Methods of forming and using mat to obtain surface finishes

Improved techniques are provided for obtaining a desirable surface finish of two or more visually distinct selected colors. A mat is prepared by selectively weaving wire between fixed pins on a board. Once removed from the pins, the mat may be molded about the surface of an object painted a first selected color. A second color is then applied over the mat and the object, resulting in a desired dual-color finish after the mat is removed. The techniques of the present invention are particularly well suited for obtaining a high quality marble-like finish on objects of various sizes, shapes, and materials.

FIELD OF THE INVENTION 
The present invention relates to techniques and materials for obtaining a 
high quality surface finish of two or more colors, and more particularly 
relates to the formation of a unique malleable mat for obtaining such high 
quality finishes. 
BACKGROUND OF THE INVENTION 
Finishes having two or more visually distinct colors have long been 
recognized to enhance the value of certain objects. In many instances, 
however, such techniques are difficult to utilize, and are accordingly 
both expensive and infrequently used. Other finishes obtainable, for 
example, from various commercially available kits produce a surface finish 
which either looses its attractive appearance with age and/or use, and 
thus is generally applied only to objects of marginal or low value. 
One of the more desirable dual color finishes is a natural or suedo marble 
finish. Marble or marble-like finishes on vases, fountains, statues, table 
tops, and other items typically represent a high quality and expensive 
product. Unfortunately, such items made from marble are very expensive, 
while available techniques for obtaining marble-like finishes result in a 
finish of relatively poor quality, and are thus perceived as being "fake" 
items. 
U.S. Pat. No. 2,266,926 is directed to forming a marble-like pattern on 
objects. A silk mat is utilized to be applied over the object prior to the 
application of the second color. U.S. Pat. No. 3,340,087 is directed to a 
mechanized process of producing a marble-like finish. A metallic wool 
material is utilized to create the dual-color surface pattern of the 
marble-like finish. As previously suggested, such mats formed from 
randomly positioned strands of silk or steel do not result in a high 
quality finish which closely resembles natural polished marble. 
Depending on the material of the object to be finished, other prior art 
pseudo-marble finishing techniques provide finishes which are, at best, of 
marginally acceptable quality. Accordingly, such techniques have not been 
widely accepted by the public, and are generally used only for relatively 
poor quality objects which offer the buyer a cheap imitation of real 
marble products. Also, if such prior art techniques are applied to objects 
of different materials, such as wood, metal, or plastic, the quality of 
the finish may be even further sacrificed. Moreover, objects having 
substantially non-planar surfaces often cannot be finished with a 
pseudo-marble appearance because the mat utilized cannot be made to 
sufficiently conform to the configuration of the surface to be painted. 
Problems similar to those described above with respect to obtaining a high 
quality marble-like finish are also applicable to prior art techniques for 
obtaining a wood-grain type finish or a high quality antiquing finish. The 
disadvantages of the prior art are, however, overcome by the present 
invention, and improved methods and apparatus are hereinafter described 
for obtaining a high quality finish of two or more visually distinct 
colors. 
SUMMARY OF THE INVENTION 
Improved methods and apparatus are provided for forming a desirable finish 
of two or more visually distinct colors on a selected object. The 
techniques of the present invention may be utilized to obtain a high 
quality marble-like finish on various objects fabricated from clay, wood, 
plastic, fiberglass, metal, glass, plaster or concrete. 
The present invention employs a malleable mat fabricated of thin wire to a 
desired size and shape. The mat may be formed on a board having upright 
pegs spaced intermittently about the perimeter of the desired shape. The 
wire is first tied to one peg, then selectively wound about an opposing 
peg, and similarly criss-crossed until a mat is formed in the area between 
the pegs. During this criss-crossing process, wire is selectively strung 
from a first peg to an intermediate wire, and thence to a second peg 
somewhat adjacent the first peg, thereby breaking the continuinty of 
straight wires in the mat. Once formed and secured, the mat may be removed 
from the pegs and a further selective adjustment made of the position of 
selected wires relative to other wires. 
After the surface of the object to be finished is prepared, a first 
selected color is applied by spraying onto the object and allowed to dry. 
Thereafter, the mat as formed above is applied over the painted object 
and, if necessary, the mat is molded to substantially conform to the 
configuration of the object. A second selected color is then sprayed onto 
the mat and the object, and the mat is then removed. Once the dual-color 
finish is dried, a transparent lacquer may be applied before the final 
finish is given to the surface. 
Accordingly, it is a feature of the invention to provide a method of 
forming a high quality finish of two or more visually distinct colors on 
an object. 
