US20020106504A1 - Faux stone concrete panel and method for making same - Google Patents
Faux stone concrete panel and method for making same Download PDFInfo
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- US20020106504A1 US20020106504A1 US10/024,600 US2460001A US2002106504A1 US 20020106504 A1 US20020106504 A1 US 20020106504A1 US 2460001 A US2460001 A US 2460001A US 2002106504 A1 US2002106504 A1 US 2002106504A1
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- layer
- mold
- concrete
- foam
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
- B28B7/0073—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces with moulding surfaces simulating assembled bricks or blocks with mortar joints
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
- B28B11/042—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with insulating material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249978—Voids specified as micro
- Y10T428/249979—Specified thickness of void-containing component [absolute or relative] or numerical cell dimension
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249978—Voids specified as micro
- Y10T428/24998—Composite has more than two layers
Definitions
- the present invention relates generally to a light-weight concrete panel or wall which appears as another building material, such as stone work, brick, wood or the like. More particularly, the present invention relates to a panel or wall having a thin concrete face layer with a molded contour or otherwise shaped to appear as stone work or the like, a reinforcing elastomer layer, and an inner foam layer.
- Prior attempts have been made to simulate such stone work or brick walls using less expensive materials and less labor-intensive methods.
- One such attempt involves constructing a wall from concrete.
- the concrete may be molded to the shape of bricks or otherwise textured to appear as brick.
- concrete sidewalks have been provided with textured surfaces by stamping a stone shape into the concrete before it hardens.
- Another such example includes manually texturing the concrete before it cures.
- One problem with using concrete is that concrete tends to have a substantially smooth texture, unlike natural stone or brick.
- Another disadvantage with such concrete walls is that solid concrete is also extremely heavy.
- Another attempt at providing such a textured or shaped surface includes veneering, in which actual or simulated stone or brick is adhered to a conventional concrete wall.
- veneering In which actual or simulated stone or brick is adhered to a conventional concrete wall.
- One disadvantage with veneering is the expense, time and care involved in providing the veneer.
- the invention provides a wall or panel with a thin concrete layer to reduce the weight of the wall or panel.
- the concrete layer has interior and exterior surfaces, and a cross-sectional contour.
- the contour projects outwardly to form macro projections in the exterior surface, and macro indentations in the interior surface.
- the contour also projects inwardly to form macro indentations in the exterior surface, and macro projections in the interior surface.
- the contour, or projections and indentations may form natural objects, such as stone work, brick, wood, and the like.
- the concrete layer has a substantially constant thickness at the projections and indentations.
- the concrete layer is less than approximately 0.5 inches thick to reduce weight.
- a foam layer is coupled to the interior surface of the concrete layer, and has protrusions mating with the indentations in the interior surface of the concrete layer.
- the foam layer provides reinforcement to the thin concrete layer and reduces the weight of the wall or panel.
- the foam layer may have fiber reinforcement.
- the wall or panel may have a thin elastomer layer affixed to the concrete layer to reinforce the concrete layer, and to provide tensile strength and impact resistance.
- the reinforcement layer may include an elastomer layer, such as a urethane layer.
- the reinforcement layer may include a high density foam, and the foam layer may include a low density foam.
- the reinforcement layer may include fiber reinforcement.
- the wall or panel may have a rigid backing layer spaced-apart from the elastomer layer, with the foam layer disposed between, and affixed to, the elastomer layer and backing layer to further reinforce the concrete layer and making the wall or panel lightweight.
- the rigid backing layer may be a second concrete layer spaced-apart from and opposite the first concrete layer.
- the second concrete layer may have a similar cross-sectional contour.
- the wall or panel may be configured to be free-standing fencing structures.
- the wall or panel may be configured as a facade to be affixed to an exterior wall of a building.
- a method for making the wall or panel includes providing a mold having an inner mold surface with macro indentations and macro protrusions.
- a wet mixture of concrete material is applied to the inner mold surface of the mold to form a concrete layer with a cross-sectional contour corresponding to the indentations and protrusions of the inner mold surface.
- the concrete material is sprayed onto the inner mold surface.
- the wet mixture of concrete material is applied in a substantially constant thickness at the projections and indentations. The concrete material is cured until dry.
- Foam is introduced into the mold to form a foam layer secured to the cement layer with the foam having protrusions mating with the concrete layer.
- the mold provides support to the concrete layer as the foam expands. The secured concrete and foam layers are removed from the mold.
- the layer of reinforcement material is applied to the concrete layer prior to introducing the foam to form a reinforcement layer.
- the reinforcement layer is sprayed onto the cured concrete layer.
- the rigid backing layer is spaced-apart from the mold surface prior to introducing the foam into the mold.
- the rigid backing layer may be applied to the foam layer.
- the mold may be disposed in a vertical orientation, either throughout the process, or just before the foam is introduced into the mold.
- the wall or panel is vertically oriented to facilitate handling and conserve space.
- FIG. 1 a is a perspective view, partially in section, of a wall or panel in accordance with the present invention
- FIG. 1 b is a more detailed, partial cross-sectional view of the wall or panel shown in FIG. 1 a;
- FIG. 2 a is a partial perspective view, partially in section, of another wall or panel in accordance with the present invention.
- FIG. 2 b is a more detailed, partial cross-sectional view of the wall or panel shown in FIG. 2 a;
- FIG. 3 is a partial cross-sectional view of another wall or panel in accordance with the present invention.
- FIG. 4 is a partial cross-sectional view of another wall or panel in accordance with the present invention.
- FIG. 5 is a partial cross-sectional view of another wall or panel in accordance with the present invention.
- FIG. 6 is a perspective view of an embodiment of a mold in accordance with the present invention, shown in an open configuration
- FIG. 7 is a perspective view of the mold of FIG. 6 shown in an closed configuration
- FIG. 8 is a perspective view of another embodiment of a mold in accordance with the present invention, shown in an open configuration
- FIG. 9 is a perspective view of the mold of FIG. 8 shown in an closed configuration
- FIGS. 10 a - 10 b are schematic views of a method in accordance with the present invention.
- FIG. 11 is a schematic view of a method in accordance with the present invention.
- walls or panels in accordance with the present invention are shown which are configured to appear as other objects or natural objects, including for example, stone work, rock, brick, or wood, and the like, and which are lightweight and durable.
- the terms “wall” and “panel” are used broadly to refer to walls or panels which may be used in building construction systems as facades, and walls used in fence systems.
- a wall or panel indicated generally at 10 in accordance with the present invention is shown configured as a wall in a fencing system.
- the wall or panel is oriented in a vertical orientation and configured to be free standing.
- the wall or panel 10 includes at least one thin concrete layer, such as first thin concrete layer 14 .
- the concrete layer 14 has an exterior surface 18 which faces outwardly to be seen, and an opposite interior surface 22 which faces inwardly.
- the concrete layer 14 advantageously has a cross-sectional contour which projects outwardly to form projections 26 in the exterior surface 18 , and indentations 30 in the interior surface 22 .
- the cross-sectional contour projects inwardly to form indentations 34 in the exterior surface 18 and projections 38 in the interior surface 22 .
- the exterior surface 18 includes projections 26 and indentations 34
- the interior surface 22 includes indentations 30 which correspond to the protrusions 26 in the exterior surface 18
- protrusions 38 which correspond to indentations 34 in the exterior surface 18 .
- the projections and indentations are “macro-projections” and “macro-indentations,” respectively, meaning they are sized to produce an architectural effect which is visible from a distance, as opposed to surface or material irregularities.
- the projections 26 and indentations 34 of the exterior surface 18 and thus the cross-sectional contour, are sized and shaped to appear as other objects, or natural objects, including for example, rocks, stone work, brick, wood or the like.
- the concrete layer 14 has a thickness t which is substantially constant throughout the portion of the concrete layer 14 including the projections and indentations. It is of course understood that the thickness of the concrete layer 14 may vary at the indentations and protrusions, or throughout the cross sectional contour, especially at areas of curvature. By a “substantially constant thickness,” it is meant that the inner surface 22 of the concrete layer 14 follows the outer surface 18 as the outer surface 18 projects inwardly and outwardly, as opposed to remaining straight. Thus, the concrete layer 14 will cure substantially evenly as discussed in greater detail below.
- the thickness t of the concrete layer 14 is preferably less than one inch, more preferably less than one-half inch, and most preferably less than one-eighth inch, to reduce the weight of the concrete layer.
- the concrete layer 14 may be formed of a concrete mix which provides a cementitious or textured surface to appear as real stone work or brick. It will be appreciated that concrete itself has a relatively smooth surface. Thus, the concrete mix preferably includes sand to provide strength to the concrete, and to provide a rougher surface texture. In addition, the concrete mix may include a plasticizer to keep the mixture as dry as possible. In addition, the concrete mix may include a polymer to add flexibility. In addition, the concrete mix may include an accelerator for faster curing. Furthermore, a coloring may be applied to the exterior surface 18 of the concrete layer 14 to further provide the desired appearance as stone work, brick, etc. For example, a stone like coloring may be added to the protrusions 28 in the exterior surface 18 , while the indentations 34 in the exterior surface 18 retain the natural coloring of the concrete mix. In addition, color or pigment may be added directly to the concrete mixture.
