The present invention relates to an apparatus and method for wall decorating by impressing a design in deformable material secured to a wall. The deformable material includes but is not limited to concrete, grout, mortar, plaster, cultured stone and veneer stone that is secured to a vertical structure inside a building, or an outside wall exposed to natural elements. The present invention includes a relatively light weight flexible fabric or board section secured to the vertical structure such that an inner side of the flexible fabric or board engages the vertical structure; and an outer side of the flexible fabric or board is configured to receive and secure the deformable material to the outer side, thereby allowing a design to be impressed into the deformable material, resulting in a permanent design upon the vertical structure after the deformable material solidifies.
Typically, a plurality of laths fabricated from wood or metal are disposed horizontally parallel on a vertical or wall structure to provide a base upon which a deformable material can be disposed and secured to the vertical structure. The secured deformable material is ultimately configured via a stamp or similar device impressing a preselected design into the deformable material. In order to maintain the position of the deformable material upon the wall structure, a plurality of laths have to be disposed parallel and in close proximity to adjacent laths upon the wall structure whereby a gap of approximately one-inch separates adjacent laths, thereby enabling a relatively viscous deformable material to adhere to the laths. This close proximate relationship between the laths results in a relatively time consuming and expensive project when a relatively large vertical structure is to be covered with the deformable material.
Beside the time and costs of using laths for a vertical structure, another problem arises when the deformable material that engages the laths has a relatively “liquid” parameter that causes the deformable material to “run” or otherwise flow upon the laths rather than maintaining a selected position.
More specifically, metal, wood or fiberglass laths need to be screwed or nailed individually into a vertical wall or similar support structure, whereby sufficient space is provided adjacent laths that allow a predetermined quantity of mortar, plaster or similar material to be applied to the support structure. The quantity of applied mortar must enable a preselected design to be raked, profiled, scratch-coated or otherwise impressed into the mortar when in a deformable condition. However, because a space is present between adjacent laths, if the individual applying a deformable material to the laths is not consistent with the manual pressure impressed upon the deformable material being applied to the laths, the material can be “wasted” by being pressed through the space and falling from the laths on the opposite side due to an excessive manual force. Further, if an insufficient quantity of manual force is impressed upon the deformable material when applied to the laths, the applied deformable material can fall from the laths causing the individual to apply a new portion of material.
A need exits for an apparatus and method that inexpensively and quickly provides a foundation or base upon a vertical structure to receive and maintain the position of deformable material when disposed upon the base, when a design is impressed upon the deformable material, and though the solidifying process of the deformable material.
It is an object of the present invention to overcome many of the disadvantages associated with prior art devices and methods for applying deformable material such as mortar or similar cementitious material onto a wall or ceiling surface, then impressing a design into the deformable material, whereupon, the deformable material hardens and the impressed design becomes a permanent configuration in the hardened deformable material. A principal object of the present invention is to provide a device and method for receiving a cementitious material that will be configured with a preselected design. A feature of the device and method is a relatively light weight flexible fabric member or substantially rigid board sections that cover the entire surface of a structure selected to display a predetermined design. An advantage of the device and method is that the light weight fabric member or rigid board section, or a combination of both fabric member and board section can be quickly secured to the surface of a selected structure, thereby saving time and costs to provide a deformable material receiving fabric member capable of supporting a deformable material when a design is forcibly impressed into the deformable material, whereupon, the design is maintained throughout the hardening process of the deformable material.
Another object of the present invention is to provide a surface configuration for an outer wall of the fabric member that promotes the securing of the deformable material upon the outer wall of the fabric member when the fabric member is orientated vertically upon a wall structure. A feature of the surface configuration of the fabric member is that the configuration corresponds to the viscosity of the deformable material. An advantage of the surface configuration corresponding to viscosity is that the less viscous (more liquid) the deformable material, the smaller the acute angle of aperture walls that engage and support the deformable material disposed upon the receiving member.
