GB2466945A

GB2466945A - Method of producing an architectural moulding

Info

Publication number: GB2466945A
Application number: GB0900522A
Authority: GB
Inventors: Susan Jane Faux
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-01-14
Filing date: 2009-01-14
Publication date: 2010-07-21
Also published as: GB0900522D0

Abstract

A method of producing an architectural moulding comprises taking a substrate 1, placing at least one existing object 2A, 2B, 2C, on the substrate, and creating a wall 3 around the substrate having a height above the height of the, or each, object on the substrate. A settable liquid flexible mould material 5 is poured over the substrate and the, or each, object, allowing the material to set to form a flexible mould. An architectural moulding is cast from the mould, for example using plaster. The substrate may be clay. Clay 4 may also be used to fair the, or each, object to reduce any recess between it and the substrate. The settable liquid may be silicone. The architectural moulding may be a ceiling moulding such as coving.

Description

Title: Method of Producing Architectural Moulding The present invention relates to a method of producing an architectural moulding.

Architectural mouldings such as plaster coving and the like are well known. Lengths of such coving are often produced by carving a mould from wood and casting the coving from the wooden mould. The process for producing the mould is time consuming and hence to costly to customise an individual coving for just say one room.

The invention seeks to provide a novel method which lends itself to small batch production of certain customised architectural mouldings.

According to the present invention there is provided a method of producing an architectural moulding comprising: a) taking a substrate, b) placing at least one existing object on the substrate, c) creating a wall around the substrate having height above the height of the or each object on the substrate, and d) pouring a settable liquid flexible mould material over the substrate and the or each object, e) allowing the material to set to form a flexible mould, and IT) casting an architectural moulding from the mould.

Preferably a space is provided between the wall and the substrate whereby the moulding includes the depth of the substrate.

Preferably the substrate is clay.

Preferably the method further comprises fairing the or each object into the substrate with material to reduce the depth of any recess between an object and the substrate. Preferably the fairing material is clay.

An embodiment of the invention will now be described with reference to the accompanying drawings in which: Figure 1 shows a perspective view of a substrate with objects in the form of cutlery on the substrate and a wall around the substrate, and Figure 2 shows a cross section view of Figure 1 along the line X-X with flexible mould material poured in between the walls.

Referring to the drawings there is shown a method of making an architectural moulding in the form of a length of coving having cutlery thereon, e.g. to decorate a restaurant wall.

A rectangular clay substrate I is taken and placed on a flat surface.

Existing objects in the form of knives, forks and spoons 2A,2B,2C are placed on the substrate 1 in a desired artistic array with spaces between the knives, forks and spoons 2A,2B,2C.

A wall in the form of a frame 3 is placed around the substrate having height above the height each knife fork and spoon 2A,2B,2C. A space "Y" is provided between the wall and the substrate around the periphery of the substrate.

Each knife fork and spoon is faired into the substrate with clay 4 to reduce the depth of any recess between an object and the substrate.

A settable liquid flexible mould material in the form of silicone 5 is poured over the substrate 1 and the knives, forks and spoons 2A,2B,2C to fill the space between the frame 3. The silicone material is allowed to set to form a flexible mould 5. Once set the mould 5 can be flexed and removed from the frame 3, substrate 1, and knives, forks and spoons 2A,2B,2C.

An architectural moulding can be cast from the removed mould 5, e.g. using plaster, to create a length of coving with the knives, forks and spoons. Several such lengths can be made and placed end to end to produce coving around the walls of a room.

It will be appreciated that as a space is provided between the wall and the substrate which is filled by silicone, the moulding produced includes the depth of the substrate 1.

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The fairing of the objects into the substrate, to reduce the depth of any recess between an object and the substrate, reduces the undercut and allows the mould 5 to be removed easily.

The method of the invention may be used to make various kinds of interior and exterior architectural mouldings other than coving, e.g. ceiling mouldings. Other casting materials may be used in the mould e.g. concrete or resin, to enable the finished cast to be used in specific architectural sites. It may sometimes be desirable for the objects on the cast to project over an edge of base to create a recess to accommodate the edge of an adjacent cast to hide a "join line" between two mouldings, or to allow different mouldings designs to be slotted together without "join lines". A modular system of inter-connectable mouldings could be made in this way.

Because each mould is made using actual objects rather than carved shapes to impart a decorative pattern, so the time required to make each mould is much reduced and requires less skill. The objects used can reflect the desired theme for the moulding, such as cutlery for restaurants, toothbrushes for dentists, or foodstuffs for kitchens.

The invention may take a form different to that specifically described above.

Further modifications will be apparent to those skilled in the art without departing from the scope of the present invention.

Claims

CLAIMS1. A method of producing an architectural moulding comprising: a) taking a substrate, b) placing at least one existing object on the substrate, c) creating a wall around the substrate having height above the height of the or each object on the substrate, d) pouring a settable liquid flexible mould material over the substrate and the or each object, e) allowing the material to set to form a flexible mould, and f) casting an architectural moulding from the mould.
2. A method according to claim 1, wherein a space is provided between the wall and the *: : : : substrate whereby the moulding includes the depth of the substrate. * S S.S*.. *.
3. A method according to claim I or 2, wherein the substrate is clay.S

S

: :*
4. A method according to any preceding claim, wherein the method further comprises fairing * . the or each object into the substrate with material to reduce the depth of any recess between an object and the substrate.
5. A method according to claim 4, wherein the fairing material is clay.
6. A method of producing an architectural moulding substantially as hereinbefore described. a... * * . a... * .SS *a.* * S S... S...S S * S* * a. S *S