Patent Application
20090235600
The present invention relates to architectural and exterior/interior decorative siding and trim elements, such as stone walls, facings, and facades, and more specifically to architectural and decorative trim elements, such as stone walls, facings, and facades, formed from cementitious slurries, especially those containing gypsum.
Many different modern building designs take advantage of various architectural and decorative siding or trim elements, including stone or brick walls, facings, and facades, for purely aesthetic purposes, e.g., to decorate the interior and/or exterior surfaces. Additional architectural and decorative trim elements can also be used in conjunction with other exterior elements of a building or structure, such as exterior doorways, arches, columns, staircases, fountains, and the like. Furthermore, interior trim elements, such as fireplace surrounds, chimney surrounds, mantle pieces, and the like can incorporate various architectural and decorative trim elements as well.
With respect to conventional stone walls, facings, and facades, they generally include a plurality of natural stone products that have been appropriately shaped or sized to be incorporated in various patterns onto a surface, either exterior or interior, with various adhesive or mounting materials, such as mortar or cement. This process is typically very expensive, labor intensive, and time consuming, as the natural stone products must first be sorted and arranged to form a desired pattern, and then carefully and slowly mounted onto the surface with the use of an appropriate material, such as mortar or cement.
The use of “man-made” or synthetic stone products has reduced the cost, labor, and time requirements to install a simulated stone wall, facing, or facade, but in some cases the overall aesthetic appearance of the simulated system is generally not acceptable, particularly those products comprising large panels, each formed to simulate a plurality of stones set in mortar, that are fixed to the wall of a structure (such as a house) in abutting, adjacent relationship with each other. Such a system tends to appear as identical fake-looking repeating units that do not look like a natural stone product. In such systems, the large, individual panels are readily discernable. Even those simulation systems that attempt to accurately recreate the surface appearance and color of natural stone products using preformed panels have not been entirely satisfactory, as they are easily detected, even by laymen, as being a non-natural stone simulation system.
Therefore, it would be advantageous to provide architectural and exterior/interior decorative trim or siding elements, including but not limited to stone work simulation systems, which overcome at least one of the aforementioned problems.
One aspect of the present invention provides a stone work simulation system adapted for being mounted to a building structure for replicating the appearance of a natural stone or brick wall. The system includes a plurality of panel units, each being molded of a cementitious material and having a molded face in which an arrangement of natural stones or bricks set in mortar is simulated. Each panel unit molded face is three dimensional, with portions of the replicated natural stones or bricks projecting outwardly from the simulated matrix of mortar in which they have the appearance of being set, each panel unit having a peripheral edge along which its molded face is provided with at least one flat space. Two of these panel units are mountable on the building structure with a flat space of one of the panel units being located adjacent a flat space of the other of the panel units. The system also includes at least one individual simulated natural stone or brick unit adapted for being positioned in overlying, bridged relation to portions of both of the adjacently located flat spaces and being mounted thereto.
Another aspect of the present invention provides a stone work simulation system adapted for being mounted to a building structure, the system including first and second panel units simulating the appearance of a plurality of building material products at least partially disposed in a supporting matrix, the panel units being molded of a cementitious material and having a molded surface, the building material products and supporting matrix being replicated by the molded surfaces. The system also includes the first and second panel units having lateral ends adapted to abuttingly cooperate when the panel units are positioned horizontally adjacent to each other when the stone work simulation system is mounted to the building structure. The abutting cooperation between the horizontally adjacent panel units' lateral ends define a seam between the first and second panel units, the seam extending unbridged in a substantially straight line over the entire vertical height of neither of the first or second horizontally adjacent panel units, whereby the installed stone work simulation system avoids the appearance of being an arrangement of individual panel units. In one embodiment of such a stone work simulation system, an individual simulated building material product unit is mountable to the surfaces of the first and second panel units in bridging, overlying relation to the seam, whereby a portion of the seam is bridged by the simulated building material product unit. In another embodiment of such a stone work simulation system, the building material products replicated in the panel units are bricks, and the supporting matrix being replicated in the panel units is a matrix of mortar. The first and second panel units each replicate a plurality of vertically adjacent courses of several bricks, the replicated bricks of two vertically adjacent courses in each panel unit being relatively offset and overlapping, whereby the abuttingly cooperating lateral ends of the horizontally adjacent first and second panel units are configured to replicate the staggered ends of bricks located in the vertically adjacent courses, the seam extending over the vertical height of either panel being substantially nonlinear.
