AU730042B2

AU730042B2 - Improvements in and relating to commemorative structures

Info

Publication number: AU730042B2
Application number: AU40027/97A
Authority: AU
Inventors: Graeme Toby Annabell; Karen Frances Annabell; Barbara Darryl Cousins; Peter William Mcconnell Cousins
Original assignee: PROMARC INTERNAT Ltd
Current assignee: PROMARC INTERNATIONAL Ltd
Priority date: 1996-10-10
Filing date: 1997-10-10
Publication date: 2001-02-22
Anticipated expiration: 2017-10-10
Also published as: AU4002797A

Description

I'/UU/U11 285/91 Regulation 3.2(2)

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Application Number: Lodged: *.o Invention Title: IMPROVEMENTS IN AND RELATING TO COMMEMORATIVE

STRUCTURES

The following statement is a full description of this invention, including the best method of performing it known to us 2 This invention relates to commemorative structures and to methods of making such structures.

Commemorative structures such as tombstones, headstones, plaques and monuments are generally made from granite or marble which have to be quarried, cut and ground in order to produce the finished article. In addition a further process of inscribing relevant details and decorations is required before the commemorative structure is put to use. These 0 processes are relatively slow and require skilled labour making them difficult to apply to mass production, **.consequently resulting in higher production costs.

Furthermore these materials are prone to deterioration over 15 time including cracking due to ingress of water and the a. growth of lichen and algae in the engraved areas making the inscription very difficult to read after time has lapsed.

Attempts to clean such growth away by way of pressure water blasting often makes the problem worse since water is forced into hairline cracks in the stone, and subsequent freezing and thawing can lead to extensive cracking which offers increased cavities for lichen and algae growth.

In addition to these short comings in commemorative structures made of granite and marble there are the limitations of choice of colour and surface finish associated with these materials. Yet a further limitation is the great weight of even small examples of structures made of granite or marble which make transportation and installation somewhat difficult and at times precarious. Often the weight of these structures makes them particularly susceptible to leaning on an angle and even toppling over due to ground movement, strong winds, or cracking base supports.

It is an object of the present invention to provide a commemorative structure made of a composite material and by a process which largely overcomes the disadvantages of conventional commemorative structures, in particular tombstones and headstones.

In a first broad aspect of the present invention there is provided a commemorative structure consisting of a ceramic shell and a decorative finish which incorporates an inscription applied to the exterior of the shell.

Ceramic shell is filled with a chemically and physically 20 stable setable filler.

In a preferred aspect of the invention, the ceramic shell is moulded from inorganic non-metallic materials such as clay and sand. Furthermore, additives may be added to the ceramic clay/sand mix to increase strength, rigidity and resistance to chipping and decrease water absorption and expansion rates of the moulded shell.

In another preferred aspect of the present invention the ceramic shell is coated with a decorative finish including an inscription which may be applied to the exterior surface of the shell after applying the coating. The decorative finish may be a glaze which is fired on at the appropriate temperature to form a thin but durable coat. The inscription may be applied to the surface of the shell in the form of paper or other like carrier medium printed with suitable colouring substances which remain on the shell when the paper or carrier medium has been vaporised away during the firing process. Therefore, according to the present invention the inscription is incorporated as part of the decorative finish 5to the ceramic shell.

In a further preferred aspect of the present invention the chemically and physically stable setable filler consists of a cementitious mixture which is introduced as a liquid into the co* preformed shell and allowed to set. The mixture preferably 20 comprises a fluid, non-shrink and high strength grout which has the desirable properties of remaining in contact with the shell upon setting and being able to withstand high impact and variable temperatures varying from, say, -20C to 50C thus making the structure of the present invention durable over time.

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20/12 '00 16:40 FAX 64 6 3590198 D HOPKINS ASSOC I1003/003 According to a second broad aspect of the present invention there is provided a method for producing a commemorative structure having a ceramic shell filled with a chemically and physically stable setable filler, and a decorative finish on the exterior of the ceramic shell incorporating an inscription, the method including the steps of: forming the ceramic shell; applying the inscription to the exterior of the shell either before or after the exterior surface has been glazed and fired; applying the final decorative finish to the shell and firing the shell; placing the setable filling in the shell and allowing the filling to set.

