Artificial stone and method of making same

• US 9,034,094 B2
• Filed: 02/07/2013
• Issued: 05/19/2015
• 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:
  US13/761,909
• Publication Number:
  US 20130145968A1
• Time in Patent Office: 831 Days
• Field of Search: 106/676
• US Class Current: 106/400
• 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 50-75% by weight; and

,

expanded glass particulate being about 20-45% by weight;

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 up to 5% additives.

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

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

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

6. The artificial stone of claim 5, said pigments being less than 5% by weight.

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

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

9. The artificial stone of claim 1 further having a density of less than about 58 pounds per cubic foot and compression strength of between about 1000 pounds per square inch and about 2200 pounds per square inch.

10. 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 50-75% by weight; and

about 20-45% by weight expanded glass;

said expanded glass being a plurality of generally spherical shaped beads, said beads having a diameter size range of about 50 percent to about 90 percent being about ¼

to about 1 millimeter, and about 10 percent to about 50 percent being about 1 to about 6 millimeters in diameter.

11. The artificial stone of claim 10, further comprising up to 5% additives.

12. The artificial stone of claim 11, said additives including at least one of pigments, plasticizers, viscosity modifiers and water repellants.

13. The artificial stone of claim 10 further comprising a plasticizer being less than about 5% by weight.

14. The artificial stone of claim 10 further comprising pigments.

15. The artificial stone of claim 14, said pigments being less than 5% by weight.

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

17. The artificial stone of claim 10 further comprising water repellant admixture being less than about 5% by weight.

18. The artificial stone of claim 10 further having a density of less than about 58 pounds per cubic foot and compression strength of between about 1000 pounds per square inch and about 2200 pounds per square inch.

19. 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 50-75% by weight;

expanded glass particulate being about 20-45% by weight;

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.

20. The artificial stone of claim 19, further comprising up to 5% additives.

21. The artificial stone of claim 20, said additives including at least one of pigments, plasticizers, viscosity modifiers and water repellants.

22. 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 50-75% by weight; and

about 20-45% by weight expanded glass;

said expanded glass being a plurality of generally spherical shaped beads, said beads having a diameter size range of about 50 percent to about 90 percent being about ¼

to about 1 millimeter, and about 10 percent to about 50 percent being about 1 to about 6 millimeters in diameter.

23. The artificial stone of claim 22, further comprising up to 5% additives.

24. The artificial stone of claim 23, said additives including at least one of pigments, plasticizers, viscosity modifiers and water repellants.