Method and apparatus for making decorative panels in relief

Abstract

A structure defining an upwardly opening tray is provided and initially filled with a hardenable mixture compactable to at least a reasonable degree and a grid is thereafter introduced into the tray and depressed downwardly into the hardenable mixture to a level spaced above the bottom of the tray and with upper portions of the grid projecting above the mixture. A second hardenable mixture is thereafter introduced into the tray within the openings formed by the grid and on top of the first mixture to a level substantially flush with the upper surfaces of the grid. A male die including coplanar spaced die members snugly receivable within the voids or spaces defined by the grid is positioned with the spaced die members in registry with the openings or spaces defined by the grid and forced into the spaces or openings so as to compress both mixtures within the tray. The step of compression is continued and the entire assembly including the tray, the grid and the male die are vibrated to compact the mixtures within the tray after which the grid and male die are coupled together for simultaneous extraction and the same are extracted from the tray and the mixtures therein during continued virbration of the tray to assist in separation of the grid and the male die members from the hardenable mixtures within the tray. Subsequently, vibration of the tray is terminated and the mixtures are allowed to fully harden resulting in the formation of a substantially rigid sheet-like panel representing the face surfaces of a mortar and brick construction.

Dependencies are inferred from the claim text.