Apparatus and method for impressing patterns in a slip-formed concrete wall

• US 6,923,630 B2
• Filed: 07/30/2001
• Issued: 08/02/2005
• Est. Priority Date: 07/30/2001
• Status: Expired due to Term

• Current Assignee: Slipstone Incorporated
• Original Assignee: Slipstone Incorporated
• Inventors: Allen, Michael B.
• Primary Examiner(s): Mackey, James P.
• Application Number:
  US09/918,617
• Publication Number:
  US 20030020191A1
• Time in Patent Office: 1,464 Days
• Field of Search: 425/89, 425/363, 425/385, 425/471, 425/63, 425/101, 404/124, 404/128
• US Class Current: 425/63
• CPC Class Codes: B28B 11/08 for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
• CPC Class Codes: E01C 19/43 Machines or arrangements for roughening or patterning freshly-laid paving courses, e.g. indenting rollers
• CPC Class Codes: E01C 19/4893 Apparatus designed for railless operation

Abstract

An apparatus and a method for impressing three-dimensional patterns in a slip-formed concrete wall. At least one impression roller is provided at the discharge end of a slip form. The impression roller includes an outer periphery, provided with a layer or coating of resilient material. The layer is pre-formed or pre-cast to include an aesthetically pleasing, three-dimensional pattern. The axis of the roller is maintained in parallel relation to the plane of the exposed surface of the wall, with the outer periphery of the roller slightly depressed into the wall surface. As the uncured concrete wall emerges from the slip form, the impression roller places a pattern into the wall surface which corresponds to the pattern on the roller. Movement of the roller along the wall causes the impression roller to rotate, impressing successively formed portions of the wall with the pattern. Additional rollers may be used to impress patterns on the opposing wall surface, as well as the top wall surface. After the concrete wall has fully cured, stain, paint, or other decorative features may be applied to the pattern, adding further visual interest and variety.

Claims

1. An apparatus for impressing a three-dimensional pattern into a wet concrete wall formed by a slip form, comprising:

an impression roller having an axis of rotation and an outer periphery impressed with a three-dimensional pattern;

means for supporting said roller for rotation about said axis with said outer periphery being partially depressed into a first exposed side surface of the wet concrete wall emerging from the slip form, said axis of said roller being maintained substantially parallel to the first exposed surface;

means for supporting said roller for advancement along the concrete wall, whereby surface engagement between said outer periphery of said impression roller and the first exposed surface of the wet concrete cause said roller to rotate and impress successive portions of the wet concrete with successive portions of said three-dimensional pattern; and

an opposing element displaced to engage a second exposed side surface opposite said first exposed side surface of said wall.

2. An apparatus as recited in claim 1, wherein said roller is elongated and right-circular cylindrical in configuration.

3. An apparatus as recited in claim 1, wherein said roller is elongated and has a two-stage outer periphery, a first stage being right-circular cylindrical in configuration and a second stage being frusto-conical in configuration.

4. An apparatus as recited in claim 1, wherein said outer periphery is made from a curable silicon, and in which said impression roller includes a rigid inner form having an outer surface, and in which said outer periphery substantially covers said outer surface.

5. An apparatus as recited in claim 1, wherein said means for supporting said roller for rotation comprises upper and lower arms rotatably attached to respective upper and a respective lower end of said impression roller, said arms extending from said means for supporting said roller for advancement.

6. An apparatus as recited in claim 1, further comprising means for applying a release agent on the wet concrete before it comes into contact with said outer periphery.

7. An apparatus as recited in claim 6, wherein said means for applying a release agent comprises a spray bar extending along said outer periphery.

8. An apparatus as recited in claim 1, further comprising means for applying a thin plastic film on the wet concrete before it comes into contact with said outer periphery.

22. An apparatus as recited in claim 1, 9, 17, 18, or 20, wherein said opposing element comprises:

a second roller displaced to engage a second exposed side surface opposite said first exposed side surface of said wall.

23. An apparatus as in claim 22, wherein the second roller has an outer periphery, at least a portion of said outer periphery impressed with a three-dimensional pattern to impress a pattern into said second exposed side surface.

24. An apparatus as recited in claim 1, 9, 17, 18, or 20, wherein said opposing element comprises:

a side wall form extending adjacent to a second exposed side surface opposite said first exposed side surface of said wall.

