The present invention is directed to an apparatus for stamping concrete with patterns, textures, or both.
Concrete is a staple in the construction industry. It is a preferred material because of its costs. Concrete is typically poured in slabs. Typically, the poured concrete slabs are given a broom finish pattern, by merely sweeping over the concrete with a broom or the like and letting it harden and dry.
Other finish patterns can be put into concrete, to create other aesthetically pleasing surfaces. These finish patterns are typically “stamped” into the concrete by placing flat mats with patterns over the concrete, tamping the mats, with rods and the like, into contact with the wet concrete, and removing these flat mats.
This method of using the patterned mats is subject to numerous drawbacks. Initially, the amount of concrete that can be worked on in a day is limited. These amounts are typically about 15 yards per pour, three times a day, resulting in about 45 yards per day. Additionally, the tamping for each 15 yard portion takes time. Should other 15 yard portions be poured in parallel, they be tamped later in time, when the concrete is tightened, resulting in a non-uniform pattern being stamped into adjacent portions. Finally, stamping in this manner requires judgement of an experienced, well trained workperson, to judge when the stamping process will be optimal. This is because this kind of stamping can not be performed when the concrete is too wet or alternately, too “tight” or dry.
The present invention provides apparatus and methods for stamping large volumes of concrete in short time spans, with stamps, of patterns, textures or both. The resultant stamping is uniform over the entire series of concrete slabs. A single apparatus of the invention can be used on concrete when it is both wet and tightening, eliminating the need for switching stamps and/or machinery to achieve uniform stamping as the concrete is worked at different stages of its tightening. The apparatus is easy to operate and can be operated by concrete workers of all skill levels, eliminating errors associated with human judgement as well as the need for skilled concrete stamping personnel. The apparatus is also such that it does not require the preparation and stamping time, as associated with conventional stamping mats, allowing for more yards of concrete to be poured and subsequently stamped in a workday or work session, than with these contemporary methods and devices.
The present invention provides an apparatus, to which weight can be added, to accommodate stamping during the tightening of the concrete. By adding this weight, a uniform stamping can be achieved, with the resultant, stamp, of patterns, textures, or both being uniform among all of the slabs in a series of poured concrete slabs.
The present invention is suitable for stamping concrete that is in an overlay. An overlay is a thin layer of concrete, placed over an existing surface, where only this overlay is worked. The apparatus of the present invention are suitable for working with an overlay, because of its light weight and the stamp on the outer surface of the roller is of a short depth.
An embodiment of the invention is directed to a stamping apparatus. This stamping apparatus includes a roller, the roller including a surface defined by a stamp; and a receiver portion, for example, a support member, for receiving the roller in a rotatable engagement. The receiver portion is configured for weighting the roller. The stamp can include a pattern, a texture, or combinations of patterns and textures.
Another embodiment is directed to a stamping apparatus including a roller received by a receiver portion, for example, a support member. The roller includes a surface defined by a stamp, and the receiver receives the roller in a rotatable engagement, and includes at least one holder for holding removable weights. The stamp includes a pattern, a texture, or combinations thereof.
Another embodiment is directed to a stamping apparatus. This apparatus includes a roller, the roller including a surface of at least one layer including a stamp therein; and a receiver portion for receiving the roller in a rotatable engagement. This receiver portion also includes at least one holder for holding removable weights. The stamp includes a pattern, a texture, or combinations thereof.
Another embodiment is directed to a method for stamping concrete. This method includes providing a stamping apparatus including a roller, the roller including a surface defined by a stamp; and a receiver portion (e.g., a support member) for receiving the roller in a rotatable engagement, the receiver portion configured for weighting the roller; weighting to the receiver portion in accordance with the tightness of the concrete being worked; and moving the apparatus over the concrete being worked for stamping the concrete in accordance with the stamp. The weighting process can include adding, subtracting or simply not adding any weight to the receiver portion. The stamp includes a pattern, a texture, or combinations thereof.
