Method for making a faux stone concrete panel
First Claim
1. A method for forming a panel, comprising the steps of:
- a) providing a mold having an inner mold surface with macro indentations and macro protrusions;
b) applying a wet mixture of concrete material to the inner mold surface of the mold to form a concrete layer including a cross-sectional contour corresponding to the indentations and protrusions of the inner mold surface;
c) curing the concrete material until dry;
d) applying a layer of elastomer material to the concrete layer to form an elastomer layer secured to the concrete layer;
e) introducing foam into the mold to form a foam layer secured to the elastomer layer; and
f) removing the secured concrete, elastomer, and foam layers from the mold.
0 Assignments
0 Petitions
Accused Products
Abstract
A wall or panel has a thin concrete layer with a cross-sectional contour having protrusions and indentations forming other objects, such as stone work, brick or wood. A reinforcement layer may be affixed to the concrete layer to provide tensile strength and impact resistance to the concrete layer. A foam layer is affixed to the reinforcement layer to further reinforce the concrete layer, and so that the wall or panel is light weight. A second concrete layer or a rigid backing layer may be disposed opposite the concrete layer so that the foam is disposed therebetween. A method for forming the wall or panel includes spraying the concrete onto a mold surface which has indentations and protrusions for forming the other objects. The reinforcement layer is sprayed onto the cured concrete layer. The mold is closed and foam is introduced into the mold.
-
Citations
39 Claims
-
1. A method for forming a panel, comprising the steps of:
-
a) providing a mold having an inner mold surface with macro indentations and macro protrusions;
b) applying a wet mixture of concrete material to the inner mold surface of the mold to form a concrete layer including a cross-sectional contour corresponding to the indentations and protrusions of the inner mold surface;
c) curing the concrete material until dry;
d) applying a layer of elastomer material to the concrete layer to form an elastomer layer secured to the concrete layer;
e) introducing foam into the mold to form a foam layer secured to the elastomer layer; and
f) removing the secured concrete, elastomer, and foam layers from the mold. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
opening the mold prior to applying the wet mixture of concrete material; and
closing the mold prior to introducing the foam.
-
-
12. A method in accordance with claim 1, wherein the step of providing the mold further includes providing a mold with a second mold surface having indentations and protrusions;
- and
wherein applying the wet mixture of concrete material further includes applying a wet mixture of concrete to both the inner mold surface to form a first concrete layer and the second mold surface to form a second concrete layer; and
wherein introducing the foam into the mold further includes introducing the foam between the first and second concrete layers to form a foam layer secured to both concrete layers.
- and
-
13. A method in accordance with claim 1, further comprising the step of:
moving the mold with a transfer system through a plurality of different stations for applying the concrete mixture, curing the concrete mixture, and introducing the foam.
-
14. A method for forming a panel, comprising the steps of:
-
a) providing a mold having an inner mold surface with macro indentations and macro protrusions;
b) applying a wet mixture of concrete material to the inner mold surface of the mold to form a concrete layer;
c) curing the concrete material until dry;
d) applying a layer of reinforcement material to the cured concrete layer to form a reinforcement layer;
e) introducing foam into the mold to form a foam layer secured to the reinforcement layer; and
f) removing the secured concrete, reinforcement and foam layers from the mold. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)
opening the mold prior to applying the wet mixture of concrete material; and
closing the mold prior to introducing the foam.
-
-
26. A method in accordance with claim 14, wherein the step of providing the mold further includes providing a mold with a second mold surface having indentations and protrusions;
- and
wherein applying the wet mixture of concrete material further includes applying a wet mixture of concrete to both the inner mold surface to form a first concrete layer and the second mold surface to form a second concrete layer; and
wherein introducing the foam into the mold further includes introducing the foam between the first and second concrete layers to form a foam layer secured to both concrete layers.
- and
-
27. A method for forming a panel, comprising the steps of:
-
a) providing a mold having an inner mold surface with macro indentations and macro protrusions;
b) applying a wet mixture of concrete material to the inner mold surface of the mold to form a concrete layer including a cross-sectional contour corresponding to the indentations and protrusions of the inner mold surface;
c) curing the concrete material until dry;
d) applying a layer of high density foam to the concrete layer to form a reinforcement layer secured to the concrete layer;
e) introducing low density foam into the mold to form a low density foam layer secured to the reinforcement layer;
f) removing the secured concrete, reinforcement and low density foam layers from the mold. - View Dependent Claims (28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
opening the mold prior to applying the wet mixture of concrete material; and
closing the mold prior to introducing the low density foam.
-
-
38. A method in accordance with claim 27, wherein the step of providing the mold further includes providing a mold with a second mold surface having indentations and protrusions;
- and
wherein applying the wet mixture of concrete material further includes applying a wet mixture of concrete to both the inner mold surface to form a first concrete layer and the second mold surface to form a second concrete layer; and
wherein introducing the low density foam into the mold further includes introducing the low density foam between the first and second concrete layers to form a low density foam layer secured to both concrete layers.
- and
-
39. A method in accordance with claim 27, further comprising the step of:
moving the mold with a transfer system through a plurality of different stations for applying the concrete mixture curing the concrete mixture, and introducing the low density foam.
Specification