EP2377689A1

EP2377689A1 - Process for preparing a wall covering with the appearance and feel of stone, and product obtained by same

Info

Publication number: EP2377689A1
Application number: EP10382082A
Authority: EP
Inventors: Jesús Merino Escamez
Original assignee: Lamistone SL
Current assignee: Lamistone SL
Priority date: 2010-04-13
Filing date: 2010-04-13
Publication date: 2011-10-19
Also published as: WO2011128478A1

Abstract

The invention relates to a process for preparing a wall covering with the appearance and feel of stone, comprising the use of a mortar, which is spread in a thin layer on a fiberglass or textile support; then making a series of irregular imprints by pouring colored dyes, pigments or paints and grains of effervescent salts on the mortar. The support and the mortar are then passed between two bands or belts advancing one above the other, being bonded to the support forming a sandwich, in which the outer face of mortar has, in addition to colored streaks, a series of cavities providing it with an appearance of stone.

Description

Object of the Invention

The invention is comprised in the sector of mortar coverings for decorating walls.

Background of the Invention

A large amount of mortars for covering walls are manufactured today. Some are used to make decorations which imitate natural stones, but they have to be applied in situ directly on the walls by specialized labor, and have to be given a traditional finish with trowels, scrapers or stamping molds, with the drawback of producing a large amount of waste, dust and dirt; these specialized jobs and drawbacks will be eliminated with the present invention

Description of the Invention

The process of the present invention for preparing the wall covering with the appearance and feel of stone on textile fabrics or fiberglass basically consists of two components which form a whole upon bonding: a textile support and a mortar which is deposited thereon, procuring its setting under conditions such that they favor the formation of a stone finish, both in the visual and tactile aspect.
The first of these components is a mortar with a thick fluid consistency, formed by different proportions of the following raw materials:

9-13% cross-linking agent: Adhesive in aqueous dispersion (base of synthetic acrylic resins and acrylic copolymers)
25-30% calcium carbonate powder
45-55% quartz or silica sand (grain size 0.5 mm)
10-15% water

The second component forms a support means for the setting of the mortar and also forms the structure of the product once finished, to that effect it is formed by a (synthetic or organic) textile type fabric or a fiberglass fabric.
The process of the invention is started by spreading the support on an impermeable conveyor belt, which is in continuous linear movement. A layer of mortar with a thickness of between 2-5 mm is then deposited evenly on the support, using to that end a trowel or running mold type leveling element, which facilitates the bonding between both components. Next, without interrupting the advance of the belt, a series of irregular and random impressions are made on the mortar using a mechanical means, different jets of colored paints, dyes or pigments, drawing streaks, are then applied thereon; as well as grains of effervescent salts (gasifying agents) which upon contacting the moisture of the mortar will give off gases which allow forming bubbles in the mortar.
This sandwich, formed by the textile support and the mortar, is then passed for a few seconds under another belt with the same features as the first one which advances parallel to the latter, separated by a distance which will be equal to the thickness of the mortar plus the support; this operation closely bonds both elements, and at the same time traps small amounts of air in the mass of the mortar which, together with the gases given off by the grains of effervescent salts, form pores and various cavities which, complemented with the drawings of the previously made colored streaks, provide the mortar with a finish with the appearance of stone when the belts are later separated.
Finally, fine grains of ground glass are sprinkled on and adhere to the mortar, and the process will end by leaving it to dry, the mortar hardening.
With this a decorative layer with the appearance of stone due to its texture, hardness, colors, streaks and feel is created on a flexible support.

Preferred Embodiment of the Invention

In a first embodiment, the following formula with the following raw materials and proportions has been used:

11% cross-linking agent: Adhesive in aqueous dispersion (base of synthetic acrylic resins and acrylic copolymers)
28% calcium carbonate powder
49% quartz or silica sand (grain size 0.5 mm)
12% water

A second embodiment uses the following formula:

12% cross-linking agent: adhesive in aqueous dispersion (base of synthetic acrylic resins and acrylic copolymers)
25% calcium carbonate powder
50% quartz or silica sand (grain size 0.5 mm.)
13% water

Once finished, the product is cut into pieces in different commercial formats, in order to be easily installed on the walls by means of a simple adhesion, without needing screwing operations or specialized labor.
The product obtained consists of a semi-rigid plate or sheet of about 2 - 5 mm thick, with a stone nature, having:

On the rear face, a textile or fiberglass element forming the support base on which the stone finish present on the front face has been manufactured.
On the front face a uniform surface of mortar, with a thickness comprised between 2 and 5 mm, in which surface there are observed various areas of different colors which imitate the streaks of stone, formed by colored dyes or pigments poured in a fanciful manner on the mortar before drying. Likewise, in the surface of its front face the mortar has multiple cavities of different sizes, created by effervescent salts which, upon being gasified, form these hollows in the surface of the mortar before it sets, which provide it with the appearance of stone, due to the texture, hardness, colors, streaks and feel thereof.

Having sufficiently described the nature of the invention as well as a preferred embodiment, it is stated for the relevant purposes that the materials, shape, size and arrangement of the described elements can be modified, provided that this does not involve an alteration of the essential features of the invention which are claimed below:

Claims

A process for preparing a wall covering with the appearance and feel of stone, characterized in that it comprises:
a) a first phase in which a support element consisting of a textile sheet or a fiberglass fabric is arranged on a conveyor belt, and on it a layer of mortar with a thick fluid consistency, formed based on very fine grain quartz or silica sand, calcium carbonate powder, cross-linking agent and water, with a uniform thickness, comprised between 2 and 5 mm, using to that end a surface leveling element, like a running mold;

b) a second phase in which various irregular impressions are made and colored paints, dyes or pigments are poured on the mortar, which form fanciful drawings imitating the streaks of stones; as well as grains of effervescent salts which, upon being gasified, create cavities in the surface of the mortar;

c) a third phase in which the sandwich formed by the textile support and the mortar deposited on the main conveyor belt, in continuous linear movement, is passed under another complementary conveyor belt advancing in parallel above the latter, sufficiently trapping both compounds to achieve their close bonding;

d) a final phase in which fine grains of ground glass are sprinkled on and adhere to the mortar, such phase ending by leaving the product to dry until the mortar sets and acquires the required stone hardness.
A product for covering walls with the appearance and feel of stone, formed by two basic elements which, upon bonding, form a semi-rigid sheet or plate with a thickness less than 5 mm, with a stone nature, which is characterized in that said sheet has:
- on the rear face an element consisting of a fiberglass or textile fabric support forming the base on which the stone finish present on the front face has been manufactured;

- on the front face a uniform layer of mortar, between 2 and 5 mm thick, in which surface there have been formed various areas of different colors, formed by colored dyes or pigments poured in a fanciful manner on the mortar before drying, which imitate the streaks of stone; likewise, the surface of the mortar has multiple cavities of different sizes, created by effervescent salts which, upon being gasified, create these hollows in the surface of the mortar before it sets.