US2474654A - Method of manufacturing artificial stone walls - Google Patents

Method of manufacturing artificial stone walls Download PDF

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US2474654A
US2474654A US5736A US573648A US2474654A US 2474654 A US2474654 A US 2474654A US 5736 A US5736 A US 5736A US 573648 A US573648 A US 573648A US 2474654 A US2474654 A US 2474654A
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Prior art keywords
dies
molds
stone
concrete
layer
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US5736A
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David F Carlson
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David F Carlson
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44FSPECIAL DESIGNS OR PICTURES
    • B44F9/00Designs imitating natural patterns
    • B44F9/04Designs imitating natural patterns of stone surfaces, e.g. marble
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/0064Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
    • B28B7/007Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces with moulding surfaces simulating natural effets, e.g. wood or stone
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/0064Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
    • B28B7/0073Moulds 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/24Unitary mould structures with a plurality of moulding spaces, e.g. moulds divided into multiple moulding spaces by integratable partitions, mould part structures providing a number of moulding spaces in mutual co-operation
    • B28B7/241Detachable assemblies of mould parts providing only in mutual co-operation a number of complete moulding spaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS, SLAG, OR MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/36Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04GSCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR OTHER BUILDING AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G9/00Forming or shuttering elements for general use
    • E04G9/10Forming or shuttering elements for general use with additional peculiarities such as surface shaping, insulating or heating, permeability to water or air

Description

June 28,1949. D, F. CARSON 2,474,654

METHOD OF MANUFACTURING ARTIFICIAL STONE WALLS Filed Feb. 2, 194a mmvrozz. Dav/a f" Car/Jon ATTORNEY Patented June 28,4949

UNITED STATES PATENT OFFICE METHOD OF ARTIFIQIAL TQNE L David F. Carlson, (foibles, Mich.

Appli ti n February 2 .9%, Serial Mi 541 6.

8 Claims. 1

This invention relates to improvements in the method of'manufacturing artificial stone walls.

The principal objects of this invention are:

First, to provide a method of manufacturing artificial stone walls by means of which highly attractive and natural appearing stone walls may be produced at low cost.

Second, to provide a manufacturing method for producing artificial stone walls with a natural stone color and surface.

Third, to provide a method for manufacturing artificial stone walls in which a large amount of thelabor can be performed by relatively inexperienced workmen.

Fourth, to provide a method for facing building walls with artificial stone slabs in which the slabs can be economically produced in a variety of wall designs at a central manufacturing point and at minimum expense for later assembly on the building.

Fifth, to provide an artificial stone facing for a building which can be assembled in a wide variety of artistic arrangements to have the appearance of natural stone.

Other objects and advantages pertaining to the details and economies of my wall construction and manufacturing method will be apparent from a consideration of the following description and claims. The drawings, of which there is one sheet, illustrate a preferred form of my wall and method of manufacture.

Fig. 1 is a plan view of a pallet or platform for forming a facing for a complete Wall of a building and with portions of the facing in various stages of completion.

Fig. 2 is a fragmentary cross sectional view along the line 2-2 and illustrating various steps in my manufacturing method.

Fig. 3 is a fragmentary perspective view of the outside of my wall slab in assembled position.

Fig. 4 is a fragmentary perspective view of the rear of my wall slab in assembled position.

In Figs. 1 and 2 I have illustrated a molding and casting platform or pallet l which is of such size as to receive slab elements for covering an entire wall or a section of a wall to be faced. The pallet l is provided with a border frame 2, and door and window frames 3 are provided in positions corresponding to the door and window openings of the wall to be faced.

As the second step in preparing the pallet for the formation of wall slab elements, I smooth a layer of clay or similar deformable plastic material over the surfa e f the pa et as indi ated at 4 in Fig. 2. 1 next press a die 5 into the smooth clay surface, the die consisting of a natural stone the edges of which have been cut or ground to have a smooth plain border between one quarter and one half inch wide completely around the face of the die as at 6. The face of the die is left with its natural cut or broken stone surface as at l and I preferably provide the die with a handle 8. It should be understood that the die 5 in Fig. 2 is representative of a series of similar dies having a wide variety of sizes and outlines corresponding to the outlines of the slab elements illustrated in Fig. 1.

While the die 5 is pressed into the clay I position a divider or partition member 9 along the exposed edges of the die and press the lower edges of the partition into the layer of clay. The partition 9 can consist of thin ductile metal or various types and thicknesses of foldable fibre board which can be shaped to conform to the outline of the die and retain its folded shape when the die is removed. I proceed to impress a series of different dies successively across the face of the pallet positioning a partition 9 between each die until the pallet has received a series of natural stone impressions outlined by narrow borders and thin partition pieces as at it in Fig. 1.

