Method and composition for car ramp concealing fiberglass artificial geological rock formation

Abstract

The present invention provides a method and composition for producing composite fiberglass artificial geological rock formation facades that can be used for concealing car ramps. In particular, the method and composition of the present invention provides for the production of a semi-unitary artificial geological rock formation facade that is uniquely lightweight, extraordinarily strong and durable, resistant to environmental forces and that has realistic natural rock characteristics, such as texture, sheen and coloration. The composition is comprised of a particular mixture of fiberglass, polyester resin, cabosil dust, ceramic dust and catalyst for curing.

1 . An artificial geological rock formation facade for use with a car ramp, comprising: 
 a body defining an external surface and an internal surface, said internal surface defining a cavity, said external surface defining a recess for receipt of the car ramp.    
   
   
       2 . The artificial geological rock formation facade of  claim 1 , wherein the facade has a center portion having a first end and a second end, a first leg and a second leg, said first leg depending from said first end of said center portion and said second leg depending from said second end of said center portion.  
   
   
       3 . The artificial geological rock formation facade of  claim 2 , wherein said first leg and said second leg slope downwardly from said center portion.  
   
   
       4 . The artificial geological rock formation facade of  claim 3 , wherein the body is made of a plurality of sections.  
   
   
       5 . The artificial geological rock formation facade of  claim 4 , wherein the plurality of sections are secured together by bolts and flanges.  
   
   
       6 . The artificial geological rock formation facade of  claim 3 , wherein the body is made of three unitary sections comprised of said center portion, said first leg and said second leg.  
   
   
       7 . The artificial geological rock formation facade of  claim 6 , wherein the three unitary sections are secured together by bolts and flanges.  
   
   
       8 . The artificial geological rock formation facade of  claim 1 , wherein the external surface has the appearance of a geological rock formation.  
   
   
       9 . The artificial geological rock formation facade of  claim 8 , wherein the facade is comprised of a fiberglass composition layer comprised of a mixture of about 30 to 70%, by volume polyester resin, about 10 to 50% by volume fiberglass, about 5 to 15% by volume cabosil dust, about 3 to 10% by volume ceramic dust, and about 2 to 10% by volume colorant, wherein the fiberglass composition is sprayed into a mold and cured with a 2% by volume catalyst for about 5 to 10 minutes at a temperature of between about 50° to 80° F., and a hardshell layer comprised of a mixture of fiberglass and polyester resin in a ratio of about 1:1, wherein the hardshell layer is sprayed into the mold and cured with a 2% by volume catalyst for about one to eight hours at a temperature of between about 50° to 80° F., and wherein the fiberglass composition layer and the hardshell layer form the composite fiberglass rockcoat, and further wherein the cured composite fiberglass rockcoat is removed from the mold.  
   
   
       10 . The artificial geological rock formation facade of  claim 8 , wherein the facade is comprised of a fiberglass composition layer comprised of a mixture of about 50% by volume polyester resin, about 30% by volume fiberglass, about 10% by volume cabosil dust, about 5% by volume ceramic dust, and about 5% by volume colorant, wherein the fiberglass composition is sprayed into a mold and cured with a 2% by volume catalyst for about 5 minutes at a temperature of about 70° F., and a hardshell layer comprised of a mixture of fiberglass and polyester resin in a ratio of about 1:1, wherein the hardshell layer is sprayed into the mold and cured with a 2% by volume catalyst for about one to eight hours at a temperature of about 70° F., and wherein the fiberglass composition layer and the hardshell layer form the composite fiberglass rockcoat, and further wherein the cured composite fiberglass rockcoat is removed from the mold.  
   
   
       11 . A combination car ramp and artificial geological rock formation facade, comprising: 
 a body defining an external surface and an internal surface, said internal surface defining a cavity, said external surface defining a recess for receipt of the car ramp, wherein said car ramp elevates and supports a car, and said recess conceals from view said car ramp.    
   
   
       12 . The artificial geological rock formation facade and car ramp of  claim 11 , wherein the facade has a center portion having a first end and a second end and a first leg and a second leg, said first leg depending from said first end of said center portion, and said second leg depending from said second end of said center portion, each of said legs sloping downwardly from said center portion, and further wherein said body of said facade is made of a plurality of sections that have the appearance of a geological rock formation, said plurality of sections secured together by bolts and flanges.  
   
