# US 2020/0078982 A1 · Multi zone cementitious product and method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2020/0078982 A1 - Document ID: US20200078982A1 - Status: Published application - Kind: A1 - Application number: 16/680,128 - Filed: 2019-11-11 - Published: 2020-03-12 - Earliest claimed: 2013-03-15 - Assignees: Four Points Developments LLC - Applicants: Four Points Developments LLC - Inventors: David M. Franke - Web page: https://patentgrep.com/patent/US20200078982A1 ## CPC - B28B 1/008: {made from two or more materials having different characteristics or properties (casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00)} - B28B 1/04: by tamping or ramming (followed by pressing B28B3/02) - B28B 1/08: by vibrating or jolting {(of moulding sand B22C15/10; of concrete in general E04G21/063)} - B28B 1/087: by means acting on the mould {; Fixation thereof to the mould} - B28B 1/16: for producing layered articles (coating B28B11/04) - B28B 3/02: wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form - B28B 3/123: {on material in moulds or on moulding surfaces moving continuously underneath or between the rollers, e.g. on an endless belt} - B28B 7/0029: {Moulds or moulding surfaces not covered by B28B7/0058 - B28B7/36 and B28B7/40 - B28B7/465, e.g. moulds assembled from several parts} - B28B 7/16: Moulds for making shaped articles with cavities or holes open to the surface {, e.g. with blind holes} - B28B 7/183: {for building blocks or similar block-shaped objects} - B28B 7/28: Cores; Mandrels {(B28B1/44 takes precedence; of special materials in general B28B7/34; cores for making blind holes in situ E04G15/04; for making recesses E04G15/06)} - B28B 11/0818: {for roughening, profiling, corrugating} - B28B 11/16: for extrusion {or for materials supplied in long webs} - B28B 11/245: {Curing concrete articles (B28B11/242 takes precedence)} - B28B 13/02: Feeding the unshaped material to moulds or apparatus for producing shaped articles - B28B 13/0225: {Feeding specific quantities of material at specific locations in the mould} - B28B 13/023: {by using a feed box transferring the moulding material from a hopper to the moulding cavities} - B28B 13/028: {Deflecting the flow of the unshaped material} - B28B 17/00: Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping (moulds B28B7/00; after-treatment B28B11/00; feeding or discharging B28B13/00; arrangements for embedding elements in the material B28B23/00) - B32B 5/14: characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces - B32B 5/145: {Variation across the thickness of the layer} - C04B 7/00: Hydraulic cements (calcium sulfate cements C04B11/00) - C04B 28/02: containing hydraulic cements other than calcium sulfates - E04C 1/40: built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts - B28B 19/0015: {on multilayered articles} - B32B 13/00: Layered products comprising a {a layer of} water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material - C04B 2111/00612: {as one or more layers of a layered structure} - E01C 5/06: made of units with cement or like binders - E04C 1/00: Building elements of block or other shape for the construction of parts of buildings (of relatively thin form E04C2/00; structural elongated elements designed for load-supporting E04C3/00, e.g. columns or pillars E04C3/30; manufacture or material of building bricks, stones, or the like B28, C03, C04; paving elements E01C; general building constructions E04B, e.g. walls E04B2/00, floors E04B5/00, roofs E04B7/00, ceilings E04B9/00; {roof coverings E04D; coverings for walls or ceilings E04F13/00; floorings E04F15/00;} structural elements specially designed for built-in conduit shafts E04F17/00; {elements for buildings for particular purposes E04H7/00}; special elements for building ovens or furnaces F24B, F27D) - E04C 2/04: of concrete or other stone-like material; of asbestos cement; {of cement and other mineral fibres}(E04C2/26 takes precedence; material or manufacture B28, C04) - Y10T 428/24322: Composite web or sheet - Y10T 428/24355: Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.] - Y10T 428/24942: including components having same physical characteristic in differing degree - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) - E01C: CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR (forming roads or like surfaces by compacting or grading snow or ice E01H) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## 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. ## Claims ### Claim 1 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 the first hopper with first cementitious material; filling the 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 feed 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 cementitious 