Abstract:
A surface veneer for simulating the appearance of stone, tile, concrete, leather, wood, stucco, etc. is disclosed. The veneer may be made by producing a mold of a desired texture, filling the mold with a mixture including portland-type cement, resin, and colorant, with the mixture being impregnated with a support mesh. The veneer may be made to have an average thickness between about 1/16 and ¼ inches in a sheet form. When produced, the veneer is flexible, being able to conform to various surfaces and applied to various surfaces using any of various adhesives, and able to be transported is a finished form to an installation site. The veneer may also be finished prior to installation with a wide range of surface finishes and textures.

Description:
FIELD 
       [0001]    This application relates generally to durable building materials. More particularly, this application relates to flexible cement-based veneer or sheet material for application on a variety of surfaces to provide decorative and protective finished surfaces. 
       BACKGROUND 
       [0002]    Concrete surfaces, particularly concrete surfaces used in high-traffic and exterior locations, can crack and otherwise break-down over time. Removing and replacing damaged concrete surfaces can be very expensive and time consuming, and may not be appropriate for all situations. Concrete sealers and other coating products may provide some protection, but the underlying damage and texture of the concrete remains. Similarly, stucco and other cement-based products may also encounter similar problems over time. 
         [0003]    Some concrete repair solutions include covering the concrete with tile, pavers, or other ceramic or rock products to hide damaged concrete. However, such products may be expensive and time consuming, requiring skilled individuals to install the products. Additionally, tile, pavers, and other stone products are stiff and brittle and tend to crack if any imperfections in the underlying concrete exist, particularly when resurfacing concrete outdoors like patios, porches, sidewalks, driveways, etc. 
       SUMMARY 
       [0004]    A surface veneer for simulating the appearance of stone, tile, concrete, leather, wood, stucco, etc. is disclosed. The veneer may be made by producing a mold of a desired texture, filling the mold with a mixture including portland-type cement, resin, and colorant, with the mixture being impregnated with a support mesh. The veneer may be made to have an average thickness between about 1/16 and ¼ inches in a sheet form. Sheets of veneer may be made in a variety of sizes, such as 4′×4′ and 4′×8′ sheets. When produced, the veneer is flexible, being able to conform to various surfaces and applied to various surfaces using any of various adhesives, and able to be transported is a finished form to an installation site. 
         [0005]    The veneer may be finished prior to installation with a wide range of surface finishes and textures. The veneer may be finished for a particular application, such as for exterior, heavy traffic use, or for decorative interior wall covering or tub and shower surrounds. In some embodiments, the veneer may also include a peel coat to protect the finish during transportation and installation. Thinset may be used to adhere the veneer to a desired surface. Excess thinset may be allowed to create grout lines between veneer panels and then leveled with a trowel. Excess thinset on the face of the veneer panel would then be removed when the peel coat is removed, leaving a clean surface and grout line edge. 
         [0006]    These and other aspects of the present invention will become more fully apparent from the following description and appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The following description can be better understood in light of Figures, in which: 
           [0008]      FIG. 1  is a cross-sectional view of an exemplary embodiment of a flexible cement veneer; 
           [0009]      FIG. 2  is an elevated perspective view of an exemplary embodiment of a flexible cement veneer during formation; 
           [0010]      FIG. 3  is a cross-sectional view of an exemplary embodiment of a flexible cement veneer during formation; 
           [0011]      FIG. 4  is a perspective view of an exemplary embodiment of a depth gauge for use in forming flexible cement veneers; 
           [0012]      FIG. 5  is a perspective view of an exemplary embodiment of a mold for use in forming flexible cement veneers; 
           [0013]      FIG. 6  is flow diagram of an exemplary method of manufacturing a flexible cement veneer; and 
           [0014]      FIG. 7  is a flow diagram of an exemplary method of installing a flexible cement veneer. 
       
    
    
       [0015]    Together with the following description, the Figures demonstrate and explain the principles of flexible cement veneers and associated methods. In the Figures, the thickness of layers and regions may be exaggerated for clarity. The same reference numerals in different drawings represent the same element, and thus their descriptions may not be repeated. 
