the wet surface. The
solution was mechanically applied with a "staccato" motion to
produce color muting, bleeding, graduation and blotching. A second
partial coating of a mixture of aggregate, sand, silica, quartz
crystal and 100% acrylic binder emulsion (DryVit.RTM. Stone Mist)
was sprayed onto the face of the pre-formed sheet. The sheet and
base coat, prime coat and aggregate coatings was then heat dried by
circulating hot air at a temperature of 100.degree. F., for a
duration of approximately fifteen minutes. A flat, semi-gloss or
high gloss (DryVit.RTM. Demandit 100% clear acrylic coating) was
then applied over the second partial coating to act as a sealer. A
solution of a flat sealer coat (DryVit.RTM. Demandit 100% clear
acrylic coating) was then applied over the second partial coating
to replicate the depth of field. The formed sheet with the
completed base coat, prime coat and aggregate coats and clear
acrylic coatings (DryVit.RTM. Demandit 100% Clear Acrylic coating)
was then heat dried by circulating hot air at a temperature of
170.degree. F., for a duration of approximately fifteen
minutes.
[0060] An alternative method of fabrication also utilizes a
thermoformable panel, as described above. A solution of water-based
pigments, dyes, emulsions or acrylics, or combinations of these
compounds, are sprayed or atomized over the surface of a body of
temperature-regulated water such as may be maintained in a vat or
pool. By their nature, these compounds are lighter than water and
thus form a sheen- or film on the water surface. This film forms
into irregularly-shaped puddles as the pigment mixture and the
water mutually repels each other.
[0061] A panel again preferably comprising a thermoplastic panel,
is heated to a temperature of some 80.degree. F. To this heated
surface, a base coat, e.g. an acrylic polymer bonding agent is
applied via spraying, brushing or atomization over the face of the
preheated panel. The substrate and base coating are heat dried by
circulating hot air at a temperature of 100.degree. F. for some
fifteen minutes.
[0062] A primer coating is then applied to the base coating by
brush, spray or atomization. This coating is also heat dried by
circulating hot air at a temperature of between 100.degree. F. for
some fifteen minutes.
[0063] A coating of aggregate, silica, sand, quartz, and 100%
acrylic binder emulsions (Dryvit Stone Mist #25 sized stone) was
sprayed onto the face of the primer coat, base coat and pre-formed
substrate. The substrate, base coat, primer coat and aggregate coat
was then heat dried by circulating air at a temperature of
100.degree. F., for the duration of 15 minutes.
[0064] The coated, front surface of the heated panel is lowered
into the film emulsion. This film adheres to the panel in the
irregular pattern which is maintained in the vat or container. This
film serves to enhance the natural, fragmented, colored,
distressed, aged, antiqued color and/or toned qualities of natural
stone. The end product is again heated to 170.degree. F. to promote
curing.
[0065] An example of this second method of fabrication is set forth
below.
EXAMPLE 2
[0066] A sheet of acrylic/pvc (Kleerdex Vinyloy 103) having a
thickness of 0.040 was thermoformed into a stone molding
configuration. The sheet was then evenly heated to 80.degree. F. A
base coating (Quickstone Conditioner) was then sprayed over the
face of the pre-formed, pre-heated acrylic/pvc formed sheet. The
substrate and base coating was then heat dried by circulating hot
air at a temperature of 100.degree. F., for the duration of
approximately fifteen minutes. A primer coating (DryVit.RTM. Color
Primer, pigmented acrylic polymer) was then sprayed over the
surface of the base coat and preformed substrate. The substrate,
base coating and prime coat were then heat dried by circulating hot
air at a temperature of 100.degree. F., for a duration of
approximately fifteen minutes. A coating of aggregate, sand,
silica, quartz crystals and 100% acrylic binder emulsions (DryVit
Color Primer) was then sprayed over the face of the primer coat,
base coat and pre-formed sheet. The substrate, base coat, primer
coat and aggregate coat were then heat dried by circulating hot air
at a temperature of 100.degree. F., for a duration of approximately
fifteen minutes.
[0067] A reservoir filled with water was heated to a temperature of
100.degree. F. An antiquing solution of a water-based pigments
(Quickstone.RTM. Custom Antiquing Colored Acrylic Paint) in a
solution of 100 parts water to 125 parts acrylic, enamel paint was
sprayed over the surface of the temperature regulated water to
produce an irregular film.
[0068] The sheet, base coat, primer coat and aggregate coat was
immersed face down into the floating film. The film maintained its
irregular and shaped puddle effect as it adhered itself to the
surface of the coating and thus created the desired replication and
effects of naturally fragmented, colored, distressed, aged,
antique, color and tonal qualities of natural stone. The substrate,
base coat, primer coat, aggregate coat and antique coat were then
heat dried by circulating hot air over the front surface of the
sheet at a temperature of 120.degree. F. for the duration of
approximately fifteen minutes.
[0069] Although particular detailed embodiments of the apparatus
and method have been described herein, it should be understood that
the invention is not restricted to the details of the preferred
embodiment. Many changes in design, composition, configuration and
dimensions are possible without departing from the spirit and scope
of the instant invention.
* * * * *