Building material for forming an architectural surface covering and method for producing the same

Abstract

A building material for use in forming exterior surface coverings. According to a preferred embodiment, the building material consists of the combination of a paper material, bonding agent, and water. The building material can either be formed directly upon a substrate, such as a wall or ceiling, or otherwise formed as a sheet of material or molding that can thereafter be affixed to a given surface or substrate. The building materials can be customized to have a specific type of color, shape and texture, and can further be utilized in a wide variety of building applications.

1 . A process for forming a building material for application to a substrate comprising the steps:
 a) selecting a paper material;   b) combining said paper material in step a) with water to form a first admixture;   c) blending said first admixture produced in step b);   d) straining said blended admixture produced in step c);   e) combining said strained admixture produced in step d) with a bonding agent to form a second admixture;   f) mixing said second admixture in step e) to form a mash;   g) providing a substrate selected from the group consisting of plywood, hardboard and drywall and applying said mash produced in step (f) to said substrate;   h) sculpting said mash applied to said substrate in step (g); and   i) drying said mash sculpted upon said substrate in step (h) to create at least one raised pattern consisting essentially of said paper material in step (a) and said bonding agent in step (e).   
   
   
       2 . The method of  claim 1  wherein in step d), said blended admixture is strained such that the ratio of paper to water is approximately 3:16 by weight. 
   
   
       3 . The method of  claim 1  wherein in step e) said second admixture comprises from 1 to 14 parts by weight of said admixture and from 1.5 to 3.5 parts by weight of said bonding agent. 
   
   
       4 . The method of  claim 3  wherein in step e) said second admixture comprises approximately 7 parts by weight of said admixture and approximately 3.5 parts by weight of said bonding agent. 
   
   
       5 . The method of  claim 1  wherein in step e) said bonding agent comprises white glue. 
   
   
       6 . The method of  claim 5  wherein said bonding agent comprises the combination of white glue and a thickening agent. 
   
   
       7 . The method of  claim 6  wherein said thickening agent comprises a mixture of water and cornstarch. 
   
   
       8 . The method of  claim 7  wherein said bonding agent comprises from 1 to 2 parts by weight of white glue and from 0.5 to 1.5 parts thickening agent. 
   
   
       9 . The method of  claim 8  wherein said bonding agent comprises approximately 2.0 parts by weight of white glue and approximately 1.5 parts by weight thickening agent. 
   
   
       10 . The method of  claim 1  further comprising the step:
 a) adding an additive to said mash formed in step f).   
   
   
       11 . The method of  claim 10  wherein said additive added to said mash is selected from the group consisting of sand, plastic particles, larger paper shreds, confetti, metallic powder and string. 
   
   
       12 . The method of  claim 10  wherein said additive added to said mash is selected from the group consisting of a flame retardant, a hardener, an antioxidant, a preservative, a dye, a scent and an antimicrobial agent. 
   
   
       13 . The method of  claim 10  wherein said mash is formed as a molding. 
   
   
       14 . The method of  claim 10  wherein said mash is formed as a sheet.