CA1080449A - Method of forming moulded articles - Google Patents
Method of forming moulded articlesInfo
- Publication number
- CA1080449A CA1080449A CA245,021A CA245021A CA1080449A CA 1080449 A CA1080449 A CA 1080449A CA 245021 A CA245021 A CA 245021A CA 1080449 A CA1080449 A CA 1080449A
- Authority
- CA
- Canada
- Prior art keywords
- expanded polystyrene
- solvent
- moulding face
- applying
- mould
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Landscapes
- Moulds, Cores, Or Mandrels (AREA)
Abstract
INVENTOR
.
PAUL RITTER
TITLE
METHOD OF FORMING MOULDED ARTICLES
ABSTRACT OF THE DISCLOSURE
Disclosed is a method of forming a moulded article having at least a portion of a mould form from an expanded polystyrene thereafter treating the moulded face of the expanded polystyrene to form a textured or patterned surface. Then, a colour composition is applied to the moulding surface of the expanded polystyrene and the mould is filled with concrete or the like. Upon solidification the concrete an organic solvent of expanded polystyrene is applied wherein a portion of the solution of the solvent and polystyrene is caused to remain on the moulded article.
The amount of this solution remaining is controlled by the amount of solvent applied to the expanded polystyrene thereby permitting the solvent to evaporate from the solution remaining on the moulded article to form a coloured glazed finish thereon.
.
PAUL RITTER
TITLE
METHOD OF FORMING MOULDED ARTICLES
ABSTRACT OF THE DISCLOSURE
Disclosed is a method of forming a moulded article having at least a portion of a mould form from an expanded polystyrene thereafter treating the moulded face of the expanded polystyrene to form a textured or patterned surface. Then, a colour composition is applied to the moulding surface of the expanded polystyrene and the mould is filled with concrete or the like. Upon solidification the concrete an organic solvent of expanded polystyrene is applied wherein a portion of the solution of the solvent and polystyrene is caused to remain on the moulded article.
The amount of this solution remaining is controlled by the amount of solvent applied to the expanded polystyrene thereby permitting the solvent to evaporate from the solution remaining on the moulded article to form a coloured glazed finish thereon.
Description
THIS INVENTION relates to a method of forming moulded articles of concrete or the like.
The term concrete or the like shall be taken to include i materials such as concrete, cement, plaster of paris or the like material which will harder permanently from a plastic-like state over a relatively short period of time.
In one form the invention resides in a method of producing a moulded article from concre-te or the like comprising;
having at least a portion of a mould formed of expanded poly-styrene; treating the moulding face of the expanded polystyrene to form a textured and/or pat-terned surface; applying a coloured composition to the moulding face of the expanded polystyrene, fi~ing the mould with concrete or the like;
upon the solidi-fication of the concrete~ applying an organic solvent to the expanded polystyrene to dissolve the polystyrene, wherein a portion of the solution of the solvent and poly-styrene is caused to remain on the moulded article, the amount of solution remaining upon the moulded article being controlled by the amount of solvent applied to the expanded polystyrene, permitting the solvent to evaporate from the solution remaining on the moulding product to form a coloured glazed finish upon the moulded product.
The invention presents a significant advance over previous methods of forming moulded articles of concrete or the like.
previous methods have involved the use of bulky, heavy and ~- .
expensive moulds. In addition the form of the moulds are fixed such that if it is desired to alter the form or pattern of the moulded article it is necessary to produce a further heavy mould. Therefore such previous methods were awkward, expensive and inflexible.
As a result of this invention the moulds used are inexpensive in regard to their basic material and may be readily formed to the shape and texture required of the moulded article.
In addition the moulds lend themselves to flexibility in production since the moulds are produced on a one-to-one basis with respect to the moulded articles to be produced.
The removal of the mould from the moulded articles by applic-ation of a solvent reduces the danger of damaging the product at a stage during which damage is an ever present problem of previous moulding processes.
It is envisaged that the invention may be used to produce moulded articles such as flower pots, lamp bases, vases, decorative sculptured articles and panels. The invention may also be used in the construction of more massive structures such as buildings, bridges, tunnels or the like where it is desired that the exposed surface of the structure has a decorative coloured finish.
The invention will be more fully understood in the light of the following description of several specific embodiments.
The descrip-tion is made with reference to the accompanying . .
~ - 3 -`~
:~
' drawings of which.`- !
