Static molds – In situ construction engineering type or building type-mold... – Forming building structure
Reexamination Certificate
2001-04-05
2003-10-21
Mackey, James P. (Department: 1722)
Static molds
In situ construction engineering type or building type-mold...
Forming building structure
C249S047000, C249S112000, C249S189000
Reexamination Certificate
active
06634617
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
A form liner for use in producing a wall, roadway, sidewalk or floor of cementitious material having the appearance of natural stone and mortar.
2. Description of the Prior Art
The high cost of labor and material have made the use of genuine brick, stone, rock and tile in construction prohibitively expensive.
As a result, relatively inexpensive polymers and concrete have become popular in the manufacture of artificial brick, stone, rock and tile. Artificial brick surfaces are relatively easy to produce. However the production of aesthetically appealing artificial stone is more difficult Specifically, replicating the texture resembling real stone and the color is often poor.
U.S. Pat. No. 5,885,502 shows a form liner having recesses configured to receive a plug along the periphery thereof.
U.S. Pat. No. 5,632,922 discloses a form liner having irregular shaped recesses.
U.S. Pat. No. 5,372,676 describes a method of producing replicated paving stone including a base having a shaded and straified layered upper surface with a plurality of simulated gourt lines formed therein. The method includes the steps of preparing a cementitious mortar, applying a release agent to the interior of a forming mold, pouring the cementitious mortar into the forming mold, leveling the mortar, vibrating the forming mold and cementitious mortar therein, allowing the cementitious mortar to cure forming a base with an upper surface, releasing the base from the forming mold, applying an acid stain to the base, allowing the acid stain to etch the base to shade the upper surface, accenting the plurality of simulated grout lines with a pigment and sealing the replicated paving stone with an acrylic polymer sealer.
U.S. Pat. No. 5,637,236 shows a method for producing a wall, roadway, sidewalk or floor of cementitious material having the appearance of natural stone and mortar including a base with an outer surface with a plurality of irregular shaped protrusions disposed in a random pattern to simulate natural stones and a plurality of simulated grout lines formed therebetween. The method includes the steps of preparing a cementitious material, pouring the cementitious material into a form, vibrating the cementitious material, allowing the cementitious material to cure forming the base with the outer surface, releasing the base with the plurality of irregular shaped protrusions disposed in the random pattern to simulate natural stones and the plurality of simulated grout lines formed therebetween from the form, coloring the outer surface and accenting the plurality of simulated grout lines.
U.S. Pat. No. 4,027,846 shows a panel for casting concrete comprising a frint casting plate having a flat front surface constituting a support surface for cast concrete and a rear plate spaced from the front plate. A lwyer of expanded plastic foam material such as polyurethane foam of high density is cast, in situ, between the plates and effects joinder of plates with the foam layer to form an assembled panel which behaves as a beam and has high resistance to bending and shear stresses.
U.S. Pat. No. 5,098,059 teaches an assembly comprising a foam piece of high density styrofoam for use in concrete casting having a front surface, a back surface and edges. The assembly further comprises a flexible, non-permeable plastic film surrounding the foam piece. In one aspect of the invention, the plastic film surrounding the foam piece is heat shrunk. In another aspect of the invention, the foam piece defines a block out for use in concrete casting.
U.S. Pat. No. 4,887,789 shows a form for molding building components such as columns from building materials such as concrete. The form is sculpted from a plastic material such as polystyrene, urethane or styrofoam.
U.S. Pat. No. 4,310,370 shows a process for producing decorative articles comprising the steps of placing into mutual contact and laminating a hardenable decorative layer and an expansion-contraction deformable sheet provided with regions susceptible to expansion contraction deformation and regions not susceptible to deformation; causing the deformable sheet to undergo deformation under pressure to impart a pattern of unevennesses to the decorative material layer in contact with the sheet; and causing the decorative material layer to fully harden. The sheet deformed under pressure imparts a pattern of surface unevenness corresponding to the two kinds of regions to the decorative material layer. The degree of surface unevenness can be controlled by adjusting the pressure. Colored patterns corresponding to the unevennesses can also be formed.
U.S. Pat. No. 3,936,619 describes a method of forming an artificial stone comprising the steps of providing a flexible mold; pouring a curable mixture of polyester plastic and catalyst in the mold to form a polyester plastic body having a configured surface; scraping off excess of the curable mixture by applying sufficient pressure to depress the edges of the mold and form a raised lip on the plastic body; curing the mixture; removing the plastic body from the mold; spraying the configured surface with a liquid color layer and drying; spraying the color layer with a curable, transparent, liquid coat and curing said coat until the outer surface is gelled; spraying a thin layer of sand on the outer surface of said transparent coat, and curing the transparent coat, thereby bonding the sand layer to the transparent coat layer.
U.S. Pat. No. 4,349,588 teaches a method for producing simulated brick, tile wall or floor using cement, water-based adhesive and water insoluble powdered pigment. The mixture is applied and then partially set. Scoring indentations are made to remove cement. After being completely set, mortar is placed in the indentations as a grout and allowed to set The final step is a clear water-resistant coating on the entire surface.
U.S. Pat. No. 4,126,727 shows a resinous polymer sheet material having selective, decorative effects comprising a first layer of a resinous polymer composition; a pattern or design printed on and adhered to the surface of the first layer of resinous polymer composition and having relatively dark colored printed portions and relatively light colored printed portions. A second layer of a resinous polymer composition is applied on and adhered to the printed pattern or design and to the first layer of resinous polymer composition. The second layer of resinous polymer composition includes a layer of relatively small flat, decorative chips or flakes comprising a very thin layer of translucent or transparent platelets provided with coating. Light wave interference and color absorptive effects are created as light waves strike and reflect from the second layer of resinous polymer composition whereby the decorative chips or flakes located over the relatively dark colored printed portions are discernible from eye-level or a distance of about five feet whereas those decorative chips or flakes located over the relatively light colored printed portions are indiscernible from eye-level or a distance of about five feet.
U.S. Pat. No. 4,105,816 describes a decorative relief finished surface formed to a substrate by applying an undercoat to a predetermined thickness and forming an uneven pattern with a rolling device having a plurality of convex parts of curved continued, disconnected or perforated line shape which are formed in a random manner, with the intervals between the convex parts being substantially equal to each other, or by spraying coating material with a spray gun so as to form a multiplicity of projections of varying height. Then, the top portions of the projections of the partially hardened surface which extend beyond a predetermined height are pressed with a pressing roll such that the projections are uniformly flattened to a predetermined thickness while the rest of the convex parts are left unflattened.
U.S. Pat. No. 3,882,218 shows embossed decorative patterns and decorative laminates, particularly textured film finished structural elements and th
Fisher III Arthur W.
Inco Chemical Supply Company, Inc.
Mackey James P.
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