- the concrete layer 14 advantageously is thin to reduce weight of the wall or panel 10 .
- the concrete layer 14 , or concrete mixture preferably and advantageously is free of fiber reinforcement.
- Concrete is often reinforced with glass fiber, which must be a special alkaline resistant glass fiber, which is very expensive. Thus, a substantial cost reduction is realized without using the more expensive glass fiber reinforced concrete. It is of course understood that the concrete layer may be fiber reinforced.
- the panel 10 may also have a second concrete layer 42 opposite and spaced-apart from the first concrete layer 14 .
- the second concrete layer 42 may be similar to the first concrete layer 14 , and includes a cross sectional contour with indentations and protrusions configured to appear as stone work, brick, etc.
- the wall or panel 10 advantageously has a reinforcement layer 46 adjacent and affixed to the concrete layer 14 .
- the reinforcement layer 46 preferably is an elastomer layer, but may also be a foam layer, such as a high density foam, as discussed in greater detail below.
- the reinforcement or elastomer layer 46 advantageously provides tensile strength and impact resistance to the concrete layer 14 .
- the concrete layer 14 is as thin as possible to save weight, and may lack fiber reinforcement to reduce cost.
- the elastomer layer 46 strengthens the thin concrete layer 14 , and provides tensile strength and impact resistance to the concrete layer 14 .
- the elastomer layer 46 preferably has a thickness between 60 and 225 mils depending on the strength required.
- the elastomer layer 46 may be reinforced with fiberglass. A less expensive fiberglass may be used in the elastomer because it does not need to be alkaline resistant.
- the elastomer layer 46 has an exterior surface 50 which is directly affixed to the interior surface 22 of the concrete layer 14 .
- the exterior surface 50 of the elastomer layer 46 has protrusions and indentations which match the respective indentations and protrusions of the inner surface 22 of the concrete layer 14 .
- the elastomer layer 46 also has an interior surface 54 .
- the interior surface 54 of the elastomer layer 46 also has indentations which correspond to protrusions in the exterior surface 50 , and protrusions which correspond to indentations in the exterior surface 50 .
- the elastomer layer 46 has a cross-sectional contour which matches or mates with the cross-sectional contour of the concrete layer 14 .
- the elastomer layer 46 has a thickness which is substantially consistent at the protrusions and indentations.
- the elastomer layer 46 preferably is a sprayable urethane, as discussed in greater detail below.
- the elastomer layer 46 or reinforcement layer alternatively may be epoxy or fiberglass polyester.
- the elastomer layer 46 may be reinforced with chopped fiberglass. Again, a less expensive fiberglass may be used in the elastomer because it does not need to be alkaline resistant.
- the concrete layer 14 protects the reinforcement layer 46 from the sun, because the reinforcement layer 46 may not be UV stable, such as with some elastomers.
- the wall or panel 10 may include a second elastomer layer 58 affixed to the second concrete layer 42 , which is similar to the first elastomer layer 46 .
- the wall or panel 10 advantageously also has a foam layer 62 disposed between the concrete layers 14 and 42 , and the elastomer layers 46 and 58 .
- the foam layer 62 is coupled or attached to the interior surfaces 54 of the elastomer layers 46 and 58 .
- the foam layer 62 advantageously has protrusions 66 which extend outwardly to mate with the indentations in the interior surface 54 of the elastomer layer 46 , and may also extend into the indentations 30 in the inner surface 22 of the concrete layer 14 .
- the foam layer 62 has a thickness which varies at the protrusions and indentations, such that the wall or panel 10 is substantially solid.
- the concrete and elastomer layers 14 and 46 may be flexible by themselves.
- the foam layer 62 advantageously is lightweight and provides further reinforcement and stiffness to the elastomer and concrete layers 46 and 14 .
- the foam layer 62 may be a MDI poly-ether, polyester, or polyether blend.
- the foam layer 62 may also be a poly-urea elastomer or polyurethane.
- the foam layer 62 preferably is low density, or has a density of two to five pounds. Alternatively, the foam layer 62 may have a density between two and thirty pounds.
- the foam layer 62 may be fiber reinforced. A less expensive fiberglass may be used in the foam because it does not need to be alkaline resistant.
- the foam layer 62 advantageously provides a filler between the concrete layers 14 and 42 to prevent unwanted voids or spaces, particularly near the concrete layer 14 , which may weaken the concrete layer.
- the foam layer 62 advantageously bonds the opposite concrete layers 14 and 42 together.
- the foam layer 62 provides thermal and sound insulation to the wall or panel 10 .
- the wall or panel 10 is configured for use as a wall of a fencing system.
- the wall 10 may have a perimeter border 70 or raised portion to frame and enclose the protrusions 26 and indentations 34 configured to appear as stone work, brick, etc.
- the border 70 may include a base 72 configured to appear as a foundation, a top 74 configured to appear as a cap, and sides 76 configured to appear as vertical support columns.
- the border 70 may be configured to appear as concrete, as shown, or may also have indentations and protrusions to appear as stone work, brick, etc.
- the border 70 may be constructed as the rest of the wall 10 , and be formed of the thin concrete layer 14 , the elastomer reinforcement layer 46 , and the foam layer 62 . Thus, an entire segment of the wall system may be formed of the wall 10 to be light weight and durable.
- an alternative embodiment of a wall or panel includes the thin concrete layer 14 , and thin elastomer layer 46 , as described above.
- the wall or panel 100 includes a rigid backing layer 104 spaced-apart from the concrete and elastomer layers 14 and 46 .
- the rigid backing layer 104 has an exterior surface 108 , and an interior surface 112 opposing an interior surface 54 of the elastomer layer 46 .
- a foam layer 116 is disposed between the rigid backing layer 104 and the elastomer layer 46 or concrete layer 14 .
- the foam layer 116 includes protrusions 120 which extend into the indentations of the elastomer layer 46 and concrete layer 14 .
- the rigid backing layer 104 may be a straight or flat layer, such as a rigid panel of fiberboard, or the like, adhered to the foam.
- the rigid backing layer 104 may be a flat concrete layer or an elastomer layer.
- the rigid backing layer 104 may be used in applications in which only a single side of the wall or panel 100 will be seen.
- the rigid backing layer 104 may be utilized to affix the wall or panel 100 to the exterior of a building to form a facade.
- the thin concrete layer 14 allows the wall or panel 100 to be light-weight, and thus more easily positioned, handled, secured, etc.
- the backing layer 104 protects the foam layer 116 .
- the wall or panel 100 may be configured as a free standing fence, or may be configured as a building panel for being affixed to a building.
- the outer surface 18 of the concrete layer 14 may have a continuous surface of protrusions 26 and indentations 34 extending over the entire surface area of the outer surface 18 of the concrete layer 14 .
- several walls or panels 100 may be positioned adjacent one another to form a continuous surface.
- the reinforcement layer 46 preferably is an elastomer layer, and most preferably a urethane layer.
- the reinforcement layer 46 may be a layer of high density foam, such as 10 to 20 pound density, while the foam layer 62 is a low density foam layer, for example, two to five pound density.
- FIG. 3 an alternative embodiment of a wall or panel 200 is shown with the concrete layer 14 and a rigid backing layer 104 (not shown in FIG. 3) as described above.
- a foam layer 204 is disposed between the concrete layer 14 and the rigid backing layer 104 .
- the foam layer 204 directly attaches to the inner surface 22 of the concrete layer 14 .
- the foam layer 204 has a varying thickness such that the foam layer 204 has projections 208 which extend into the indentations 30 in the inner surface 22 of the concrete layer 14 .
- the foam layer 204 preferably is a high density foam for greater durability and strength, but may be a low density foam depending on the application.
- the high density foam layer 204 acts as both the reinforcement layer and the filler.
- the wall or panel 200 may be configured to be attached to the exterior of a building as a facade.
- the wall or panel 200 preferably is relatively thin, and thus the foam layer 204 preferably is a thin, high density foam.
- the foam layer 204 may have a thickness less than a few inches.
- an alternative embodiment of a wall or panel indicated generally at 300 , has a thin concrete layer 14 , a thin elastomer layer 46 , and a rigid backing layer 104 as described above.
- the wall or panel 300 has a layer of rigid, high density foam 304 adjacent and affixed to the elastomer layer 406 , and a layer of low density foam 308 disposed between the rigid backing layer 104 and the layer of high density foam 304 .
- the layer of high density foam 304 provides additional rigidity and stiffness to the wall or panel 300 , while the low density foam 308 reduces the weight of the wall or panel 300 .
- FIG. 5 an alternative embodiment of a wall or panel, indicated generally at 400 , is shown with increased sound reduction, or noise insulation properties.
- the wall or panel 400 may be similar to any of the walls or panels described hereto, and thus has at least a thin concrete layer 14 , and a foam layer 404 .
- the various walls or panels preferably have a solid interior, or at least lack inadvertent voids, particularly near the concrete layer 14 , which may result in weak or damaged portions.
- the foam layer 404 includes a plurality of voids 408 or cavities formed in the foam layer 404 to improve the sound dampening qualities of the wall or panel 400 .