~ig. 1 is a perspective view of one for~ of an electric cutting tool which may be used in forming of the mould; and ~ig. 2 is a perspective view of ano-ther form of an electric cutting tool which may be used in the forming of the mould.
One embodiment of the invention resides in the production of decorative concrete panels for the mounting to the facades of buildings. The mould for ~uch panels comprises a base sheet of expanded polystyrene and a border around the edges to the desired thickness of the final product. The mould may be formed completely of expanded polystyrene, or may only have a base of expanded polystyrene, or may be in -the form of a tray of a non-destructi~le nature into the base of which a sheet of expanded polystyrene foam may be inserted.
Before installation in the mould the moulding face of the base sheet is treated to provide a patterned or textured moulding face. The method of treatment may comprise the spraying onto the moulding face a small quantity of an organic solvent which will dissolve the expanded polystyrene (eg. toluol or petrol3. The amount sprayed should only be enough to affect the surface of the expanded polystyrene sheet. 9y the use of the spraying method toge-ther with a masking of the moulding .~
face a large variety of patterns may be produced.
Another method of treatment of the moulding face is by means of electrically heated printing toolsO ~asically the printing ~,~
tools (as seen in Figures 1 or 23 comprise an element 11 shaped to produce a particular pattern upon the expanded polystyrene sheet. The element is fixed to a support frame and/or handle 13 by a heat sin~ 15. The element is connected at either end to a source of electricity the flow of which through the element will heat -the element. The tool may take the form as shown in figure 1 wherein the element is shaped to form a geometric shaped impression in the moulding face.
The shape of the element may be singular like the form shown in figure 1 or may comprise a multiplicity of shapes to produce a composite pattern.
The printing tool as seen in figure 2 represents a tool of a shearing form wherein the element 11 is drawn longitudinally through the moulding face to produce a grooved pattern on the moulding face. The tool has a support frame 13 and a heat sink at each end thereo~ which are to be connected to a source of electricity. An element 11 is moun-ted between the heat sinks and may be of any desired shape such that when drawn through the expanded polystyrene sheeting the element will cut grooves into the sheeting of the desired shape. The tool shown in figure 2 comprises a series of substantially U-shaped loops wherein the termination of each loop is fixed to the support frame by a screw 17 and washers 19. '~he screw and washers serve not only to attach -the element to -the support frame but also act as heat sinks. In use the tools of the form similar to that shown in figure 2 may be drawn through the sheet along a straight line, or pivotted about a fixed point either on the sheet or outside the sheet. r~he support frame _ 5 _ may also be fixed to a base in order that the sheet is pushed past the element.
The purpose of the heat sinks is to remove excess heat from the non-working portions of the element and so prevent burning out of the element.
Once the moulding face of the base sheet has been treated -to provide a patterned or textured surface a colouring composition is applied to the moulding face. ~he application of the colouring composition may be by any known method howeve~ it is necessary tha-t the composition contain very little or no substance which will a-ffect the surface of the expanded poly-styrene. The colouring composi-tion may comprise spraying paint having organic solvents in it which is sprayed onto the moulding face with a very light spray such that most of the solvent has evaporated from the paint before it contacts the surface of the expanded polystyrene. Ano-ther method of application comprises mixing an adhesive used with expanded polystyrene with a dye or tinting composition and applying the mixture to the moulding face. An example of the adhesive that may be used is manufactured by 3M Australia ~ty. ~tdo under the code EC2296.
"
Once the moulding face of the base sheet of the mould has been textured and coloured in the manner desired the mould is put together and is filled with concrete or the like material which is then allowed to set. ~he polystyrene portion ` of the mould is partially removed from the formed article by ~ .
g the application of an organic solvent or the like which will dissolve the expanded polystyrene. The application of the solvent transforms the expanded polystyrene into a solution form. The amount of solvent applied to the moulded article is governed by the amount of polystyrene solution i-t is desired to retain upon the article and so the desired finish required of the ar-ticle. If the article ls dipped into a bath of solvent only a small quantity of -the resultant solution of polystyrene is retained upon the article and the resultant finish is a dull glaze upon the coloured surface of the moulded article. Alternatively if only a small quantity of solvent is applied to the expanded polystyrene by a spraying or brushing technique most of the resultant solution of polystyrene isretained upon the surface of the moulded article.
