# US 8,771,526 B2 · Composite concrete article and method of manufacture thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,771,526 B2 - Document ID: US8771526B2 - Status: Granted - Kind: B2 - Application number: 13/254,576 - Filed: 2010-03-03 - Published: 2012-07-26 - Granted: 2014-07-08 - Earliest claimed: 2009-03-04 - Assignees: University of Ulster - Applicants: Patricia Clare Belford; Ruth Ellen Morrow - Inventors: Patricia Clare Belford; Ruth Ellen Morrow - Web page: https://patentgrep.com/patent/US8771526B2 ## CPC - B28B 19/0092: {to webs, sheets or the like, e.g. of paper, cardboard} - B28B 23/0006: {the reinforcement consisting of aligned, non-metal reinforcing elements} - Y10T 428/22: Nonparticulate element embedded or inlaid in substrate and visible - Y10T 428/23943: Flock surface - Y10T 428/24331: including nonapertured component - Y10T 428/24793: Comprising discontinuous or differential impregnation or bond - Y10T 428/2481: including layer of mechanically interengaged strands, strand-portions or strand-like strips - Y10T 428/249921: Web or sheet containing structurally defined element or component - Y10T 442/10: Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.] - Y10T 442/30: Woven fabric [i.e., woven strand or strip material] - 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) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of manufacturing a composite concrete article comprising affixing at least one layer of textile to a base layer and incorporating the base layer into a body of wet uncured concrete such that the base layer becomes embedded in the concrete, whereby at least a portion of the at least one textile layer defines at least a portion of a surface of the cured concrete article with the base layer embedded within the concrete to anchor the textile layer to the concrete. ## Claims ### Claim 1 A method of manufacturing a composite concrete article comprising: affixing at least one layer of textile to a base layer; and incorporating the base layer into a body of wet uncured concrete such that the base layer becomes embedded in the wet uncured concrete, whereby when the concrete is cured to form a cured concrete article, at least a portion of the at least one textile layer defines at least a portion of an exposed surface of the cured concrete article with the base layer at least partially embedded within the concrete to anchor the textile layer to the concrete. ### Claim 2 (depends on 1) A method as claimed in claim 1, wherein the base layer comprises a porous fabric. ### Claim 3 (depends on 1) A method as claimed in claim 1, further comprising the step of forming stitched patterns in the at least one textile layer or stitching or bonding additional materials onto the at least one textile layer to create different visual or textural effects on the surface of the finished product before the base layer is incorporated into the body of wet uncured concrete. ### Claim 4 (depends on 1) A method as claimed claim 1, wherein the at least one textile layer affixed to the base layer form a resultant laminate that is placed in a mould with the textile layer in contact with a face of the mould, and uncured concrete is poured into the mould such that the concrete flows into the base layer to anchor the textile layer to the concrete. ### Claim 5 (depends on 1) A method as claimed in claim 1, wherein the base layer comprises a mesh or apertured sheet or cloth through which the uncured concrete flows. ### Claim 6 (depends on 5) A method as claimed in claim 5, wherein the base layer comprises a polymeric mesh. ### Claim 7 (depends on 6) A method as claimed in claim 6, wherein the base layer comprises a polyester or nylon mesh. ### Claim 8 (depends on 1) A method as claimed in claim 1, wherein the at least one textile layer is affixed to the base layer by means of an adhesive. ### Claim 9 (depends on 8) A method as claimed in claim 8, wherein the at least one textile layer is affixed to the base layer by means of a laminating film. ### Claim 10 (depends on 9) A method as claimed in claim 9, wherein the at least one textile layer is bonded to the laminating film before the textile layer is applied to the base layer by means of the laminating film. ### Claim 11 (depends on 1) A method as claimed in claim 1, wherein a pattern is formed in at least a portion of the at least one textile layer. ### Claim 12 (depends on 11) A method as claimed in claim 11, wherein the pattern is formed by laser cutting or ablation or a chemical etching process. ### Claim 13 (depends on 11) A method as claimed in claim 11, wherein the pattern is formed in the at least one textile layer before the base layer is incorporated into the body of wet uncured concrete. ### Claim 14 (depends on 1) A method as claimed in claim 1, wherein at least a portion of the at least one textile layer comprises a layer of flock adhesively secured to the base layer before the base layer is incorporated into the body of wet uncured concrete. ### Claim 15 (depends on 14) A method as claimed in claim 14, wherein the method comprises applying adhesive to the base layer and applying flock onto the adhesive layer to bond the flock to the base layer by electrostatic spraying of fine particles of flock onto the adhesive layer. ### Claim 16 (depends on 15) A method as claimed in claim 15, wherein the adhesive is applied to the base layer in a particular pattern by a screen printing process. ### Claim 17 (depends on 1) A method as claimed in claim 1, comprising affixing two or more textile layers to the base layer. ### Claim 18 (depends on 17) A method as claimed in claim 17, wherein the two or more textile layers may be at least partially superimposed upon one another or located adjacent each other to form a desired visual or textural effect. ### Claim 19 (depends on 17) A method as claimed in claim 17, wherein the two or more textile layers are formed from different materials, or comprise different textures or patterns, or are applied to the base layer by two or more different processes.