Composite coating for architectural pieces

Abstract

The present invention relates to a composite coating for architectural pieces used in building and remodeling of existing buildings. The architectural pieces include plastics, polyurethanes, wood and glass decorative items, granite and all manners of stone, wood inlays, wood flooring products, full size brick and pavers as well as thin veneer varieties such as brick or stone veneer. In addition, the invention relates to a method for grouting the architectural pieces.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The objects of the invention are achieved as set forth in the illustrative embodiments shown in the drawings which form a part of the specification.

FIG. 1 is a perspective view of one method of applying the composite coating to veneer pieces in one embodiment of the present invention;

FIG. 2 is a perspective view of a subsequent step to FIG. 1 of the method of the present invention;

FIG. 3 is a perspective view of another step of the method of the present invention; and

FIG. 4 is a perspective view of a further step of the method of the present invention.

Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what I presently believe is the best mode of carrying out the invention. As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

FIG. 1 is a perspective view of step one of a method for one embodiment of the present invention. A spray applicator 10 is mounted above a conveyor 12. The conveyor 12 moves a veneer piece 14 (in this embodiment the architectural piece is a brick veneer) beneath a sprayer 16 which sprays the composite coating 20 on to the brick 14 passing beneath the sprayer 16. A coated brick 22 continues on the conveyor where it is cooled until the coating becomes solid and the brick 22 can be stored until time for its use. The coating composition is formed in the mixer 24 and passed through a heating station 26 where the coating composition is a free-flowing liquid. The liquid is then conveyed through an insulated feeder pipe 18 to the sprayer 16 above the conveyor 12. The sprayer 16 is metered so as to spray only on the brick 22 as it passes beneath the sprayer 16.

FIGS. 2 and 3 illustrate the ease with which grout 32 can be applied to a pattern of the coated bricks 22. Conventionally when laying a pattern of bricks 22 a base 28 is provided. The base 28 may be poured concrete, a wood floor or other suitable substrate. A layer of adhesive 30 is applied to the substrate 28 prior to laying the bricks 22 in their desired pattern. A suggested adhesive product is MegaLite Crack Prevention Mortar sold by Custom Building Products, Seal Beach, Calif. Products of this nature are identified in the industry as “thin-set” adhesive. The thin-set adhesive 30 is applied by use of a rake trowel to the surface 28 to be covered with the bricks 22. Grout 32 is applied without regard for the coated surfaces of the bricks 22. The grout 32 is simply applied over the entire surface of bricks 22 with a suitable applicator 34. As shown in FIG. 3 the surface of the bricks 22 may be substantially covered with grout 32 so as to fill all of the spaces between the bricks 22 with grout 32. The grout 32 on the surfaces of the bricks 22 is then swept away with a squeegee or other appropriate tool.

FIG. 4 illustrates the final step in the procedure of applying grout 32 to a pattern of coated bricks 22. The coating 36 on each brick 22 is simply peeled from the brick 22 after the grout 32 has been cured. The surface of each brick 22 is clean and dry and ready for any finishing coating and the like. The peeled coating pieces 36 can be recycled to the mixing bin 24 of FIG. 1.

Advantages of the present invention are many. The coated pieces, after the coating has cooled and stabilized, can be packaged and shipped just as conventional architectural pieces are shipped. Since the coating of the architectural pieces is UV resistant, the coated pieces can be stored outside without damage to the coating or the pieces. The presence of the coating also helps to prevent chipping of the architectural pieces when shipping and handling.

Highly skilled labor is not required to build a patio or driveway surface or side to a building of architectural pieces resulting in a functioning and appealing finished product. In fact, the grout can be applied to the entire surface (FIG. 3) and then the excess grout is easily wiped away (FIG. 4) after which the grout 32 is cured and then the pieces of coating 36 are removed. A conventional sealant can then be applied, if desired.

EXAMPLE 1

In a typical example of the present invention, the following constituents are mixed in a mixer 24:

Parts by weight
Cellulose acetate butyrate       55
Dioctyl terephthalate (or triethyl citrate) 47
Epoxidized soy bean oil          2
Di-n-octyl tin bis isooctyl maleate 1
Butyl stearate                   0.5

The mixed ingredients are heated in a heater 26 to about 350° F. whereupon the mixture is liquid and is pumped through an insulated pipe 18 to a spray applicator 16 as depicted in FIG. 1. The spray applicator 16 provides hot air to maintain the temperature of the liquid being sprayed at approximately 350° F. The spray applicator 16 is programmed to spray substantially only the surface of the brick veneer piece 14 as the brick 14 passes beneath the spray 20. The coated bricks 22 are conveyed by the conveyor 12 to a cooling area (not shown). Once the coated bricks 22 have cooled to room temperature, they are ready for shipping and use.

The coating 36 (FIG. 4) generally has a thickness from about 1 mm to about 20 mm and is adhered to the surface of the brick veneer 22 with a tack requiring a pull force of about 1 to about 4 psi to remove the coating 36 from the brick veneer piece 22. The surface of the coating 36 has a very low friction coefficient which allows the grout to pass over the coating into the spaces between the veneer pieces 22 when applying the grout.

Once the coated bricks 22 are laid and grout applied as shown in FIGS. 2, 3 and 4, and the grout has cured, the coating 36 on the bricks 22 can be removed by simply peeling the coating 36 from the brick veneer pieces 22.

EXAMPLE 2

In another example of the present invention, the following constituents are mixed in a mixer 24:

Parts by weight
Cellulose acetate butyrate       50
Diisodecyl phthalate             50
Triethylene glycol               2
Diisophenyl phosphite            2
Wax                              2
Ditertiary butyl methyl propylene 2
Dithioerythritol                 2

The mixed ingredients are heated in a heater 26 to about 350° F., and applied in a manner similar to Example 1.