Upon the evaporation of solvent the resultant finish upon the moulded article is highly glazed. The transformation of the expanded polystyrene by the action of the solvent also involves s~me intermixing with the colouring composition which becomes at least partially incorporated in the resultant solution of polystyrene. Such intermixing can produce some interesting effects on the surface of the moulded article.
A further method of removing the expanded polystyrene from the moulded article comprises saturating the polystyrene with an inflammable solvent and then igniting the solvent.
~he heat so produced melts the polystyrene and burns a portion of it away. However not all of the polystyrene is consumed and upon the article cooling the melted polystyrene solidifies to produce an attractive glaze.
The progress of the invention may be applied to the production of three dimensional articles having a pat-terned surface such as flower pots, lamp bases,sculptured decorative articles and the like. In such a case the inside of ^the mould is treated in the manner as described for the panels and the des-truction of the mould is controlled by the amount of solvent to be applied to the mould.
An added advantage of this method of producing moulded articles is -that, particularly in the case of panels, the destruction of the mould from the article can be after the article has been installed in position. Therefore the mould also serves in protecting the surface thereof during installation.
. .
.~ ~
. .
.~' ~ .
. I .
The term concrete or the like shall be taken to include i materials such as concrete, cement, plaster of paris or the like material which will harder permanently from a plastic-like state over a relatively short period of time.
In one form the invention resides in a method of producing a moulded article from concre-te or the like comprising;
having at least a portion of a mould formed of expanded poly-styrene; treating the moulding face of the expanded polystyrene to form a textured and/or pat-terned surface; applying a coloured composition to the moulding face of the expanded polystyrene, fi~ing the mould with concrete or the like;
upon the solidi-fication of the concrete~ applying an organic solvent to the expanded polystyrene to dissolve the polystyrene, wherein a portion of the solution of the solvent and poly-styrene is caused to remain on the moulded article, the amount of solution remaining upon the moulded article being controlled by the amount of solvent applied to the expanded polystyrene, permitting the solvent to evaporate from the solution remaining on the moulding product to form a coloured glazed finish upon the moulded product.
The invention presents a significant advance over previous methods of forming moulded articles of concrete or the like.
previous methods have involved the use of bulky, heavy and ~- .
expensive moulds. In addition the form of the moulds are fixed such that if it is desired to alter the form or pattern of the moulded article it is necessary to produce a further heavy mould. Therefore such previous methods were awkward, expensive and inflexible.
As a result of this invention the moulds used are inexpensive in regard to their basic material and may be readily formed to the shape and texture required of the moulded article.
In addition the moulds lend themselves to flexibility in production since the moulds are produced on a one-to-one basis with respect to the moulded articles to be produced.
The removal of the mould from the moulded articles by applic-ation of a solvent reduces the danger of damaging the product at a stage during which damage is an ever present problem of previous moulding processes.
It is envisaged that the invention may be used to produce moulded articles such as flower pots, lamp bases, vases, decorative sculptured articles and panels. The invention may also be used in the construction of more massive structures such as buildings, bridges, tunnels or the like where it is desired that the exposed surface of the structure has a decorative coloured finish.
The invention will be more fully understood in the light of the following description of several specific embodiments.
The descrip-tion is made with reference to the accompanying . .
~ - 3 -`~
:~
' drawings of which.`- !
~ig. 1 is a perspective view of one for~ of an electric cutting tool which may be used in forming of the mould; and ~ig. 2 is a perspective view of ano-ther form of an electric cutting tool which may be used in the forming of the mould.
One embodiment of the invention resides in the production of decorative concrete panels for the mounting to the facades of buildings. The mould for ~uch panels comprises a base sheet of expanded polystyrene and a border around the edges to the desired thickness of the final product. The mould may be formed completely of expanded polystyrene, or may only have a base of expanded polystyrene, or may be in -the form of a tray of a non-destructi~le nature into the base of which a sheet of expanded polystyrene foam may be inserted.
Before installation in the mould the moulding face of the base sheet is treated to provide a patterned or textured moulding face. The method of treatment may comprise the spraying onto the moulding face a small quantity of an organic solvent which will dissolve the expanded polystyrene (eg. toluol or petrol3. The amount sprayed should only be enough to affect the surface of the expanded polystyrene sheet. 9y the use of the spraying method toge-ther with a masking of the moulding .~
face a large variety of patterns may be produced.
