FR2725150A1 - Method of enhancement of natural material e.g. stone block for building - Google Patents

Abstract

The enhancement of a natural material (4) consists of coating it with a coating material (5), generally coloured concrete, mortar or cement. The coating is carried out in the following stages, a mould (2) formed from four walls, two of which on the mould interior are plane and parallel, is placed on a plane surface (1). The next stage is a supple pad (3) of sand, sawdust, plastics or granules being placed on the surface inside the mould. A frame (6) can be placed on the surface of the supple pad opposite to the surface (1) and in contact with the mould to form a recess. The natural material is placed on the pad, with a demoulding material be applied to the mould walls and/or to the natural material. The coating material is then flowed to the desired height (l), and once the coated material has hardened it is taken from the mould.

Description

 The invention relates to a process for recovering a natural material such as a stone block.

 The invention also relates to the valued material obtained and the structures which it makes it possible to produce.

EIAT DE LA TECHNIOUE
Although, today, in many fields, the tendency is to approach the environment and to replace artificial or synthetic materials by natural materials, the use of natural materials such as blocks of stone resulting, by example, a career, is relatively limited because it generally faces a number of problems, including, in particular, the establishment and implementation of these materials.

 Indeed, natural materials generally have random, irregular shapes and their implementation often requires the intervention of heavy equipment and specialized companies, which leads to high costs.

 In order to facilitate this implementation, it is sometimes possible to saw these materials. However, such a solution, in addition to the technical difficulty which it implies, considerably increases the selling price of the material.

 We can also consider the manufacture of rubble stone. But the rubble, whose maneuverability is easy, also requires for their implementation several operations (plastering, etc ....).

 Imitations of natural materials were then proposed. These imitations, which are prefabricated materials, are of course easier to use than natural materials, but their appearance is still insufficient to date from an aesthetic point of view and does not manage to bear comparison with the natural appearance of a real stone.

 Until now, there has been no technique allowing the recovery of natural materials, that is to say giving them a manipulable, transportable, stackable character, while retaining much of their natural appearance.

SUMMARY OF THE INVENTION
The applicant has now succeeded in developing a process which satisfactorily fills the gaps in the state of the art. This process which makes it possible to develop a natural material consists in coating with a coating material said natural material so as to create a volume with at least six faces, said natural material being visible on at least one of said six faces and two other faces being at least essentially plane and at least essentially parallel to one another.

The method according to the invention thus generally has at least the following advantages:
- it is very simple,
- it makes it possible to obtain a valued material whose shape and d
dimensions can be standardized,
- it requires only a small amount of
coating material and generally a short time,
- it is applicable to natural material without limitation of shape or
size, and
- it has a low cost of implementation.

 The invention also relates to the valued materials obtained by this process. These valued materials therefore have regular, standardized shapes, they have a relatively low content of coating material, they are easy to handle, transportable, stackable on top of each other and therefore storable, and they have great aesthetic value. They can also be very resistant to compression and easily juxtaposed with each other.

 The invention also relates to the structures that the recovered materials make it possible to obtain by juxtaposition and / or stacking.

 Other advantages of the recovery process, recovered materials and structures according to the invention will emerge on reading the following description which is attached by way of illustration and not limitation, Figures 1 to 16.

DESCRIPTION OF SUMMARY OF FIGURES
Figure 1 is a schematic illustration of a mold during the implementation of the method according to the invention.

 Figure 2 is a top view of the mold of Figure 1.

 Figure 3 shows schematically and in perspective, a recovered material according to the invention.

 Figures 4, 5, 6, 7, 8, 9, 10 and 11 show schematically and in perspective, variants of the recovered material according to the invention.

 Figure 12 is a schematic and partial representation of a section of the recovered material of Figure 11, taken along the plane WX.

 FIG. 13 schematically represents another variant of the recovered material according to the invention.

 Figure 14 is a schematic and partial representation of a section of the recovered material of Figure 13, made according to the YZ plane.