- the cavities 408 are macro-voids, or sized to reduce sound, as opposed to the smaller voids inherent in the cell structure of the foam.
- any of the walls or panels described above may have double faces or be two-sided, such as the wall or panel 10 shown in FIG. 1, with both faces being configured to appear as stone work, brick, etc.
- any of the wall or panel members described above may have a single face which is shaped and configured to appear as stone work, brick, etc., and an opposite face which is configured to be attached to another object, or simply to remain plain, such as walls and panels 100 , 200 , 300 , and 400 , shown in FIGS. 2 - 5 .
- the second concrete layer 42 in FIG. 1 may be replaced with a rigid backing layer.
- the rigid backing layers 104 in FIGS. 2 - 5 may be replaced with a second concrete layer which is configured to appear as stone work, brick or the like.
- the various walls or panels described above may be configured to be attached to other objects or other walls or panels.
- the sides of the walls or panels may be configured with tongue and groove type interconnections, with a first panel having a tongue, and a second panel having a groove, such that the tongue of the first panel may be inserted into the groove of an adjacent second panel to facilitate securing adjacent panels.
- tongue and groove type interconnections may be formed integrally with the walls and panels.
- the panels may have inserts for interconnecting the panels to one another, or other objects.
- the various walls or panels described above may contain other structural members to reinforce the panels or facilitate attachment of the panels to other objects, such as the exterior of a building.
- elongated metal bars may be disposed in the foam layer to provide additional structural rigidity to large panels.
- the walls or panels of the present invention advantageously are light weight and durable.
- the walls or panels may be easily manufactured at a facility, easily transported, and easily arranged at a building site.
- the present invention also involves a method for making the walls or panels.
- a mold indicated generally at 500 , is shown for forming the panels or walls of the present invention.
- the mold 500 preferably has first and second mold halves 504 and 508 .
- the mold 500 and thus the mold halves 504 and 508 , may be oriented vertically in order to save space.
- the mold halves 504 and 508 preferably are pivotally coupled along one side, such that the mold halves 504 and 508 may be pivoted with respect to one another between an open position as shown in FIG. 6 and a closed position as shown in FIG. 7.
- the first mold half 504 includes an inner mold surface 512 which includes macro-indentations 516 and macro-protrusions 520 .
- the indentations and protrusions 516 and 520 are configured to produce the protrusions 26 and indentations 34 in the concrete layer 14 .
- the second mold half 508 may include a second mold surface 524 which may also have indentations and protrusions. It is of course understood that both mold surfaces 512 and 524 will have indentations and protrusions to form a dual sided wall or panel 10 as shown in FIG. 1. Alternatively, only the first mold surface 512 may have indentations and protrusions if the mold is to be used to produce a wall or panel with a single shaped face.
- the mold 500 may be opened so that both mold surfaces 512 and 524 are easily accessible.
- Color or pigment may be applied to the indentations 516 in the mold surface 512 .
- the color or pigments correspond to the desired color of the stone or brick.
- color or pigment may be added directly to the concrete mixture of the concrete layer 14 .
- FIGS. 8 and 9 another mold 550 is shown for forming the walls or panels of the present invention.
- the mold 550 preferably has first and second mold halves 554 and 558 .
- the mold halves 554 and 558 preferably are pivotally coupled to each other or the ground at their bottom sides, so that the mold halves 554 and 558 , may be oriented horizontally in the open position, as shown in FIG. 8, and vertically in the closed position, as shown in FIG. 9.
- the first mold half 554 of mold 550 includes the inner mold surface 512 which includes macro-indentations 516 and macro-protrusions 520 .
- the second mold half 558 may include the second mold surface 524 which may also have indentations and protrusions. As shown in FIG. 8, the mold 550 may be opened so that both mold surfaces 512 and 524 are easily accessible.
- a mold such as molds 500 (FIG. 6) or 550 (FIG. 8) is provided with at least the mold surface 510 .
- the mold is initially open into an open configuration, as shown in FIG. 6 or 8 .
- a wet mixture of concrete material is applied to at least the first mold surface 512 to form the first concrete layer 14 .
- the wet mixture of concrete material may also be applied to the second mold surface 524 to produce the second concrete surface 42 for a double sided wall or panel.
- the concrete preferably is sprayed, indicated by arrow 580 , onto the mold surface 512 with a sprayer in a thin layer preferably between one-eighth of an inch to one-half of an inch or more.
- the concrete material preferably is applied as thinly as possibly to reduce weight.
- the concrete material preferably is free of glass reinforcement to reduce the cost associated with alkali resistant fiberglass.
- the concrete material may be reinforced with alkali resistant fiberglass.
- the concrete material preferably is applied to the mold surface 512 in a consistent or uniform thickness at the indentations and protrusions 516 and 520 .
- variations in thickness may occur as a result of overlapping spray patterns, or at changes in curvature in the mold surface 512 .
- wide variations in concrete thickness preferably are avoided by refraining from filling the indentations 516 in the mold surface 512 with the concrete material.
- the concrete material is then allowed to cure or harden into the concrete layers 14 and 42 .
- the concrete material cures more evenly due to the constant thickness of the concrete layer 14 .
- a reinforcement material such as an elastomer material
- the elastomer material or reinforcement material preferably is sprayed onto the concrete layers 14 and 42 , indicated by arrow 584 .
- the elastomer material sets up almost immediately as it is applied to the concrete layers 14 and 42 .
- the elastomer material preferably is applied in a thin layer of between 60 to 225 mils, depending on the strength required.
- the concrete layers 14 and 42 preferably are thin to reduce weight and lack glass reinforcement to reduce cost.
- the elastomer layers 46 and 58 advantageously provide tensile strength and impact resistance to the concrete layers 14 and 42 .
- the elastomer material bonds to the concrete layers as it is applied.
- the elastomer material may include fiber reinforcement. It will be appreciated that glass fiber reinforcement for the elastomer is much less expensive than the special alkali resistant glass fiber required when mixed with concrete.
- the mold halves 504 and 508 , or 554 and 558 are pivoted to the closed position, such that the mold halves are spaced-apart from one another, and a gap or space 528 formed between the concrete layers 14 and 42 and elastomer layers 46 and 58 .
- foam is then introduced into the mold 500 (FIG. 7) or 550 (FIG. 9), or the space 528 between the mold halves 504 and 508 (FIG. 7), or 554 and 558 (FIG. 9), as indicated by arrow 588 .
- the foam is an expandable foam which expands to fill the space 528 between the concrete layers 14 and 42 and elastomer layers 46 and 58 .
- the foam material expands, it creates the protrusions 66 which extend into the indentations 30 in the concrete layer 14 .
- the foam stiffens the panel and further reinforces the concrete layers 14 and 42 .
- the foam preferably is a low density foam between two and five pounds to be lightweight.
- glass reinforcement may be added to the foam. Again, it will be appreciated that glass reinforcement for foam is much less expensive than a special alkali resistant glass reinforcement required for concrete.
- the mold 500 or 550 may then be opened and the resulting panel, or combined concrete layers 14 and 42 , elastomer layers 46 and 58 , and foam layer 62 , removed.
- the mold 500 preferably is oriented vertically in order to save space and facilitate handling, thus reducing the need for large equipment to lift and handle heavy molds.
- the vertically oriented molds which pivot open allow workers easy access to the interior of the molds.
- the mold 550 is preferably oriented horizontally while the concrete is applied to prevent the concrete from running, but vertically while the foam is injected.
- the vertically oriented molds 500 and 550 result in vertically oriented walls or panels, again saving space.
- the method and molds described above also may also be used to manufacture a single sided panel.
- the concrete and elastomer materials are applied to a single sided mold, as described above.
- the second mold surface 524 may be flat, or may not have the indentations and protrusions to form stone work, brick, or the like as in the first mold surface 512 .
- a gap or space is formed between the mold halves or between the elastomer layer 46 and the second mold surface 524 .
- the foam material is introduced into the mold and expands between the elastomer layer 46 and the second mold surface 524 .
- the resulting panel may be removed and a rigid backing layer 104 , such as plywood or the like, may be adhered to the exposed foam surface.
- an elastomer material or the like may be added to the exposed foam layer, forming the rigid backing layer.
- the concrete and elastomer layers 14 and 46 by themselves are relatively flexible. Therefore, the molds 500 and 550 , or mold halves 504 and 508 , 554 and 558 , provide rigidity to the concrete and elastomer layers 14 and 46 as the foam material expands.
- the rigid backing material 104 such as a plywood sheet, may be placed in the mold adjacent the second mold surface 524 such that the foam material is introduced between the elastomer layer 46 and the rigid backing layer 104 so that the foam bonds to the rigid backing layer 104 in the mold itself.
- a concrete material may be applied in a flat layer to the second surface 524 of the mold, and foam introduced so that the resulting wall or panel has a rigid backing layer 104 of concrete formed in the foam material.
- the reinforcement layer may be formed by applying a high density foam material directly to the interior surface 22 of the concrete layer 14 and then introducing a lightweight foam material into the mold.
- the molds may have a single mold half.