Still another aspect of the present invention provides a process for manufacturing a stone work simulation system, including: providing a first lower mold surface member including a first mold surface having a plurality of depressions separated by interstices, the depressions simulating the shape and texture of portions of building material products to be replicated by panel units of the stone work simulation system; applying a first colorant to the interstices of the first mold surface; applying a second colorant different from the first colorant to the depressions of the first mold surface; placing a fibrous mat of reinforcing material over the first mold surface; introducing a slurry of cementitious material into the first lower mold surface member, the slurry impregnating and encapsulating the mat and filling the first lower mold surface member with slurry to a desired level above the interstices; permitting the slurry to cure, whereby a molded panel unit of the stone work simulation system is formed; separating the molded panel unit from the first lower mold surface member; and repeating the above steps to form another panel unit of the stone work simulation system. The process also includes providing a second lower mold surface member including a second mold surface having a plurality of depressions, the depressions simulating the shape and texture of portions of building material products to be replicated by individual simulated building material product units of the stone work simulation system; applying a third colorant different from the first colorant to the depressions of the second mold surface; introducing a slurry of cementitious material into the second lower mold surface member, the slurry filling the depressions of the second lower mold surface member; permitting the slurry to cure, whereby a plurality of molded individual simulated building material product units of the stone work simulation system are formed; and separating the molded individual simulated building material product units from the second lower mold surface member.
The present invention provides an architectural and/or exterior/interior decorative trim or siding element, such as but not limited to a stone work simulation system, and such as but not limited to simulated stone or brick walls, facings, and facades, comprised of cement or cementitious materials, including those containing gypsum (e.g., calcined gypsum) or hydraulic cement. The stone work simulation system can be mounted to any number of interior or exterior surfaces of a building by any number of methods, including but not limited to mechanical fasteners, adhesives, glues, mortars, cements, grouts, caulks, and/or the like.
Certain embodiments of the system provide a plurality of panel units replicating or simulating the appearance of natural stone set in mortar, the panel units arranged in abutting, adjacent relationship with each other and affixed to the interior or exterior of a structure. The panel units are preferably sized for easy shipping, handling and installation, and to be secured to the structure with, for example, a fastener located at each corner thereof. For example, a panel unit of the inventive system may be two foot square secured to the structure with four screws—one at each corner. Each corner of the panel unit, and perhaps locations along the panel edges, being a substantially flat area void of a simulated stone.
Subsequent to installation of the panel(s), individual stone elements, similar in general size, shape and color to the stones simulated in the panels, are affixed to these flat areas, typically overlying portions of two or more adjacent panels and thus locally bridging portions of the seams between those panels as well as covering the heads of the screws at the abutting corners, and thereby the installed system avoids the appearance of being an arrangement of individual panel units.
Certain other embodiments of the system provide a plurality of units replicating or simulating the appearance of, for example, bricks set in mortar. The brick simulation system may include a plurality of panel units each replicating one or more courses of bricks, each panel being several “bricks” long. If each panel replicates two or more courses, the lateral ends of the panels would be configured to represent the staggered ends of offset, overlapping bricks located in the vertically adjacent courses. The abutting staggered ends of horizontally adjacent brick simulation panels are interfitted and abutted to provide the appearance of continuing the courses of full bricks set in mortar, and thereby the system, when installed, avoids the appearance of being an arrangement of individual panel units. Such panels may, for example, be secured to the interior or exterior structure by fasteners driven through the panels in “mortared” areas between the simulated bricks, a chinking material matching the simulated mortar then being applied over the fastener head to hide it. Alternatively, the brick simulation system may be substantially identical to the above-described system for simulating stone work, with replicated bricks being substituted for the replicated natural stones in a panel having flat areas at locations on the panel at which it is secured, by screws for example, to the underlying structure, with individual brick units then being secured to the flat areas, overlying portions of adjacent panels and bridging portions of seams between the panels and covering the fastener heads.