 FIG. 15 represents a structure produced from recycled materials according to the invention.

 FIG. 16 represents another structure produced from recycled materials according to the invention.

 For reasons of simplification, the elements common to the different figures are designated by the same reference signs.

DETAILED PRESENTATION OF THE INVENTION
According to the invention, the natural materials to be recovered can be of variable trekking natures. They are generally blocks of stone from quarries.

 Their dimensions are also very variable. The method according to the invention is particularly advantageous when the dimensions of the materials are large.

 The shapes of the materials according to the invention are also very variable. The method according to the invention makes it possible to enhance natural materials whatever their dimensions and shapes.

The coating of the natural material is generally carried out using a hydraulic binder and by molding. We can then proceed as follows, illustrated by FIGS. 1 and 2:
a) a mold 2 is preferably provided on a surface 1, preferably at least approximately flat, with at least four walls, at least two of which are, at least on the interior side of the mold 2, at least essentially flat and at least essentially parallel to each other,
b) the surface 1 is coated with a flexible cushion 3 inside the mold 2
c) the natural material 4 is deposited on said flexible cushion 3
d) the coating material 5 is poured up to the desired height 1
e) once the coating material 5 has hardened, it is removed from the mold (the
mold).

 In step c) the natural material 4 is deposited so that it is located at least approximately in the center of the mold 2 and the face of this material which should be visible in the recovered material after demolding is in contact with the flexible cushion 3.

 The flexible cushion 3 can consist of sand, sawdust, plastic, granules, etc.

 The hydraulic binder 5 is generally concrete, mortar or cement. I1 may include conventional additives for hydraulic binder, such as thinners, setting accelerators or retarders, air entraining agents, etc.

 Preferably this hydraulic binder is colored.

 Before pouring it into the mold 2, it is also possible to apply, in a known manner, to the walls of the mold 2 and / or to the natural material 4, a conventional release agent.

 Between step b) and step c) or between step c) and step d) it is possible to place on the surface of the flexible cushion 3 opposite the surface 1, and against the mold 2 (in contact with the mold 2), a frame or piece of frame 6 with a view to making a withdrawal (the role of which will be explained below, with reference to FIG. 7).

 Additional details of the molding operation can easily be deduced from the description of the recovered material obtained after demolding and as shown in FIG. 3 schematically. This valued material comprises a single block of stone 4, visible on a front face A, a first layer 7 of coating material 5 whose face opposite to that in contact with the stone block 4 constitutes side B, a second layer 8 of coating material 5, the opposite of which in contact with the stone block 4 constitutes the face C, a third layered layer 11 of coating material 5 situated between the stone block 4 and the lateral face E and a fourth lateral layer 13 of coating material 5 situated between the stone block 4 and the lateral face F.

 The underside 9 of said layer 7 constitutes part of the face A.

The sub-Etce 10 of said layer 8 also constitutes part of the face
AT.

 The underside 12 of said side layer 1 1 also constitutes part of the face A.

 The underside 14 of said side layer 13 also constitutes part of the face A.

 Consequently, on face A, the sub-faces 9, 10, 12 and 14 surround the visible part of the stone block 4.

 The faces B and C are at least essentially plane and at least essentially parallel to one another.

 Preferably, the sub-faces 9, 10, 12 and 14 are at least essentially perpendicular to the faces B and C.

 The side A is generally predominantly constituted by the block of stone 4. The latter generally projects from the sub-faces 9, 10, 12 and 14.

 The volume of the stone block 4 generally represents at least 50% of the total volume of the recovered material (volume of the stone block 4 plus volume of coating material), and preferably at least 75% of this volume.

 If to model, we assimilate the shape of the stone block 4 to a parallelepiped and the visible part of the stone block 4 to a rectangle, the width hl of this rectangle can be equal to at least 75% of the height H of the valued material and its length L1 can be equal to at least the coast L.

