Textured-foam coated urethane wall and ceiling covering and method of making the same

A method for producing a composite building material having a continuously textured surface, comprising:

• a. providing (i) a foamed emulsion of an uncured and uncross-linked elastomeric resin composition and (ii) a self supporting resilient urethane foam substrate having an irregular sea sponge cell structure;
• b. disposing said foamed elastomeric resin composition onto a surface of said urethane substrate;
• c. skimming said foamed elastomeric resin composition to form a uniform coating of predetermined thickness on the substrate, said thickness being such as to permit the irregular cell structure of the underlying sea sponge substrate to affect the exposed surface of the foamed elastomeric layer in the subsequent step (e) so that after the composite structure is fully processed said textured surface is formed therein;
• d. drying said elastomeric resin foam coating until said elastomeric resin foam forms a layer which is only partially cured and partially cross-linked, such that when said partially cured elastomeric layer of the composite structure is crushed, it will deform the cells of the underlying urethane and become interlocked therein to prevent delamination of said elastomeric layer;
• e. crushing said composite structure so that said partially cured elastomeric layer is densified and caused to be interlocked into the adjacent cells on said urethane substrate surface which cells have been distorted by the crushing, the resultant partial compression and distortion of the elastomeric foam creating a continuous texture on the exposed surface thereof;
• and
• f. further curing said textured elastomeric layer to hold said textured surface and to form said composite building material.

A method for producing a composite polymeric building material having a continuously textured surface useful as a wall and ceiling covering, comprising:

• a. providing (i) a foamed emulsion of an uncured and uncross-linked acrylic resin and (ii) a self-supporting resilient urethane foam substrate having an irregular sea sponge cell structure;
• b. disposing said foamed acrylic resin onto a surface of said urethane substrate;
• c. skimming said foamed acrylic resin to form a uniform coating of predetermined thickness on the substrate, said thickness be such as to permit the irregular cell structure of the underlying sea sponge substrate to affect the exposed surface of the foamed acrylic layer in the subsequent step (e) so that afer the composite structure is fully process said textured surface is formed therein;
• d. drying said acrylic resin foam coating until said acrylic resin foam layer is only partially cured and partially cross-linked, such that when said partially cured acrylic layer of the composite structure is crushed, it will deform the cells of the underlying urethane and become interlocked therein to prevent delamination of said acrylic layer;
• e. crushing said composite structure so that said partially cured acrylic coating is densified and caused to be interlocked into the adjacent cells on said urethane substrate surface which cells have been distorted by the crushing, the resultant partial compression and distortion of the acrylic foam creating a continuous texture on the exposed surface thereof;
• and
• f. further curing said acrylic layer to hold said textured surface and forming said composite building material.