By way of non-limiting examples, the above-described units of the stone work simulation system (regardless of particular form) can be formed by an open-mold casting process or by a closed-mold injection molding process similar to resin transfer molding, from cementitious slurry comprising gypsum cement (e.g., calcined gypsum) and an optional latex/water mixture, or a hydraulic cement. The slurry can also contain other materials, such as but not limited to reinforcement materials (e.g., fibers), as well as other materials that are known in the art (e.g., activators, set preventers, plasticizers, fillers, and/or the like), which can be added before and/or after the combination of the gypsum and latex/water mixture. Preferably, the casting or injection molding process includes providing a reinforcing mat of woven fiberglass material in the mold, and then introducing the slurry into the mold and impregnating and enveloping the mat with the slurry, which fills the mold. The reinforcing material may alternatively take the form of a mat, scrim, netting, mesh, or the like. Once the slurry has cured, the reinforcing mat captured therein provides the resulting unit with improved strength and integrity and, in the case of the injection molded part, which tends to be rather thin in material cross section, a desirable degree of flexibility that helps to avoid easy breakage. Preferably, the meshed reinforcement material is a continuous strand natural fiberglass mat having a weight of approximately 0.75 ounce per square foot.
With respect to an open mold casting process for forming a panel unit simulating natural stones set in mortar, the reinforcing mat is placed in the mold and an appropriate amount of the cementitious slurry is added onto the mold surface member to a desired depth, the slurry impregnating and enveloping the reinforcing mat. The mold surface can include several spaced apart depressions formed therein to closely resemble a pattern of stones at least partially disposed in a mortar matrix. Preferably, the mold includes flat spaces formed at each corner, and optionally at locations along the panel edges between depressions. The mold surface can include surface features that closely recreate the shape, size, and surface textures of real stone products, e.g., granite block, river rock, slate, sandstone, marble, and/or the like. The open mold surface can alternatively include depressions and features closely recreating the shape, size and surface textures of man-made products, such as bricks and/or the like, or of other building products.
If a color effect is intended to be imparted to the stone work simulation system, a colorant can be applied to the surface (or portions thereof) of the mold surface member before the slurry is added. Alternatively, the colorant can be applied to the stone work simulation system after the molding process. In accordance with still another alternative, the slurry can be provided with a colorant dispersed therein to provide a color effect throughout the slurry. Thus, even if the finished stone work simulation system is chipped or cracked in the future, the color effect will be maintained throughout the depth of the stone work simulation system, obviating the need for color touchups.
The open mold can be vibrated to ensure that the slurry infiltrates the various surfaces of the mold surface and fully encapsulates the impregnated reinforcing mat. After an appropriate curing or drying time, the product, e.g., an individual panel of the stone work simulation system, is removed from the mold and is ready for immediate use and/or further processing, such as but not limited to coloring or painting and/or the like.
With respect to an injection mold process for forming a panel unit simulating natural stones set in mortar, a lower mold surface member, similar to the mold surface member described above in connection with the open mold casting process, and an upper mold surface member or core that substantially matches the configuration of, and is intended to cooperate with, the lower mold surface member and which includes a sprue, are provided. When the mold is closed, with the lower and upper mold surface members assembled, the interfacing surfaces of the lower and upper mold surface members are separated by a distance corresponding to the material thickness of the resulting panel unit, for example, ¼ inch. Prior to closing the mold, the reinforcing mat is overlaid onto the lower mold surface member, preferably with the edges of the mat overlapping and extending beyond the periphery of the lower mold surface member. The upper mold surface member is then fitted onto the lower mold surface member, sandwiching the extending edges of the mat between their interfacing peripheral surfaces. Preferably, at least one edge of the mat is exposed to the ambient environment outside of the closed mold.