Another method of treatment of the moulding face is by means of electrically heated printing toolsO ~asically the printing ~,~
tools (as seen in Figures 1 or 23 comprise an element 11 shaped to produce a particular pattern upon the expanded polystyrene sheet. The element is fixed to a support frame and/or handle 13 by a heat sin~ 15. The element is connected at either end to a source of electricity the flow of which through the element will heat -the element. The tool may take the form as shown in figure 1 wherein the element is shaped to form a geometric shaped impression in the moulding face.
The shape of the element may be singular like the form shown in figure 1 or may comprise a multiplicity of shapes to produce a composite pattern.
The printing tool as seen in figure 2 represents a tool of a shearing form wherein the element 11 is drawn longitudinally through the moulding face to produce a grooved pattern on the moulding face. The tool has a support frame 13 and a heat sink at each end thereo~ which are to be connected to a source of electricity. An element 11 is moun-ted between the heat sinks and may be of any desired shape such that when drawn through the expanded polystyrene sheeting the element will cut grooves into the sheeting of the desired shape. The tool shown in figure 2 comprises a series of substantially U-shaped loops wherein the termination of each loop is fixed to the support frame by a screw 17 and washers 19. '~he screw and washers serve not only to attach -the element to -the support frame but also act as heat sinks. In use the tools of the form similar to that shown in figure 2 may be drawn through the sheet along a straight line, or pivotted about a fixed point either on the sheet or outside the sheet. r~he support frame _ 5 _ may also be fixed to a base in order that the sheet is pushed past the element.
The purpose of the heat sinks is to remove excess heat from the non-working portions of the element and so prevent burning out of the element.
Once the moulding face of the base sheet has been treated -to provide a patterned or textured surface a colouring composition is applied to the moulding face. ~he application of the colouring composition may be by any known method howeve~ it is necessary tha-t the composition contain very little or no substance which will a-ffect the surface of the expanded poly-styrene. The colouring composi-tion may comprise spraying paint having organic solvents in it which is sprayed onto the moulding face with a very light spray such that most of the solvent has evaporated from the paint before it contacts the surface of the expanded polystyrene. Ano-ther method of application comprises mixing an adhesive used with expanded polystyrene with a dye or tinting composition and applying the mixture to the moulding face. An example of the adhesive that may be used is manufactured by 3M Australia ~ty. ~tdo under the code EC2296.
"
Once the moulding face of the base sheet of the mould has been textured and coloured in the manner desired the mould is put together and is filled with concrete or the like material which is then allowed to set. ~he polystyrene portion ` of the mould is partially removed from the formed article by ~ .
g the application of an organic solvent or the like which will dissolve the expanded polystyrene. The application of the solvent transforms the expanded polystyrene into a solution form. The amount of solvent applied to the moulded article is governed by the amount of polystyrene solution i-t is desired to retain upon the article and so the desired finish required of the ar-ticle. If the article ls dipped into a bath of solvent only a small quantity of -the resultant solution of polystyrene is retained upon the article and the resultant finish is a dull glaze upon the coloured surface of the moulded article. Alternatively if only a small quantity of solvent is applied to the expanded polystyrene by a spraying or brushing technique most of the resultant solution of polystyrene isretained upon the surface of the moulded article.
Upon the evaporation of solvent the resultant finish upon the moulded article is highly glazed. The transformation of the expanded polystyrene by the action of the solvent also involves s~me intermixing with the colouring composition which becomes at least partially incorporated in the resultant solution of polystyrene. Such intermixing can produce some interesting effects on the surface of the moulded article.
A further method of removing the expanded polystyrene from the moulded article comprises saturating the polystyrene with an inflammable solvent and then igniting the solvent.
~he heat so produced melts the polystyrene and burns a portion of it away. However not all of the polystyrene is consumed and upon the article cooling the melted polystyrene solidifies to produce an attractive glaze.
The progress of the invention may be applied to the production of three dimensional articles having a pat-terned surface such as flower pots, lamp bases,sculptured decorative articles and the like. In such a case the inside of ^the mould is treated in the manner as described for the panels and the des-truction of the mould is controlled by the amount of solvent to be applied to the mould.
An added advantage of this method of producing moulded articles is -that, particularly in the case of panels, the destruction of the mould from the article can be after the article has been installed in position. Therefore the mould also serves in protecting the surface thereof during installation.
. .
.~ ~
. .
.~' ~ .
. I .