I next sift a thin layer ll of crushed finely divided natural stone into each pocket of the mold, selecting different colors of crushed stone for different pockets to provide an artistic color arrangement in the finished wall. After the layer of crushed stone is in place I pour a mixture of concrete into all of the pockets as at I2 and strike off the surface of the entire pallet along the level of the frames 2 and 3 so that all slabs are of equal thickness. Preferably I press a code number into each individual slab as indicated at l3 so that the proper location of the slabs can be determined after they have been removed from the mold.

The concrete mixture poured onto the layer of crushed stone will penetrate into the layer of crushed stone and pick up or assimilate the crushed stone along the front surface of each slab. After the concrete has set, the frames 2 and 3 are removed and the individual slabs are separated from the partitions 9 for transportation to the building Wall to be faced. The slabs can then be laid up on the wall and cemented in place by ordinary brick layers or masons without particular artistic skill to provide a facing for the wall which closely resembles a natural stone wall. It is desirable to make a chart of the several slab elements corresponding to the code numbers l3 when the wall mold is assembled to furnish to he mas s ho r o ect the wa My method of forming wall facings permits a single set of natural stone dies to be used in a central manufacturing point to form a wide variety of slab arrangements in any wall size desired, the'only limiting factor being the space available for laying out the pallets I. A single Workman with artistic skill can select and impress the stone dies into the clay and locate the partitions 9 after which the sprinkling of the crushed stone and pouring of the concrete and numbering of the slab elements can be carried out by relatively inexperienced workmen. The finished. wall is highly attractive and durable and can be de-' signed for any shape and size of building.

I have thus described a highly satisfactory method for forming my wall facing and. slab elements so that others may practice the same without further disclosure.

Having thus described my invention, what I claim as new and desire to secure by Letters Patcut is:

1. The method of forming an artificial stone Wall facing on a building wall which comprises the steps of, laying out a frame corresponding to the outline of the wall to be faced on a pallet, spreading a layer of clay within the outline of said frame, successively impressing a series of natural stone dies into said layer of clay and pressing divider plates into said clay along the edges of each of said dies to form a series of molds, said dies haVing a narrow plane border formed around their front edge, removing said dies, depositinga thin layer of finely divided natural stone into each of the molds formed by said dies, the crushed stone in some molds varying in appearance from the stone in other molds, pouring concrete into the molds on said crushed stone and striking the concrete off fiush with the top of said frame and said dividers, impressing a code indicia into the top of the concrete in each of said molds and permitting said concrete to set, and disassembling the slab elements thus cast and re-assembling the elements according to the code indicia on the wall to be faced with a cement mortar.

2. The method of forming an artificial stone wall facing on a building wall which comprises the steps of, laying out a frame corresponding to the outline of the wall to be faced on a pallet, spreading a layer of clay within the outline of said frame, successively impressing a series of natural stone dies into said layer of clay and pressing divider plates into said clay along the edges of each of said dies to form a series of molds, removin said dies, depositing a layer of finely divided natural stone into each of the molds formed by said dies, the crushed stone in some molds varying in appearance from the stone in other molds, pouring concrete into the molds on said crushed stone and striking the concrete ofi flush with the top of said frame, impressing a code indicia into the top of the concrete in each of said molds and permitting said concrete to set, and disassembling the slab elements thus cast and re-assembling the elements according to the code indicia on the wall to be faced with a mortar.

3. The method of forming an artificial stone wall facing on a building wall which comprises the steps of, laying out a frame corresponding to the outline of the wall to be faced on a pallet, spreading a layer of clay within the outline of said frame, successively impressing a, series of natural stone dies into said layer of clay and pressing divider plates into said clay along the 4 removing said dies, depositing a layer of finely divided natural stone into each of the molds formed by said dies, pouring concrete'into the molds and striking the concrete off flush with the top of said frame, impressing a code indicia into "the top of the concrete in each of said molds and permitting said concrete to set, and disassembling the slab elements thus cast and re-assembling the elementsaccording to the code indicia on the Wall to be faced with a mortar.

4. The method of forming an artificial stone Wall facing on a building wall'which comprises the steps of, layin out a frame corresponding to the outline of the wall to be faced on a pallet, spreading a layer of clay within the outline of said frame, successively impressing a series of natural stone dies into said layer of clay and pressing divider plates into said clay along the edges of each of said dies to form a series of molds, removing said dies, depositing a layer of finely divided natural stone into each of the molds formed by said dies, pouring concrete into the molds and striking the concrete off flush with the top of said frame, permitting said concrete to set, and disassembling the slab elements thus cast and re-assembling the elements on the wall to be faced with a mortar.