- the rigid backing layer 104 such as a plywood layer, may be utilized as the second mold half.
- a plurality of molds 600 may be disposed on a transfer system 604 , such as a moving conveyor, etc., and moved through a plurality of stations, indicated by arrow 608 .
- the concrete mixture may be applied 580 to the mold 600 .
- the mold 600 is then moved to a curing station 616 where the concrete mixture is cured.
- the curing station 616 may be on the transfer system 604 , or the molds may be removed from the transfer system 604 to a separate curing station 620 .
- the mold 600 may then be moved to a reinforcing station 624 where a reinforcement material, such as the elastomer material, is applied 584 to the concrete layer 14 .
- the mold 600 is then moved to a foam and/or backing layer station 628 where the foam material is applied to the concrete and/or reinforcement layers 14 and 46 , and the backing layer 104 is applied.
- the foam material may be applied, and then the backing layer 104 may be positioned by a press 632 as shown.
- the foam and backing layer 104 may be applied at the same station 628 , as shown, or at different stations.
- the walls or panels may be removed from the mold 600 at a different station.
- the mold 600 may be moved directly from the curing station 616 or 620 to the foam and/or backing layer station 628 .
- the transfer system 604 and plurality of molds 600 facilitate manufacturing larger quantities of walls or panels, and speeds manufacturing.
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Abstract
A wall or panel has a thin concrete layer with a cross-sectional contour having protrusions and indentations forming other objects, such as stone work, brick or wood. A reinforcement layer may be affixed to the concrete layer to provide tensile strength and impact resistance to the concrete layer. A foam layer is affixed to the reinforcement layer to further reinforce the concrete layer, and so that the wall or panel is light weight. A second concrete layer or a rigid backing layer may be disposed opposite the concrete layer so that the foam is disposed therebetween. A method for forming the wall or panel includes spraying the concrete onto a mold surface which has indentations and protrusions for forming the other objects. The reinforcement layer is sprayed onto the cured concrete layer. The mold is closed and foam is introduced into the mold.
Description
- 1. The Field of the Invention
- The present invention relates generally to a light-weight concrete panel or wall which appears as another building material, such as stone work, brick, wood or the like. More particularly, the present invention relates to a panel or wall having a thin concrete face layer with a molded contour or otherwise shaped to appear as stone work or the like, a reinforcing elastomer layer, and an inner foam layer.
- 2. The Background Art
- Traditional walls have been constructed from individual stones, rocks, blocks, or bricks assembled together into the shape of a wall and held together with mortar. One problem with traditional walls of this type is they are typically expensive and time-consuming to construct. Another problem is their great weight.
- Prior attempts have been made to simulate such stone work or brick walls using less expensive materials and less labor-intensive methods. One such attempt involves constructing a wall from concrete. The concrete may be molded to the shape of bricks or otherwise textured to appear as brick. For example, concrete sidewalks have been provided with textured surfaces by stamping a stone shape into the concrete before it hardens.
- Another such example includes manually texturing the concrete before it cures. One problem with using concrete is that concrete tends to have a substantially smooth texture, unlike natural stone or brick. Another disadvantage with such concrete walls is that solid concrete is also extremely heavy.
- Another attempt at providing such a textured or shaped surface includes veneering, in which actual or simulated stone or brick is adhered to a conventional concrete wall. One disadvantage with veneering is the expense, time and care involved in providing the veneer.
- Another attempt simply involves making panels from plastic which has been molded. One disadvantage with such plastic panels is that they often do not provide a realistic appearance.
- In addition, attempts have been made to reduce the weight of concrete, load bearing building elements. Such attempts include the addition of fillers into concrete. Another technique involves bonding a plurality of laminations, including adhering a lightweight laminate to the concrete laminate. Such techniques typically involve a foam block onto which a concrete mixture is applied or onto which a concrete laminate is adhered. One disadvantage with these techniques is that the foam block must be pre-shaped. Another disadvantage is that the building elements have thick concrete layers, and thus are heavy.
- It has been recognized that it would be advantageous to develop a wall or panel which has the appearance of natural stone work, rock, brick, wood, or the like, which is lightweight and durable. The invention provides a wall or panel with a thin concrete layer to reduce the weight of the wall or panel. The concrete layer has interior and exterior surfaces, and a cross-sectional contour. The contour projects outwardly to form macro projections in the exterior surface, and macro indentations in the interior surface. The contour also projects inwardly to form macro indentations in the exterior surface, and macro projections in the interior surface. The contour, or projections and indentations, may form natural objects, such as stone work, brick, wood, and the like. In a more detailed aspect of the invention, the concrete layer has a substantially constant thickness at the projections and indentations. In another more detailed aspect of the invention, the concrete layer is less than approximately 0.5 inches thick to reduce weight.
- A foam layer is coupled to the interior surface of the concrete layer, and has protrusions mating with the indentations in the interior surface of the concrete layer. The foam layer provides reinforcement to the thin concrete layer and reduces the weight of the wall or panel. The foam layer may have fiber reinforcement.
- In accordance with one aspect of the present invention, the wall or panel may have a thin elastomer layer affixed to the concrete layer to reinforce the concrete layer, and to provide tensile strength and impact resistance. In a more detailed aspect of the invention, the reinforcement layer may include an elastomer layer, such as a urethane layer. Alternatively, the reinforcement layer may include a high density foam, and the foam layer may include a low density foam. The reinforcement layer may include fiber reinforcement.
- In accordance with another aspect of the present invention, the wall or panel may have a rigid backing layer spaced-apart from the elastomer layer, with the foam layer disposed between, and affixed to, the elastomer layer and backing layer to further reinforce the concrete layer and making the wall or panel lightweight.
- The rigid backing layer may be a second concrete layer spaced-apart from and opposite the first concrete layer. The second concrete layer may have a similar cross-sectional contour.
- The wall or panel may be configured to be free-standing fencing structures. Alternatively, the wall or panel may be configured as a facade to be affixed to an exterior wall of a building.
- A method for making the wall or panel includes providing a mold having an inner mold surface with macro indentations and macro protrusions. A wet mixture of concrete material is applied to the inner mold surface of the mold to form a concrete layer with a cross-sectional contour corresponding to the indentations and protrusions of the inner mold surface. Preferably, the concrete material is sprayed onto the inner mold surface. Preferably, the wet mixture of concrete material is applied in a substantially constant thickness at the projections and indentations. The concrete material is cured until dry.
- Foam is introduced into the mold to form a foam layer secured to the cement layer with the foam having protrusions mating with the concrete layer. The mold provides support to the concrete layer as the foam expands. The secured concrete and foam layers are removed from the mold.
- In accordance with one aspect of the method of the present invention, the layer of reinforcement material is applied to the concrete layer prior to introducing the foam to form a reinforcement layer. Preferably, the reinforcement layer is sprayed onto the cured concrete layer.
- In accordance with another aspect of the method of the present invention, the rigid backing layer is spaced-apart from the mold surface prior to introducing the foam into the mold. Alternatively, the rigid backing layer may be applied to the foam layer.
- In accordance with another aspect of the method of the present invention, the mold may be disposed in a vertical orientation, either throughout the process, or just before the foam is introduced into the mold. Thus, the wall or panel is vertically oriented to facilitate handling and conserve space.
- Additional features and advantages of the invention will be set forth in the detailed description which follows, taken in conjunction with the accompanying drawing, which together illustrate by way of example, the features of the invention.
- FIG. 1a is a perspective view, partially in section, of a wall or panel in accordance with the present invention;
- FIG. 1b is a more detailed, partial cross-sectional view of the wall or panel shown in FIG. 1a;
- FIG. 2a is a partial perspective view, partially in section, of another wall or panel in accordance with the present invention;
- FIG. 2b is a more detailed, partial cross-sectional view of the wall or panel shown in FIG. 2a;
- FIG. 3 is a partial cross-sectional view of another wall or panel in accordance with the present invention;
- FIG. 4 is a partial cross-sectional view of another wall or panel in accordance with the present invention;
- FIG. 5 is a partial cross-sectional view of another wall or panel in accordance with the present invention;
- FIG. 6 is a perspective view of an embodiment of a mold in accordance with the present invention, shown in an open configuration;
- FIG. 7 is a perspective view of the mold of FIG. 6 shown in an closed configuration;
- FIG. 8 is a perspective view of another embodiment of a mold in accordance with the present invention, shown in an open configuration;
- FIG. 9 is a perspective view of the mold of FIG. 8 shown in an closed configuration;
- FIGS. 10a-10 b are schematic views of a method in accordance with the present invention; and
- FIG. 11 is a schematic view of a method in accordance with the present invention.
- For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.
- As illustrated in the Figures, walls or panels in accordance with the present invention are shown which are configured to appear as other objects or natural objects, including for example, stone work, rock, brick, or wood, and the like, and which are lightweight and durable. As used herein, the terms “wall” and “panel” are used broadly to refer to walls or panels which may be used in building construction systems as facades, and walls used in fence systems.
