US 6,599,452 B1 · Method for manufacturing simulated architectural forms

Abstract

A method is provided for manufacturing molded simulated stone and wood architectural articles for buildings and homes. The method incorporates a unique mold assembly including a resilient silicone rubber mold supported within a rigid mold cradle/foundation, and a vented lid having a High-Density Polyethylene (HDPE) interior surface. The silicone rubber mold is initially treated with a liquid polyester gel coating that is cured and then coated with an acrylic/vinyl ester back coating. Once the back coating is cured, a predetermined volume of a modified high-density, natural mineral fiber-reinforced, 2-component hybrid polyurethane liquid expanding composition is dispensed therein and the mold is covered with the vented lid. The system is pressurized and heated to produce a molecularly-fused, lightweight rigid article having the desired architectural shape.

Claims12

Dependent claims

A method for manufacturing a mold assembly to produce an article having a simulated stone or wood appearance, comprising the steps of:

providing a master form having a predetermined shape, surface contour and surface texture;
mounting the master form on a base substrate;
providing a master mold cradle having a mold cavity formed therein, the mold cavity having a shape and surface contour substantially complementary to the shape and surface contour of the master form but having dimensions greater than the corresponding dimensions of the master form;
positioning the master mold cradle over the master form to define a gap therebetween;
filling the gap with a resilient material;
curing the resilient material;
and
separating the master form and master form base from the master mold cradle.

5 more elements

Dependencies are inferred from the claim text.

Method for manufacturing simulated architectural forms

Life of this patent

Method for manufacturing simulated architectural forms

Life of this patent

Abstract

Claims12