Another embodiment is directed to a method for making a concrete stamp. This method includes providing a mold for a roller having a substantially cylindrical shaped cavity and an inner wall, the inner wall including an imprint corresponding to a stamp; placing material into contact with the inner wall to form a layer that includes a stamp corresponding to the imprint; and filling at least a substantial portion of the remaining cavity with a filler material to form a body for the roller. The roller can then be released from the mold. The imprint for the stamp can include a pattern, a texture or combinations thereof.
Another embodiment is directed to a stamping apparatus having a roller, including a surface defined by a stamp, a receiver portion for receiving the roller in a rotatable engagement, and a fluid transport system. The fluid transport system includes at least one conduit for providing fluid to the roller along the surface. The fluid facilitates release (separation) of the roller from the concrete, and can be for example, water, oil, a water-based composition, an oil-based composition, a petroleum-based composition, or the like. The at least one conduit is typically a single conduit or line that typically branches into sublines, or alternately a single subline. These sublines are configured for extending at least to the receiver portion for providing fluid to the roller along the surface.
Another embodiment is directed to a stamping apparatus having a roller, the roller including a surface defined by a stamp, a receiver portion for receiving the roller in a rotatable engagement, the receiver portion configured for weighting the roller; and a fluid transport system. This fluid transport system includes at least one conduit for providing fluid to the roller along the surface. The at least one conduit is typically a single conduit or line that typically branches into sublines, or alternately a single subline. These sublines are configured for extending at least to the receiver portion for providing fluid to the roller along the surface.
Another embodiment is directed to a method for stamping concrete. This method includes providing a stamping apparatus having a roller, the roller including a surface defined by a stamp, a receiver portion for receiving the roller in a rotatable engagement, and a fluid transport system, the system including at least one conduit for providing fluid to the roller along the surface. The apparatus is then moved over the concrete being worked for stamping the concrete in accordance with the stamp, and typically when needed, the fluid transport system is activated, releasing fluid onto the surface of the roller.
Another embodiment details a method for stamping concrete, where there is provided a stamping apparatus including a roller, the roller including a surface defined by a stamp, a receiver portion for receiving the roller in a rotatable engagement, the receiver portion configured for weighting the roller, and a fluid transport system, the system including at least one conduit for providing fluid to the roller along the surface. The receiver portion is weighted in accordance with the tightness of the concrete being worked, and the apparatus is moved over the concrete being worked for stamping the concrete in accordance with the stamp. Typically, when needed, the fluid transport system is activated, releasing fluid onto the surface of the roller.
Another embodiment of the invention is directed to a stamping apparatus. The stamping apparatus includes, a roller, the roller including a surface defined by a stamp, a receiver portion for receiving the roller in a rotatable engagement, a fluid transport system, the system including at least one conduit for providing fluid for releasing the roller from the surface over which it rides, and, oppositely disposed rods proximate to the opposite ends of the receiver portion. The rods are such that they accommodate weights in at least a plurality of positions on the rods, to adjustably weight the apparatus to control the stamping by the roller.
Another embodiment of the invention is directed to stamping apparatus, that includes a roller, the roller including a surface defined by a stamp, a receiver portion for receiving the roller in a rotatable engagement, and, a fluid dispersing system. The fluid dispensing system includes at least one fluid receiving member with at least one port, through which fluid is discharged, for example, by spraying, for providing fluid for releasing the roller from the surface over which it rides (operates), the fluid receiving member moveable between at least a first position and at least a second position.
Still another embodiment of the invention is directed to a stamping apparatus. The stamping apparatus includes, a roller, the roller including a surface defined by a stamp; a receiver portion for receiving the roller in a rotatable engagement; a fluid dispersing system, and oppositely disposed rods proximate to the opposite ends of the receiver portion. The fluid dispensing system includes at least one fluid receiving member with at least one port, through which fluid is discharged (for example, sprayed), for providing fluid for releasing the roller from the surface over which it rides (operates), the fluid receiving member moveable between at least a first position and at least a second position. The rods accommodate weights in at least a plurality of positions on the rods, to adjustably weight the apparatus to control the stamping by the roller.