A slurry injection nozzle is then inserted into the sprue and an appropriate amount of the cementitious slurry, the delivery of which may be in a timed shot, is then injected into the closed mold. By extending the edges of the mat over the periphery of the mold, and sandwiching it between the assembled upper and lower mold surface members, the mat additionally functions to vent the mold through its thickness of woven fibers during slurry injection, obviating the need to provide vent holes in the mold itself.
As described above, the lower mold surface member can include several spaced apart depressions formed therein to closely resemble a pattern of stones at least partially disposed in a mortar matrix, and the cooperating upper and lower mold surface members can include flat spaces formed at each corner of the mold, and optionally at locations along the panel edges between the depressions in the lower mold surface member and their corresponding core projections in the upper mold surface member. The lower mold surface can include surface features that closely recreate the shape, size, and surface textures of real stone or man-made building products, as described above.
As described above in connection with the open mold casting process, if a color effect is intended to be imparted to the stone work simulation system, a colorant can be applied to the surface (or portions thereof) of the lower mold surface member before the mat is overlaid onto it. Alternatively, the colorant can be applied to the stone work simulation system after the molding process. The slurry can be alternatively provided with a colorant dispersed therein to provide a color effect throughout the slurry, maintaining the color effect throughout the depth of the unit, obviating the need for color touchups if the finished stone work simulation system is chipped or cracked in the future.
By way of a non-limiting example, to provide further distinctiveness to the above-described stone work simulation system comprising molded panel units replicating natural stone or bricks set in a mortar matrix, a plurality of individual simulated stone or brick units (e.g., that have been formed separately or as a separable unit, e.g., according to a process described above) that are generally sized, shaped, and colored substantially similar to those replicated in the panel units, can be incorporated onto the flat spaces formed on the system panel units as described above to form a unique finished product that does not look like an arrangement of panels when installation is complete. A number of variously shaped, individual simulated stone units may be cast in a single lower mold surface member using the open mold casting process described herein. Owing to the relatively small size and thickness of these individual stone units, a reinforcing mat material is not used in producing them. Preferably, too, the reverse surfaces of these individual stone units are substantially flat, facilitating their mounting, as through use of a construction adhesive, to the flat portions of the system panels.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposed of illustration only and are not intended to limit the scope of the invention.
Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
Corresponding reference characters indicate corresponding parts throughout the several views. While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and may herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
Moreover, it is to be noted that the Figures are not necessarily drawn to scale and are necessarily not drawn to the same scale. In particular, the scale of some of the elements of the Figures is greatly exaggerated to emphasize characteristics of the elements. Elements shown in more than one Figure that may be similarly configured have been indicated using the same reference numerals.
The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention or its uses.
Referring to the Figures generally, and specifically to
The stone work simulation system 10 can be mounted to a dwelling or other residential or commercial building.
One embodiment of stone work simulation system 10 includes one or more panel units 16, a representative example of which is shown in
Referring to
By way of a non-limiting example, to provide further distinctiveness to the stone work simulation system, a plurality of individual simulated stones 400 (e.g., that have been formed separately or as a separable unit, e.g., according to a molding process described herein) that are generally sized, shaped, and colored similarly to or differently from those simulated in the panel units 16 of the system, can be incorporated onto the flat spaces 18 formed on panel units 16 of the stone work simulation system 10 after installation of the panels 16 to form a unique finished product. The individual simulated stones 400 can be mounted onto the stone work simulation system 10 by any number of methods, including but not limited to mechanical fasteners, adhesives, glues, mortars, cements, grouts, caulks, and/or the like. In this manner, the installer can quickly and easily create a simulated stone pattern that is truly unique by consistently varying the size, shape, or color of the individual simulated stones 400 that are being used as accent pieces. Thus, an entire subdivision of houses could have the stone work simulation system 10 applied to an exterior wall thereof with each house having a unique and distinctive appearance.