9. An apparatus for impressing a three-dimensional pattern into a wet concrete wall formed by a slip form, comprising:

an impression roller, said roller having an axis of rotation and an outer periphery, at least a portion of said outer periphery including an outer layer of material having an outwardly facing pattern side, impressed with a three-dimensional pattern;

means for supporting said roller for rotation about said axis with said outer layer being partially depressed into a first exposed side surface of the wet concrete wall just emerging from the slip form, said axis of said roller being substantially parallel to the first exposed surface;

means for supporting said roller for advancement along the concrete wall, whereby surface engagement between said outer periphery of said impression roller and the first exposed surface of the wet concrete cause said roller to rotate and impress successive portions of the first exposed surface with said three-dimensional pattern; and

an opposing element displaced to engage a second exposed side surface opposite said first exposed side surface of said wall.

10. An apparatus as recited in claim 9, wherein said roller is elongated and right-circular cylindrical in configuration.

11. An apparatus as recited in claim 9, wherein said roller is elongated and has a two-stage outer periphery, a first stage being right-circular cylindrical in configuration and a second stage being frusto-conical in configuration.

12. An apparatus as recited in claim 9, wherein said outer layer is made from a curable silicon, and in which said impression roller includes a rigid inner form having an outer surface, and in which said outer layer substantially covers said outer surface.

13. An apparatus as recited in claim 9, wherein said means for supporting said roller for rotation comprises upper and lower arms rotatably attached to a respective upper and a respective lower end of said impression roller, said arms extending from said means for supporting said roller for advancement.

14. An apparatus as recited in claim 9, further comprising means for applying a release agent on the wet concrete, before it comes into contact with said outer periphery.

15. An apparatus as recited in claim 14, wherein said means applying a release agent comprises a spray bar extending along said outer periphery.

16. An apparatus as recited in claim 9, further comprising means for applying a thin plastic film on the wet concrete before it comes into contact with said outer periphery.

17. An apparatus for slip-forming a concrete wall and impressing a three-dimensional pattern into an exposed surface of the wall, comprising:

an impression roller having an axis of rotation and an outer periphery impressed with a three-dimensional pattern;

means for supporting said roller for rotation about said axis with said outer periphery being partially depressed into a first exposed side surface of the wet concrete wall emerging from a slip form assembly at a discharge end, said axis of said roller being substantially parallel to the first exposed surface;

wherein said roller moves at the same speed and in the same direction as the forward advancement of said slip form assembly, whereby surface engagement between said outer periphery of said impression roller and the first exposed surface of the wet concrete cause said roller to rotate and impress successive portions of the concrete with said three-dimensional pattern; and

an opposing element displaced to engage a second exposed side surface opposite said first exposed side surface of said wall.

18. An apparatus for impressing a three-dimensional pattern into a wet concrete wall formed by a slip form, comprising:

an impression roller having an axis of rotation and an outer periphery, at least a portion of said outer periphery impressed with a three-dimensional pattern;

upper and lower arms rotatably attached to a respective upper and a respective lower end of said impression roller;

said arms extending from a support frame;

said support frame configured for coupling to a slip form machine;

said arms configured to support said roller for rotation about said axis with said outer periphery being partially depressed into a first exposed side surface of the wet concrete wall emerging from said slip form, said axis of said roller being maintained substantially parallel to the first exposed surface;

whereby surface engagement between said outer periphery of said impression roller and the exposed surface of the wet concrete cause said roller to rotate and impress successive portions of the wet concrete with successive portions of said three-dimensional pattern; and

an opposing element displaced to engage a second exposed side surface opposite said first exposed side surface of said wall.

19. An apparatus as recited in claim 18, wherein said outer periphery is made from a curable silicon, and in which said impression roller includes a rigid inner form having an outer surface, and in which said outer periphery substantially covers said outer surface.

20. An apparatus for impressing a three-dimensional pattern into a wet concrete wall formed by a slip form, comprising:

an impression roller having an axis of rotation and an outer periphery, at least a portion of said outer periphery including an outer layer of material having an outwardly facing pattern side, impressed with a three-dimensional pattern;

upper and lower arms rotatably attached to a respective upper and a respective lower end of said impression roller;

said arms extending from a support frame;

said support frame configured for coupling to a slip form machine;

said arms configured to support said roller for rotation about said axis with said outer periphery being partially depressed into a first exposed side surface of the wet concrete well emerging from said slip form, said axis of said roller being maintained substantially parallel to the exposed surface;

whereby surface engagement between said outer periphery of said impression roller and the first exposed surface of the wet concrete cause said roller to rotate and impress successive portions of the wet concrete with successive portions of said three-dimensional pattern; and

an opposing element displaced to engage a second exposed side surface opposite said first exposed side surface of said wall.

21. An apparatus as recited in claim 20, wherein said outer layer is made from a curable silicon, and in which said impression roller includes an rigid inner form having an outer surface, and in which said outer layer substantially covers said outer surface.