It is also a feature of the invention to provide a method of forming a high 
quality finish which may be used for objects of various sizes, shapes, and 
materials. 
It is another feature of the invention to provide a malleable mat for 
forming a high quality finish of two or more colors, wherein the mat is 
fabricated by selectively winding a wire between pegs on the board, and 
between pegs and intermediate wires. 
Finally, it is a feature of the present invention to provide methods and 
apparatus for forming a painted finish of two or more colors which does 
not appear to be painted by conventional techniques.

DETAILED DESCRIPTION OF THE INVENTION 
The present invention may be used to form a painted surface of two or more 
visually distinct colors on any number of objects of various sizes, 
shapes, and materials. 
The techniques of the present invention may be utilized to form a desired 
finish on a relatively planar surface (such as a desk top), and elongate 
strips of material (such as moldings), and three dimensional ornamental or 
utilitarian objects (such as telephones, statues, animal replicas or water 
fountains), an artistic products (such as lamp bases or vases), and 
numerous other products. In particular, the techniques of the present 
invention may be used for any object which may be painted, and are 
particularly well suited for objects of substantial aesthetic value. The 
techniques of the invention are well suited to products made from wood, 
plastic, metal, fiberglass, clay, plaster, glass, concrete, or other 
commonly painted materials. 
The teachings of the present invention produce a high quality surface 
having two or more visually distinct colors. Modifications may be made to 
vary the appearance of the finish, as explained hereafter. Particularly, 
the teachings of the present invention may be used to form a high quality 
marble-like surface, a surface having a natural wood grain appearance, a 
surface having an antique appearance, or a surface with a finish 
resembling a turtoise shell. The selection of the colors according to the 
invention is at the discretion of the user, although high quality and 
aesthetically pleasing surfaces frequently result from a selection of 
colors including black and a relatively dark color, e.g., dark green, dark 
blue or dark red, or from the selection of two shades from the same color, 
e.g., light brown and dark brown, light blue and dark blue. 
MAT FORMATION 
The teachings of the present invention include the formation and 
utilization of a malleable mat. This mat may be formed on a planar 
surface, such as a board, or on a surface contour approximating the 
contour of the object to be painted. As shown in FIG. 3, object 10 has a 
relatively flat surface 12, an upwardly projecting portion with a 
curvalinear top 13 and sides 14 perpendicular to surface 12, and a 
triangle-shaped flat surface 16. Since the mat of the present invention is 
malleable, it should be understood that a relatively flat mat may be bent 
along the outer surfaces of the object in order that the mat may 
subsequently obtain a contour approximating the contour of the surfaces to 
be painted. 
Accordingly, the mat for assisting in preparation of the painted surfaces 
for object 10 may be fabricated on a flat board 18 fabricated from, e.g., 
1/4" plywood. A plurality of pegs 20 are affixed to the board 18, and 
extend upward from a horizontally positioned board. Pegs 20 may be formed 
from wood, metal, or plastic, and typically are cylindrical in 
configuration. According to one embodiment, pegs 20 are nails extending 
through the thickness of board 18, with the nail heads being raised above 
the top surface shown in FIG. 1. As explained subsequently, a mat having 
an area approximating the area to be painted is desired, although 
preferably the mat will be slightly larger than the area to be painted. To 
form a substantially planar mat, pegs 20 may be positioned about the 
perimeter of the desired mat area. Although the spacing of the pegs is not 
critical, a high quality marble-like finish results when pegs 20 are 
spaced from between 1/4' to 1 1/4", and preferably from 5/8" to 3/4", 
about the perimeter of the desired mat area. 
Malleable wire is preferably used to form the mat according to the present 
invention, and copper wire having a mean diameter of 0.012" to 0.018" is 
preferable. Wire 22 can be unwound from a spool (not shown) and first tied 
to one peg, e.g. 20A. The wire is then extended to and wrapped around peg 
20B, and then consecutively to pegs 20C, 20D, 20E, and 20F, forming 
substantially straight wire segments 22A-B, 22B-C, 22C-D, 22D-E, and 
22E-F, as shown. Wire is thus run from one peg to a selected peg 
substantially opposite thereto, thereby forming a mat-like substance. If 
desired, however, the wire may intermittedly be extended from one peg, 
e.g., peg 20G, to a peg not opposite but substantially adjacent that peg, 
e.g., to peg 20E. This technique may be utilized intermittedly to 
strengthen the rigidity of the perimeter of the mat, and enables the wire 
to subsequently extend from a more preferable peg, e.g., peg 20E. 