       DETAILED DESCRIPTION 
       [0016]    In the illustrated embodiments, aspects and features of flexible cement veneer products and associated methods are disclosed and described below. The following description supplies specific details in order to provide a thorough understanding. Nevertheless, the skilled artisan would understand that the apparatus and associated methods of using the apparatus can be implemented and used without employing these specific details. Indeed, the devices and associated methods can be placed into practice by modifying the illustrated devices and associated methods and can be used in conjunction with any other apparatus and techniques conventionally used in the industry. 
         [0017]    Exemplary flexible cement veneers that may be formed using the methods described herein are illustrated in  FIG. 1 .  FIG. 1  illustrates a cross-sectional view of an exemplary flexible cement veneer  100 , which may include base  110 , mesh layers  142 ,  144 , finish layer  150 , and peel layer  160 . In  FIG. 1  the dimensions of flexible cement veneer  100  and its various components and layers are exaggerated for illustrative purposes. 
         [0018]    Body  110  may be a cement-based mixture formed as described below, and made of a mixture of water-based epoxy, resin, water, colorants or pigments, sand, and cement. In some embodiments, the epoxy may be provided to the mixture as a separate resin and catalyst, such as those offered by Tresco Paint in Hayward, Calif. Similarly, the resin may be Astro 600 resin also offered by Tresco Paint. The sand may be dolomite sand, such as Dolowhite sand offered by Chemical Lime of Salinas, Calif., and the cement may be portland, white, type I or II, or any mixture thereof to achieve a desired color along with colorants, which may be any colorants used in producing colored cement products. For example, in some embodiments the quantity of cement in the mixture may be apportioned between white and grey portland-type cements depending on the desired final color, or shading to enhance selected colorants. 
         [0019]    The proportion of the various materials in the mixture of base  110 , may vary, depending on the desired hardness, durability, flexibility, veneer thickness, color, shade, or other desired characteristics. In some embodiments, for example, the cement may be between about 5 and about 10 lbs., the Astro 600 resin may be between about 12 and 72 oz., the sand may be total between about 15 and 50 lbs, with any combination of dolomite, or other similar sand products, and the epoxy amounts may vary. Of course the amount of water added may be adjusted depending on desired thickness and workability of the mixture. In some exemplary embodiments, the proportions of the various components by volume of the mixture may be about the following amounts: 
         [0020]    32 oz. epoxy part A from Tresco Paints; 
         [0021]    16 oz. epoxy part B from Tresco Paints; 
         [0022]    36 oz. Astro 600 resin from Tresco Paints; 
         [0023]    70 oz. water; 
         [0024]    colorants as desired; 
         [0025]    22 lbs. dolowhite #70 sand from Chemical Lime; 
         [0026]    9 lbs. dolowhite #100 sand from Chemical Lime; and 
         [0027]    7.85 lbs cement. 
         [0028]    The mixture above may be produced by first mixing the epoxy components, resin, and water, followed by colorants, sand and cement to create the desired mixture for producing breakable cement veneer  100 . In addition to the components described above, base  110  may also include other additives in the mixture such as hardeners, UV resistant or reflective materials, low-heat materials, recycled materials such as ground concrete, plastic, glass, etc., or any other cement additive as desired by one of ordinary skill that provides a cement veneer as described. For example, ground concrete and glass, along with lime, may be substituted for some or all of the dolomite sand. 
         [0029]    Mesh layers  142 ,  144  may be any mesh to provide structural support in base  110 , allowing flexible cement veneer an extent of flexibility and handling beyond a veneer of cement mixture of base  110  alone. Mesh layers  142 ,  144  may be nylon, metal, plastics, or any other material sufficient to be embedded in flexible cement veneer  100  and provide desirable structural characteristics. In some embodiments, mesh  142 ,  144  may be provided such that the material of base  110  extends through mesh  142 ,  144  such that mesh  142 ,  144  is embedded within base  110 . Mesh  142 ,  144 , may be any mesh pattern, dimensions of mesh openings, or other material characteristics such as woven, glued, welded meshes as desired to provide structural support for flexible cement veneer  100 . 