- Referring to FIGS. 1a and 1 b, a wall or panel indicated generally at 10 in accordance with the present invention is shown configured as a wall in a fencing system. Thus, the wall or panel is oriented in a vertical orientation and configured to be free standing. The wall or
panel 10 includes at least one thin concrete layer, such as first thinconcrete layer 14. Theconcrete layer 14 has anexterior surface 18 which faces outwardly to be seen, and an oppositeinterior surface 22 which faces inwardly. - The
concrete layer 14 advantageously has a cross-sectional contour which projects outwardly to formprojections 26 in theexterior surface 18, andindentations 30 in theinterior surface 22. In addition, the cross-sectional contour projects inwardly to formindentations 34 in theexterior surface 18 andprojections 38 in theinterior surface 22. Thus, theexterior surface 18 includesprojections 26 andindentations 34, while theinterior surface 22 includesindentations 30 which correspond to theprotrusions 26 in theexterior surface 18, andprotrusions 38 which correspond toindentations 34 in theexterior surface 18. - The projections and indentations are “macro-projections” and “macro-indentations,” respectively, meaning they are sized to produce an architectural effect which is visible from a distance, as opposed to surface or material irregularities. The
projections 26 andindentations 34 of theexterior surface 18, and thus the cross-sectional contour, are sized and shaped to appear as other objects, or natural objects, including for example, rocks, stone work, brick, wood or the like. - The
concrete layer 14 has a thickness t which is substantially constant throughout the portion of theconcrete layer 14 including the projections and indentations. It is of course understood that the thickness of theconcrete layer 14 may vary at the indentations and protrusions, or throughout the cross sectional contour, especially at areas of curvature. By a “substantially constant thickness,” it is meant that theinner surface 22 of theconcrete layer 14 follows theouter surface 18 as theouter surface 18 projects inwardly and outwardly, as opposed to remaining straight. Thus, theconcrete layer 14 will cure substantially evenly as discussed in greater detail below. The thickness t of theconcrete layer 14 is preferably less than one inch, more preferably less than one-half inch, and most preferably less than one-eighth inch, to reduce the weight of the concrete layer. - The
concrete layer 14 may be formed of a concrete mix which provides a cementitious or textured surface to appear as real stone work or brick. It will be appreciated that concrete itself has a relatively smooth surface. Thus, the concrete mix preferably includes sand to provide strength to the concrete, and to provide a rougher surface texture. In addition, the concrete mix may include a plasticizer to keep the mixture as dry as possible. In addition, the concrete mix may include a polymer to add flexibility. In addition, the concrete mix may include an accelerator for faster curing. Furthermore, a coloring may be applied to theexterior surface 18 of theconcrete layer 14 to further provide the desired appearance as stone work, brick, etc. For example, a stone like coloring may be added to the protrusions 28 in theexterior surface 18, while theindentations 34 in theexterior surface 18 retain the natural coloring of the concrete mix. In addition, color or pigment may be added directly to the concrete mixture. - The
concrete layer 14 advantageously is thin to reduce weight of the wall orpanel 10. In addition, theconcrete layer 14, or concrete mixture, preferably and advantageously is free of fiber reinforcement. Concrete is often reinforced with glass fiber, which must be a special alkaline resistant glass fiber, which is very expensive. Thus, a substantial cost reduction is realized without using the more expensive glass fiber reinforced concrete. It is of course understood that the concrete layer may be fiber reinforced. - The
panel 10 may also have a secondconcrete layer 42 opposite and spaced-apart from the firstconcrete layer 14. The secondconcrete layer 42 may be similar to the firstconcrete layer 14, and includes a cross sectional contour with indentations and protrusions configured to appear as stone work, brick, etc. - The wall or
panel 10 advantageously has areinforcement layer 46 adjacent and affixed to theconcrete layer 14. Thereinforcement layer 46 preferably is an elastomer layer, but may also be a foam layer, such as a high density foam, as discussed in greater detail below. The reinforcement orelastomer layer 46 advantageously provides tensile strength and impact resistance to theconcrete layer 14. As stated above, theconcrete layer 14 is as thin as possible to save weight, and may lack fiber reinforcement to reduce cost. Thus, theelastomer layer 46 strengthens the thinconcrete layer 14, and provides tensile strength and impact resistance to theconcrete layer 14. Theelastomer layer 46 preferably has a thickness between 60 and 225 mils depending on the strength required. In addition, theelastomer layer 46 may be reinforced with fiberglass. A less expensive fiberglass may be used in the elastomer because it does not need to be alkaline resistant. - The
elastomer layer 46 has anexterior surface 50 which is directly affixed to theinterior surface 22 of theconcrete layer 14. Thus, theexterior surface 50 of theelastomer layer 46 has protrusions and indentations which match the respective indentations and protrusions of theinner surface 22 of theconcrete layer 14. Theelastomer layer 46 also has aninterior surface 54. Theinterior surface 54 of theelastomer layer 46 also has indentations which correspond to protrusions in theexterior surface 50, and protrusions which correspond to indentations in theexterior surface 50. Thus, theelastomer layer 46 has a cross-sectional contour which matches or mates with the cross-sectional contour of theconcrete layer 14. In addition, theelastomer layer 46 has a thickness which is substantially consistent at the protrusions and indentations. - The
elastomer layer 46 preferably is a sprayable urethane, as discussed in greater detail below. Theelastomer layer 46 or reinforcement layer alternatively may be epoxy or fiberglass polyester. In addition, theelastomer layer 46 may be reinforced with chopped fiberglass. Again, a less expensive fiberglass may be used in the elastomer because it does not need to be alkaline resistant. Theconcrete layer 14 protects thereinforcement layer 46 from the sun, because thereinforcement layer 46 may not be UV stable, such as with some elastomers. - In addition, the wall or
panel 10 may include asecond elastomer layer 58 affixed to the secondconcrete layer 42, which is similar to thefirst elastomer layer 46. - The wall or
panel 10 advantageously also has afoam layer 62 disposed between theconcrete layers foam layer 62 is coupled or attached to the interior surfaces 54 of the elastomer layers 46 and 58. Thefoam layer 62 advantageously hasprotrusions 66 which extend outwardly to mate with the indentations in theinterior surface 54 of theelastomer layer 46, and may also extend into theindentations 30 in theinner surface 22 of theconcrete layer 14. Thus, thefoam layer 62 has a thickness which varies at the protrusions and indentations, such that the wall orpanel 10 is substantially solid. The concrete andelastomer layers foam layer 62 advantageously is lightweight and provides further reinforcement and stiffness to the elastomer andconcrete layers - The
foam layer 62 may be a MDI poly-ether, polyester, or polyether blend. Thefoam layer 62 may also be a poly-urea elastomer or polyurethane. Thefoam layer 62 preferably is low density, or has a density of two to five pounds. Alternatively, thefoam layer 62 may have a density between two and thirty pounds. In addition, thefoam layer 62 may be fiber reinforced. A less expensive fiberglass may be used in the foam because it does not need to be alkaline resistant. - The
foam layer 62 advantageously provides a filler between theconcrete layers concrete layer 14, which may weaken the concrete layer. In addition, thefoam layer 62 advantageously bonds the oppositeconcrete layers foam layer 62 provides thermal and sound insulation to the wall orpanel 10. - As shown in FIG. 1a, the wall or
panel 10 is configured for use as a wall of a fencing system. Thewall 10 may have aperimeter border 70 or raised portion to frame and enclose theprotrusions 26 andindentations 34 configured to appear as stone work, brick, etc. Theborder 70 may include a base 72 configured to appear as a foundation, a top 74 configured to appear as a cap, and sides 76 configured to appear as vertical support columns. Theborder 70 may be configured to appear as concrete, as shown, or may also have indentations and protrusions to appear as stone work, brick, etc. Theborder 70 may be constructed as the rest of thewall 10, and be formed of the thinconcrete layer 14, theelastomer reinforcement layer 46, and thefoam layer 62. Thus, an entire segment of the wall system may be formed of thewall 10 to be light weight and durable. - Referring to FIGS. 2a and 2 b, an alternative embodiment of a wall or panel, indicated generally at 100, includes the thin
concrete layer 14, andthin elastomer layer 46, as described above. In addition, the wall orpanel 100 includes arigid backing layer 104 spaced-apart from the concrete andelastomer layers rigid backing layer 104 has anexterior surface 108, and aninterior surface 112 opposing aninterior surface 54 of theelastomer layer 46. Afoam layer 116 is disposed between therigid backing layer 104 and theelastomer layer 46 orconcrete layer 14. As described above, thefoam layer 116 includesprotrusions 120 which extend into the indentations of theelastomer layer 46 andconcrete layer 14. Therigid backing layer 104 may be a straight or flat layer, such as a rigid panel of fiberboard, or the like, adhered to the foam. Alternatively, therigid backing layer 104 may be a flat concrete layer or an elastomer layer. - The
