# US 6,293,065 B1 · High strength porous concrete structure and method of manufacturing the high strength porous concrete structure > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 6,293,065 B1 - Document ID: US6293065B1 - Status: Granted - Kind: B1 - Application number: 09/232,735 - Filed: 1999-01-19 - Granted: 2001-09-25 - Earliest claimed: 1998-02-16 - Assignees: Sumitomo Osaka Cement Co., Ltd. - Inventors: Hiroaki Suzuki; Kikuo Tachibana; Tatsuji Tanahashi; Tetsuo Kobayashi - Web page: https://patentgrep.com/patent/US6293065B1 ## CPC - B28B 7/007: {with moulding surfaces simulating natural effets, e.g. wood or stone} - B28B 7/346: {Manufacture of moulds} - B44C 5/0438: {containing stone elements} - B44C 5/0453: {produced by processes involving moulding} - Y10T 428/24372: Particulate matter - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)} - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract This invention is intended to provide a high strength porous concrete structure which is preferably applied to a water permeable pavement, a draining pavement, a sound insulating board, a sound-proofing barrier, a sound absorbing block for acoustic, a block for plants, a riverbed block, a water purifying matrix, a gas absorbing matrix, a decorative board for building, a fish reef, a block for fish reef or a block for breeding algae and to provide a method of manufacturing the high strength porous concrete structure. The high strength porous concrete structure 1 having an arrangement in which a plurality of lumps 2 whose configuration is rough aggregates are integrally formed with the same concrete tissue and a gap 3 formed between the lumps 2 is through to a back side 2a of the lump 2 is manufactured by putting a thermoplastic material 8 into contact with a surface of a porous concrete structure 6 using rough aggregates 10 so as to form a form 9 and placing mortar or concrete 13 which does not include rough aggregates into the form 9. ## Claims ### Claim 1 A high strength porous concrete structure having a surface configuration corresponding to a surface configuration of an original object, manufactured by a method comprising the steps of: contacting a heated-to-melt thermoplastic material, which cures to an elastically deformable form, with a surface of the original object; curing the thermoplastic material to make the elastically deformable form; detaching the elastically deformable form from the original object; placing mortar or concrete into the elastically deformable form; and curing the mortar or concrete to obtain the high strength porous concrete structure, wherein a plurality of lumps whose surface configuration is similar to the surface configuration of the original object are interconnected and exposed to a surface of the high strength porous concrete structure and a gap is formed between said lumps through to a back side of the lumps, wherein said lumps are arranged over all the thickness of said high strength porous concrete structure and the lumps are integrally formed of the same concrete. ### Claim 2 A high strength porous concrete structure having a surface configuration corresponding to a surface configuration of an original object, manufactured by a method comprising the steps of: contacting a heated-to-melt thermoplastic material, which cures to an elastically deformable form, with a surface of the original object; curing the thermoplastic material to make the elastically deformable form; detaching the elastically deformable form from the original object; placing mortar or concrete into the elastically deformable form; and curing the mortar or concrete to obtain the high strength porous concrete structure, wherein a plurality of lumps whose surface configuration is similar to the surface configuration of the original object are interconnected and exposed to a surface of the high strength porous concrete structure and a gap is formed between said lumps through to a back side of the lumps, wherein the high strength porous concrete structure comprises a surface portion where the lumps are arranged within a certain thickness of the surface portion and a solid tightly filled backing portion and the lumps of the surface portion and the backing portion are integrally made of the same concrete. ### Claim 3 A high strength porous concrete structure having a surface configuration corresponding to a surface configuration of an original object, manufactured by a method comprising the steps of: contacting a heated-to-melt thermoplastic material, which cures to an elastically deformable form, with a surface of the original object; curing the thermoplastic material to make the elastically deformable form; detaching the elastically deformable form from the original object; placing mortar or concrete into the elastically deformable form; and curing the mortar or concrete to obtain the high strength porous concrete structure, wherein a plurality of lumps whose surface is a configuration of rough aggregates are interconnected and exposed to a surface of the high strength porous concrete structure and a gap is formed between said lumps through to a back side of the