The individual stone units 400 are preferably placed on the flat spaces 18 of the panel units 16 such that they overlie adjacent, abutting panel units, thereby bridging and hiding portions of the seams 22 between the adjacent panels 16. The individual stone units 400 are also placed over the heads of the fasteners 20, which may each be located at a corner flat space 18 of each panel unit 16, that secure the panel units to the underlying structure, and may also extend over and cover fasteners 20 at adjacent panel corners. Placing the individual stone units 400 in this manner permits the stone work simulation system 10, when installed, to avoid the appearance of being an arrangement of individual panel units.
Further, to hide the seam lines 22 between adjacent panel units 16 of the stone work simulation system 10 or between the individual simulated stone units 400 and flat spaces 18 in the panel units 16 of the stone work simulation system 10, an appropriate cement, grout, caulking, or other suitable material can be applied thereto to cover the seam and simulate a realistic mortar or “chinking” effect that would be seen on real stone walls, facings, or facades. Thus, the appearance to observers would that of a natural stone surface. Preferably, the chinking material matches the color and texture of the mortar being simulated in the panel units.
In accordance with one aspect of the present invention, the cementitious material is formed from cementitious or cement slurry. The slurry can include hydraulic cement including, but not limited to, Portland, sorrel, slag, fly ash, or calcium alumina cement. Additionally, the cement can include a calcium sulfate alpha hemihydrate or calcium sulfate beta hemihydrate. The slurry can also utilize natural, synthetic, or chemically modified beta gypsum or alpha gypsum cement. The cementitious slurry preferably includes gypsum cement and a sufficient amount of water added thereto to produce a slurry having the desired consistency, i.e., not too dry nor not too watery. In accordance with one aspect of the present invention, the water is present in combination with a latex material, such that the powdered gypsum material is combined with the latex/water mixture to form the cementitious slurry.
Gypsum is a naturally occurring mineral, calcium sulfate dihydrate, CaSO4.2H2O (unless otherwise indicated, hereafter, “gypsum” will refer to the dihydrate form of calcium sulfate). After being mined, the raw gypsum is thermally processed to form a settable calcium sulfate, which can be anhydrous, but more typically is the hemihydrate, CaSO4−1/2H2O, e.g., calcined gypsum. For the familiar end uses, the settable calcium sulfate reacts with water to solidify by forming the dihydrate (gypsum). The hemihydrate has two recognized morphologies, alpha and beta hemihydrate. These are selected for various applications based on their physical properties. Upon hydration, alpha hemihydrate is characterized by giving rise to rectangular-sided crystals of gypsum, while beta hemihydrate is characterized by hydrating to produce needle-shaped crystals of gypsum, typically with large aspect ratio. In the present invention, either or both of the alpha or beta forms can be used, depending on the mechanical performance required. The beta form generates less dense microstructures and is preferred for low density products. Alpha hemihydrate could be substituted for beta hemihydrate to increase strength and density or they could be combined to adjust the properties.
The cementitious slurry can also include other additives. The additives can include, without limitation, accelerators and set preventers or retarders to control the setting times of the slurry. For example, appropriate amounts of set preventers or retarders can be added to the mixture to increase the shelf life of the resulting slurry so that it does not cure prematurely. When the slurry to be used in molding operations, a suitable amount of an accelerator can be added to the slurry, either before or after the pouring operation, so as to increase the drying and/or curing rate of the slurry. Suitable accelerators include aluminum sulfate, potassium sulfate, and Terra Alba ground gypsum. Additional additives can be used to produce colored stone work simulation systems 10, such dry powder metallic oxides such as iron and chrome oxide and pre-dispersed pigments used for coloring latex paints.