rigid backing layer 104 may be used in applications in which only a single side of the wall orpanel 100 will be seen. For example, therigid backing layer 104 may be utilized to affix the wall orpanel 100 to the exterior of a building to form a facade. Again, the thinconcrete layer 14 allows the wall orpanel 100 to be light-weight, and thus more easily positioned, handled, secured, etc. In addition, thebacking layer 104 protects thefoam layer 116. - As shown in FIG. 2a, the wall or
panel 100 may be configured as a free standing fence, or may be configured as a building panel for being affixed to a building. In either case, theouter surface 18 of theconcrete layer 14 may have a continuous surface ofprotrusions 26 andindentations 34 extending over the entire surface area of theouter surface 18 of theconcrete layer 14. Thus, several walls orpanels 100 may be positioned adjacent one another to form a continuous surface. - As stated above, the
reinforcement layer 46 preferably is an elastomer layer, and most preferably a urethane layer. Alternatively, as indicated above, thereinforcement layer 46 may be a layer of high density foam, such as 10 to 20 pound density, while thefoam layer 62 is a low density foam layer, for example, two to five pound density. - Referring to FIG. 3, an alternative embodiment of a wall or
panel 200 is shown with theconcrete layer 14 and a rigid backing layer 104 (not shown in FIG. 3) as described above. Afoam layer 204 is disposed between theconcrete layer 14 and therigid backing layer 104. Thus, thefoam layer 204 directly attaches to theinner surface 22 of theconcrete layer 14. As described above, thefoam layer 204 has a varying thickness such that thefoam layer 204 hasprojections 208 which extend into theindentations 30 in theinner surface 22 of theconcrete layer 14. Thefoam layer 204 preferably is a high density foam for greater durability and strength, but may be a low density foam depending on the application. Thus, the highdensity foam layer 204 acts as both the reinforcement layer and the filler. - The wall or
panel 200 may be configured to be attached to the exterior of a building as a facade. In such case, the wall orpanel 200 preferably is relatively thin, and thus thefoam layer 204 preferably is a thin, high density foam. Thefoam layer 204 may have a thickness less than a few inches. - Referring to FIG. 4, an alternative embodiment of a wall or panel, indicated generally at300, has a thin
concrete layer 14, athin elastomer layer 46, and arigid backing layer 104 as described above. In addition, the wall orpanel 300 has a layer of rigid,high density foam 304 adjacent and affixed to the elastomer layer 406, and a layer oflow density foam 308 disposed between therigid backing layer 104 and the layer ofhigh density foam 304. The layer ofhigh density foam 304 provides additional rigidity and stiffness to the wall orpanel 300, while thelow density foam 308 reduces the weight of the wall orpanel 300. - Referring to FIG. 5, an alternative embodiment of a wall or panel, indicated generally at400, is shown with increased sound reduction, or noise insulation properties. The wall or
panel 400 may be similar to any of the walls or panels described hereto, and thus has at least a thinconcrete layer 14, and afoam layer 404. As described above, the various walls or panels preferably have a solid interior, or at least lack inadvertent voids, particularly near theconcrete layer 14, which may result in weak or damaged portions. Thefoam layer 404 includes a plurality ofvoids 408 or cavities formed in thefoam layer 404 to improve the sound dampening qualities of the wall orpanel 400. Thecavities 408 are macro-voids, or sized to reduce sound, as opposed to the smaller voids inherent in the cell structure of the foam. - It will of course be understood that any of the walls or panels described above may have double faces or be two-sided, such as the wall or
panel 10 shown in FIG. 1, with both faces being configured to appear as stone work, brick, etc. It is also understood that any of the wall or panel members described above may have a single face which is shaped and configured to appear as stone work, brick, etc., and an opposite face which is configured to be attached to another object, or simply to remain plain, such as walls andpanels concrete layer 42 in FIG. 1 may be replaced with a rigid backing layer. Likewise, therigid backing layers 104 in FIGS. 2-5 may be replaced with a second concrete layer which is configured to appear as stone work, brick or the like. - In addition, the various walls or panels described above may be configured to be attached to other objects or other walls or panels. For example, the sides of the walls or panels may be configured with tongue and groove type interconnections, with a first panel having a tongue, and a second panel having a groove, such that the tongue of the first panel may be inserted into the groove of an adjacent second panel to facilitate securing adjacent panels. Such tongue and groove type interconnections may be formed integrally with the walls and panels. As another example, the panels may have inserts for interconnecting the panels to one another, or other objects.
- In addition, the various walls or panels described above may contain other structural members to reinforce the panels or facilitate attachment of the panels to other objects, such as the exterior of a building. For example, elongated metal bars may be disposed in the foam layer to provide additional structural rigidity to large panels.
- The walls or panels of the present invention advantageously are light weight and durable. Thus, the walls or panels may be easily manufactured at a facility, easily transported, and easily arranged at a building site.
- The present invention also involves a method for making the walls or panels. Referring to FIG. 6, a mold, indicated generally at500, is shown for forming the panels or walls of the present invention. The
mold 500 preferably has first and second mold halves 504 and 508. Themold 500, and thus the mold halves 504 and 508, may be oriented vertically in order to save space. The mold halves 504 and 508 preferably are pivotally coupled along one side, such that the mold halves 504 and 508 may be pivoted with respect to one another between an open position as shown in FIG. 6 and a closed position as shown in FIG. 7. - The
first mold half 504 includes aninner mold surface 512 which includesmacro-indentations 516 andmacro-protrusions 520. The indentations andprotrusions protrusions 26 andindentations 34 in theconcrete layer 14. Similarly, thesecond mold half 508 may include asecond mold surface 524 which may also have indentations and protrusions. It is of course understood that bothmold surfaces panel 10 as shown in FIG. 1. Alternatively, only thefirst mold surface 512 may have indentations and protrusions if the mold is to be used to produce a wall or panel with a single shaped face. - As shown in FIG. 6, the
mold 500 may be opened so that bothmold surfaces indentations 516 in themold surface 512. The color or pigments correspond to the desired color of the stone or brick. Alternatively, color or pigment may be added directly to the concrete mixture of theconcrete layer 14. - Referring to FIGS. 8 and 9 another
mold 550 is shown for forming the walls or panels of the present invention. Themold 550 preferably has first and second mold halves 554 and 558. The mold halves 554 and 558 preferably are pivotally coupled to each other or the ground at their bottom sides, so that the mold halves 554 and 558, may be oriented horizontally in the open position, as shown in FIG. 8, and vertically in the closed position, as shown in FIG. 9. - Similar to the
mold 500 shown in FIGS. 6 and 7, thefirst mold half 554 ofmold 550 includes theinner mold surface 512 which includesmacro-indentations 516 andmacro-protrusions 520. Similarly, thesecond mold half 558 may include thesecond mold surface 524 which may also have indentations and protrusions. As shown in FIG. 8, themold 550 may be opened so that bothmold surfaces - Referring to FIG. 10a, a mold, such as molds 500 (FIG. 6) or 550 (FIG. 8) is provided with at least the mold surface 510. Preferably, the mold is initially open into an open configuration, as shown in FIG. 6 or 8. Referring to FIG. 10b, a wet mixture of concrete material is applied to at least the
first mold surface 512 to form the firstconcrete layer 14. In addition, the wet mixture of concrete material may also be applied to thesecond mold surface 524 to produce the secondconcrete surface 42 for a double sided wall or panel. The concrete preferably is sprayed, indicated byarrow 580, onto themold surface 512 with a sprayer in a thin layer preferably between one-eighth of an inch to one-half of an inch or more. As stated above, the concrete material preferably is applied as thinly as possibly to reduce weight. In addition, the concrete material preferably is free of glass reinforcement to reduce the cost associated with alkali resistant fiberglass. Alternatively, the concrete material may be reinforced with alkali resistant fiberglass. - In addition, the concrete material preferably is applied to the
mold surface 512 in a consistent or uniform thickness at the indentations andprotrusions mold surface 512. But wide variations in concrete thickness preferably are avoided by refraining from filling theindentations 516 in themold surface 512 with the concrete material. - The concrete material is then allowed to cure or harden into the
concrete layers concrete layer 14. - Referring to FIG. 10c, a reinforcement material, such as an elastomer material, is applied to the cured concrete layer 14 (and 42) to form the reinforcement layer 46 (and 58). The elastomer material or reinforcement material preferably is sprayed onto the
concrete layers arrow 584. In the case of an elastomer material, the elastomer material sets up almost immediately as it is applied to theconcrete layers concrete layers concrete layers - The elastomer material may include fiber reinforcement. It will be appreciated that glass fiber reinforcement for the elastomer is much less expensive than the special alkali resistant glass fiber required when mixed with concrete.