5. The method of forming an artificial stone wall facing for a building wall which comprises the steps of, layin out a frame corresponding to the outline of the wall to be faced on a base, spreading a layer of deformable plastic material within the outline of said frame, successively impressing a series of natural stone dies into said layer of material and pressing divider plates into said material along the edges of each of said dies, removing said dies, depositing a thin layer of finely divided natural stone into each of the molds formed by said dies, the crushed stone in some molds varying in appearance from the stone in other molds, pouring concrete into the mold, impressing a codeindicia into the top of the concrete in each of said molds and permitting said concrete to set, and disassembling the slab elements thus cast.

6. The method of forming an artificial stone wall facing for a building wall which comprises the steps of, layin out a frame corresponding to the outline of the wall to'be faced on a base spreading a layer of deformable plastic material within the outline of said frame, successively impressing a series of natural stone dies into said layer of material and pressing divider plates into said material along the edges of each of said dies, removing said dies, depositing a thin layer of finely divided natural stone into each of the molds formed by said dies, pouring concrete into the mold, impressing a code indicia into the top of the concrete in each of said molds and permitting said concrete to set, and disassembling the slab elements thus cast.

'7. The method of forming an artificial stone wall facing for a wall which comprises the steps of, layiing out a frame corresponding tothe outline of the wall to be faced on a base, spreading a layer of deformable plastic material within the outline of said frame, successively impressing a series of irregularly surfaced dies into said layer of material and pressing divider plates into said material along the edges of each of said dies, removing said dies, pouring concrete into the mold, permitting said concrete to set, and disassembling the slab elements thus cast.

8. The method of forming an artificial stone edges of each of said dies to form a series of molds, wall facing for a wall which comprises the steps of, laying out a frame corresponding to the outline of the wall to be faced on a base, spreading a layer of deformable plastic materialwithin the outline of said frame, successively impressing a series of dies into said layer of material and pressing divider plates into said material along the edges of each of said dies, removing said dies,

pouring concrete into the mold, permitting said concrete to set, and disassemblin the slab ele- 'ments thus cast.

DAVID F. CARLSON.

No references cited.

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Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2543892A (en) * 1948-12-29 1951-03-06 John H K Carpenter Inner collapsible molding form
US2577241A (en) * 1947-06-25 1951-12-04 Gibson Alfred Method of making textured building blocks
US2811767A (en) * 1953-08-31 1957-11-05 Harry M Dufford Plastic mix texturing device
US4573301A (en) * 1983-02-18 1986-03-04 Wilkinson Rudolph P Interlocking building blocks
US4573295A (en) * 1984-06-13 1986-03-04 Wilkinson Rudolph P Set of building articles and method of making and using the set to construct a predesigned, pre-engineered structure
US4694624A (en) * 1986-01-21 1987-09-22 Juhas William M Modular pre-insulated, pre-finished building block
US5225134A (en) * 1991-02-08 1993-07-06 Concrete Design Specialties, Inc. Methods of forming contoured walls
US5232646A (en) * 1990-11-07 1993-08-03 Concrete Design Specialties, Inc. Methods of forming contoured walls
EP0603807A1 (en) * 1992-12-23 1994-06-29 Zapf Gmbh + Co. Stonelayer of a packaging unit, its use, method for making and packing same and mould
US5536557A (en) * 1990-11-07 1996-07-16 Concrete Design Specialties, Inc. Single stone form liner
US5624615A (en) * 1995-08-29 1997-04-29 Sandorff; Daniel R. Method of manufacturing modular stone panels
US5885502A (en) * 1995-12-20 1999-03-23 Bomanite Corporation Method of forming patterned walls
US6129329A (en) * 1990-11-07 2000-10-10 Concrete Design Specialties, Inc. Gang form including single stone liners
US20060174569A1 (en) * 2004-10-27 2006-08-10 Stott Gale J Apparatus for pre-casting concrete structures
US20060260264A1 (en) * 2005-05-23 2006-11-23 Scott Reynolds Method of making a stone wall
US20070062142A1 (en) * 2005-09-20 2007-03-22 Stott Gale J Concrete structure system
US20090173872A1 (en) * 2008-01-07 2009-07-09 Intellectual Property Management Llc Method and System for Forming Pre-Cast Concrete Columns
US8162638B2 (en) 2008-01-08 2012-04-24 Intellectual Property Management Llc Method and system for forming vertical pre-cast concrete structures
US9975272B1 (en) 2009-04-28 2018-05-22 Natural Stone Wall Solutions Stone wall construction method
US9993943B2 (en) 2014-08-19 2018-06-12 Cambria Company Llc Processed slabs, and systems and methods related thereto
US10105868B2 (en) * 2015-01-30 2018-10-23 Cambria Company Llc Processed slabs, and systems and methods related thereto

