US 5,637,236 AGranted

Method for producing a wall, roadway, sidewalk or floor of cementitious material

OwnerMichael Loweinventor

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Abstract

A method for producing a wall, roadway, sidewalk or floor of cementitious material having the appearance of natural stone and mortar including a base with an outer surface with a plurality of irregular shaped protrusions disposed in a random pattern to simulate natural stones and a plurality of simulated grout lines formed therebetween, the method including the steps of preparing a cementitious material, pouring the cementitious material into a form, vibrating the cementitious material, allowing the cementitious material to cure forming the base with the outer surface, releasing the base with the plurality of irregular shaped protrusions disposed in the random pattern to simulate natural stones and the plurality of simulated grout lines formed therebetween from the form, coloring the outer surface and accenting the plurality of simulated grout lines.

Claims16

Dependent claims

A method for producing a wall, roadway, sidewalk or floor of at least one panel of cementitious material having an appearance of natural stone and mortar including a base with an outer surface with a plurality of irregularly shaped protrusions disposed in a random pattern to simulate natural stones and a plurality of simulated grout lines formed therebetween comprising the following steps:

(a) preparing a cementitious material;
(b) pouring the cementitious material into a form including an obverse block forming mold with a contoured or irregular bottom having a plurality of recesses formed therein corresponding to individual stone elements or protrusions and a plurality of raised grout line forming edges extending upwardly therefrom corresponding to the simulated grout lines;
(c) vibrating the cementitious material causing finer or smaller sand and aggregate particles to migrate to the contoured or irregular bottom to form a relatively nonporous upper decorative surface;
(d) allowing the cementitious material to cure forming the panel of cementitious material;
(e) releasing the panel of cementitious material from the obverse block forming mold;
(f) applying an acid stain comprising an acid and pigment to the upper decorative surface of the panel of cementitious material;
(g) allowing the acid stain to etch into the upper decorative surface causing the pigment to diffuse into the upper decorative surface to create a secondary random irregular variegated pattern therein.

4 more elements

Dependencies are inferred from the claim text.

Facts

Application: 08/298,188Filed 1 Sep 1994 · continuation in part
Priority: 15 May 1991
Granted: 10 Jun 1997
Term ends: Not estimatedThe source records don’t support an estimate.

Classification15 codes

B28B 11/0872
For reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads: non-mechanical reshaping of the surface, e.g. by…
B28B 7/007
Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces: with…
B28B 7/0073
Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces: with…
B28B 11/001
Apparatus or processes for treating or working the shaped or preshaped articles: applying decorations on shaped articles, e.g. by painting

Family

Serial700,623Parent of this continuation · filed 15 May 1991
Serial84,081Parent of this continuation-in-part · filed 28 Jun 1993
Serial231,028Parent of this continuation-in-part · filed 22 Apr 1994
US 5,372,676 AParent of this continuation-in-part
US 5,637,236 AThis patent

From the US filing history. Foreign family members aren’t listed.