- Referring to FIGS. 7 and 9, the mold halves504 and 508, or 554 and 558, are pivoted to the closed position, such that the mold halves are spaced-apart from one another, and a gap or
space 528 formed between theconcrete layers elastomer layers space 528 between the mold halves 504 and 508 (FIG. 7), or 554 and 558 (FIG. 9), as indicated byarrow 588. Preferably, the foam is an expandable foam which expands to fill thespace 528 between theconcrete layers elastomer layers protrusions 66 which extend into theindentations 30 in theconcrete layer 14. The foam stiffens the panel and further reinforces theconcrete layers - The
mold concrete layers foam layer 62, removed. - It will be noted that the
mold 500 preferably is oriented vertically in order to save space and facilitate handling, thus reducing the need for large equipment to lift and handle heavy molds. In addition, the vertically oriented molds which pivot open allow workers easy access to the interior of the molds. Alternatively, themold 550 is preferably oriented horizontally while the concrete is applied to prevent the concrete from running, but vertically while the foam is injected. In addition, the vertically orientedmolds - The method and molds described above also may also be used to manufacture a single sided panel. The concrete and elastomer materials are applied to a single sided mold, as described above. The
second mold surface 524 may be flat, or may not have the indentations and protrusions to form stone work, brick, or the like as in thefirst mold surface 512. Thus, when the mold is closed, a gap or space is formed between the mold halves or between theelastomer layer 46 and thesecond mold surface 524. Thus, the foam material is introduced into the mold and expands between theelastomer layer 46 and thesecond mold surface 524. The resulting panel may be removed and arigid backing layer 104, such as plywood or the like, may be adhered to the exposed foam surface. Alternatively, an elastomer material or the like may be added to the exposed foam layer, forming the rigid backing layer. - The concrete and
elastomer layers molds mold halves elastomer layers - Alternatively, the
rigid backing material 104, such as a plywood sheet, may be placed in the mold adjacent thesecond mold surface 524 such that the foam material is introduced between theelastomer layer 46 and therigid backing layer 104 so that the foam bonds to therigid backing layer 104 in the mold itself. - Alternatively, a concrete material may be applied in a flat layer to the
second surface 524 of the mold, and foam introduced so that the resulting wall or panel has arigid backing layer 104 of concrete formed in the foam material. - Alternatively, the reinforcement layer may be formed by applying a high density foam material directly to the
interior surface 22 of theconcrete layer 14 and then introducing a lightweight foam material into the mold. - It is of course understood that the molds may have a single mold half. In addition, the
rigid backing layer 104, such as a plywood layer, may be utilized as the second mold half. - Referring to FIG. 11, a plurality of
molds 600 may be disposed on atransfer system 604, such as a moving conveyor, etc., and moved through a plurality of stations, indicated byarrow 608. At afirst station 612, the concrete mixture may be applied 580 to themold 600. Themold 600 is then moved to a curingstation 616 where the concrete mixture is cured. The curingstation 616 may be on thetransfer system 604, or the molds may be removed from thetransfer system 604 to aseparate curing station 620. Themold 600 may then be moved to a reinforcingstation 624 where a reinforcement material, such as the elastomer material, is applied 584 to theconcrete layer 14. Themold 600 is then moved to a foam and/orbacking layer station 628 where the foam material is applied to the concrete and/or reinforcement layers 14 and 46, and thebacking layer 104 is applied. The foam material may be applied, and then thebacking layer 104 may be positioned by a press 632 as shown. The foam andbacking layer 104 may be applied at thesame station 628, as shown, or at different stations. In addition, the walls or panels may be removed from themold 600 at a different station. Alternatively, themold 600 may be moved directly from the curingstation backing layer station 628. Thetransfer system 604 and plurality ofmolds 600 facilitate manufacturing larger quantities of walls or panels, and speeds manufacturing. - It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention and the appended claims are intended to cover such modifications and arrangements. Thus, while the present invention has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment(s) of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made, without departing from the principles and concepts of the invention as set forth in the claims.
Claims (54)
1. A panel comprising:
a) a concrete layer having interior and exterior surfaces, and a cross-sectional contour which (i) projects outwardly to form macro projections in the exterior surface and macro indentations in the interior surface, and (ii) projects inwardly to form macro indentations in the exterior surface and macro projections in the interior surface; and
b) a foam layer, coupled to the interior surface of the concrete layer, having protrusions mating with the indentations in the interior surface of the concrete layer.
2. A panel in accordance with claim 1 , wherein the projections and indentations are sized and shaped to appear as another object.
3. A panel in accordance with claim 1 , wherein the projections and indentations are sized and shaped to appear as another object selected from the group consisting of: rock, stone work, brick, and wood.
4. A panel in accordance with claim 1 , wherein the concrete layer has a substantially constant thickness at the projections and indentations.
5. A panel in accordance with claim 1 , further comprising:
a rigid backing layer, spaced-apart from the concrete layer, having an interior surface opposing the interior surface of the concrete layer; and
wherein the foam layer is disposed between the concrete layer and hacking layer.
6. A panel in accordance with claim 1 , wherein the concrete layer includes a first concrete layer, and further comprising:
a) a second concrete layer, spaced-apart from and opposite the first concrete layer, having interior and exterior surfaces, and a cross-sectional contour which (i) projects outwardly to form macro projections in the exterior surface and macro indentations in the interior surface, and (ii) projects inwardly to form macro indentations in the exterior surface and macro projections in the interior surface; and
wherein the foam layer is coupled to the interior surface of both of the first and second concrete layers, and has protrusions mating with the indentations in the interior surface of both of the first and second concrete layers.
7. A panel in accordance with claim 1 , further comprising:
a reinforcement layer, disposed between the concrete layer and foam layer, and directly affixed to the concrete layer, configured to provide impact resistance and tensile strength the concrete layer.
8. A panel in accordance with claim 7 , wherein the reinforcement layer includes an elastomer material.
9. A panel in accordance with claim 7 , wherein the reinforcement layer includes a urethane material.
10. A panel in accordance with claim 7 , wherein the reinforcement layer includes a high density foam, and the foam layer includes a low density foam.
11. A panel in accordance with claim 7 , wherein the reinforcement layer includes a high density foam of between approximately 10-20 lbs, and the foam layer includes a low density foam of between approximately 2-5 lbs.
12. A panel in accordance with claim 7 , wherein the reinforcement layer includes fiber reinforcement.
13. A panel in accordance with claim 1 , wherein the concrete layer has a thickness less than approximately 0.5 inches.
14. A panel in accordance with claim 1 , further comprising a plurality of voids formed in the foam layer and sized and shaped to reduce sound.
15. A panel in accordance with claim 1 , wherein the concrete layer and foam layer are configured to enable being affixed to an exterior wall of a building.
16. A panel in accordance with claim 1 , configured to be usable in a free-standing fencing structure.
17. A panel comprising:
a) a concrete layer;
b) a elastomer layer, affixed to the concrete layer;
c) a rigid backing layer, spaced-apart from the elastomer layer; and
d) a foam layer, disposed between and affixed to the elastomer layer and backing layer.
18. A panel in accordance with claim 17 , wherein
the concrete layer has an exterior surface with protrusions and indentations, and an interior surface with indentations corresponding to the protrusions in the exterior surface, and protrusions corresponding to indentations in the exterior surface, the concrete layer having a substantially constant thickness at the projections and indentations; and
wherein the elastomer layer has an interior surface with indentations and protrusions corresponding to respective indentations and protrusions of the interior surface of the concrete layer, the elastomer layer having a substantially constant thickness at the projections and indentations.
19. A panel in accordance with claim 17 , wherein the protrusions and indentations of the exterior surface of the concrete layer are sized and shaped to appear as another object selected from the group consisting of: rock, stone work, brick, and wood.
20. The device of claim 17 , wherein the concrete layer includes a first concrete layer, and the rigid backing layer includes a second concrete layer having an exterior surface with protrusions and indentations, and an interior surface with indentations corresponding to the protrusions in the exterior surface, and protrusions corresponding to indentations in the exterior surface, the second concrete layer having a substantially constant thickness at the projections and indentations, and a second elastomer layer including an interior surface with indentations and protrusions corresponding to respective indentations and protrusions of the interior surface of the second concrete layer, the elastomer layer having a substantially constant thickness at the projections and indentations.
21. A panel in accordance with claim 17 , wherein the reinforcement layer includes a urethane material.
22. A panel in accordance with claim 17 , wherein the elastomer layer includes fiber reinforcement.
23. A panel in accordance with claim 17 , wherein the concrete layer has a thickness less than approximately 0.5 inches.
24. A panel in accordance with claim 17 , configured to enable being affixed to a wall of a building.
25. A panel in accordance with claim 17 , configured to be usable in a free-standing fencing structure.
26. A method for forming a panel, comprising the steps of:
a) providing a mold having an inner mold surface with macro indentations and macro protrusions;
b) applying a wet mixture of concrete material to the inner mold surface of the mold to form a concrete layer including a cross-sectional contour corresponding to the indentations and protrusions of the inner mold surface;
c) curing the concrete material until dry;
d) introducing foam into the mold to form a foam layer secured to the cement layer with the foam having protrusions mating with the concrete layer; and
e) removing the secured concrete and foam layers from the mold.
27. A method in accordance with claim 26 , wherein the step of providing the mold further includes providing a mold with indentations and protrusions sized and shaped to create another object selected from the group consisting of: rock, stone work, brick, and wood.
28. A method in accordance with claim 26 , wherein the step of applying the wet mixture of concrete mixture further includes applying the wet mixture of concrete material in a substantially constant thickness at the projections and indentations.
29. A method in accordance with claim 26 , further comprising the step of placing a rigid backing layer spaced-apart from the mold surface prior to introducing the foam into the mold.
30. A method in accordance with claim 26 , further comprising the step of applying a rigid backing layer to the foam layer.