 The stone block 4 is visible because of its color difference compared to the undersides 4 and 5 or because of the light effects exerted by its relief.

 According to the invention, this stone block 4 extends from the Eace A towards the rear, that is towards the rear face D. The latter is generally entirely made up of the coating material, but the stone block 4 may also appear there.

The rear face D can be arbitrary. It is however preferably generally flat. n is moreover desirable that it is generally perpendicular to the faces B and C
The extension of the stone block 4 towards the rear, quantified by the dimension 11, can repise at least 90% of the dimension l.

 Thus, stone block 4 occupies 75% * 75% * 9096, or more than 50% of the total volume of the recovered material.

 Consequently, the content of coating material of the material recovered according to the invention is relatively low.

 The sides B and C are intended to be oriented horizontally. Because of their flatness and their parallelism, they allow easy stacking of valued materials. and stability of the assembly obtained by stacking.

 In general, the stone block 4 occupies the central part of the valued material in which it is almost entirely embedded. lt is preferable that it does not overflow on the lateral faces E and F, that is to say that it is invisible on these faces, and that it emerges only on the side A.

 The sides E and F can be any.

 They can be tilted as illustrated in Figure 4, so that the side A has the shape of a trapezoid.

 They can also be arranged as shown in FIG. 5, the face A then having the shape of a parallelogram or of a rhombus.

 Preferably, at least one of the faces E and F is at least essentially perpendicular to the faces A, B and C. It is in fact thus possible to obtain greater ease of juxtaposition of several valued materials.

 Advantageously, the two faces E and F are at least essentially perpendicular to the faces A, B and C, as illustrated in FIG. 6, so as to obtain maximum ease of juxtaposition since the valued material is then generally a para-helepiped, and even, if applicable, a cube.

 According to a variant illustrated in FIG. 7, the face A is provided with a recess or recess 15 intended to increase the aesthetic character of the material valued according to the invention. This recess 15 extends along at least part, on one or more sides of the face A. Preferably, it continuously borders the entire face A.

 This withdrawal 15 is carried out during molding, with a frame 6, as explained above.

 Although the cross section of this recess 15 is generally rectangular, it could also be triangular. The recess 15 would then simply be a chamfer.

 Of course, if the valued material has been manufactured so that the stone block 4 is also visible on the rear face D, it is also possible to provide the latter with a similar withdrawal.

 According to an advantageous version represented by FIGS. 8, and 9, the recovered material is provided with juxtaposition means 16, 17, 18, 19 favoring the placing and maintaining in lateral position of several recovered materials of the same type.

 These juxtaposition means 16, 17, 18, 19 can for example take semi-cylindrical hollow shapes 16 and full 17, or constitute a twin assembly of the dovetail type 18, 19.

 According to another advantageous version illustrated by FIG. 10, the recovered material according to the invention is provided with stacking means 20, 21 favoring the stacking and the maintenance in a stacked state of several recovered materials of the same type.

 These stacking means 20, 21 may for example be in the form of prisms in the middle 20 and in the hollow 21.

 According to yet another advantageous version represented by FIGS. 11, 12, 13 and 14, the recovered material is provided with gripping or handling means 22,23,24,25 facilitating their transport and / or their juxtaposition and / or their stacking .

 These handling means can be composed (FIGS. 11 and 12) of a groove 18 located in the upper face B of the recovered material, and of one or more handles 23 arranged inside the groove 22 and anchored in the coating material and preferably also in the stone block 4, as shown in Figure 12.

The handling means can also be composed (fig. 13 and 14) of a hollow 24 of for example semi-spherical shape, formed in the upper face
B and at least one hook 25 anchored in the coating material and preferably also in the stone block 4, as shown in FIG. 14.

 The handles 23 and the hook 25 must not protrude from the side B so as not to hinder the stacking.

 The handling means 22, 23, 24, 25 are preferably invisible when there is a second similar valued material on a first recovered material, by stacking.