Another embodiment of the invention is directed to a method for stamping curing concrete. The method includes, providing an apparatus including, a roller, the roller including a surface defined by a stamp, a receiver portion for receiving the roller in a rotatable engagement, and, a fluid dispersing system, the system including at least one fluid receiving member with at least one port, through which fluid is discharged (sprayed), for providing fluid for releasing the roller from the surface over which it rides (operates). The fluid receiving member is moveable between at least a first position and at least a second position. The at least one fluid receiving member is moved into at least one position where fluid is released in the direction the roller is to be advanced; and the apparatus is moved such that roller contacts the fluid that has been released as the roller advances. The method also includes releasing fluid onto the surface over which the apparatus operates in the direction the roller is advancing.
Attention is now directed to the attached drawings, wherein like reference numerals indicate corresponding or like components. In the drawings:
Turning also to
Alternately, as shown in
These lateral members 36 are supported by a crossbar 40 of the support member 31. The lateral members 36 and crossbar 40 are typically of metal, such as aluminum, stainless steel or the like. This crossbar 40 typically attaches to the lateral members 36 by bolts, screws or other mechanical type fasteners. Additional securement may be with welds, adhesives and the like. Alternately, the support member 31 may be unitary member, formed of metal, such as aluminum, stainless steel or the like, with the lateral members 36 bent downward from the crossbar 40. A joint 42, typically pivotal, for receiving and engaging the handle 21 is typically attached to the crossbar 40, for example, by conventional fastening structures and methods.
The crossbar 40 itself is of a weight, such that a sufficient imprinting or stamping can be made in wet concrete. The crossbar 40 is also of sufficient strength such that it can support additional weight, that is placed onto it when desired. Weight holders, for example, posts 44, extend from the crossbar 40, that coupled with the surface 48 of the crossbar 40, support weights 50. These weights 50 are such that they can be added or removed by the user (as shown by the hand 51), depending on the dryness (tightness) of the concrete. These weights 50 are typically small weights, with holes in the middle, but other shapes and configurations of weights and corresponding weight holders on the crossbar 40 are also suitable.
This arrangement of weights 50 allows the apparatus 20 to be weighted adjustably, such that the concrete 22 can be imprinted uniformly, even though different portions of the concrete 22 are imprinted when the concrete 22 is at different stages of tightening (hardening). By allowing for adjustable weighting, a single apparatus 20 can be used for the entire area of concrete 22 that has been poured.
The stamp or imprint 26 defining the outer surface 28 of the roller 24 is typically in the layer of material 30. The stamp or imprint 26 is typically a pattern, such as bricks, a texture, such as a worn surface (in relief to various depths), or both (a pattern and a texture, for example, in various combinations), such as worn bricks. The layer of material 30 is typically an elastomeric or polymeric material, one such material being urethane rubber. However, other materials are also suitable, provided they are able to release from concrete, either alone or with the assistance of a release agent or coating.
The material layer 30 may be as thick as desired, provided the desired imprint or stamp 26 is contained therein. This material layer 30 is typically supported by foam 54 or other filling material, that fills the cavity 110 (and accordingly, the interior of the roller 24, defining a body 55 for the roller 24), surrounded by the material layer 30 during manufacturing of the roller 24, as shown in
Turning to
A leveling stand 104 is placed below the mold 100. The surface 101 of the mold 100 is then coated with a material, typically urethane rubber or other curable material, to the desired thickness, to form the material layer 30 that retains the imprint. The material layer 30, for example, is a rubber layer, that is left to cure. This material layer 30 surrounds a cavity 110 in the mold 100. A cap 112, for fitting over the open end of the mold 100, is placed over the open end of the mold 100, for example in a friction fit. The cap 112 includes openings 114, 115. A rod 116, that becomes the axle 32 in the finished roller 24 is placed into aligned openings 115, 117 (in the leveling stand 104) and temporarily affixed in place by bolt assemblies 118 or other suitable fastening means. Once the rubber has cured, foam is added to the cavity 110 through the openings 114, where it hardens (forming the body 55 for the roller 24). The ends of the now formed roller 24 (
The alternate roller 24 of
As shown in
Turning also to
Rubber, such as urethane, or other polymeric material, typically that is curable, is then poured into the mold 100, in the space between the surface 101 and the core 130 (PVC pipe). The rubber or other polymeric material then cures, to form the material layer 30′ for the roller 24′ of the apparatus 20′ shown in
Alternately, the rod 116 need not be included and the core 130 can be filled as detailed above (with the opening 117 in the leveling stand 104 plugged, as detailed above). Axle portions, such as those 32a, 32b of
In an alternate apparatus 220, as shown in
Turning back to
Alternately, the apparatus 20 can be pushed. In this exemplary pushing mode of operation, the apparatus 20 would function similarly to that described above.
