Composition and method for installing a simulated natural surface

a natural surface and composition technology, applied in the field of compositions and methods for producing a simulated natural surface, can solve the problems of increasing the total prior art methods failing to provide a commercially feasible process, and increasing the cost of a project, so as to reduce the amount of trowelling, reduce labor, and the effect of less tim

US20100005753A1Inactive Publication Date: 2010-01-14SCHIFFER HENRY
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Patent Information

Authority / Receiving Office
US · United States
Current Assignee / Owner
Publication Date
2010-01-14
Estimated Expiration
Not applicable · inactive patent

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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.
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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...

Examples

Embodiment Construction

[0018]A first mixture for use in producing a simulated surface is prepared by mixing together a 40% polymer liquid with 60% water. In a preferred embodiment, the polymer liquid is a masonry coating polymer. The first mixture, providing a boding agent, is applied to an existing surface using a roller. Next, a second mixture is prepared by mixing together 80% water with 20% polymer having a self-leveling characteristic. In a preferred embodiment, the polymer is a masonry coating polymer. A cementous mixture comprising 50% Portland cement and 50% sand is combined with the second mixture and fully mixed to provide a self-leveling cementous mixture. The self-leveling cementous mixture is applied to the surface, using a trowel in a minimal action to evenly spread the self-leveling cementous mixture over the surface. When the mixture is partially cured, a tool is used to score in the desired grout pattern by scraping away a portion of the cementous mixture. The created grout lines resemble...