Still another object of the present invention is to secure the fabric member to a structure with fastener members that do not obstruct the impressing of a design into the deformable material. A feature of the device and method is that the fastening members are disposed in the recesses that receive and support the deformable material. An advantage of the device and method is that the recessed fastening members prevent engagement between a tool that impresses a design into the deformable material and one or more of the fastening members.
Yet another object of the present invention is to provide an air gap between the deformable material receiving member and a wall structure. A feature of the device and method is offset strips vertically secured to the wall structure, whereby the offset strips are horizontally separated a predetermined distance. Another feature of the device and method is that the offset strips are dimensioned to separate the fabric member from the wall structure a predetermined distance after the fabric member is attached to the offset strips. An advantage of the offset strips separation and dimensions is that an air gap is formed that prevents moisture from being trapped between the receiving member and the wall structure, resulting in the prevention of mold or decay of the fabric member and/or the wall structure.
The foregoing invention and its advantages may be readily appreciated from the following detailed description of the preferred embodiment, when read in conjunction with the accompanying drawings in which:
Referring to
The fasteners 16 that secure and maintain the relative position of the fabric 12 member upon the wall structure 14 when the predetermined quantity of deformable material 22 is disposed upon the flexible fabric 12 are well known to those of ordinary skill in the art and include, but are not limited to screws, nails, glue, bolts and combinations thereof that are fabricated from stainless steel, copper, polymers, and similar materials that provide for indoor and outdoor usage. The deformable material 22 disposed upon the fabric member 12 ultimately completely covers all portions of the fabric 12, which covers all preselected portions of the wall structure 14. The fasteners 16 continue to maintain the relative position of the fabric member 12 and the deformable material 22 disposed upon the fabric member 12 when a preselected stamp (not depicted) is forcibly urged into the deformable material 22. The stamp ultimately forms a predetermined configuration or design in the deformable material 22; whereupon, the stamp is removed from the deformable material 22 and the deformable material 22 ultimately solidifies to form a permanent configuration or design in the deformable material 22. The deformable material 22 and the design thereon appear to be integrally joined to the wall structure 14 by an observer irrespective of the observer's direction of view of the wall structure 14 due to the flexible fabric member 12 totally covering the wall structure 14 and the deformable material 22 totally covering the fabric member 12, whereby, the fabric member 12 supporting the deformable material 22 cannot be seen by the observer before or after the material 22 hardens.
The flexible fabric 12 can be fabricated from a myriad of relatively strong materials having substantial tensile strength including but not limited to cotton, synthetic resin and fiber materials, fiberglass, basalt, calcium silicate hydrate, polymers including rigid polymer foam (polyurethane), light weight concrete, and combinations thereof. The flexible fabric 12 can be heat formed or extruded into flexible rolls or rigid sections or panels having predetermined configurations. The flexible fabric 12 can be a textile resin material lightly coated with an epoxy or a urethane acrylic compound on an inner side 24 that ultimately engages a cooperating surface of the wall structure 14. The slightly wet resin of the outer side 26 of the fabric member 12 receives a “broadcast” coating of silica sand (not depicted). The silica sand attaches to or “sticks” on the outer side 26, resulting in the reduction of flexibility of the fabric member 12 to maintain a predetermined configuration for the outer side 26 of the fabric 12 that promotes the securing of the deformable material 22 to the outer side 26 of the flexible fabric 12. The silica sand on the outer side 26 of the fabric member 12 enables the outer side 26 side to chemically react with the cement compounds in the deformable material 22 to form chemical bonds between the flexible fabric 12 and the deformable material 22, resulting in the binding of the deformable material 22 to the flexible fabric 12.