The apparatus 300 includes a roller apparatus 320 and a tank 325 or other fluid source connected by a line 326. The roller apparatus 320 is similar to the apparatus 20 (detailed above), and is therefore numbered with the same numbers to indicate identical or like components. The support member 331 is similar to support member 31 detailed above, but also includes rings 331 a for receiving sublines 333, that branch from the line 326. The support member 331 can also be weighted in the same manner as the support member 31, as detailed above (components are numbered identically).
The sublines 333 are constructed to be retained in the rings 331ato extend beyond the support member 331, so as to provide fluid, such as lubricant or release fluid (typically in a spray stream 335) to the roller 24 (on its surface 28). The sublines 333 typically terminate in spray nozzles 336 or the like, to allow for distribution of the fluid from the tank 325 over the entire roller 24.
Alternately, the sublines 333 could be positioned so as to release fluid directly onto the concrete 370 (
The tank 325 is typically a vessel, closed by a lid 337 or other similar closure. The tank 325 is typically portable, in the form of a backpack, and includes straps 339 for receiving the arms of a user 360 (
The line 326 extends from the tank 325 through the handle 341 (similar to the handle 21 detailed above, except that it accommodates the line and includes openings 345 for the sub-lines 333). Alternately, a tank need not be used and the line 326 can connect to any other sprayer system.
The handle 341 also supports a grip 351, typically spring biased (movable in accordance with the arrow 352), that activates a pressuring member (not shown), When squeezed inward, toward the handle, pressure is placed on the line 325 by the pressuring member, causing fluid to be released from the sublines 333, onto the roller 24.
Turning to
Although not shown, should a support capable of accommodating weights be used, as the concrete 22 tightens, weights 50 can be added to the apparatus 320. Operation would be similar to that for the apparatus 20 as detailed above. Weighting (as well as removal of weights 50) continues for as long as desired, depending on the tightness of the concrete 370. This pulling of the apparatus 320 continues until all of the desired concrete area has been stamped.
Turning now to
Alternately, the line 325 can be positioned such that it releases the fluid directly onto the concrete 370 (
Turning now to
Turning also to
A continuous bore 544 extends through the crossbar 540, from the top (top side) 540b of the crossbar 540 to a second lateral side 540c, defining a pathway for fluid. Heads (or receivers) 545 are typically seated in the bore 544 and extend from the top 540b of the crossbar 540, to receive sub lines 546 (similar to sub lines 333), that extend from a main line 547 (similar to line 326) from a tank or other fluid source 548 (similar to the tank 325) of a fluid dispensing system, with fluid dispensed by squeezing a grip 549 of a flow control mechanism at the handle 521 (similar to the grip 351 and associated components detailed above), causing spraying of the fluid upon discharge from the apparatus 520, similar to the fluid dispensing system shown in
Nozzles 556 extend from the other end of the bores 544, and provide an outlet for the fluid. The nozzles 556 typically seat in the bore 544, and extend from the second side 540c of the crossbar 540. These nozzles 556 typically connect to the crossbar 540 by being threaded and being received by a correspondingly threaded portion of the bore 544 in the crossbar 540.
As shown in
In other alternates, the nozzles 556, as described above, may be on the first lateral side 540a of the crossbar 540 (with the second side 540c closed), with a corresponding bore extending through the crossbar 540. There may also be nozzles 556 on both lateral sides 540a, 540c of the crossbar 540, with a corresponding bore in the crossbar 540. The nozzles 556 may be angled as desired, depending if fluid is desired to be sprayed directly onto the ground surface, the roller 524 or portions of both the ground surface and the roller 524. In the case of nozzles 556 on both lateral sides 540a, 540c of the crossbar 540, valves may also be placed into the bore 544. These valves would be user actuated (manually actuated or remote controlled) to permit fluid egress from any or all of the desired nozzles 546 (on either side 540a, 540c of the crossbar 540). The valves may be three way valves, to allow for fluid to be dispensed from either of the nozzles along the bore 544, or both of the nozzles along the bore 544.
