FOAMING OF SIMULATED STONE STRUCTURES

• US 20090056257A1
• Filed: 03/27/2008
• Published: 03/05/2009
• Est. Priority Date: 10/24/2003
• Status: Abandoned Application

• Current Assignee: General Electric Company
• Original Assignee: Crane Building Products LLC
• Inventors: Crist, Paul Anthony, Lambert, Larry, Adur, Ashok M., Mollinger, Paul J., Fairbanks, Larry R., Frechette, John P., Nasr, Moe, Kuriger, Kurt
• Application Number:
  US12/057,244
• Publication Number:
  US 20090056257A1
• Time in Patent Office: Days
• US Class Current: 52/314
• CPC Class Codes: B29C 2037/0035 the coating being applied as liquid, gel, paste or the like
• CPC Class Codes: B29C 2037/0039 the coating being applied in powder or particle form
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 2791/007 Using fluid under pressure
• CPC Class Codes: B29C 37/0032 the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat B29C44/14 and B29C44/32 take precedence
• CPC Class Codes: B29C 39/02 for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29C 41/04 Rotational or centrifugal casting, i.e. coating the inside of a mould by rotating the mould
• CPC Class Codes: B29C 41/08 Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder spray-up of reinforcing fibres B29C70/305
• CPC Class Codes: B29C 41/22 Making multilayered or multicoloured articles
• CPC Class Codes: B29C 43/003 characterised by the choice of material
• CPC Class Codes: B29C 44/1271 the preformed parts being partially covered
• CPC Class Codes: B29C 45/14778 the article consisting of a material with particular properties, e.g. porous, brittle
• CPC Class Codes: B29C 49/00 Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
• CPC Class Codes: B29C 51/00 Shaping by thermoforming , i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor blow moulding of tubular preforms B29C49/00, deforming of tubular or hollow preforms B29C67/0014
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 67/243 for making articles of definite length
• CPC Class Codes: B29K 2105/0005 containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29K 2995/0072 Roughness, e.g. anti-slip
• CPC Class Codes: B29L 2031/102 Bricks
• CPC Class Codes: B29L 2031/702 Imitation articles, e.g. statues, mannequins medical equipment B29L2031/753; models B29L2031/40
• CPC Class Codes: B44C 5/0453 : produced by processes involving moulding
• CPC Class Codes: B44C 5/0461 : used as wall coverings
• CPC Class Codes: B44F 11/00 : Designs imitating artistic work
• CPC Class Codes: B44F 9/04 : of stone surfaces, e.g. marble
• CPC Class Codes: E04F 13/0862 : composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
• CPC Class Codes: E04F 13/147 : with an outer layer imitating natural stone, brick work or the like
• CPC Class Codes: E04F 13/185 : with an outer layer imitating natural stone, brick work, tiled surface or the like

Abstract

Simulated stone, masonry, and brick textured products such as siding having a foam backing or with the hollow parts injected with foam or molded with foam in one or more steps, obtained when specially selected materials are properly admixed and formed via molding techniques. The foam backing is applied to the product in either a one or two step process. The foam backing may be used on panels, wall structures, and other products that may have contoured and textured surfaces and may simulate the appearance of conventional building and construction materials including, but not limited to, stone, brick, masonry, concrete, stucco, wood, other conventional building materials, and combinations of any of these materials are disclosed. The foam backing provides improves thermal insulation, improved sound reduction, improved rigidity, and improved dimensional stability. The disclosed invention is not limited to products in the building or construction industries and may be applied in the manufacture of a wide variety of products in other industries.

Claims

1. A simulated stone panel comprising:

a front surface having a panoply of colors or texturing materials corresponding to stone, masonry, brick, or other substrates being simulated;

a rear surface;

a foam substantially adjacent to the rear surface; and

at least one edge adapted to join to an adjacent panel.

2. The simulated stone panel in claim 1 wherein the rear surface is concave.

3. The simulated stone panel in claim 1 wherein the foam is selected from a group consisting of:

polyurethane, polyethylene, and expanded polystyrene.

4. The simulated stone panel in claim 3 wherein the foam is applied to the rear surface of the simulated panel by injection.

5. The simulated stone panel in claim 3 wherein the foam is a backer panel applied to the rear surface of the simulated stone panel.

6. The simulated stone panel in claim 4 wherein the foam is applied to the rear surface of the simulated stone panel during a molding process.

7. The simulated stone panel in claim 3 wherein the foam is applied to the rear surface of the simulated stone panel during the cooling phase of manufacturing.

8. The simulated stone panel in claim 3 wherein the foam is adapted to provide shape retention and sound deadening properties to simulates stone panel.

9. The simulated stone panel in claim 1 wherein the simulated stone panel has a hollow interior.

10. The simulated stone panel in claim 9 wherein the foam is injected into the hollow interior of the simulated stone panel by a process selected from a group consisting of:

molding and extrusion.

11. The simulated stone panel of claim 1, wherein the simulated stone panel is made by a process selected from a group consisting of:

rotational molding, compression molding, vacuum molding, compression casting, injection molding, extrusion blown molding, vacuum thermoforming, pressure thermoforming, casting, spray-up techniques and other suitable molding techniques.