It is a particular feature of the present invention, however, to 
selectively disrupt the continuity of the straight wire segments or 
"destroy" the straight lines that extend between opposite pegs. 
Accordingly, FIG. 1 depicts that the wire segment extending from 20H 
extends to wire 22C-D. The wire may be wound around or tied by knot 24 to 
segment 22C-D, and extend from knot 24 to a selected peg 20G. In this 
case, peg 20G should be understood to be either a peg opposite peg 20H, or 
a peg substantially adjacent peg 20H. In either case, the crosscross 
pattern of the wire is continued. When the wire is pulled toward peg 20G, 
straight line segment 22C-D will be "broken", i.e., the wire of 22C-D will 
bend somewhat in a manner similar to the dashed lines shown in FIG. 1. In 
a similar manner, wire 22 may continue to be wound to new or previously 
employed pegs, and selectively interconnected to existing wire segments by 
knots 24. Thus, the wire may be unwound from the spool and continue to 
extend from one peg to another peg, or from one peg to an existing wire 
within the mat and then onto another peg in order to form the mat. 
Although completion of the mat is somewhat subjective, a typical mat 
according to the present invention will generally have no open area (an 
area without any wire within that area), of no greater than approximately 
1/2" by 1/2", and generally less than approximately 3/8" by 3/8". The 
wire density within a typical mat is such that the mat would generally 
have from 15" to 36", and preferably from 25" to 28" of wire length per 
square inch of mat. Similarly, the number of knots 24 or interconnections 
of a wire to existing wire within the mat rather than to an opposing peg 
is also somewhat determined by subjective criteria, although the number of 
such knots for interconnections (not counting knots to the pegs) is 
generally from four to ten, and preferably from six to eight knots per 25 
square inches of mat. Thus, it should be understood that although FIG. 1 
depicts only the beginnings of a mat, a mat may be easily formed by 
continuing the process described above until the mat is complete. 
Once the desired density of the mat is obtained, the wires to each peg 
should be tied off to secure the mat once the pegs are removed. Referring 
to FIG. 4, wire is thus wrapped around each of the wires leading to a peg, 
and that loop of wire is then snugly tied in a knot closely adjacent the 
peg to hold the wires substantially in place. The wires to each peg are 
similarly tied off in this manner. An edge portion of a mat formed 
adjacent two pegs is shown in FIG. 4, with wire 34 being used to tie off 
the peg wires to secure the edge of the mat once removed from the pegs. 
In order to remove the mat from the board 18, the mat may be slowly lifted 
upward to slide the mat off the pegs 20. Also, if nails are used to form 
the pegs, the nails may be pulled from the board, thus leaving the mat on 
the board to be easily removed. In either case, removal of the mat from 
the pegs will further destroy the straight line segments, since tension in 
the wire segments cannot exist once the mat is removed from the pegs. 
Finally, it may be preferable to even further destroy the straight line 
segments by bending and reforming the malleable mat by simple manual 
manipulation. Since the mat is flexible, it should be understood that the 
mat formed according to the techniques described above may then be easily 
configured to conform substantially to the surfaces 12, 13, 14, and 16 of 
the object shown in FIG. 3. 
MATERIAL PREATION AND PAINTING OF THE UNDERLYING COAT 
As previously indicated, an underlying coat is applied to the object prior 
to utilization of the mat described above to form the desired finish 
according to the present invention. As customary with conventional 
painting techniques, the object to be painted may first be sanded, unless 
the surface contains no rough areas. In the case of wood, fiberglass, 
plastic, and clay materials, dry sanding with number 120 grit paper is 
customary; in the case of metal goods, wet sanding with number 240 grit 
paper is customary. After sanding, defects on the surface will generally 
become more noticeable than before sanding. Holes, cracks, or other 
defects on the object's surface may be repaired with, for example, an 
appropriate filling agent. A fine coarse grain filler mixed with primer or 
gum lacquer is customarily utilized for wooden products; metal, 
fiberglass, clay, or plastic goods may typically be repaired with DuPont 
Pirocilin filler. 
After sanding the filled joints and cracks to the smoothness of the object 
generally, several layers of primer may then be applied with a spray gun. 
As is conventional for quality spray finishes, the primer may be mixed 
with an equal proportion of thinner prior to spraying and, after drying, 
the surface is again sanded with number 240 grit paper. In the case of 
wooden materials, it has been found preferable after the sanding operation 
to manually polish the surface using, for example, a cotton ball coated 
with a mixture of primer and thinner. 