The crossbar 540 itself is of a weight, such that a sufficient imprinting or stamping can be made in wet concrete. The crossbar 540 is also of sufficient strength such that it can support additional weight, that is placed onto it when desired. Weight holders, for example, rods 564, extend from the crossbar 540, typically from the first side 540a of the crossbar 540. The rods 564 fit into openings 564a in the crossbar 540. The rods 564 fit into the openings 564a in the crossbar 540 by, for example, threaded mechanisms (correspondingly threaded portions of the rod 564 with its respective opening 564a), friction fits, welds, combinations thereof, and the like.
The rods 564 are, typically oriented at an angle Φ with respect to the horizontal, sufficient to allow the apparatus 520 to be easily pushed or pulled, and such that the weights 570 will remain proximate to the crossbar 540 (and if not restricted by pins, fall off of the rod 564). For example, angle Φ may be approximately 10° to approximately 70°, with a typical angle being approximately 30°. The rods 564 support weights 570, each weight having a central bore 570a therethrough, to be slideable on the rods 564. These weights 570 are held in position by removable pins 572 (each pin 572 typically attached to the crossbar 540 by a line 572a or the like) that extend through corresponding openings 573 on the rods 564. The rods 564 include another set of openings 574 to accommodate the pins 572. The weights 570 are typically cylindrical in shape, but other shapes and configurations of weights are also suitable.
The weights are such that they can be added, positioned (for example, below the first opening 573, between the openings 573, 574, or above the opening 574, with the pins 572 in the respective openings 573, 574 to support these positions) or removed by the user. Different ends of the crossbar 540 may be weighted differently, and multiple weights may be placed on one or both of the rods 564. Weighting of the apparatus 520 is adjusted depending on the dryness (tightness) of the concrete to be worked (stamped or imprinted). By weighting the apparatus 520 at the ends of the crossbar 540, the roller 524 is weighted adjustably, such that the concrete 522 can be imprinted uniformly, even though different portions of the concrete 522 may be at different stages of tightening (hardening). By allowing for adjustable weighting of the roller 524, a single apparatus 520 can be used for the entire area of concrete 522 that has been poured.
Turning now to
The roller 624 connects to the handle 621 by a support member 631. The roller 624 is rotatably attached to the support member 631 by an axle 632, whose ends are received in the lateral members 636 of the support member 631, and are mounted therein by conventional techniques and fasteners, such as bolts 638, caps or the like. The lateral members 636 are supported by a crossbar 640, the lateral members 636 and crossbar 640 defining the support member 631. The lateral members 636 and crossbar 640 are typically of metal, such as aluminum, stainless steel or the like. The crossbar 640 is, for example, v-shaped, so as to have two sides 640a, 640b. The crossbar 640 typically attaches to the lateral members 636 by bolts, screws, welds or other mechanical type fasteners. Additional securement may be with adhesives and the like.
The handle 621 connects to the crossbar 640 of the support member 631 at a joint 642. The joint 642 is formed by a plate 621a of the handle 621, movably, and typically, rotatably, attached, by a bolt or other rotational fastening mechanism, to a portion of a central support 643, the central support attached to the crossbar 640.
A tube 644 is supported on the crossbar 640 by lateral supports 646, with the central support 643 intermediate the lateral supports 646. The lateral supports 646 are attached to the crossbar 640 similar to the central support 643. As shown in
At least one of the rings 650 includes protrusions 652a, 652b, such as bolts or the like, that serve as stops for the rotational movement of the tube 644. The tube 644 is in it maximum rotational position when the corresponding protrusion 652a, 652b is in abutment with the corresponding side 640a, 640b of the crossbar 640.
