Printing – Stenciling – Processes
Reexamination Certificate
1999-08-09
2001-06-26
Colilla, Daniel J. (Department: 2854)
Printing
Stenciling
Processes
C101S127000
Reexamination Certificate
active
06250219
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to the field of interior/exterior decorating and more particularly it relates to a stencil system and methods for applying a pattern of setting-type embossing material onto a rough-textured surface such as that of a pre-existing ceiling.
BACKGROUND OF THE INVENTION
For enhancing the appearance and architectural merit of walls or ceilings, it is frequently required to add a decorative pattern in selected areas; this is particularly effective when applied to existing rough-textured ceilings of sprayed-on acoustic material.
It has been well known to utilize a stiff stencil, temporarily held against or fastened to the surface, configured with openings that define the regions to be embossed by adding new material, e.g. by spray or trowel, while masking off areas that are not to receive the new material.
There is a particular problem that arises when it is attempted to utilize such a stencil to mask a rough-textured surface: failure of the stencil to conform to the topography of the rough-textured surface introduces random irregularities at the edges of the stencil openings, rendering the edges of the finished embossed pattern rough and fuzzy instead of yielding the desired clean-cut reproduction of the pattern.
The stencil needs to be made compliant enough to be pressed in place to conform closely to the topography of the rough-textured surface, and to remain in close conformity, especially at the edges of the stencil openings, while the embossing material is applied. This requires the stencil material to be highly compliant so that it can stretch and expand as required to conform to the hills and valleys of the texture, but it must be non-elastic to prevent any loss of conformity while applying the embossing material.
Suitable compliant stencil material tends to be excessively flimsy and generally difficult to handle since it is susceptible to stencil damage and/or distorted pattern registration. For satisfactory deployment, special procedures are required particularly if the stencil pattern is unusually open and/or complex, and/or it is to be applied to a ceiling, to which the invention is mainly directed.
DISCUSSION OF RELATED KNOWN ART
U.S. Pat. No. 5,243,905 to Webber discloses a stencil process and system for applying a decorative coating atop a substrate such as horizontal concrete or like surface comprising a plurality of stencils with lock and tab means for interlocking adjacent stencils
U.S. Pat. No. 3,853,561 by Reichel discloses a chemical binder process for preparation of screen printing stencils using to intermediate support for light sensitive layer.
U.S. Pat. No. 4,129,699 by Lopez discloses a method of applying decorative designs to surfaces through a stencil comprising a laminated sheet consisting of two layers of waterproof adhesive tapes staggered to cover the seams.
U.S. Pat. No. 5,816,269 to Mohammed discloses a tattoo stencil mechanism wherein a flexible stencil sheet with openings defining the pattern is sandwiched between a backing sheet and a protective carrying sheet. After removal of the backing sheet, the stencil sheet, preloaded with adhesive is adhesively attached to the skin of the subject, then the carrier sheet is peeled off leaving the stencil sheet, through which colored dye is applied to the skin to form a temporary tattoo.
U.S. Pat. No. 3,929,068 to Budden for STENCILS typifies stencil systems of known art that are directed to painting onto smooth surfaces, but that fail to address the special problems of applying embossing material onto a rough-textured surface, and would therefore prove to be excessively non-compliant, and would fail to conform to rough-textured surfaces, and thus would merely demonstrate the very problems which have been addressed and solved by the novel compliant laminated stencil structure taught by the present invention.
OBJECTS OF THE INVENTION
It is a primary object of the present invention to provide a stencil system and related methods for applying setting-type embossing material onto a rough textured surface in a desired decorative pattern.
It is a further object to enable a stencil to conform to the rough-textured surface and to be thusly retained during application of embossing material so as to yield sharp and clean edges in the finished embossed pattern.
It is a further object to provide practicable procedures for satisfactory application of the relatively flimsy compliant to a rough-textured ceiling surface so that it remains closely conformed to the texture surface with the pattern accurately registered without distortion during application of the embossing material, particularly when the pattern is unusually open and/or complex.
It is a further object to provide a stencil structure utilizing material that are common, readily available and inexpensive.
SUMMARY OF THE INVENTION
The above mentioned objects have been accomplished by the present invention of a simple basic stencil system and process utilizing readily available inexpensive materials. The basic steps in the procedure, common to all embodiments, involves deploying a thin plastic sheeting from which portions have been cut away according to the pattern to form a compliant stencil, and arranging for this to be attached temporarily to the textured surface with a non-setting adhesive, where it is urged into close compliance with the topography of the textured surface by a roller and/or by hand. Then after troweling on the setting-type embossing material to a desired thickness, the stencil is removed along with surplus embossing material, and typically discarded, leaving the embossing material bonding to the textured surface, cleanly defining the embossed pattern in the regions that were defined by the stencil.
Optional preparatory procedures are disclosed for overcoming difficulties associated with particular situations such as working with ceilings, and unusual openness and/or complexity of the stencil pattern. A simple pattern with small openings could be cut into the compliant stencil before attachment to a ceiling; however, to avoid distortions in a relatively open and/or complex pattern, the compliant sheet of stencil material can be first applied to the ceiling and then cutting the pattern away with the stencil material adhered to the ceiling, then completing the procedure in the normal manner described.
Generally, in a preferred embodiment, to avoid the difficulty of cutting out complex openings of a stencil pattern on a ceiling, the compliant layer is pre-laminated with a backing layer using a non-setting adhesive. The stencil openings are then cut through both layers or, using a heat cutting process, cut through the compliant layer only. The backing supports the compliant stencil and keeps the pattern in shape during attachment to the ceiling; then, in the normal embossing process, the laminated stencil, with the pattern cut through one or both layers, is rolled/pressed into place into the texture, the backing is removed leaving only the compliant stencil, which can then be urged into even more intimate compliance with the rough texture; then the embossing material is applied and the compliant stencil is removed along with surplus material, leaving the embossed pattern.
When the laminated stencil has the pattern cut out from the compliant layer only (using a heat-cutting process) the cut-out regions can be removed prior to attachment to the ceiling, or these regions can be left in place until after attachment to the ceiling, then removed along with the backing layer before completing the process as described.
This embossing process is particularly beneficial for applying a pattern such as a border to restyle an existing rough-textured ceiling.
REFERENCES:
patent: 2025457 (1935-12-01), Kavanaugh
patent: 2251647 (1941-08-01), Wartha
patent: 3929068 (1975-12-01), Rudden
patent: 4129669 (1978-12-01), Lopez
patent: 5460087 (1995-10-01), Ogorzalek
patent: 5816269 (1998-10-01), Mohammed
Colilla Daniel J.
McTaggart J. E.
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