Methods and apparatus for replicating original objects
AssigneePolyRock Technologies, LLC
InventorBruce E. Harrington
Life of this patent
Estimating the term…
Abstract
Methods and apparatus for producing cast articles with characteristics of original objects such as a stone panel. The cast articles can replicate the contours, textures, and colors of all or a portion of the original object and can be made in any shape or size and specifically can be formed to simulate rock walls, carved stone architecture details, and other construction components normally created by stone masons or sculptors on site and at a high cost. The processes used in making the cast articles include the production of a series of molds. The molds seek to replicate the size, shape, contour, and surface texture of an original object with or without modifications to the original object.
Claims66
A method for making a cast article replicating on
- a part of the surface thereof, a portion of a surface of one of a natural stone article or a brick article, said method comprising:
- making a first mold that replicates in a first negative reproduction at least said surface portion of the one stone or brick article;
- filling said first mold with a first castable material;
- curing the first castable material in the first mold to produce a master reproduction, the master reproduction including a first positive reproduction of the first negative reproduction, the first positive reproduction replicating said surface portion of the one stone or brick article;
- making a flexible second mold that replicates the first positive reproduction of the master reproduction as a second negative reproduction of said surface portion of the one stone or brick article, the second mold having a cavity which includes the second negative reproduction;
- placing said second mold in a closable support structure made from rigid material, the closable support structure comprising a bottom to support the second mold and a top to cover the cavity of the second mold, the bottom supporting the second mold with the cavity facing the top when closed;
- closing the top over the cavity of the second mold;
- filling said second mold between the cavity and the closed top with a
- second castable material;
- and
- curing the second castable material within the cavity while the top is closed to produce said cast article having a front exterior surface area formed as a second positive reproduction from the second negative reproduction, the front exterior surface area replicating said surface portion of the one stone or brick article.
A method for making a cast article replicating on at least a part of the surface thereof, a portion of a surface of one of a natural stone article or a brick article, said method comprising:
- making a first flexible mold that replicates in a first negative reproduction said surface portion of the one stone or brick article;
- lining an inner surface of a first support structure with said first flexible mold so that the first negative reproduction of said first flexible mold faces away from the inner surface of said first support structure;
- filling said first support structure with a first castable material;
- curing the first castable material in the first mold to produce a master reproduction of said first flexible mold in said first support structure, the master reproduction including a first positive reproduction of the first negative reproduction, the first positive reproduction replicating said surface portion of the one stone or brick article;
- inserting said master reproduction into a second support structure;
- making a flexible second mold of said master reproduction while inserted in the second support structure, the second mold having a cavity which includes a second negative reproduction formed from the first positive reproduction;
- placing said second mold in a closable support structure made from rigid material, the closable support structure comprising a bottom to support the second mold and a top to cover the cavity of the second mold, the bottom supporting the second mold with the cavity facing the top when closed;
- closing the top over the cavity of the second mold;
- filling said second mold between the cavity and the closed top with a second castable material;
- and
- curing the second castable material within the cavity while the top is closed to produce said cast article having a front exterior surface area formed as a second positive reproduction from the second negative reproduction, the front exterior surface area replicating said surface portion of the one stone or brick article.
Dependencies are inferred from the claim text.