Multi zone cementitious product and method
OwnerDavid M. Frankeinventor
Life of this patent
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Abstract
A multi-zone cementitious product, which includes a base zone made of a first cementitious material composition and forming a portion of the product. At least one facing zone is adjacent to and bonded to the base zone, the facing zone made of a second cementitious material composition and forming at least one exterior face of said product which is visible when the product is installed. A disrupted boundary layer is between the facing zone and the base zone, and includes material from both the facing zone and the base zone. The disrupted boundary layer bonds the facing zone to the base zone. The facing zone has a thickness sufficient to prevent the base zone from being visible when the product is installed.
Claims20
A multi-zone cementitious product comprising:
- a base zone made of a first cementitious material composition and forming a portion of the product;
- at least one facing zone adjacent to and bonded to the base zone, the at least one facing zone made of a second cementitious material composition and forming at least one exterior face of the product which is visible when the product is installed;
- a disrupted boundary layer between the at least one facing zone and the base zone including material from both the at least one facing zone and the base zone;
- the disrupted boundary layer bonding the at least one facing zone to the base zone;
- and
- the at least one facing zone having a thickness sufficient to prevent the base zone from being visible when the product is installed.
A method for making a cementitious product comprising the steps of:
- depositing a cementitious material onto a base conveyor in a material input section of a multi-forming machine;
- passing the cementitious material under a top former, thereby forming an uncured slab between the top former, the base conveyor, and at least one side conveyor;
- and
- ejecting the uncured slab from the multi-forming machine.
A method for making a multi-zone cementitious product comprising the steps of:
- preparing a first cementitious material;
- preparing a second cementitious material;
- providing a molding machine including a mold with at least one mold cavity, a first and second hopper, and at least one feed carriage;
- the at least one feed carriage having a plurality of feed cavities;
- filling first hopper with the first cementitious material;
- filling second hopper with second cementitious material;
- transferring first cementitious material from the first hopper into at least one of the plurality of feed cavities;
- transferring second cementitious material from the second hopper into at least one of the plurality of cavities;
- inserting a transfer plate under the mold;
- moving the feed carriage over the mold;
- inserting at least one zone separator into the mold cavity;
- depositing the first and second materials into the mold cavity, the materials separated by the at least one zone separator;
- removing the at least one zone separator from the mold cavity;
- returning the feed carriage to a position under the first and second hoppers;
- applying a forming force to the mold to form an uncured multi-zone cementitious product;
- ejecting the uncured multi-zone cementitious product from the mold onto the transfer plate;
- and
- curing the uncured multi-zone cementitious product.
Dependencies are inferred from the claim text.