         [0030]    In some embodiments, flexible cement veneer  100  may have a single mesh layer  142 , or multiple mesh layers, (i.e., 3, 4, 5, etc.), depending on desired qualities of finished cement veneer  100 . Similarly each of mesh layers  142 ,  144 , or a single layer, may be located at and depth and at any spacing within base  110 , and the direction of filaments of mesh  142 ,  144  may be set at any angle with respect to the external edges of flexible cement veneer  100 . 
         [0031]    As shown in  FIGS. 2 and 3 , mold  120  may be placed on support surface  130 . Support surface  130  may be a movable support such as a board or other stiff support material such as a table, conveyor surface, etc. that may be used to support mold  120  during manufacture of flexible cement veneer  100 . Depth gauge  170  may be disposed over mold  120  during manufacture of flexible cement veneer  100  as described below. 
         [0032]    As generally illustrated in the flow-chart of  FIG. 6 , in some embodiments, flexible cement veneer  100  may be manufactured by providing mold  120  on support surface  130 , and applying a cement mixture of base  110  to mold  120 . A release agent may be applied to mold  120  prior to applying any of the cement mixture of base  110 . A first amount of cement mixture may be applied to mold  120  and brushed, pressed, troweled, or otherwise forced into features  122  (see  FIG. 5 ) of mold  120 . Depth gauge  170 , as shown in  FIGS. 2 and 4 , may then be placed over mold  120  having a first amount of mixture on the mold surface of mold  120 . Sufficient mixture of base  110  may then be applied over depth gauge  170  and leveled with a trowel, float, oscillations, vibrations, or other device or process such that the thickness of base  110  approximates the thickness of gauge wires  174  to provide a generally uniform thickness. 
         [0033]    In some embodiments, base  110  may have a generally uniform thickness generally slightly more than the thickness of gauge wires  174  of depth gauge  170 . Gauge wires  174  may be random in pattern within frame  172 , sufficiently spaced to provide for a generally uniform depth of base  110  without imparting a pattern into base  110  as a result of depth gauge  170 . Depth gauge  170  may be selected based on the desired finished thickness of flexible cement veneer  100 . Frame  172  may be stiffer than gauge wires  174  to provide sturdy frame  172  of depth gauge  170 , while having the same gauge as gauge wires  174 . In some embodiments, frame  172  may be coupled side-by-side layers of gauge wires to provide the framing and stiffness for depth gauge  170 . Depth gauge  170 , frame  172 , and gauge wires  174  may be metal, plastic, or any other suitable material, or any combination of those materials. 
         [0034]    In some embodiments, depth gauge  170  may not be needed where an automated process levels base  110 , where mold  120  has upwardly extending edges that may allow screeding or leveling based on the depth of mold  120 , electronic confirmation of thickness, or other mechanized or automated process or device to provide a generally uniform thickness. The thickness of flexible cement veneer  100  may be between about 1/16 and ¼ inch, as desired. In some embodiments, thicknesses of more than ¼ inch may be achieved, as desired. 
         [0035]    Once the thickness of base  110  is established, depth gauge  170  may be removed, if used, and mesh layer  144  may be placed on base  110  and worked into base  110  with troweling or other process. This process may remove any lingering pattern from depth gauge  170  in base  110 . Mesh layer  142  may then be similarly embedded into base  110 . In some embodiments, mesh layer  144  may be placed on mold  120  after applying the first amount of mixture and before applying additional mixture and using depth gauge  170 , with mesh layer  144  following removal of depth gauge  170  and leveling base  110 . 