In accordance with one aspect of the present invention, a reinforcing material can also be disposed within the cementitious slurry, either prior to or after the introduction of the water thereto. The reinforcing material can include, without limitation, fibers, e.g., either chopped or continuous fibers, comprising at least one of polypropylene fibers, polyester fibers, glass fibers, and/or aromatic polyamide fibers. By way of a non-limiting example, the reinforcing material can include a combination of the fibers, such as the polypropylene fibers and the glass fibers or the polyester fibers and the glass fibers or a blend of the polypropylene fibers and the polyester fibers and the glass fibers. If included in the fiber composition, the aromatic polyamide fibers are formed from poly-paraphenylene terephthalamide, which is a nylon-like polymer commercially available as KEVLAR® from DuPont of Wilmington, Del. Of course, aromatic polyamide fibers other than KEVLAR® are suitable for use in the fiber composition of the present invention.
The cementitious slurry can then be mixed, either manually or automatically, so as to adequately combine the various ingredients thereof and optionally can also be agitated, e.g., by a vibrating table, to remove or lessen any air bubbles that formed in the cementitious slurry.
In accordance with one aspect of the present invention, the cementitious slurry includes a gypsum cement material, such as but not limited to calcined gypsum (e.g., calcium sulfate hemihydrate), also commonly referred to as plaster of Paris. One source of a suitable gypsum cement material is readily commercially available from United States Gypsum Company (Chicago, Ill.) and is sold under the brand name HYDROCAL® FGR 95. According to the manufacturer, HYDROCAL® FGR 95 includes more than 95 wt. % plaster of Paris and less than 5 wt. % crystalline silica.
The gypsum cement material should include an approximate 30% consistency rate. That is, for a 10 lb. amount of gypsum cement material, approximately 3 lbs. of water of would be needed to properly activate the gypsum cement material. If a latex/water mixture is being used to create the cementitious slurry, and the mixture contains approximately 50 wt. % latex solids, then approximately 6 lbs. of the latex/water mixture would be needed, as the latex/water mixture only contains approximately 50 wt. % water, the remainder being the latex solids themselves.
In accordance with another aspect of the present invention, the cementitious slurry includes a melamine resin, e.g., in the dry form, which acts as a moisture resistance agent. The melamine resin is present in an amount of about 10% of the weight of the gypsum cement material. For example, if 10 lbs. of gypsum cement material are used, then approximately 1 lb. of the melamine resin would be used. One source of a suitable melamine resin is readily commercially available from Ball Consulting Ltd. (Ambridge, Pa.).
In accordance with still another aspect of the present invention, the cementitious slurry includes a pH adjuster, such as but not limited to ammonium chloride, a crystalline salt, which acts to ensure proper cross-linking of the latex/water mixture with the dry ingredients, especially the melamine resin. The ammonium chloride is present in an amount of about 1% of the weight of the gypsum cement material. For example, if 10 lbs. of gypsum cement material are used, then approximately 0.1 lbs. of the ammonium chloride would be used. One source of a suitable ammonium chloride is readily commercially available from Ball Consulting Ltd. (Ambridge, Pa.).
In accordance with yet another aspect of the present invention, the cementitious slurry includes a filler such as but not limited to fly ash (e.g., cenosphere fly ash), which acts to reduce the overall weight and/or density of the slurry. The fly ash is present in an amount of about 30% of the weight of the gypsum cement material. For example, if 10 lbs. of gypsum cement material are used, then approximately 3 lbs. of the fly ash would be used. One source of a suitable fly ash is readily commercially available from Trelleborg Fillite Ltd. (Runcorn, England).
Several of the wet and/or dry components of the cementitious slurry of the present invention are readily commercially available in kit form from the United States Gypsum Company under the brand name REDI-ROCK®. Additional information regarding several suitable components of the cementitious slurry of the present invention can be found in U.S. Pat. No. 6,805,741, the entire specification of which is expressly incorporated herein by reference.
One or more of the dry ingredients are to be combined with the liquid portion of the cementitious slurry, i.e., the latex/water mixture. If the latex/water mixture includes 50 wt. % latex solids, with the rest being water, then the latex/water mixture is present in an amount of about 60% of the weight of the gypsum cement material. For example, if 10 lbs. of gypsum cement material are used, then approximately 6 lbs. of the latex/water mixture would be used. One source of a suitable latex/water mixture is readily commercially available from Ball Consulting Ltd. (Ambridge, Pa.) under the brand name FORTON® VF-812. According to the manufacturer, FORTON® VF-812 is a specially formulated, all acrylic co-polymer (50% solids) which crosslinks with a dry resin to make the system moisture resistant and UV stable.