Preferred embodiments of the invention will now be described with reference to the following drawings in which:-

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*5*5 S S 55 Urn7 20/12 '00 WED 14:40 [TX/RX NO 7335] Figure 1 is a perspective view of a headstone or tombstone incorporating the invention; and Figure 2 is a cross sectional view through the headstone or tombstone of Figure 1.

In a preferred embodiment of the invention the commemorative structure may be a headstone or tombstone as illustrated in Figure 1 but can also be of other configuration such as a plaque or monument. The tombstone 10 consists of an outer 10 ceramic shell 11, an inner cementitious filling 12 (see Figure A thin decorative finish 13 on the exterior surface of shell 11 will usually incorporate an inscription 14 including any designs, symbols, pictorial representations and like indicia.

S ee The ceramic shell 11 is made from suitable clay and sand materials, including additives, colouring agents and of a thickness to produce a tombstone 10 of the desired appearance and durability. The ceramic shell 11 may be formed by any known method including slip casting and pressing. Moulded ceramic tomb stones of the present invention may be produced in a wide variety of different shapes, sizes and colours and have the additional major advantage of being able to be mass produced from the same mould thus keeping costs down.

The ceramic shell 11 is preferably 10mm thick and is allowed to dry before bisque-firing. It is envisaged that 10mm will be the minimum thickness. A glaze is then applied over the entire exterior surface of the ceramic shell 11 and the coated shell is then fired at the appropriate temperature and allowed to cool leaving a durable decorative finish 13. The inscription and any designs or symbols can then be applied to the fired shell 11.

Applying the decorative finish 13 involves the steps of first applying paper or other carrier medium bearing the 10 inscription and designs or symbols 14, to the exterior surface of the shell 11 at an appropriate place on the tombstone 10. The paper or other carrier medium is vaporised in a firing process leaving behind the colouring substances of the inscription, designs and symbols 14 as permanent 15 markings embodied in the glaze.

Therefore, according to the present invention it is possible to apply any type of inscription and design to commemorative structures including very ornamental and complex inscriptions and in a variety of colours. In particular it is envisaged that desktop publishing techniques using computer generated graphics may be applied to the method of the present invention whereby the inscription is incorporated as an integral part of the commemorative structure.

The thickness of each glaze coating 13 is preferably less than 1mm, typically, 0.25mm. The glaze itself may be coloured as desired to produce a variety of effects including simulations of marble, granite or stone.

As a variation on the above process an additional glazing step may be introduced after forming the ceramic shell 11, but prior to applying the inscription 14. This multiple glazing process produces the effect of depth in the decorative finish 13.

10 As a further variation the glazing step and the application of the inscription may be undertaken simultaneously prior to .o firing of the ceramic shell.

The ceramic shell 11 of the present invention, having been 15 coated with a decorative finish 13 incorporating inscription 14, is then filled with a cementitious setable filler 12 which is allowed to set. The filler 12 gives the ceramic shell 11 improved structural strength and resistance to **impact.

It is important that the materials comprising the filler 12 are chemically and physically stable once they have been introduced and allowed to dry and set. These properties will ensure that the filler 12 will not deteriorate over time nor detach itself from the inner surface of the ceramic shell 11 due to shrinkage.

A suitable material to be used as filler 12 is a grout with graded sand and non-shrink agents mixed with cement. As an additional or alternative material, filler 12 may comprise resin-based fillers including extenders such as polyurethane structural foam. These foams have the added advantage of being relatively light weight compared to cementitious materials which therefore aids transportation of the structure.