31. A method in accordance with claim 26 , further comprising the steps of:
a) applying a layer of reinforcement material to the concrete layer prior to introducing the foam to form a reinforcement layer; and
b) wherein the step of introducing the foam further includes introducing the foam into the mold to form a foam layer secured to the reinforcement layer.
32. A method in accordance with claim 26 , further comprising the steps of:
a) applying a layer of elastomer material to the concrete layer prior to introducing the foam to form an elastomer layer; and
b) wherein the step of introducing the foam further includes introducing the foam into the mold to form a foam layer secured to the elastomer layer.
33. A method in accordance with claim 26 , further comprising the steps of:
a) applying a layer of high density foam to the concrete layer prior to introducing the foam to form a reinforcement layer; and
b) wherein the step of introducing the foam further includes introducing a low density of foam into the mold to form a low density foam layer secured to the reinforcement layer.
34. A method in accordance with claim 26 , wherein the step of applying a wet mixture of concrete material further includes applying the wet mixture of concrete material in a layer having a thickness less than approximately 0.5 inches.
35. A method in accordance with claim 26 , wherein the step of providing the mold further includes providing the mold in a vertical orientation.
36. A method in accordance with claim 26 , wherein the step of applying a wet mixture of cement material further includes spraying the wet mixture of cement material onto the inner mold surface.
37. A method in accordance with claim 26 , wherein the step of introducing foam into the mold further includes introducing an expandable foam into the mold which expands to fill the indentations in the inner mold surface.
38. A method in accordance with claim 26 , wherein the step of providing a mold further includes providing a mold with a second mold surface opposing the inner mold surface; and wherein the step of introducing foam into the mold further includes introducing an expandable foam between the concrete layer and second mold surface.
39. A method in accordance with claim 26 , wherein the step of providing a mold further includes providing a mold with a second mold surface pivotally coupled to the inner mold surface such that the inner mold surface and second mold surface pivot between an open position and a closed position in which the mold surfaces oppose one another; and further including the steps of:
opening the mold prior to applying the wet mixture of cement material; and
closing the mold prior to introducing the foam.
40. A method in accordance with claim 26 , wherein the step of providing the mold further includes providing a mold with a second mold surface having indentations and protrusions; and
wherein applying the wet mixture of concrete material further includes applying a wet mixture of concrete to both the inner mold surface to form a first cement layer and the second mold surface to form a second cement layer; and
wherein introducing the foam into the mold further includes introducing the foam between the first and second foam layers to form a foam layer secured to both concrete layers.
41. A method in accordance with claim 26 , further comprising the step of:
moving the mold with a transfer system through a plurality of different stations for applying the concrete mixture, curing the concrete mixture, and introducing the foam.
42. A method for forming a panel, comprising the steps of:
a) providing a mold having an inner mold surface with macro indentations and macro protrusions;
b) applying a wet mixture of concrete material to the inner mold surface of the mold to form a concrete layer;
c) curing the concrete material until dry;
d) applying a layer of reinforcement material to the cured concrete layer to form a reinforcement layer;
e) introducing foam into the mold to form a foam layer secured to the reinforcement layer; and
f) removing the secured concrete, reinforcement and foam layers from the mold.
43. A method in accordance with claim 42 , wherein applying the wet mixture of concrete further includes applying the wet mixture of concrete in a substantially constant thickness at the indentations and protrusions; and wherein applying the reinforcement material further includes applying the reinforcement material in a substantially constant thickness at the indentations and protrusions.
44. A method in accordance with claim 42 , wherein the step of providing the mold further includes providing a mold with indentations and protrusions sized and shaped to create another object selected from the group consisting of: rock, stone work, brick, and wood.
45. A method in accordance with claim 42 , further comprising the step of placing a rigid backing layer spaced-apart from the mold surface prior to introducing the foam into the mold.
46. A method in accordance with claim 42 , further comprising the step of applying a rigid backing layer to the foam layer.
47. A method in accordance with claim 42 , wherein applying the reinforcement material further includes applying a layer of elastomer material to the cement layer to form an elastomer layer.
48. A method in accordance with claim 42 , wherein the step of applying the wet mixture of concrete material further includes applying the wet mixture of concrete material in a layer having a thickness less than approximately 0.5 inches.
49. A method in accordance with claim 42 , wherein the step of applying the wet mixture of cement material further includes spraying the wet mixture of cement material onto the inner mold surface.
50. A method in accordance with claim 42 , wherein the step of applying the reinforcement material further includes spraying the reinforcement material onto the cured cement layer.
51. A method in accordance with claim 42 , wherein the step of introducing foam into the mold further includes introducing an expandable foam into the mold which expands to fill the indentations in the inner mold surface.
52. A method in accordance with claim 42 , wherein the step of providing a mold further includes providing a mold with a second mold surface opposing the inner mold surface; and wherein the step of introducing foam into the mold further includes introducing an expandable foam between the concrete layer and second mold surface.
53. A method in accordance with claim 42 , wherein the step of providing a mold further includes providing a mold with a second mold surface pivotally coupled to the inner mold surface such that the inner mold surface and second mold surface pivot between an open position and a closed position in which the mold surfaces oppose one another; and further including the steps of:
opening the mold prior to applying the wet mixture of concrete material; and
closing the mold prior to introducing the foam.
54. A method in accordance with claim 42 , wherein the step of providing the mold further includes providing a mold with a second mold surface having indentations and protrusions; and
wherein applying the wet mixture of cement material further includes applying a wet mixture of cement to both the inner mold surface to form a first concrete layer and the second mold surface to form a second concrete layer; and
wherein introducing the foam into the mold further includes introducing the foam between the first and second concrete layers to form a foam layer secured to both concrete layers.
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-
2001
- 2001-02-28 WO PCT/US2001/006310 patent/WO2001065017A2/en active Application Filing
- 2001-02-28 AU AU2001239918A patent/AU2001239918A1/en not_active Abandoned
- 2001-12-17 US US10/024,600 patent/US20020106504A1/en not_active Abandoned
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US20050183632A1 (en) * | 2004-02-11 | 2005-08-25 | Sturre Daryl J. | Lightweight cast stone composition and method |
US20050183385A1 (en) * | 2004-02-13 | 2005-08-25 | Viken Ohanesian | Wall system and method |
US7165374B2 (en) * | 2004-02-13 | 2007-01-23 | Viken Ohanesian | Wall system and method |
US20070113501A1 (en) * | 2004-02-13 | 2007-05-24 | Viken Ohanesian | Wall system and method |
US20050252103A1 (en) * | 2004-05-03 | 2005-11-17 | Cook Vaughn A | Textured window well |
US7966776B2 (en) * | 2004-05-03 | 2011-06-28 | Cook Vaughn A | Textured window well |
US20070096369A1 (en) * | 2005-11-01 | 2007-05-03 | Fox Stone, Inc. | Methods and apparatus for the separation of molded products from flexible mold pieces |
US20070187864A1 (en) * | 2006-02-11 | 2007-08-16 | Kenneth Mincey | System and method for manufacturing and constructing a mold for use in generating cast polymer products resembling natural stonework |
US20080174041A1 (en) * | 2007-01-23 | 2008-07-24 | Douglas Keller Firedman | Concrete block making machine and method |
US8691340B2 (en) | 2008-12-31 | 2014-04-08 | Apinee, Inc. | Preservation of wood, compositions and methods thereof |
US9314938B2 (en) | 2008-12-31 | 2016-04-19 | Apinee, Inc. | Preservation of wood, compositions and methods thereof |
US8454742B2 (en) | 2010-07-12 | 2013-06-04 | Tom Scanlan | Artificial stone and method of making same |
US8926873B2 (en) | 2010-07-12 | 2015-01-06 | Tom Scanlan | Artificial stone and method of making same |
US9034094B2 (en) | 2010-07-12 | 2015-05-19 | Tom Scanlan | Artificial stone and method of making same |
US10035730B2 (en) | 2010-07-12 | 2018-07-31 | Tom Scanlan | Artificial stone and method of making same |
US9878464B1 (en) | 2011-06-30 | 2018-01-30 | Apinee, Inc. | Preservation of cellulosic materials, compositions and methods thereof |
US8852724B2 (en) | 2011-08-29 | 2014-10-07 | Advanced Formliners, Llc | Bridge member spanning formliner joint |
US10060143B2 (en) | 2011-09-28 | 2018-08-28 | Advanced Formliners | Formliner layout member |
US10106989B2 (en) | 2013-03-14 | 2018-10-23 | Advanced Formliners, Llc | Apparatus for setting objects |
US10119280B2 (en) | 2014-07-11 | 2018-11-06 | Advanced Formliners, Llc | Form liner for visually enhanced concrete |
US10753101B1 (en) | 2016-12-09 | 2020-08-25 | Baton, LLC | Artificial lightweight stone |
USD860479S1 (en) | 2017-12-01 | 2019-09-17 | SpeedyMason, LLC | Architectural panel |
Also Published As
Publication number | Publication date |
---|---|
WO2001065017A2 (en) | 2001-09-07 |
WO2001065017A3 (en) | 2002-03-21 |
AU2001239918A1 (en) | 2001-09-12 |
US6355193B1 (en) | 2002-03-12 |
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