         [0036]    Flexible cement veneer  100  may then be allowed to dry. Once dry, flexible cement veneer  100  may be removed from mold  120 , with features  122  of mold  120  resulting in corresponding features in flexible cement veneer  100 . Mold  120  may have any pattern desired in flexible cement veneer  100 , such as brushed concrete, leather, brick, skip trowel, stucco, stone, sand, or virtually any desired pattern that may be molded into mold  120 . Mold  120  may be made of flexible material such as rubber, foam, latex, or other mold material, or may be hard, such as metal, ceramic, or other hard molds. 
         [0037]    After removal from mold  120 , the molded surface of flexible cement veneer  100  may then be processed and/or finished using any known cement finishing process such as acid wash, stain, epoxy coating, etc., resulting in finish layer  150 . Finish layer  150  may be made to virtually any color (translucent, solid, mixed, blended, etc.) and finish quality (such as waterproof, water penetrable, water vapor penetrable, gloss, satin, flat, etc. finishes). Once finish layer  150  is completed, peel layer  160  may be applied to protect finish layer  150  of flexible cement veneer  100 . Peel layer  160  may be any coating, such as a brush or spray on liquid polymer coating that dries to a peelable layer, with the advantage of adhering to each surface feature  122  of finish layer  150 . Similarly, other membranes or covering, such as plastic sheeting or other known coatings may be used. 
         [0038]    As generally shown in  FIG. 7 , flexible cement veneer  100  may be installed by first preparing a surface for installation of flexible cement veneer  100 . Depending on the surface and the desired final appearance, preparation may include patching, grinding, cleaning, leveling, etc., the surface to be covered. The surface to be covered may be a wall, ceiling, floor, or other desired surface, and may be and exterior on interior surface. Additionally, the flexible nature of flexible cement veneer  100  may allow installation of flexible cement veneer  100  on cracked, somewhat uneven, curved, sloping, etc, surfaces. Flexible cement veneer  100  may be installed on a surface that will allow adhesive bonding of flexible cement veneer  100 . Flexible cement veneer  100  may be adhered to a desired surface using any known adhesive or bonding medium, such as various thinsets, glues, etc., used to adhere building materials to each other 
         [0039]    Once flexible cement veneer  100  is applied and in place, peel coat  160  may be removed to reveal finished layer  150 . Peel coat  160  may provide ease of installation because installers need not worry about cleaning excess adhesives or materials from the presented surface of flexible cement veneer  100  because any materials deposited on the presented surface may be removed along with peel coat  160 . Similarly, peel coat  160  may provide protection from dirt, scratches, or other damage prior to and during the installation process. 
         [0040]    In some embodiments, flexible cement veneer  100  may be manufactured in sheets of material with any desired dimension, depending on the size of mold  120  and a desired finished dimension. For example, flexible cement veneer  100  may be made in 4′×4′ or 4′×8′ sheets. Of course, virtually any size may be produced, limited only by the transportation and handling considerations of manufacture and subsequent installation. Similarly, mold  120  may be made in a variety of shapes and designs, such as a 90 degree angle mold for corners, stair treads, etc., undulating, corrugated, curved, or other desired contour. 
         [0041]    In some embodiments, flexible cement veneer  100  may stiffen over time once installed, gaining strength and durability as the cement in flexible cement veneer  100  fully cures. A desired shape or contour of flexible cement veneer  100  may also be achieved by placing flexible cement veneer in a desired shape, wetting veneer  100 , and allowing veneer  100  to dry while being held in the desired shape. 
         [0042]    In some embodiments, base layer  110  maybe formed using a mix, with the dry portions of the mix being premixed and the liquid portions being provided in separate containers. For example, a kit having each of the components of the mix may be provided and assembled at the site where the veneer is to be placed. The mix may be used as the adhesive, or may be used to prepare the surface to be covered prior to covering, or may be used to cover a portion of the floor alone. 
         [0043]    In addition to any previously indicated modification, numerous other variations and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of this description, and appended claims are intended to cover such modifications and arrangements. Thus, while the information has been described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred aspects, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, form, function, manner of operation and use may be made without departing from the principles and concepts set forth herein. Also, as used herein, examples are meant to be illustrative only and should not be construed to be limiting in any manner.