10 In a preferred embodiment of the tombstone the ceramic shell S"11 is moulded in such a shape as represented in Figures 1 and 2, or such other shape as may be required, and filler 12 does not completely fill shell 11 but leaves a vacant space defined by the base 15 of shell 11. The base of shell 11 can 15 be moulded in such a way as to form a good fit with a raised portion of a concrete base 16 on which the tombstone finally rests. A suitable glue material can then be used to firmly couple the tombstone to concrete base 16 thus providing a strong support for the tombstone when in place.

In addition, to further enhance the physical strength of the connection between tombstone 10 and concrete base 16 a single metal rod 17 or plurality of rods of any cross-sectional configuration may either be inserted in base 16 or filler 12 before the setable materials comprising base 16 or filler 12 have set. A coinciding hole is then preformed in either filler 12 or base 16 respectively, dimensioned so as to receive rod 17 in a tight fit when the tombstone is placed on base 16.

Therefore, from the above disclosure it can be seen that commemorative structures of the present invention offer a number of advantages over conventional structures in that they offer a great degree of flexibility in size, shape, colour and design; they are long lasting yet relatively light and easy to transport; and they are able to be mass produced 10 with relative cost effectiveness.

e* An advantage of the present invention is to be found in the method of making the inscription an integral part of the ceramic shell so as to produce a highly appealing and durable 15 appearance where there is practically no limit to the choice of design for the inscription. The further advantage of using ceramic materials as opposed to quarried materials is that there is no dependence on the availability and quality of the latter materials.

Claims

1. A commemorative structure consisting of a ceramic shell and a decorative finish which incorporates an inscription applied to the exterior of the shell.

2. The structure according to claim 1 wherein the ceramic shell is formed from inorganic non-metallic material.

3. The structure according to claim 1 or 2 wherein the shell is filled with a chemically and physically stable settable filler. 15 4. The structure as claimed in claim 3 wherein the filler consists of a cementitious mixture. The structure as claimed in claim 4 wherein the settable o *filler includes a fluid, non-shrink and high strength S 20 grout.

6. The structure according to any one of the preceding claims wherein the decorative finish is a glaze.

7. The structure according to any one of claims 1 to 6 wherein the decorative finish is achieved by one or more glazings.

8. The structure according to any one of claims 1 to 7 wherein the ceramic shell includes a mounting portion.

9. The structure according to claim 8 wherein the mounting portion is a hollow base. The structure according to any one of claims 1 to 7 wherein the ceramic shell includes a mounting portion which is at least partially unfilled with said filler, there being anchor means which extends from the filler and into said mounting portion. The structure according to claim 3 wherein the f iller includes resin-based fillers including extenders. The structure according to claim 311 wherein the filler includes a polyurethane foam. p 20 13. A method for producing a commemorative structure, the Smetho15 includes resincluding th-based fillers of forincluding a extenderamic shell, applying an inscription to the exterior of the shell So.. e12. The structu before aor afteding to he exterior surface has been includes a polyufired, optionally applying a final decorative 20 13. A method for producing a commemorative structure, the method including the steps of forming a ceramic shell, applying an inscription to the exterior of the shell either before or after the exterior surface has been glazed and fired, optionally applying a final decorative finish to the shell and firing the shell and placing a settable filling in the shell and allowing the filling to set. OFF\

14. A method according to claim 13 wherein an inscription is applied to the surface of the shell in the form of a carrier medium printed with suitable print substances which remain on the shell when the carrier has vaporised during the firing step of the method. A commemorative structure as claimed in any one of claims 1 to 12 or formed by the method of claim 13 or 14 wherein the structure is in the form of a tombstone, headstone, plaque or monument. o

16. A commemorative structure substantially as herein *....described with reference to the accompanying drawings. S 0

17. A method of producing a commemorative structure substantially as herein described. **oo oo* DATED this 'Thi. day of October 2000. S &AN Peter William Mcconnell Cousins; Rar-.bara .arryl Cousins; Grame Toby U) i G Annabell-- and Karont-Frances 2' Annabel A Patent Attorneys for the Applicants/Nominated Person DON HOPKINS ASSOCIATES