The above examples of a coating composition of the present invention are merely exemplary. Example 1 is the preferred embodiment at this time, but modifications of the formulation are included herein. For instance, there are several thermoplastic resins which will work in the formulation of the composite coating. These are known to those skilled in the art. The same is true for the plasticizer, the stabilizer and the release agent.

The coating components are generally in bulk form, e. g., in pellets, granules, small pieces or liquid. This bulk form allows mixing to take place uniformly resulting in a substantially uniform melt when heated to a temperature of about 350° F. The melt, in a fluid state, permits pumping of the fluid to a sprayer for application to the architectural pieces or such application may be effected with a spray gun, a roller, a brush or the like. The composite coating in its melted state has pore filling characteristics assisting in the adherence of the coating to the substrate whether the architectural piece is tile or brick or stone or wood or glass or the like.

The composite coating upon cooling quickly forms a relatively hard, but flexible outer shell. The surface of the composite coating has low friction properties which prevents the coated pieces from sticking to each other. Furthermore, when the grout or other adhering material is applied, the low friction surface allows the grout to slide off of the coating thus leaving the grout in between the coated pieces. Quite simply, after the pieces are laid in the desired pattern, the grout is “slopped on” the entire surface area and then worked in between the veneer pieces by use of a squeegee tool making sure that all voids between the coated pieces are filled. The grout is allowed to cure and then the composite coating is peeled from each architectural piece leaving substantially no residue and the architectural pieces are ready for any finishing treatment desired.

The composite coating provides a protective shell for the architectural pieces during shipping and handling. The protective shell prevents the coated pieces from sticking together. Furthermore, the adherence of the protective shell prevents grout or moisture from seeping under the coating when the coated pieces are stored or in the process of grouting. The composite coating is ultra violet resistant preventing damage from occurring when the coated pieces are stored outside in the weather. The composite coating has a softening temperature of at least 170° F. so that the coating remains in its relatively hard shell condition when the coated pieces are stored outside.

The composite coating has sufficient clarity to see through the coating to permit visual inspection of the product and the product color.

The composite coating adheres to any and all surfaces. For example, sanded brick has become very popular as the exterior of a wall. When uncoated sanded bricks are placed in a liner as discussed above, the water from the concrete poured to form the wall stains the sanded brick while the concrete wall is curing. The brick then has to be power washed, but power washing tends to destroy a significant amount of the sand on the brick. When the composite coating of the present invention is utilized, the concrete water does not seep onto the sanded brick surface but the composite adheres to the brick surface until the coating is peeled from the surface of the sanded brick.

In view of the above, it will be seen that the several objects and advantages of the present invention have been achieved and other advantageous results have been obtained.

Claims

1. A composite coating suitable for coating the upper surface of an architectural piece, which comprises major portions of a thermoplastic resin and a plasticizer and minor portions of a stabilizer and a release agent in such proportions that the resulting mixture when mixed and melted and applied to the upper surface of an architectural piece and cooled provides a coating which has a softening point above about 170° F., a low friction surface, is waterproof, has a low tack and is peelable from the architectural piece using from about 1 to about 4 psi of pull.

2. The composite coating of claim 1 wherein the thermoplastic resin is cellulose acetate butyrate.

3. The composite coating of claim 1 wherein the plasticizer is dioctyl terephthalate

4. The composite coating of claim 1 wherein the stabilizer is di-n-octyl tin bis isooctyl maleate.

5. The composite coating of claim 1 wherein the release agent is butyl stearate.

6. An architectural piece having a composite coating on the upper surface of the architectural piece, the coating comprising major portions of a thermoplastic resin and a plasticizer and minor portions of a stabilizer and a release agent in such proportions that the resulting mixture when mixed and melted and applied to the upper surface of the architectural piece and cooled provides a coating which has a softening point above about 170° F., a low friction surface, is waterproof, has a low tack and is peelable from the architectural piece using from about 1 to about 4 psi of pull.

7. The coated architectural piece of claim 6 wherein the architectural piece is selected from the group consisting of stone, slate, travestine, wood, glass, porcelain, plastics, polyurethanes, granite, wood inlays, wood flooring products, full size brick, full size pavers, brick veneer and stone veneer.

8. The coated architectural piece of claim 6 wherein the thermoplastic resin is cellulose acetate butyrate.

9. The coated architectural piece of claim 6 wherein the plasticizer is dioctyl terephthalate or triethyl citrate.

10. The coated architectural piece of claim 6 wherein the stabilizer is di-n-octyl tin bis isooctyl maleate.

11. The coated architectural piece of claim 6 wherein the release agent is butyl stearate.

12. A method for grouting coated architectural pieces which comprises: a. fixing the architectural pieces in a predetermined pattern,b. applying grout or an adhering material over the coated pieces without regard for the coated pieces,c. allowing the grout or adhering material to cure, andd. removing the composite coating from the architectural pieces.

13. A method for making a concrete wall having brick or stone veneer pieces which comprises: a. providing an embossed liner having a desired pattern to hold the veneer pieces in place in the base of a concrete wall form;b. spraying an adhesive onto the embossed liner;c. placing composite coated veneer pieces onto the liner with the composite coated side of the veneer pieces contacting the adhesive on the liner;d. pouring concrete into the concrete wall form;e. allowing the concrete to cure forming a concrete wall;f. removing the form from the concrete wall; andg. removing the liner along with the coating from the veneer pieces resulting in a concrete wall containing veneer pieces.

14. A concrete wall prepared by the method of claim 13 wherein the composite coated veneer pieces are sanded brick veneer pieces.