Methods and apparatus for replicating original objects
AssigneePolyRock Technologies, LLC
InventorBruce E. Harrington
Life of this patent
Estimating the term…
Abstract
Methods and apparatus for producing cast articles with characteristics of original objects such as a stone panel. The cast articles can replicate the contours, textures, and colors of all or a portion of the original object and can be made in any shape or size and specifically can be formed to simulate rock walls, carved stone architecture details, and other construction components normally created by stone masons or sculptors on site and at a high cost. The processes used in making the cast articles include the production of a series of molds. The molds seek to replicate the size, shape, contour, and surface texture of an original object with or without modifications to the original object.
Claims49
A method for making a cast article replicating on at least a part of the surface thereof, at least a portion of the surface of an original object, said method comprising:
- (a) making a first mold that replicates at least said portion of the surface of the original object;
- (b) filling said first mold with a first castable material to produce a cast reproduction;
- (c) modifying said cast reproduction to form a master reproduction;
- (d) making a second mold that replicates at least part of the surface of the master reproduction;
- (e) filling said second mold with a second castable material;
- and
- (f) curing the second castable material to produce said cast article that replicates at least said portion of the surface of the original object.
A method for making a cast article replicating on at least part of the surface thereof, at least a portion of the surface of an original object, said method comprising the steps of:
- (a) making a first flexible mold that replicates at least said portion of the surface of the original object;
- (b) lining at least a portion of the inner surface of a first support structure with said first flexible mold so that the surface of said first flexible mold replicating at least said portion of the surface of said original object faces away from the inner surface of said first support structure;
- (c) filling said first support structure with a first castable material so as to produce a master reproduction of said first flexible mold in said first support structure;
- (d) inserting said master reproduction into a second support structure;
- (e) making a second mold of said master reproduction;
- and
- (f) filling said second mold with a second castable material to produce said cast article.
A system for production of cast articles replicating on at least part of the surface of each of the cast articles, a portion of the surface of an original object, said system comprising:
- a first mold that replicates said portion of the surface of the original object;
- a master reproduction made from the first mold;
- a second mold made from the master reproduction;
- a first conveyor;
- said second mold being positioned on said first conveyor, said second mold replicating at least part of the surface of the master reproduction;
- a dispenser positioned adjacent to said first conveyor for filling said second mold with a castable material;
- and
- a second conveyor positioned adjacent to said first conveyor for substantially confining said castable material to said second mold.
A method for production of cast articles replicating on at least part of the surface of each of the cast articles, at least a portion the surface of an original object, said method comprising the steps of:
- (a) placing on a first conveyor a mold that replicates at least said portion of the surface of said original object;
- (b) conveying said mold to a dispenser of castable material;
- (c) filling said mold from said dispenser with castable material;
- and
- (d) confining said castable material to said mold.
A method for making a cast article replicating on at least part of the surface thereof, at least a portion of the surface of a modified object, said method comprising the steps of:
- (a) modifying the surface of said object to a predetermined configuration to produce a modified object,
- (b) making a first mold that replicates at least said portion of the surface of said modified object,
- (c) filling said first mold with a first castable material to produce a master reproduction,
- (d) making a second mold that replicates at least part of the surface of said master reproduction, and
- (e) filling said second mold with a second castable material to produce a cast article of at least part of the surface of said second mold.
Apparatus for production of a cast article replicating on at least part of the surface thereof, at least a portion of the surface of an original object, said apparatus comprising:
- a first mold replicating at least said portion of the surface of the original object;
- a master reproduction made with a first castable material placed in the first mold;
- a second mold that replicates at least a part of the surface of the master reproduction;
- and
- a closable support structure having a bottom to support the second mold and a top to cover the second mold.
Dependencies are inferred from the claim text.