Composition and method for installing a simulated natural surface

Abstract

A method of producing a simulated natural surface, such as stone, tile, brick or wood planking uses all environmentally friendly components. First, a water-based polymer liquid is applied to the existing surface using a roller. Next, a self-leveling mixture of water, polymer, cement and sand is applied with minimal trowelling in order to spread the mixture evenly over the surface. The applied mixture settles in a self-leveling manner. When partially cured, a desired grout pattern is scored in the applied cementous mixture to create the desired pattern (i.e., brick, stone, tile, wood planking). Next, the entire surface is painted with a prime coat of an acrylic paint including the scored grout lines. Once the prime coat dries, shading containing an organic oxide pigment is applied using a sponge. Alternatively, a marble appearance is created by applying drops of ink or other liquid pigment to the self-leveling cementous layer while still wet, which allows the drops to bleed and create a natural marble veining appearance. Lastly, a water-based glaze is applied over the entire surface as a sealer.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of the Invention[0002]The present invention relates to compositions and methods for producing a simulated natural surface and, more particularly, to a composition containing environmentally friendly components and a method of installation requiring minimal labor to create a highly aesthetic surface that simulates natural stone, brick, tile or wood planking.[0003]2. Discussion of the Related Art[0004]Building materials, such as natural stone, tile, brick and wood planking have become considerably expensive in the present construction and home improvement market. Moreover, installation of such materials for flooring, walls and outdoor surfaces is labor intensive and requires skilled labor, thus adding to the total cost of a project.[0005]Producing a simulated natural surface is a cost effective alternative, particularly when upgrading old surfaces, such as unsightly concrete decks, driveways and indoor floors. In the past, others have proposed...

AI Technical Summary

Benefits of technology

[0007]Considering the foregoing, it is a primary object of the present invention to provide a composition and method for producing a simulated natural surface using environmentally friendly components, with minimal labor, thereby improving on the prior art methods and compositions.

[0008]It is a further object of the present invention to provide a composition for creating a simulated natural surface, and wherein, the composition includes self-leveling characteristic, thereby minimizing labor by reducing the amount of trowelling required to spread the composition evenly over a surface.

[0009]It is still a further object of the present invention to provide a composition and method for installing a simulated natural surface that is waterproof, fireproof, lightweight and termite proof.

[0010]It is still a further object of the present invention to provide a composition and method for installing a simulated natural surface in less time, with less labor and at a lower cost than comparable compositions and methods in the prior art.

[0011]These and other objects and advantages of the present invention are more readily apparent with reference to the detailed description and accompanying drawings.

[0012]The composition and the method of the present invention are directed to producing a simulated surface, such as stone, tile, brick or wood planking

Problems solved by technology

Building materials, such as natural stone, tile, brick and wood planking have become considerably expensive in the present construction and home improvement market.

Moreover, installation of such materials for flooring, walls and outdoor surfaces is labor intensive and requires skilled labor, thus adding to the total cost of a project.

However, these prior art methods failed to provide a commercially feasible process for making a simulated brick or tile that had durability and produced the appearance of the genuine natural product.

However, my prior methods were somewhat labor intensive, requiring the installer to trowel the applied mixture while down on the knees, in order to smooth the entire surface.

A further limitation of my prior inventions involves the use of polyvinyl acetate latex, epoxy resin, epoxy hardener and other components that are not environmentally friendly.

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