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, the removal of the zone separator forming a boundary between the first and second cementitious materials in the mold cavity; returning the feed carriage to a position under the first and second hoppers; densifying the first and second cementitious materials in the mold to form an uncured multi-zone cementitious product; ejecting the uncured multi-zone cementitious product from the mold; and curing the uncured multi-zone cementitious product. ### Claim 2 (depends on 1) The method of claim 1, further including the step of disrupting the boundary between the first and second cementitious materials in the mold cavity. ### Claim 3 (depends on 2) The method of claim 2, further including the step of disrupting the boundary between the first and second cementitious materials, causing the materials to intermingle. ### Claim 4 (depends on 2) The method of claim 2, wherein the boundary between the first and second cementitious materials is disrupted mechanically. ### Claim 5 (depends on 2) The method of claim 2 wherein the zone separator includes a plurality of prongs that disrupt the boundary when the zone separator is removed from the mold. ### Claim 6 (depends on 1) The method of claim 1, wherein densification is achieved by applying a forming force. ### Claim 7 (depends on 6) The method of claim 6, wherein the forming force is applied in a direction that is non-parallel to the boundary. ### Claim 8 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 the first hopper with first cementitious material; filling the 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 into the mold; aligning the feed carriage with the mold; inserting at least one zone separator into the mold cavity; depositing 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, the removal of the zone separator forming a boundary between the first and second materials in the mold cavity; disrupting the boundary between the first and second materials in the mold cavity; returning the feed carriage to a position under the first and second hoppers; densifying the first and second materials in the mold to form an uncured multi-zone cementitious product; ejecting the uncured multi-zone cementitious product from the mold; and curing the uncured multi-zone cementitious product. ### Claim 9 (depends on 8) The method of claim 8, wherein densification of the material in the mold is achieved by vibrating the mold. ### Claim 10 (depends on 8) The method of claim 8, wherein the densification of the material in the mold is achieved by applying a forming force to the material in the mold. ### Claim 11 (depends on 8) The method of claim 8, wherein the boundary between the first and second materials is disrupted mechanically. ### Claim 12 (depends on 8) The method of claim 8, wherein the forming force is applied in a direction that is non-parallel to the boundary. ### Claim 13 A method for making a multi-zone cementitious product comprising the steps of: preparing at least two cementitious materials; providing a molding machine including a mold with at least one mold cavity, at least two hoppers, and at least one feed carriage; the at least one feed carriage having a plurality of feed cavities; filling each of the hoppers with one of the cementitious materials; transferring the cementitious materials from the hoppers into at least one of the plurality of feed cavities; inserting a transfer plate into the mold; aligning the feed carriage with the mold; inserting at least one zone separator into the mold cavity; depositing the cementitious materials into the mold cavity, each of the materials separated by the at least one zone separator; removing the at least one zone separator from the mold cavity, the removal of the zone separator forming a boundary between the cementitious materials in the mold cavity; disrupting the boundary between the cementitious materials in the mold cavity; returning the feed carriage to a position under the hoppers; densifying the cementitious materials in the mold to form an uncured multi-zone cementitious product; ejecting the uncured multi-zone cementitious product from the mold; and curing the uncured multi-zone cementitious product. ### Claim 14 (depends on 13) The method of claim 13, wherein densification of the material in the mold is achieved by vibrating the mold. ### Claim 15 (depends on 13) The method of claim 13, wherein the boundary between the first and second materials is disrupted mechanically. ### Claim 16 (depends on 13) The method of claim 13, wherein the densification of the material in the mold is achieved by applying a forming force to the material in the mold. ### Claim 17 (depends on 16) The method of claim 16, wherein the forming force is applied in a direction that is non-parallel to the boundary.