12. The simulated stone panel of claim 11, wherein the simulated stone panel is a component selected from a group consisting of:

posts, columns, half columns, rectangular bases, half round columns, bird fixtures, stands, arbors, pergolas, outdoor sectionals, garbage concealment units, deck posts, integrated deck posts, signage, corrals, bicycle racks, golf course features, outdoor plumbing, barricades, retaining wall fascia, sound barrier facades, security walls, concrete forms, concrete finishing systems, decorative facing, post covers, fencing, walkways, stepping stones, pavers, cladding, mailboxes, benches, tables, bars, coolers, storage bench, sheds, garden tools, seating accessories, recycling containers, water collection, hose containers, trash containers, firewood box, hot tub, pool surrounding, spa surround, knee wall, tree base wrap bench, roofing panels, stackable modular units, landscape edging, portable heater, propane tank concealment, well pump cover concealment, satellite dish concealment, air-conditioning unit concealment, address plates, interior wall covering, basement finishing, wet walls, stables, winery, and acoustic walls.

13. A simulated stone panel comprising:

a front surface having a panoply of colors or texturing materials corresponding to stone, masonry, brick, or other substrates being simulated;

a rear surface having a concave shape;

a foam substantially adjacent to the rear surface; and

at least one edge adapted to join to adjacent panels.

14. The simulated stone panel of claim 13 wherein the foam is selected from a group consisting of:

polyurethane, polyethylene, and expanded polystyrene.

15. The simulated stone panel in claim 14 wherein the foam is applied to the rear surface of the simulated panel by injection.

16. The simulated stone panel in claim 14 wherein the foam is a backer panel applied to the rear surface of the simulated stone panel.

17. The simulated stone panel in claim 15 wherein the foam is applied to the rear surface of the simulated stone panel during the molding process.

19. The simulated stone panel in claim 14 wherein the foam is applied to the rear surface of the simulated stone panel during the cooling phase of manufacturing.

20. The simulates stone panel in claim 14 wherein the foam is adapted to provide shape retention and sound deadening properties to simulates stone panel.

21. A simulated stone panel comprised of:

a polymer selected in about 10-95 parts by weight;

at least one mineral aggregate, in about 1-50 parts by weight;

an adhesive, in about 0.01-10 parts by weight;

at least one colorant, in about 0.01-10 parts by weight; and

a foam substantially adjacent to a rear surface of the panel;

wherein the composite is adapted to be used to produce building or construction materials selected from a group comprising panels, cladding, siding, mailboxes and other similar parts.

22. The simulated stone panel in claim 21 wherein the simulated stone panel has a front and rear surface.

23. The simulated stone panel in claim 22 wherein the rear surface is concave.

24. The simulated stone panel in claim 23 wherein the foam is applied to the rear surface of the simulated stone panel.

25. The simulated stone panel in claim 21 wherein the foam is selected from a group consisting of:

polyurethane, polyethylene, and expanded polystyrene.

26. The simulated stone panel in claim 21 wherein the foam is adapted to provide shape retention and sound deadening properties to simulates stone panel.

27. A simulated stone panel comprising:

a surface having a panoply of colors or texturing materials corresponding to stone, masonry, brick, or other substrates being simulated;

a hollow interior;

a foam is placed within the hollow interior of the simulated stone panel; and

at least one edge adapted to join to adjacent panels.

28. The simulated stone panel in claim 27 wherein the foam is selected from a group consisting of:

polyurethane, polyethylene, expanded polystyrene, or other suitable foaming material.

29. The simulated stone panel in claim 28 wherein the foam is injected into the hollow interior of the simulated stone panel during the molding process.

30. The simulated stone panel in claim 28 wherein the foam is adapted to provide shape retention and sound deadening properties to simulates stone panel.

31. The simulated stone panel in claim 29 wherein the foam is injected into the hollow interior of the simulated stone panel by a process selected from a group consisting of:

molding and extrusion

32. The simulated stone panel in claim 27 wherein the foam is heat activated.

33. The simulated stone panel in claim 32 wherein the heat activated foam expands during a heating process.

34. The simulated stone panel of claim 27, wherein the simulated stone panel is made by a process selected from a group consisting of:

rotational molding, compression molding, vacuum molding, compression casting, injection molding, extrusion blown molding, vacuum thermoforming, pressure thermoforming, casting, spray-up techniques and other suitable molding techniques.

35. The simulated stone panel of claim 34, wherein the simulated stone panel is a component selected from a group consisting of:

posts, columns, half columns, rectangular bases, half round columns, bird fixtures, stands, arbors, pergolas, outdoor sectionals, garbage concealment units, deck posts, integrated deck posts, signage, corrals, bicycle racks, golf course features, outdoor plumbing, barricades, retaining wall fascia, sound barrier facades, security walls, concrete forms, concrete finishing systems, decorative facing, post covers, fencing, walkways, stepping stones, pavers, cladding, mailboxes, benches, tables, bars, coolers, storage bench, sheds, garden tools, seating accessories, recycling containers, water collection, hose containers, trash containers, firewood box, hot tub, pool surrounding, spa surround, knee wall, tree base wrap bench, roofing panels, stackable modular units, landscape edging, portable heater, propane tank concealment, well pump cover concealment, satellite dish concealment, air-conditioning unit concealment, address plates, interior wall covering, basement finishing, wet walls, stables, winery, and acoustic walls.