Once the surface has been properly primed, the selected color of base paint 
is applied, preferably by spraying. The base color may similarly be cut 
with thinner, and generally two or three spray applications are preferable 
to completely and uniformly cover the surface. At this stage, the object 
will therefore resemble a conventional high-quality painted object. 
APPLICATION OF OVERLYING PAINT 
The mat as described above is utilized in the step of spraying the second 
color paint on the object. Very thin wire is utilized to form the mat, and 
it is preferable to spray two or more layers on lacquer on the mat before 
applying a mat to the object. The mat as prepared above may then be 
manually molded to substantially conform to the surface shape of that 
portion of the object to be painted with the second color paint. As shown 
in FIG. 3, therefore, object 10 will have been prepared and painted with 
the base color as described above. Mat 26 is then laid on the top surface 
12 to be painted, and the mat is bent so that the perpendicular side 14 
and curvalinear top surface 13 to be painted are similarly covered. 
Preferably, the mat 26 is slightly larger than the surface to be painted, 
since the perimeter of the mat contains wire previously wound around pegs, 
and this perimeter of the mat would therefore not produce the same effect 
as that produced by that portion of the mat covered by areas 12, 13, 14, 
and 16. 
Once the mat is applied over that portion of the object to be painted a 
second color, the second color of paint is applied, preferably by 
spraying, over the mat and onto the surfaces 12, 13, 14, and 16. Again, 
this second color of paint is generally cut with equal amounts of primer. 
During the spraying operation, which again may take two or more coats, the 
mat 26 is not moved with respect to the object. The mat may be removed 
from the object after the second color of paint has dried on both the mat 
and the object. 
It should be understood that the mat may be reused for additional spraying 
applications, either on the same or a different object. If necessary, the 
malleable mat may be formed to a new shape or used to paint another 
portion of the object. The same mat may be used for several second coat 
applications without cleaning. If too much paint accumulates on the mat, 
the appearance of the finish will be altered, and the mat may therefore be 
cleaned or stripped of accumulated paint with thinner or other stripping 
material, than reused in the manner as described above. 
FINISHING OPERATIONS 
Once the mat has been removed from the object, one or more layers of 
transparent lacquer may be sprayed onto the object in order to protect the 
desired dual-color finish. After the transparent lacquer dries, it may be 
dry sanded with number 600 grit paper. If the painted object was wooden, 
this sanded surface may again be manually polished with a cotton ball 
coated with a mixture of transparent lacquer and thinner. Preferably, this 
polishing operation is performed in consecutively perpendicular directions 
to obtain the desired high-polished appearance. 
The surface as prepared above may subsequently be polished with a cloth 
coated with a commercial polishing compound, such as Brasso. If desired, 
the cloth may first be moistened with gasoline to better enable the cloth 
to easily slide over the surface, and then applying the rubbing compound 
on the cloth and polishing the surface in a conventional manner. Once 
polished, a layer of conventional furniture polish (silicon oil) may be 
applied, and the surface then cleaned with a cloth. A picture of a 
finished surface 28 according to the present invention of two colors 30 
and 32 is shown in FIG. 5. 
The techniques of the present invention are preferably utilized to obtain a 
spray painted surface of two visually distinct colors. It should be 
understood, however, that the concepts of the present invention may be 
utilized to similarly form a painted surface of more than two colors. In 
other words, after the base coat has been applied, the mesh may be applied 
over the object and the object painted a second color. Once this surface 
has dried and is sanded, a same or a different mat may be reapplied over 
the surface, and the individual wires of the mat would normally not occupy 
the same position previously held when the second color of paint was 
applied. With the mat reapplied this second time, the mat and object may 
then be painted a third color. Similarly, additional colors of paint may 
be applied utilizing the mat of the present invention. Once the final 
layer of paint has been applied, the surface finishing operations as 
described above may then occur. 
Depending on the configuration of the object to be painted, it may be 
difficult to apply a mat formed in a plane uniformly over a relatively 
large irregularly shaped object. Even though the mat is flexible, such a 
flat mat cannot be practically deformed to uniformly cover very erratic 
shapes. In such cases, it may be necessary or beneficial that the mat be 
formed on an object which more closely resembles the surface configuration 
of that portion of the object to be painted. If, for example, the mat has 
to cover a large curvilinear surface, it may be preferable that the mat 
according to the present invention be formed on a device that has an outer 
configuration substantially identical to the object to be painted. 
These and other features and advantages of the present invention will be 
apparent from the specific embodiments disclosed herein. Accordingly, the 
apparatus and methods as described herein should be understood as 
exemplary of the invention, and not as limitations thereto.