# US 9,943,980 B2 · Multi zone cementitious product and method

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- Number: US 9,943,980 B2
- Document ID: US9943980B2
- Status: Granted
- Kind: B2
- Application number: 14/577,835
- Filed: 2014-12-19
- Published: 2015-04-30
- Granted: 2018-04-17
- Earliest claimed: 2013-03-15
- Assignees: Four Points Developments LLC
- Applicants: David M. Franke
- Inventors: David M. Franke
- Web page: https://patentgrep.com/patent/US9943980B2

## CPC

- B28B 1/008: {made from two or more materials having different characteristics or properties (casting for producing layered articles B28B1/16; feeding several succesive layers, optionally of different materials B28B13/022; coating B28B11/04; applying material to surfaces to form a permanent layer thereon B28B19/00)}
- B28B 3/123: {on material in moulds or on moulding surfaces moving continuously underneath or between the rollers, e.g. on an endless belt}
- B28B 7/183: {for building blocks or similar block-shaped objects}
- B28B 7/28: Cores; Mandrels {(B28B1/44 takes precedence; of special materials in general B28B7/34; cores for making blind holes in situ E04G15/04; for making recesses E04G15/06)}
- B28B 13/0225: {Feeding specific quantities of material at specific locations in the mould}
- B28B 13/023: {by using a feed box transferring the moulding material from a hopper to the moulding cavities}
- B28B 19/0015: {on multilayered articles}
- C04B 28/02: containing hydraulic cements other than calcium sulfates
- C04B 2111/00612: {as one or more layers of a layered structure}
- Y10T 428/24322: Composite web or sheet
- Y10T 428/24355: Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
- 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)
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A multi-zone cementitious product, which includes a base zone made of a first cementitious material composition and forming a portion of the product. At least one facing zone is adjacent to and bonded to the base zone, the facing zone made of a second cementitious material composition and forming at least one exterior face of said product which is visible when the product is installed. A disrupted boundary layer is between the facing zone and the base zone, and includes material from both the facing zone and the base zone. The disrupted boundary layer bonds the facing zone to the base zone. The facing zone has a thickness sufficient to prevent the base zone from being visible when the product is installed.

## Claims

### Claim 1

A machine for molding a multi-zone cementitious product comprising:
a hopper having a plurality of hopper sections, each section capable of containing cementitious material;
a mold having at least one mold cavity;
a feed carriage having a plurality of feed carriage cavities, at least some of the carriage cavities corresponding to at least some of the hopper sections, the teed carriage being capable of being selectively aligned with the hopper and the mold; and
the feed carriage further including at least one mold zone separator to guide material from the feed carriage to particular locations within the mold cavity as material is transferred from the feed carriage into the mold cavity;
wherein the at least one mold zone separator is capable of being extended into the mold cavity, and the at least one mold zone separator is capable of being retracted back into the feed carriage once filling of the mold cavity is complete.

### Claim 2 (depends on 1)

The mold machine of claim 1, wherein the machine further includes least one compression ram for densifying material within the mold cavity.

### Claim 3 (depends on 1)

The mold machine of claim 1, wherein the machine further includes at least one vibrator for densifying material within the mold cavity.

### Claim 4 (depends on 1)

The mold machine of claim 1, wherein the mold is open on the top and bottom and rests on a transfer plate that provides a bottom surface of the mold, for use in transferring an uncured multi-zone cementitious product to a remote location for curing.

### Claim 5 (depends on 1)

The mold machine of claim 1, wherein at least one agitator aids the flow of materials from the feed carriage into the mold cavity.

### Claim 6 (depends on 1)

The mold machine of claim 1, wherein the mold zone separator is a solid plate.

### Claim 7 (depends on 1)

The mold machine of claim 1, wherein the mold zone separator includes at least one opening to encourage intermingling of material on either side of the mold zone separator.

### Claim 8 (depends on 1)

The mold machine of claim 1, wherein the mold zone separator includes a support base and a plurality of rods spaced along the support base.

### Claim 9 (depends on 1)

The mold machine of claim 1, wherein material flows from the hopper to the feed carriage by gravity.

### Claim 10 (depends on 1)

The mold machine of claim 1, wherein material is forced from the hopper to the feed carriage by at least one auger.

### Claim 11 (depends on 1)

The mold machine of claim 1, wherein the mold zone separator extends and retracts by mechanical means.

### Claim 12 (depends on 1)

The mold machine of claim 1, wherein the mold zone separator extends and retracts by hydraulic means.