US 5,787,667 A · Molded simulated stone product and method

Abstract

An inexpensive, lightweight, strong and durable casting that has a surface appearance simulating carved stone, and is especially adapted for use as a transition between a brick or stone wall and window and door openings. Further, it provides architectural detail to building constructions, especially as a surround for window and door openings. The casting is produced from a mixture of graded aggregates and a resin binder, combined in predetermined proportions to make a soupy mixture that is cast in a mold. The mold is vibrated to cause migration of air bubbles away from the surface of the molded product, and to cause realignment and orientation of the aggregate materials in a way to enhance the structure and surface density of the product. After the casting has set, it is removed from the mold and cured and the surface is sandblasted to erode away some of the resin binder and portions of the aggregate at the surface to produce an appearance that is an accurate simulation of carved stone. The cast product, when used as a trim component for architectural detail in building construction, may have shaped portions to accommodate straight runs of brick or stone work, minimizing the need for cutting or shaping the bricks or stones to fit around the casting.

Claims21

Dependent claims

A simulated stone casting for use as a building component in lieu of natural carved stone and cementitious materials, especially to provide fine architectural detail and transition between masonry structures and window and door openings, wherein:

said casting is molded with a predetermined shape and thin wall construction, with a front surface to be exposed to view during use, and comprises a matrix of polyester resin surrounding and bonding together a mixture of graded aggregate particles including predetermined proportions of crushed limestone, silica sand and calcium carbonate, said aggregate particles being concentrated at the front surface, with a substantial portion of the crushed limestone particles exposed through the front surface, and only small interstices of resin matrix exposed at the surface between the particles;
and
said front sureface is sandblasted to remove any resin film from the front surface and to etch exposed surfaces of the aggregate particles to produce a textured front surface on the casting made up primarily of exposed portions of the aggregate particles, thereby simulating the appearance of carved stone.

A building component for use as a transition between masonry structure and window and door openings, as a fireplace surround, or for providing architectural accent to a structure, comprising:

a casting with a front surface exposed to view when in use and that simulates carved stone in appearance, said casting having an open rear surface and a hollow interior defining a thin wall structure of substantially uniform thickness, wherein said casting comprises a matrix of polyester resin surrounding and bonding together a mixture of graded aggregate particles including predetermined proportions of crushed limestone, silica sand and calcium carbonate, said aggregate particles being concentrated at the front surface, with a substantial portion of the crushed limestone particles exposed through the front surface, and only small interstices of resin matrix exposed at the surface between the particles;
and
said front surface is sandblasted to remove resin film from the front surface and to etch exposed surfaces of the aggregate particles to produce a textured front surface on the casting made up primarily of exposed portions of the aggregate particles, simulating the appearance of carved stone in a lightweight and easy to handle structure to thereby facilitate installation and minimize cost.

Dependencies are inferred from the claim text.

Molded simulated stone product and method

Life of this patent

Molded simulated stone product and method

Life of this patent

Abstract

Claims21