The tube 644 is a hollow member, closed on one lateral side 653a, and open on the other lateral side 653b, to receive a line 656, hose or the like hose, for supplying fluid to the tube 644. The tube 644 typically includes a plurality of ports (not shown) for fluid discharge from the tube 644. For example, there are two ports in the tube 644, that receive nozzles 660 (for example, that are threadably fitted into the correspondingly threaded ports), through which fluid exits the tube 644. The nozzles 660 are, for example, oriented with respect to each other to be at least substantially collinear and at least substantially parallel to the horizontal, and typically, are collinear with respect to each other and parallel to the horizontal.
For example, in
When the apparatus 620 is in operation, for example, the nozzles 660, and accordingly, the tube 644, are oriented such that fluid is sprayed in the direction that the roller 624 is advancing. By spraying fluid in the advancing direction, the roller 644 can release easily from the concrete being worked. The nozzles 660 are, for example, oriented to spray fluid onto the concrete or ground surface (in advance of the roller 624). As shown in
Alternately, for example, with the apparatus 620, the fluid could be released behind the roller 624, or onto the roller 624 at its trailing side, if desired.
The line 656 (similar to the line 326 described above) receives fluid from a tank 664 or other fluid source (portable or non-portable). The tank 664 may be a backpack or the like, and is similar to the tank 325 detailed above. Fluid flow through the line 656 is controlled by a gripping mechanism 658, that activates a pressuring member (not shown) for creating fluid spraying, similar to the grip 351 and pressuring member shown in
The crossbar 640 itself is of a weight, such that a sufficient imprinting or stamping can be made in wet concrete. The crossbar 640 is also of sufficient strength such that it can support additional weight, that is placed onto it when desired. Weight holders, for example, removable rods 674, fit into tubes 676 that extend through openings in the respective sides 640a, 640b of the crossbar 640. The rods 674 are retained in position, by pins 677 that extend through aligned openings 679a, 679b in the tubes 676 and rods 674 (openings not shown in rods 674).
The rods 674, are similar to the rods 564 described above, as they also support weights 680 (similar to the weights 570 described above) with a central bore 680a therethrough, to be slideable on the rods 674. The rods 674 are typically oriented at an angle with respect to the horizontal, sufficient to allow the apparatus 620 to be easily pushed or pulled, and such that the weights 680 will remain proximate to the crossbar 640 (and if not restricted by pins, fall off of the rod 674). This angle is similar to angle Φ shown in
The weights 680 are held in position by removable pins 682, that extend through corresponding openings 683 on the rods 674. The rods 674 include another set of openings 684 to accommodate the pins 682, or additional pins. The weights 680 are typically cylindrical in shape, but other shapes and configurations of weights are also suitable.
The weights 680 are such that they can be added, positioned (for example, below the first opening 683, between the openings 683, 684, or above the opening 684, with the pins 682 in the respective openings 683, 684 to support these positions) or removed by the user. Different ends of the crossbar 640 may be weighted differently, and multiple weights may be placed on one or both of the rods 674. Weighting of the apparatus 620 is adjusted depending on the dryness (tightness) of the concrete to be worked (stamped or imprinted). By weighting the apparatus 620 at the ends of the crossbar 640, the roller 624 is weighted adjustably, such that the concrete can be imprinted uniformly, even though different portions of the concrete may be at different stages of tightening (hardening). By allowing for adjustable weighting of the roller 624, a single apparatus 620 can be used for the entire area of concrete that has been poured.
Thus, there has been shown and described apparatus and processes for stamping concrete It is apparent to those skilled in the art, however, that many changes, variations, modifications, and other uses and applications for the above described embodiments are possible, and also such changes, variations, modifications, and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is limited only by the claims which follow.
This application is a continuation-in-part of U.S. patent application Ser. No. 10/697,364, entitled: CONCRETE STAMPING APPARATUS, filed Oct. 30, 2003, which is a continuation-in-part of U.S. patent application Ser. No. 10/603,340, entitled: CONCRETE STAMPING APPARATUS, filed on Jun. 25, 2003. Both U.S. patent application Ser. No. 10/697,364 and Ser. No. 10/603,340 are incorporated by reference herein.
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Number | Date | Country | |
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20050051041 A1 | Mar 2005 | US |
Number | Date | Country | |
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Parent | 10697364 | Oct 2003 | US |
Child | 10932822 | US | |
Parent | 10603340 | Jun 2003 | US |
Child | 10697364 | US |