Claims (14)
1. A method of forming a moulded article from concrete or the like comprising; the steps of treating a moulding face of the mould possessing expanded polystyrene to form a tex-tured surface applying a coloured composition to the moulding face of the expanded polystyrene; filling the mould with con-crete or the like; allowing solidification of the concrete or the like, applying an organic solvent to the expanded poly-styrene, wherein a portion of the solution of the solvent and polystyrene is caused to remain on the moulded article, the amount of solution remaining upon the moulded article being controlled by the amount of solvent applied to the expanded polystyrene; permitting the solvent to evaporate from the solution remaining on the moulded article to form a coloured glazed finish upon the moulded product.
2. The method as claimed in claim 1 wherein the treating step treats the moulding surface into a pattern shape.
3. A method as claimed in claim 1 or 2 wherein the treat-ment of the moulding face of the expanded polystyrene com-prises applying a small quantity of solvent to the moulding face to dissolve the surface of the expanded polystyrene.
4. A method as claimed in claim 1 or 2 wherein the treat-ment of the moulding face of the expanded polystyrene comprises applying a masking material to portions of the moulding face and applying a small quantity of solvent to the moulding face to dissolve the surface of the expanded polystyrene not covered by the masking material.
5. A method as claimed in claim 1 or 2 wherein the treat-ment of the moulding face comprises applying a heating element having a decorative shape to the moulding face to form a decorative contour in the moulding face.
6. A method as claimed in claim 1 or 2 wherein the co-loured composition comprises a mixture of an adhesive for expanded polystyrene and a dye.
7. A method as claimed in claim 1 or 2 wherein the coloured composition is sprayed onto the moulding face.
8. A method as claimed in claim 1 or 2 wherein the method of applying the organic solvent to the mould com-prises dipping the moulded article and mould into a con-tainer holding a quantity of the solvent.
9. A method as claimed in claim 1 or 2 wherein the method of applying the organic solvent to the mould comprises spraying the solvent into the mould.
10. A method of forming a moulded article from concrete or the like comprising the steps of; treating a moulding face of the mould possessing expanded polystyrene by applying a small quantity of solvent to the moulding face to dissolve the surface of the expanded polystyrene applying a heated element to the moulding face to form a textured surface;
applying a coloured composition to the moulding face, wherein the coloured composition does not dissolve the expanded polystyrene; filling the mould with concrete or the like;
allowing the concrete or like composition to set; applying an organic solvent to the expanded polystyrene, wherein a portion of the solution of the solvent and polystyrene is caused to remain on the moulded article, the amount of solution remaining upon the moulded article being controlled by the amount of solvent applied to the expanded polystyrene;
permitting the solvent to evaporate from the solution re-maining on the moulded article to form a coloured glazed finish upon the moulded product.
applying a coloured composition to the moulding face, wherein the coloured composition does not dissolve the expanded polystyrene; filling the mould with concrete or the like;
allowing the concrete or like composition to set; applying an organic solvent to the expanded polystyrene, wherein a portion of the solution of the solvent and polystyrene is caused to remain on the moulded article, the amount of solution remaining upon the moulded article being controlled by the amount of solvent applied to the expanded polystyrene;
permitting the solvent to evaporate from the solution re-maining on the moulded article to form a coloured glazed finish upon the moulded product.
11. The method as claimed in claim 10 wherein the applying a heating element step forms a patterned surface.
12. A method as claimed in claim 1 or 2 wherein the organic solvent is inflammable and after its application to the expanded polystyrene it is ignited to cause the poly-styrene to melt, a portion of which is burnt away while a portion remains on the moulded article to solidify on cooling.
13. A method as claimed in claim 1, 2 or 10 wherein the treatment of the moulding face comprises the application of an electrically heated element to imprint upon the moulding face a pattern or shape.
14. A method as claimed in claim 1, 2 or 10 wherein the treatment of the moulding face comprises the drawing of an electrically heated element through the expanded polystyrene parallel to the place thereof.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA245,021A CA1080449A (en) | 1976-02-04 | 1976-02-04 | Method of forming moulded articles |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA245,021A CA1080449A (en) | 1976-02-04 | 1976-02-04 | Method of forming moulded articles |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1080449A true CA1080449A (en) | 1980-07-01 |
Family
ID=4105150
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA245,021A Expired CA1080449A (en) | 1976-02-04 | 1976-02-04 | Method of forming moulded articles |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1080449A (en) |
-
1976
- 1976-02-04 CA CA245,021A patent/CA1080449A/en not_active Expired
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |