# US 2016/0258166 A1 · Artificial stone construction material and method of making

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- Number: US 2016/0258166 A1
- Document ID: US20160258166A1
- Status: Published application
- Kind: A1
- Application number: 15/063,281
- Filed: 2016-03-07
- Published: 2016-09-08
- Earliest claimed: 2015-03-06
- Inventors: JACOB CAVAL
- Web page: https://patentgrep.com/patent/US20160258166A1

## CPC

- E04F 13/147: {with an outer layer imitating natural stone, brick work or the like}
- B28B 1/005: {Devices or processes for obtaining articles having a marble appearance (producing decorative effects B44C; design of stone surfaces, e.g. marble, B44F9/04)}
- B28B 23/02: wherein the elements are reinforcing members {(B28B23/0006 takes precedence)}
- B29C 39/00: Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor (B29C41/00 takes precedence)
- C04B 28/04: Portland cements
- E04F 13/0837: {extending completely through the covering elements}
- E04F 13/141: {with an outer layer of concrete (E04F13/147 takes precedence)}
- B28B 1/16: for producing layered articles (coating B28B11/04)
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 13/02: with fibres or particles {being present as additives in the layer}
- B32B 13/06: of metal
- B32B 15/02: {Layer formed of wires, e.g. mesh}
- B32B 2419/04: Tiles for floors or walls
- C04B 2111/00612: {as one or more layers of a layered structure}
- C04B 2111/30: Nailable or sawable materials
- C04B 2111/54: Substitutes for natural stone, artistic materials or the like
- C04B 2111/802: {White cement}
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

An artificial stone building tile and method. Disclosed is an artificial stone building tile and a method of making the building tile. The building tile has a low density and significant flexibility, and is nailable without cracking. It is made by layers of cement formulations separated by layers of metal mesh. Color batches of cement are prepared and placed in the bottom of a mold, with the color batches becoming the visible face of the building tile.

## Claims

### Claim 1

A method of making an artificial stone building slab, comprising the steps of:
placing a generally rectangular mold on a working surface, said mold having a bottom and sidewalls, and having an open top;
mixing one or more color pastes comprised of stone powder, cement, water and pigment, with said stone powder comprised of particles of a mesh size less than 200;
adding said at least one color paste to form a color layer to said mold;
placing a layer of metal mesh on top of said color layer in said mold, said metal mesh sized to substantially fill the interior of the 4 sided mold;
mixing a first backing layer using a mixture of stone powder of less than 200 mesh and stone particles approximately ⅛ inch in size, cement and water;
adding said first backing layer on top of said metal mesh in said mold;
allowing said color layer and said first backing layers to cure into an artificial stone building slab, and removing said artificial stone building slab from said mold;
forming when cured an artificial stone building slab having flexibility to allow at least 1 ¼ inch of flex in a 48 inch piece, and a density of approximately 4 lb per square foot, and a Mohr hardness of 3-4 which permits polishing like stone.

### Claim 2 (depends on 1)

The method of making an artificial stone building slab of claim 1, in which the step of adding at least one color paste to form a color layer results in a color layer approximately ¼ inch thick.

### Claim 3 (depends on 1)

The method of making an artificial stone building slab of claim 1, in which the step of adding said first backing layer on top of said metal mesh results in a first backing layer approximately ¼ inch thick.

### Claim 4 (depends on 1)

The method of making an artificial stone building slab of claim 1, which further comprises the steps of adding a 2nd layer of metal mesh on top of said backing layer; and
adding a second backing layer on top of said 2nd layer of metal mesh, with said second backing layer comprised of approximately 20% fine stone powder, approximately 40% ⅛ inch aggregate, and approximately 40% ¼ inch aggregate.

### Claim 5 (depends on 4)

The method of making an artificial stone building slab of claim 4, which further comprises the steps of adding a third layer of metal mesh on top of said second backing layer; and
adding a third backing layer on top of said third layer of metal mesh, with said third backing layer comprised of approximately 20% ⅛ inch particles, approximately 40% ¼ inch pieces, and approximately 40% ⅜ inch particles of stone.

### Claim 6 (depends on 5)

The method of making an artificial stone building slab of claim 5, which further comprises the steps of adding a fourth layer of metal mesh on top of said third backing layer; and adding a fourth backing layer comprised of approximately 10% ⅛ inch stone pieces, 30% ¼ inch aggregate, 30% ⅜ inch aggregate, and 30% ½ inch aggregate.

### Claim 7 (depends on 1)

The method of making an artificial stone building slab of claim 1, in which said step of forming an artificial stone building slab results in a building slab which may be nailed in place without cracking.

### Claim 8 (depends on 1)

The method of making an artificial stone building slab of claim 1 in which said stone powder is selected from the group consisting of marble powder, granite powder, pumice powder, quartz powder, or chalk.

### Claim 9 (depends on 1)

The method of making an artificial stone building slab of claim 1 in which said ratio to stone powder mix to cement mix is approximately 45 to 25.

### Claim 10

Method of making an artificial stone building material comprising steps of:
placing a generally rectangular mold on a working surface, said mold having a bottom and sidewalls, and having an open top;
mixing one or more color pastes comprised of stone powder, cement, water and pigment, with said stone powder comprised of particles of a mesh size less than 200;
adding said at least one color paste to form a color layer to said mold;
placing a layer of metal mesh on top of said color layer in said mold, said metal mesh sized to extend from sidewall to sidewall of said mold;
mixing a first backing layer using a stone mixture of stone powder of less than 200 mesh and stone particles approximately ⅛ inch in size, in approximately equal proportions of stone powder to stone particles, plus cement and water, with a ratio of stone mixture to cement of approximately 45 to 25;
adding said first backing layer on top of said metal mesh in said mold;
allowing said color layer and backing layers to dry into an artificial stone building slab, and removing said artificial stone building slab from said mold;
with said artificial stone building slab having flexibility to allow at least 1 ¼ inch of flex in a 48 inch piece, and a density of approximately 4 lb per square foot.

### Claim 11 (depends on 10)

The method of making an artificial stone building material of claim 10 which further comprises the steps of:
applying adhesive to a vertical wall surface; and
placing said artificial building slab on said vertical wall surface, and nailing said artificial building slab to said vertical wall surface.

### Claim 12 (depends on 10)

The method of making an artificial stone building slab of claim 10 in which said stone powder is selected from the group consisting of marble powder, granite powder, pumice powder, quartz powder, or chalk.

### Claim 13 (depends on 10)

The method of making an artificial stone building slab of claim 10 which further comprises the steps of adding a second layer of metal mesh to said first backing layer, and adding a second backing layer on top of said 2nd layer of metal mesh, with said second backing layer comprised of approximately 20% fine stone powder, approximately 40% ⅛ inch aggregate, and approximately 40% 1/4 inch aggregate.

### Claim 14 (depends on 13)

The method of making an artificial stone building slab of claim 13, which further comprises the steps of adding a third layer of metal mesh on top of said second backing layer; and
adding a third backing layer on top of said third layer of metal mesh, with said third backing layer comprised of approximately 20% ⅛ inch particles, approximately 40% ¼ inch pieces, and approximately 40% ⅜ inch particles of stone.

### Claim 15 (depends on 14)

The method of making an artificial stone building slab of claim 14, which further comprises the steps of adding a fourth layer of metal mesh on top of said third backing layer; and adding a fourth backing layer comprised of approximately 10% ⅛ inch stone pieces, 30% ¼ inch aggregate, 30% ⅜ inch aggregate, and 30% ½ inch aggregate.

### Claim 16

An artificial stone building slab, comprising:
a color layer made up of at least one colored cement mix, comprised of stone powder, cement, pigment and a glue, said color layer configured for placement on a vertical wall surface facing away from said vertical wall surface;
a metal mesh layer embedded between said color layer and a backing layer;
a backing layer adjacent to said metal mesh layer, configured for placement against said vertical wall and made up of stone mix comprised of half stone powder and half stone pieces less than ⅛ inch in size;
with said artificial stone building slab having flexibility to allow at least 1 ¼ inches of flex in a 48 inch piece, and a density of approximately 4 lb per square foot, and a hardness of greater than Mohr 3 to allow sanding of said slab, and said slab being sufficiently resilient to allow nailing without cracking.

### Claim 17 (depends on 16)

The artificial stone building slab of claim 16 in which said color layer is comprised of 45 units of stone powder and 25 units of cement.

### Claim 18 (depends on 16)

The artificial stone building slab of claim 16 in which said stone powder is selected from the group consisting of marble powder, granite powder, pumice powder, quartz powder, or chalk.

### Claim 19 (depends on 16)

The artificial stone building slab of claim 16 which further comprises a 2nd metal mesh layer against said backing layer, and a 2nd backing layer over said 2nd metal mesh layer.