 The materials recovered according to the invention can be used to produce, by stacking and / or juxtaposition, very numerous and varied structures.

 In these valued materials, the natural material or stone block 4 is the main element. It is therefore possible to produce immense structures with a relatively small amount of coating material.

 The natural material 4 gives the valued material at least most of its solidity. It is he who plays the role of structure or support soul.

 From the point of view of mechanical resistance, in particular to compression, the coating material only plays an accessory role, the main role being assumed by the natural material.

 The materials recovered according to the invention therefore do not need any internal metallic reinforcement.

 They make it possible to produce structures such as, for example, interior or exterior walls (for villas, etc.), retaining walls (for retaining embankments of motorways, railways, etc.) or d containment (dikes, harbors, etc.).

 Figures 15 and 16 give examples of structures according to the invention.

 In Figure 15 is shown a wall composed of several materials valued according to the invention, stacked and / or juxtaposed.

 In Figure 16 is shown in section a slope retainer produced by stacking with offset and / or juxtaposition of construction elements according to the invention.

 Obviously, the invention is not in any bottle limited by the particulars which have been specified in what precedes or by the details of the embodiments chosen to illustrate it. A number of modifications can be made to the particular embodiments which have been described by way of illustration and to their constituent elements without thereby departing from the scope of the invention. The latter therefore includes all the means constituting technical equivalents of the means described as well as their combination.

Claims (16)

1. Process for developing a natural material (4) characterized in that  coating with a coating material (5) said natural material (4) of  so as to create a volume with at least six sides (A, B, C, D, E, F), said material  natural (4) being visible on at least one (A) of said six faces  (A, B, C, D, E, F) and two other faces (B, C) being at least essentially  flat and at least essentially parallel to each other. 2. Method according to claim 1, characterized in that the coating is carried out  so that the face (A) is mainly made up of said material  natural (4). 3. Method according to claim 1 or claim 2, characterized in that the  face (A) comprises at least four sub-faces (9,10,12,14) at least essentially  perpendicular to the faces (B, C). 4. Method according to any one of claims 1 to 3, characterized in that  the two lateral faces (E, F) are perpendicular to the faces (A, B and C). 5. Method according to any one of claims 1 to 4, characterized in that  the rear face D is generally flat. 6. Method according to any one of claims 1 to 5, characterized in that  the rear face D is generally perpendicular to the faces B and C. 7. Method according to any one of claims 1 to 6, characterized in that the face (A) comprises a recess (15). 8. method according to any one of claims 1 to 7, characterized in that  the coating is carried out by means of a hydraulic binder (5). 9. Method according to any one of claims 1 to 8, characterized in that  the coating is carried out as follows:  a) there is arranged on a surface (1) preferably at least approximately flat a  mold (2) formed by at least four walls, at least two of which are, at  less on the inside of the mold (2), at least essentially flat  and at least essentially parallel to each other,  b) the surface (1) is coated with a flexible cushion (3) inside the mold (2)  c) the natural material (4) is placed on said flexible cushion (3)  d) a coating material (5) is poured up to the desired height (1)  e) once the coating material (5) has hardened, it is removed from the mold. 10. Recovered material characterized in that it is obtained by the process according to one  any of claims 1 to 9. 11. Recovered material according to claim 10, characterized in that it is also  provided with juxtaposition means (16,17,18,19). 12. Recovered material according to claim 10 or claim 11, characterized  in that it is further provided with stacking means (20,21). 13. Recovered material according to one of claims 10 to 12, characterized in  that it is further provided with handling means (22,23,24,25). 14. Recovered material according to claim 13, characterized in that said  handling means (22,23,24,25) are invisible when one disposes by  stacking on a first recovered material, a second recovered material  similar. 15. Recovered material according to any one of claims 10 to 14,  characterized in that the volume of the natural material (4) represents at least  50X and preferably at least 75% of the total volume of the recovered material. 16. Structure characterized in that it comprises at least one valued material  according to one of claims 10 to 15.