   
       13 . The artificial geological rock formation facade and car ramp of  claim 11 , wherein the facade has a center portion having a first end and a second end and a first leg and a second leg, said first leg depending from said first end of said center portion, and second leg depending from said second end of said center portion, each of said legs sloping downwardly from said center portion, and wherein said body of said facade is made of three unitary sections comprised of said center portion, said first leg and said second leg, said three unitary sections having the appearance of a geological rock formation, and further wherein said three unitary sections are secured together by bolts and flanges.  
   
   
       14 . The artificial geological rock formation facade and car ramp of  claim 11 , wherein the facade is comprised of a fiberglass composition layer comprised of a mixture of about 50% by volume polyester resin, about 30% by volume fiberglass, about 10% by volume cabosil dust, about 5% by volume ceramic dust, and about 5% by volume colorant, wherein the fiberglass composition is sprayed into a mold and cured with a 2% by volume catalyst for about 5 minutes at a temperature of about 70° F., and a hardshell layer comprised of a mixture of fiberglass and polyester resin in a ratio of about 1:1, wherein the hardshell layer is sprayed into the mold and cured with a 2% by volume catalyst for about one to eight hours at a temperature of about 70° F., and wherein the fiberglass composition layer and the hardshell layer form the composite fiberglass rockcoat, and further wherein the cured composite fiberglass rockcoat is removed from the mold.  
   
   
       15 . A method of manufacturing an artificial geological rock formation facade, comprising: 
 applying a layer of a fiberglass composition into a mold, wherein the fiberglass composition is comprised of a mixture of about 30 to 70% by volume polyester resin, about 10 to 50% by volume fiberglass, about 5 to 15% by volume cabosil dust, about 3 to 10% by volume ceramic dust, and about 2 to 10% by volume colorant;    curing the fiberglass composition layer with a catalyst;    applying a layer of a mixture of fiberglass and polyester resin in a ratio of about 1:1 into the mold to form a hardshell layer;    curing the hardshell layer with a catalyst, wherein the fiberglass layer and the hardshell layer form a composite fiberglass rockcoat; and    removing the composite fiberglass rockcoat from the mold.    
   
   
       16 . The method of  claim 15 , wherein the fiberglass composition layer is comprised of a mixture of about 50% by volume polyester resin, about 30% by volume fiberglass, about 10% by volume cabosil dust, about 5% by volume ceramic dust, and about 5% by volume colorant.  
   
   
       17 . The method of  claim 15 , wherein the catalyst is selected from the group consisting of luperox DDM-30 and norox MEKP-925, and further wherein about 2% by volume of the catalyst is used to cure the fiberglass composition layer and the hardshell layer.  
   
   
       18 . The method of  claim 15 , wherein the fiberglass composition layer and the hardshell layer are sprayed into the mold from a spray gun.  
   
   
       19 . The method of  claim 18 , wherein the fiberglass composition layer is sprayed into the mold to build up a thickness within the mold of between about ⅛ to 1 inch, and wherein the hardshell layer is sprayed into the mold to build up a thickness within the mold of between about ⅛ to ½ inch.  
   
   
       20 . The method of  claim 19 , wherein the spray has a spray temperature parameter that uses a primary heater of about 100° F.  
   
   
       21 . The method of  claim 20 , wherein the spray has a spray pressure from between about 500 PSI to 3500 PSI.  
   
   
       22 . The method of  claim 21 , wherein the fiberglass composition layer is cured for between about 5 to 10 minutes and the hardshell layer is cured for between about one to eight hours, and wherein the fiberglass composition layer and the hardshell layer are cured at a temperature of about 70° F.  
   
   
       23 . An artificial geological rock formation facade manufactured according to the method of  claim 15 .  
   
   
       24 . A composite fiberglass rockcoat facade in the form of a geological rock formation, comprising a fiberglass composition layer and a hardshell layer, said fiberglass layer and hardshell layer comprising the composite fiberglass rockcoat facade, said fiberglass composition layer comprised of a mixture of about 50% by volume polyester resin, about 30% by volume fiberglass, about 10% by volume cabosil dust, about 5% by volume ceramic dust, and about 5% by volume colorant, said hardshell layer is comprised of a mixture of fiberglass and polyester resin in a ratio of about 1:1, wherein the fiberglass composition layer is cured with a 2% by volume catalyst for between about 5 to 10 minutes at a temperature of about 70° F., and wherein the hardshell layer is sprayed into the mold and cured with the 2% catalyst for about one to eight hours at a temperature of about 70° F., and wherein the fiberglass composition layer and the hardshell layer are each sprayed into the mold at a spray temperature parameter that uses a primary heater of about 100° F. and a spray pressure from between about 500 PSI to 3500 PSI, and further wherein the cured composite fiberglass rockcoat facade is removed from the mold.