Artificial stone and method of making same

• US 10,035,730 B2
• Filed: 05/18/2015
• Issued: 07/31/2018
• Est. Priority Date: 07/12/2010
• Status: Active Grant

• Current Assignee: Tom Scanlan
• Original Assignee: Tom Scanlan
• Inventors: Scanlan, Tom
• Primary Examiner(s): SWAIN, MELISSA STALDER
• Application Number:
  US14/715,111
• Publication Number:
  US 20150251954A1
• Time in Patent Office: 1,170 Days
• Field of Search: None
• CPC Class Codes: C04B 14/00 Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone expanding or defibrillating materials C04B20/00
• CPC Class Codes: C04B 14/24 porous, e.g. foamed glass
• CPC Class Codes: C04B 16/08 porous, e.g. expanded polystyrene beads or microballoons
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2103/30 Water reducers, plasticisers, air-entrainers, flow improvers
• CPC Class Codes: C04B 2103/54 Pigments; Dyes
• CPC Class Codes: C04B 2111/1056 Silica-free or very low silica-content materials
• CPC Class Codes: C04B 2111/40 Porous or lightweight materials
• CPC Class Codes: C04B 2111/542 Artificial natural stone
• CPC Class Codes: C04B 24/2676 Polystyrenes
• CPC Class Codes: C04B 28/02 containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 32/00 Artificial stone not provided for in other groups of this subclass

Abstract

A lightweight artificial stone system comprises a plurality of artificial stones, each of the artificial stones formed of at least some portion of cement, expanded glass, the lightweight artificial stones having a density in the range of between about 30 and 70 pounds per cubic foot.

Claims

1. An artificial stone comprising:

a relatively lightweight molded stone having an appearance of stone on at least one surface;

said molded stone having a substantially sand-free homogeneous mixture of;

cement being between about 50-89% by weight of said mixture wherein said cement includes slag; and

,

expanded glass particulate being between about 9-45% by weight of said mixture;

said expanded glass being a plurality of generally spherical shaped beads, said beads having a diameter size range of about 10 percent to about 50 percent being about ¼

to about 1 millimeter, and about 50 percent to about 90 percent being about 1 to about 6 millimeters in diameter.

2. The artificial stone of claim 1 further comprising fly ash.

3. The artificial stone of claim 1 further comprising pozzolans.

4. The artificial stone of claim 1 further comprising silica fume.

5. The artificial stone of claim 1 further comprising lime.

6. The artificial stone of claim 1 further comprising clay.

7. The artificial stone of claim 1 further comprising up to 5% additives.

8. The artificial stone of claim 1, said additives including at least one of pigments, plasticizers, viscosity modifiers and water repellants.

9. The artificial stone of claim 1 further comprising a plasticizer being less than about 5% by weight.

10. The artificial stone of claim 1 further comprising viscosity modifying admixture being less than about 5% by weight.

11. The artificial stone of claim 1 further comprising water repellant admixture being less than about 5% by weight.

12. An artificial stone comprising:

a relatively lightweight molded stone having an appearance of stone on at least one surface;

said molded stone having a substantially sand-free homogeneous mixture of;

cement and SCMs being between about 50-89% by weight of said mixture, said cement including slag;

expanded glass particulate being about 9-45% by weight of mixture;

said expanded glass being a plurality of generally spherical shaped beads, said beads having a diameter size range of about 10 percent to about 50 percent being about ¼

to about 1 millimeter, and about 50 percent to about 90 percent being about 1 to about 6 millimeters in diameter.

13. The artificial stone of claim 12, further comprising up to 5% additives.

14. The artificial stone of claim 13, said additives including at least one of pigments, plasticizers, viscosity modifiers and water repellants.