Method of producing patterned shaped article

A method for producing a patterned concrete shaped article, comprising the steps of:

• laying a mat on an inside bottom surface of a main form for molding said shaped article;
• disposing on said mat at a prescribed position a water soluble cell form comprising a plurality of cylindrical cells which have an equal height and are arranged in a contiguous manner;
• charging a prescribed amount of dry concrete material for forming a pattern-course of said shaped article into a prescribed number of cells of said water soluble cell form conforming to a shape of a pattern to be formed;
• charging a prescribed amount of concrete material for forming a base-course of said shaped article into a remaining space within said main form;
• causing said water soluble cell form to dissolve and said dry pattern-course concrete material and said base-course concrete material to set within said main form into said shaped article with water or with water under a pressure application, wherein said mat laid on said inside bottom surface of said main form permits an absorption of excess water and a supply of said excess water to a portion of said dry pattern-course concrete material and said base-course concrete material which lack moisture, and a degassing of said dry pattern-course concrete material and said base-course concrete material under said pressure application;
• and
• removing said shaped article from said main form.

A method for producing a patterned artificial stone shaped article, comprising the steps of:

• laying a mat on an inside bottom surface of a main form for molding said shaped article;
• disposing on said mat at a prescribed position a cell form comprising a plurality of cylindrical cells which have an equal height and are arranged in a contiguous manner;
• charging a prescribed amount of dry aggregate which is an artificial stone material for forming a pattern-course of said shaped article into a prescribed number of cells of said cell form conforming to a shape of a pattern to be formed;
• charging a prescribed amount of aggregate which is an artificial stone material for forming a base-course of said shaped article into a remaining space within said main form;
• removing said cell form from said main form;
• charging a setting agent into spaces between said dry pattern-course aggregate and said base-course aggregate to cause said aggregate to set within said main form into said shaped article with said setting agent or with said setting agent under a pressure application, wherein said mat laid on said inside bottom surface of said main form permits an absorption of excess setting agent and a supply of said excess setting agent to a portion of said artificial stone materials which lack setting agent, and a degassing of said artificial stone materials under said pressure application;
• and
• removing said shaped article from said main form.

A method for producing a patterned artificial stone shaped article, comprising the steps of:

• laying a mat on an inside bottom surface of a main form for molding said shaped article;
• disposing on said mat at a prescribed position a soluble cell form comprising a plurality of cylindrical cells which have an equal height and are arranged in a contiguous manner;
• charging a prescribed amount of dry aggregate which is an artificial stone material for forming a pattern-course of said shaped article into a prescribed number of cells of said soluble cell form conforming to a shape of a pattern to be formed;
• charging a prescribed amount of aggregate which is an artificial stone material for forming a base-course of said shaped article into a remaining space within said main form;
• charging a setting agent containing water or solvent into spaces between said dry pattern-course aggregate and said base-course aggregate to cause said soluble cell form to dissolve and said dry pattern-course aggregate and said base-course aggregate to set within said main form into said shaped article with said water or solvent or with said setting agent under a pressure application, wherein said mat laid on said inside bottom surface of said main form permits an absorption of excess setting agent and a supply of said excess setting agent to a portion of said aggregates which lack setting agent, and a degassing of said aggregates under said pressure application;
• and
• removing said shaped article from said main form.

A method for producing a patterned ceramic shaped article, comprising the steps of:

• laying a mat on an inside bottom surface of a main form for molding said shaped article;
• disposing on said mat at a prescribed position a cell form comprising a plurality of cylindrical cells which have an equal height and are arranged in a contiguous manner;
• charging a prescribed amount of dry ceramic material for forming a pattern-course of said shaped article into a prescribed number of cells of said cell form conforming to a shape of a pattern to be formed;
• charging a prescribed amount of ceramic material for forming a base-course of said shaped article into a remaining space within said main form;
• removing said cell form from said main form;
• charging at least one of water and lubricant-bonding agent into said main form to cause said pattern-course material and said base-course material to set under pressure within said main form into said shaped article with said at least one of water and lubricant-bonding agent, wherein said mat laid on said inside bottom surface of said main form permits an absorption of excess water or excess lubricant-bonding agent and a supply of said excess water or said excess lubricant-bonding agent to a portion of said ceramic materials which lack water or lubricant-bonding agent, and a degassing of said ceramic materials under said pressure;
• removing said shaped article from said main form;
• and
• sintering said shaped article.

A method for producing a patterned ceramic shaped article, comprising the steps of:

• laying a mat on an inside bottom surface of a main form for molding said shaped article;
• disposing on said mat at a prescribed position a soluble cell form comprising a plurality of cylindrical cells which have an equal height and are arranged in a contiguous manner;
• charging a prescribed amount of dry ceramic material for forming a pattern-course of said shaped article into a prescribed number of cells of said soluble cell form conforming to a shape of a pattern to be formed;
• charging a prescribed amount of ceramic material for forming a base-course of said shaped article into a remaining space within said main form;
• charging at least one of water and lubricant-bonding agent into said main form to cause said soluble cell form to dissolve and said pattern-course ceramic material and said base-course ceramic material to set under pressure within said main form into said shaped article with said at least one of water and lubricant-bonding agent, wherein said mat laid on said inside bottom surface of said main form permits an absorption of excess water or excess lubricant-bonding agent and a supply of said excess water or said excess lubricant-bonding agent to a portion of said ceramic materials which lack water or lubricant-bonding agent, and a degassing of said ceramic materials under said pressure;
• removing said shaped article from said main form;
• and
• sintering said shaped article.