The fabric member 12 is light weight and can be shipped in rolls or stacked sheets for reducing the cost of shipping and handling of the fabric 12. Further, rolls of the fabric member improves safety and reduces time when cutting the fabric 12 to cover portions or the entire surface of the wall structure 14. The fabric member 12 is ready to receive the deformable material 22 after the fabric member 12 is secured to the wall structure 14; resulting in the reduction of time and money to secure the deformable material 22 to the wall structure 14, when compared to the time and cost to secure laths or similar prior art members that support deformable material 22.
The offset strips 20 for forming an air gap 18 between the flexible fabric 12 and the wall structure 14 are dimensioned to include a lateral dimension, when taking a front elevation view (see
The offset strips 20 can be fabricated from the relatively rigid materials discussed above (including fiberglass, calcium silicate hydrate and polymers) configured in rolls or relatively thin sheets, or can be fabricated from different materials such as wood or metal having structural strength capable of supporting the fabric 12 and the attached deformable material 22. The flexible fabric 12 is ultimately joined to the offset strips 20 (via the fasteners 16 discussed above) after the strips 20 are secured to the wall structure 14. The air gap 18 prevents moisture and/or condensation from becoming trapped between the flexible fabric 12 and the wall structure 14. The trapped condensation can result in a mold health problem, and/or the decay of the offset strips 20. Further, the offset strips 20 enable a user of the apparatus to better “stretch” the flexible fabric 12 when securing the fabric 12 upon the offset strips 20 to the fabric or rigid board 12 after being secured to the wall structure 14.
The outer side 26 of the fabric or relatively rigid board 12 includes a resin, silane or broadcast silica treatment that bonds to cementitious materials. The selected resin includes hydroxyl bonding capabilities that forms chemical bonds, including but not limited to alkoxy silane forming silicon-oxygen binds. For example, silica sand can be broadcast on the surface of epoxy resin that is integral to the fabric or flexible board 12, resulting in aa rougher profile and the forming of silicates (i.e. ettringite, calcium silicate hydrate) that ultimately bond with a cementitious material. Referring to side elevation
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In operation, a method for decorating a deformable material 22 secured to a wall structure 14 such that a design can be impressed into the deformable material 22, then allowed to solidify, Includes the step of selecting a deformable material 22 capable of withstanding or otherwise cooperating with the ambient elements (“inside or outside”) of the location of the wall structure to be decorated. After selecting the type of deformable material 22 (concrete, plaster, mortar, grout, etc.) and the viscosity for the selected type of deformable material 22, a fabric member 12 is selected having a configuration that cooperates with the viscosity of the deformable material 22 to be disposed upon the wall structure 14. The fabric member 12 is then secured to the wall structure 14 via fasteners well known to those of ordinary skill in the art.
If the presence of moisture is possible, an air gap 18 is required between the flexible fabric 12 and the wall structure 14. If an air gap 18 is required, the method includes the added step of securing multiple offset strips 20 to the wall structure 14; then securing the fabric member 12 to the offset strips 20 or in the alternative, securing a flexible fabric 12 having offset strips integrally joined to an inner wall of the fabric member 12 to the wall structure 14. Irrespective of the fabric member 12-offset strip 20 combination, fasteners 16 are selected to secure the relative positions of the fabric member 12 and the offset strips 20 upon the wall structure 14 when a predetermined deformable material 22 is applied to the fabric member 12. After securing the fabric member 12 to the wall structure 14, a preselected stamp or similar design tool is impressed into the deformable material 22 after the deformable material 22 has sufficiently hardened to accept the stamp without deforming the deformable material 22; whereupon, the stamp is removed from the deformable material 22 before the deformable material has solidified, resulting in a permanent design impressed into the deformable material 22.
The foregoing description is for the purpose of illustration only and is not intended to limit the scope of protection accorded this invention. The scope of protection is to be measured by the following claims, which should be interpreted as broadly as the inventive contribution permits.
This Utility Patent Application is based on Provisional Patent Application No. 62/827,024 filed on Mar. 30, 2019.
Number | Date | Country | |
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62827024 | Mar 2019 | US |