lumps, wherein said lumps are arranged all over the thickness of the high strength porous concrete structure and are integrally formed of the same concrete. ### Claim 4 A high strength porous concrete structure having a surface configuration corresponding to a surface configuration of an original object, manufactured by a method comprising the steps of: contacting a heated-to-melt thermoplastic material, which cures to an elastically deformable form, with a surface of the original object; curing the thermoplastic material to make the elastically deformable form; detaching the elastically deformable form from the original object; placing mortar or concrete into the elastically deformable form; and curing the mortar or concrete to obtain the high strength porous concrete structure, wherein a plurality of lumps whose configuration of the surface is a configuration of rough aggregates are interconnected and exposed to a surface of the high strength porous concrete structure and a gap is formed between said lumps through to a back side of the lumps, wherein the high strength porous concrete structure comprises a surface portion where the lumps are arranged within a certain thickness of the surface portion and a solid tightly filled backing portion and that the lumps of the surface portion and the backing portion are integrally made of the same concrete. ### Claim 5 (depends on 1) The high strength porous concrete structure as described in claim 1, wherein a plurality of continuous air bubbles are arranged in said concrete and part of the continuous air bubbles is open to the surface of the high strength porous concrete structure. ### Claim 6 (depends on 4) The high strength porous concrete structure as described in claim 4 wherein a plurality of continuous air bubbles are arranged in said concrete and part of the continuous air bubbles is open to the surface of the high strength porous concrete structure. ### Claim 7 A high strength porous concrete structure having a surface configuration corresponding to a surface configuration of an original object, manufactured by a method comprising the steps of: contacting a heated-to-melt thermoplastic material in a melted condition, which cures to an elastically deformable form, with a surface of the original object; curing the thermoplastic material to make the elastically deformable form; detaching the elastically deformable form from the object; placing mortar or concrete into the elastically deformable form; and curing the mortar or concrete to form a surface layer and obtain the high strength porous concrete structure comprising a surface layer and a backing layer which has water permeability or a draining function and which is united with said surface layer, wherein said surface layer has an arrangement in which a plurality of lumps whose configuration is similar to a configuration of the original object and each of which is interconnected and exposed to a surface of the surface layer, that a gap is formed between said lumps through from the surface of said surface layer to a boundary between the surface layer and the backing layer, and that the lumps are integrally formed of the same concrete. ### Claim 8 (depends on 7) The high strength porous concrete structure as described in claim 7, wherein the backing layer is made of porous concrete using rough aggregates. ### Claim 9 (depends on 7) The high strength porous concrete structure as described in claim 7, wherein the backing layer is made of solid tight concrete and provided with a water through hole. ### Claim 10 A high strength porous concrete structure having a surface configuration corresponding to a surface configuration of an original object, manufactured by a method comprising the steps of: contacting a heated-to-melt thermoplastic material in a melted condition, which cures to an elastically deformable form, with a surface of the original object; curing the thermoplastic material to make the elastically deformable form; detaching the elastically deformable form from the object; placing mortar or concrete into the elastically deformable form; and curing the mortar or concrete so as to form a surface layer and obtain the high strength porous concrete structure, comprising a surface layer and a backing layer which has water permeability or a draining function and which is united with said surface layer, wherein said surface layer has an arrangement in which a plurality of lumps which have a configuration of rough aggregates and each of which is interconnected and exposed to a surface of the surface layer, that a gap is formed between said lumps through from the surface of said surface layer to a boundary between the surface layer and the backing layer, and that the lumps are integrally formed of the same concrete. ### Claim 11 (depends on 10) The high strength porous concrete structure as described in claim 10, wherein the backing layer is made of porous concrete using rough aggregates. ### Claim 12 (depends on 10) The high strength porous concrete structure as described in claim 10, wherein the backing layer is made of solid tight concrete and provided with a water through hole.