Method of casting materials using a flexible resilient mold
OwnerMilomir Jevticinventor
Life of this patent
Estimating the term…
Abstract
A process for preparing cast articles includes preparing a primary mold of a flexible resilient bag-shaped membrane, disposing casting material in a flowable state into the primary mold and allowing the casting material to harden. Optionally, a relatively fixed secondary mold or a combination of relatively fixed secondary molds can be used adjacent the outside of the primary mold to impart a predetermined shape to portions of the cast object. A continuous ultra-smooth surface is created on the cast objects duplicating the surface of smooth naturally weathered stone.
Claims13
A process for producing a cast article having an ultra-smooth, highly polished exterior surface with rounded edges simulating naturally weathered smooth stone, comprising:
- (a) providing a secondary mold having a predetermined inner shape;
- (b) disposing at least a portion of a primary mold within the secondary mold, the primary mold comprising a resilient flexible membrane which in a relaxed state thereof has generally a bag shape of a predetermined size having an interior portion and an exterior surface and which in the relaxed state has a thickness of less than 6 mils and which, further, is stretchable to four times the predetermined size of the relaxed state without danger of rupturing;
- (c) disposing a mass of concrete or plaster casting material in a wet flowable state into the interior portion of the primary mold in the relaxed state, so that the casting material becomes substantially enclosed by the primary mold, which primary mold provides for formation of an ultra-smooth, highly polished exterior surface on an article cast therein;
- (d) stretching the primary mold out of the relaxed state due to forces from the mass of the casting material disposed into the interior portion of the primary mold to expand the primary mold to fill and substantially acquire the predetermined inner shape of the secondary mold;
- (e) allowing the casting material to harden;
- and
- (f) removing the secondary mold and the primary mold from the hardened cast article to provide the cast article with the ultra-smooth, highly polished exterior surface with rounded edges simulating naturally weathered smooth stone.
A method of producing cast articles, each article having an ultra-smooth, highly polished exterior surface with rounded edges simulating naturally weathered smooth stone, comprising:
- (a) providing a primary mold comprising a flexible resilient membrane having generally a bag shape of a predetermined size in a relaxed state thereof and having an inner surface and an exterior surface, the membrane having a thickness of less than 6 mils in the relaxed state and further having a capacity to be stretched to four times the predetermined size of the relaxed state without danger of rupturing;
- (b) disposing a mass of concrete of plaster casting material while in a wet flowable state into an interior portion of the primary mold defined by the inner surface of the primary mold in the relaxed state, so that the casting material becomes substantially enclosed by the primary mold, which primary mold provides for formation of an ultra-smooth, highly polished exterior surface on an article cast therein;
- (c) stretching the primary mold out of the relaxed state due to forces from the mass of the casting material disposed into the interior portion of the primary mold defined by the inner surface of the primary mold to expand the primary mold;
- (d) allowing the casting material to harden;
- and
- (e) removing the primary mold from the hardened cast article to provide the cast article with the ultra-smooth, highly polished exterior surface with rounded edges simulating naturally weathered smooth stone.
Dependencies are inferred from the claim text.