The resulting cementitious slurry of the present invention should possess the following attributes: (1) it should stay wet or flowable for as long as possible, e.g., days, weeks, months, as circumstances warrant; (2) it should self level, i.e., the slurry should level by itself without intervention from the user when introduced into or onto a mold face surface; and (3) it should contain a limited water content (e.g., compared to conventional gypsum cement slurries), i.e., it should not be so wet so as to take a very long time (e.g., several hours or even days) to dry or cure.
Alternatively, the cementitious slurry can preferably be a mixture of rapidly setting hydraulic cement (not a Portland cement) that may or may not contain fiberglass fillers. RapidSet Construction Cement manufactured by CTS Cement Manufacturing Corp. of Cypress, Calif. (www.RapidSet.com) is an acceptable alternative to the above-discussed Gypsum/Latex material, although it is somewhat more brittle and sets in a short time, necessitating its being mixed in rather small batches that can be quickly used. This hydraulic cement is, however, much cheaper than the Gypsum/Latex mixture, and bonds better to fiberglass.
Referring to
The mold surface member 206 includes several spaced apart depressions 206b formed therein to closely resemble a pattern of stones at least partially disposed in a mortar matrix, recreated by interstices 206c formed around the depressions 206b. Certain embodiments of mold surface member 206 include a number of flat spaces 206d formed between the depressions 206b and/or along one or more edges of the mold surface member, and/or at each corner of the mold surface member 206, mold flat spaces 206d provided to form flat spaces 18 in molded panel units 16, the intended purpose of which is described above. In accordance with another embodiment, the mold surface member 206 can be formed so as not to have any flat spaces, i.e., the mold surface member includes several closely spaced depressions with little space in between adjacent depressions. Such a mold surface member embodiment may be preferably employed in molding panel units replicating portions of a brick wall, as discussed further herein below.
Additionally, the mold surface member 206 preferably includes a peripheral lip member 210 (
Because of the weights involved of the various mold components, as well as the cementitious slurry, a transport device, such as a conveyor system 350 (e.g., see
If a color effect is intended to be imparted to the stone work simulation system 10, then, after mold surface member 206 is placed in mold retainer support 202 (
In accordance with still another alternative, the slurry can be provided with a colorant dispersed therein to provide a color effect throughout the slurry, thus, if the finished stone work simulation system 10 is chipped or cracked in the future, the color effect will be maintained throughout the material depth of the panel unit 16 of stone work simulation system 10, thus lessening or eliminating the future need for color touchups.
Referring to
Panel units 16 molded in accordance with the above described open mold casting process generally have a cross section as shown in
The cementitious slurry is then allowed to dry, harden or cure for a sufficient amount of time, which may depend, at least in part, on the specific composition of the cementitious slurry used. The mold system 200 can also be shuttled off of the conveyor system 350 and stored in a storage area (not shown) so that other stone work simulation system panel units 16 can be made in the interim.
Referring to
Referring to
Preferably the reverse faces of the individual stone units 400 are flat, to facilitate their mounting, as by an adhesive, to flat spaces 18 on panel units 16, as described above. Therefore, optionally, an upper or top mold surface member (not shown) can be used with molding surface member 220 and casting system 200 to ensure that the individual stone units 400 of stone work simulation system 10 are formed having a flat reverse surface for ease of mounting. As described above, such an upper or top mold surface member (not shown) would not typically include a mold face per se that functions as a core and imparts a surface feature into the reverse side of the final product, but rather would be used to assist in the molding process itself.
Referring to
Here too, the mold surface member 206 includes several spaced apart depressions 206b formed therein to closely resemble a pattern of stones at least partially disposed in a mortar matrix, recreated by interstices 206c (best shown in
Peripheral lip member 210 of lower mold surface member 206 facilitates grasping for removal of the mold surface member 206 from the cavity 208. Conveyor system 350 may be advantageously used as described above with injection molding system 250.