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None *

Cited By (32)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2577241A (en) * 1947-06-25 1951-12-04 Gibson Alfred Method of making textured building blocks
US2543892A (en) * 1948-12-29 1951-03-06 John H K Carpenter Inner collapsible molding form
US2811767A (en) * 1953-08-31 1957-11-05 Harry M Dufford Plastic mix texturing device
US4573301A (en) * 1983-02-18 1986-03-04 Wilkinson Rudolph P Interlocking building blocks
US4573295A (en) * 1984-06-13 1986-03-04 Wilkinson Rudolph P Set of building articles and method of making and using the set to construct a predesigned, pre-engineered structure
US4694624A (en) * 1986-01-21 1987-09-22 Juhas William M Modular pre-insulated, pre-finished building block
US5232646A (en) * 1990-11-07 1993-08-03 Concrete Design Specialties, Inc. Methods of forming contoured walls
US6129329A (en) * 1990-11-07 2000-10-10 Concrete Design Specialties, Inc. Gang form including single stone liners
US5386963A (en) * 1990-11-07 1995-02-07 Concrete Design Specialties, Inc. Form liner
US5536557A (en) * 1990-11-07 1996-07-16 Concrete Design Specialties, Inc. Single stone form liner
US5632922A (en) * 1991-02-08 1997-05-27 Concrete Design Specialties, Inc. Form liner
US5225134A (en) * 1991-02-08 1993-07-06 Concrete Design Specialties, Inc. Methods of forming contoured walls
US6808667B2 (en) 1991-02-08 2004-10-26 Concrete Design Specialties, Inc. Form liner method
WO1994015025A1 (en) * 1992-12-23 1994-07-07 Werner Zapf Kg Set of artificial stone building elements
EP0603807A1 (en) * 1992-12-23 1994-06-29 Zapf Gmbh + Co. Stonelayer of a packaging unit, its use, method for making and packing same and mould
US5624615A (en) * 1995-08-29 1997-04-29 Sandorff; Daniel R. Method of manufacturing modular stone panels
US5885502A (en) * 1995-12-20 1999-03-23 Bomanite Corporation Method of forming patterned walls
US20060174569A1 (en) * 2004-10-27 2006-08-10 Stott Gale J Apparatus for pre-casting concrete structures
US7665712B2 (en) * 2004-10-27 2010-02-23 Intellectual Property Management, Llc Apparatus for pre-casting concrete structures
US20060260264A1 (en) * 2005-05-23 2006-11-23 Scott Reynolds Method of making a stone wall
US7730696B2 (en) * 2005-05-23 2010-06-08 Scott Reynolds Method of making a stone wall
US20070062142A1 (en) * 2005-09-20 2007-03-22 Stott Gale J Concrete structure system
US7802409B2 (en) 2005-09-20 2010-09-28 Intellectual Property Management, Llc System of concrete structures having panel and column portions with rigid member and end of panel portion of one structure received in slot of column portion of adjacent structure
US20090173872A1 (en) * 2008-01-07 2009-07-09 Intellectual Property Management Llc Method and System for Forming Pre-Cast Concrete Columns
US8162638B2 (en) 2008-01-08 2012-04-24 Intellectual Property Management Llc Method and system for forming vertical pre-cast concrete structures
US9975272B1 (en) 2009-04-28 2018-05-22 Natural Stone Wall Solutions Stone wall construction method
US9993943B2 (en) 2014-08-19 2018-06-12 Cambria Company Llc Processed slabs, and systems and methods related thereto
US9993942B2 (en) 2014-08-19 2018-06-12 Cambria Company Llc Processed slabs, and systems and methods related thereto
US10300626B2 (en) 2014-08-19 2019-05-28 Cambria Company Llc Synthetic molded slabs, and systems and methods related thereto
US10105868B2 (en) * 2015-01-30 2018-10-23 Cambria Company Llc Processed slabs, and systems and methods related thereto
US10195762B2 (en) 2015-01-30 2019-02-05 Cambria Company Llc Processed slabs, and systems and methods related thereto
US10252440B2 (en) 2015-01-30 2019-04-09 Cambria Company Llc Processed slabs, and systems and methods related thereto

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