Simulated Rock Panels

Abstract

The appearance of natural rock faces are formed on planar panels or part portions thereof that disposed horizontally by stamping or texturizing a cementitious mixture of veneer material and then selectively applying colorant matter, which may include combinations of stains and mineral.

I claim: 
     
         1 . A panel member having a simulated rock face appearance, comprising:
 a. at least one planar portion,   b. a colored veneer layer deposited on an outer surface of the at least one planar portion, the colored veneer layer having an outer surface with a non-planar texture to resemble a natural rock face, in which the colored veneer layer consists essentially of a cured cementitious mixture,   c. a coloring layer deposited on selective portion of at least one of the outer surface of the colored veneer layer and planar portion that is not covered by the colored veneer layer to create a contrasting color appearance to adjacent portions of the colored veneer layer.   
     
     
         2 . The panel member of  claim 1  in which the coloring layer comprises a coloring agent selected from the group consisting of concrete stain, natural minerals and artificial minerals. 
     
     
         3 . The panel member of  claim 1  in which the coloring layer is selectively applied to a first regions of the colored veneer layer, the first region having a different texture than a texture on a second region of one or more adjacent portions of the veneer layer that is not covered by the coloring layer. 
     
     
         4 . The panel member of  claim 2  in which the coloring layer comprises a coloring agent in which an aggregate of at least one of natural minerals and artificial minerals is disposed in a concrete stain, in which the concrete stain at least partially penetrates into or adheres to the textured veneer layer. 
     
     
         5 . The panel member of  claim 1  in which the colored veneer layer has a thickness of at least about 9 mm and is substantially free of cracks and crazes. 
     
     
         6 . The panel member of  claim 1  in which the colored veneer layer on the at least one planar portion of the panel member has a depth of at least 0.5 mm and less than 75 mm to provide a depth variation between a highest position on each panel member and a lowest position on each panel member that is between 10-75 mm. 
     
     
         7 . The panel member of  claim 6  having peripheral edges that are covered with the colored veneer layer to provide a variation in thickness at the peripheral edges that is at least equal to the depth variation between the highest position on the panel member and the lowest position on the panel member. 
     
     
         8 . The panel member of  claim 6  in which the colored veneer layer has a thickness of at least about 9 mm and is substantially free of cracks and crazes. 
     
     
         9 . The panel member of  claim 7  in which the colored veneer layer has a thickness of at least about 9 mm and is substantially free of cracks and crazes. 
     
     
         10 . The panel member of  claim 1  having a width and a height of at least 4 feet and the appearance of a continuous rock face on a side opposite the at least one planar portion. 
     
     
         11 . The panel member of  claim 1  in which at least one selective portion that receives the coloring layer is a valley within the colored veneer layer that extends to the at least one planar portion. 
     
     
         12 . A method of fabricating a simulated rock surface, the method comprising the steps of:
 a. providing a planar support panel,   b. applying a fluid cementitious mixture onto an upper surface of the planar support panel while the planar support panel is disposed in a horizontal orientation,   c. applying one or more molds or stamps to texturize an upper surface of the fluid cementitious mixture,   d. curing the fluid cementitious mixture at least partially with the mold or stamp in place to form a hardened rock like texture,   e. removing the one or more stamps or molds from the hardened rock like texture,   f. applying a coloring layer on one or more first selective portions of an outer surface of the hardened rock like texture to create a contrasting color appearance to adjacent portions of hardened rock like texture that do not receive the application of the coloring layer.   
     
     
         13 . The method of fabricating a simulated rock surface according to  claim 11  wherein the fluid cementitious mix is applied with a cone slump viscosity of at least about 9 inches. 
     
     
         14 . The method of fabricating a simulated rock surface according to  claim 11  wherein the mold has sufficient depth to form a peek to valley height of at least about 9 mm. 
     
     
         15 . The method of fabricating a simulated rock surface according to  claim 11  in which the coloring layer comprises a coloring agent selected from the group consisting of concrete stain, natural minerals and artificial minerals. 
     
     
         16 . The method of fabricating a simulated rock surface according to  claim 11  in which the coloring layer is selectively applied to at least one portion of the hardened rock like texture that have a different texture than adjacent portions of the hardened rock like texture that are not covered by the coloring layer. 
     
     
         17 . The method of fabricating a simulated rock surface according to  claim 11  in which the coloring layer comprises a coloring agent comprising one or more of concrete stain, natural minerals, artificial miners, concrete stain further comprising one or more of natural minerals and artificial minerals in which the concrete stain at least partially penetrates into or adheres to the textured veneer layer. 
     
     
         18 . The method of fabricating a simulated rock surface according to  claim 11  in which the cured fluid cementitious mixture having a hardened rock like texture on the at least one planar portion of the panel member has a depth of at least 0.5 mm and less than 75 mm to provide a depth variation between a highest position on each panel member and a lowest position on each panel member that is between 10-75 mm. 
     
     
         19 . The method of fabricating a simulated rock surface according to  claim 11  in which planar support panel has peripheral edges that are covered with the cured fluid cementitious mixture having a hardened rock like texture to provide variations in thickness at the peripheral edges that is at least equal to the depth variation between the highest position on the panel member and the lowest position on the panel member. 
     
     
         20 . The method of fabricating a simulated rock surface according to  claim 11  in which the cured fluid cementitious mixture having a hardened rock like texture has a thickness of at least about 9 mm and is substantially free of cracks and crazes.