If a color effect is intended to be imparted to the stone work simulation system 10, the same processes applicable to open mold casting system 200 and its process, are likewise applicable to injection molding system 250 and its process.
Reinforcing material mat 30 is placed over and covers mold face 206a subsequent to any pre-molding colorant application process. Preferably, edges 32a-32d of mat 30 extend well beyond the periphery of lower mold surface 206, for reasons explained further below.
Injection molding system 250 further includes upper mold surface member 260 that is placed over and cooperates with lower mold surface member 206 to close the interior of the mold. Preferably, upper mold surface member 260 is formed of the same material as lower mold surface member 206. Upper mold surface member 260 includes sprue 262 in fluid communication with the interior of the closed mold, and which receives injector nozzle 270 insertable by an operator for delivering and injected quantity of the cementitious slurry into the mold cavity. The slurry injected into the mold may be a predetermined volume, or an amount corresponding with a timed shot of slurry into the mold cavity.
The upper mold surface member 260 has an interior mold surface, best seen in
Referring to
The cementitious slurry is then allowed to dry, harden or cure for a sufficient amount of time, which may depend, at least in part, on the specific composition of the cementitious slurry used. The mold system 250 can also be shuttled off of the conveyor system 350 and stored in a storage area (not shown) so that other stone work simulation system panel units 16 can be made in the interim.
As with the open mold casting process of system 200, once the injection molded cementitious slurry has dried, hardened or cured, and the upper and lower mold surface members separated, mold surface member 206 and the molded panel unit 16 of stone work simulation system 10 is removed from the mold retainer support 202. The mold surface member 206 can be removed from the cavity 208 by grapping the peripheral lip member 210 and lifting the mold surface member 206 upwardly and out of the cavity 208. The mold surface member 206 is then removed from the molded panel unit 16 of stone work simulation system 10 as described above, thus exposing a panel unit that is preferably allowed to dry to a suitable extent, after which time flash consisting of slurry and peripheral portions of mat 30 are trimmed from the edges of the panel unit. Panel unit 16 may then be used immediately or further processed, e.g., painted or otherwise treated.
Panel units 16 molded in accordance with the above described injection molding process generally have a cross section as shown in
Referring to
The abutting staggered ends of adjacent brick simulation panels 16A are interfitted as shown to provide the appearance of continuing the courses of full bricks set in mortar, and thereby system 10A, when installed, avoids the appearance of being an arrangement of individual panel units. Panels 16A may, for example, be secured to the interior or exterior structure by adhesive, or fasteners driven through the panels in “mortared” areas between the simulated bricks, a chinking material matching the simulated mortar then being applied over the fastener head to hide it. Panels 16A of stone work simulation system 10A may be molded by the above-described open mold casting system 200 and casting process, resulting in a panel unit 16A as shown in
Alternatively, a brick simulation system may be substantially identical to the above-described system 10 for simulating natural stone work. In such a stone work simulation system 10, replicated bricks are substituted for the above-described replicated natural stones in a panel unit 16 having flat spaces 18 at locations on the panel unit 16 at which it is secured, by screws 20 for example, to the underlying structure, with individual brick units 400 then being secured to the flat spaces 18, overlying portions of adjacent panels 16 and bridging portions of seams 22 between the panels and covering the fastener heads, as described above.
As previously noted, the present invention can be used to produce other architectural and exterior/interior decorative trim elements. Thus, the present invention can produce many different types of architectural and decorative trim elements for use in conjunction with other exterior elements of a building or structure, such as but not limited to exterior doorways, arches, columns, fountains, and the like. Furthermore, the present invention can produce many interior trim elements, such as but not limited to fireplace surrounds, chimney surrounds, mantle pieces, and the like.
While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
The present application claims priority to U.S. Provisional Patent Application Ser. No. 61/038,632, filed Mar. 21, 2008, the disclosure of which is hereby expressly incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61038632 | Mar 2008 | US |
