Note: Descriptions are shown in the official language in which they were submitted.
CA 02307039 2000-03-15
- WO 99/25933 PCTlIL98/0052'1 .
1
s ATTACHED DECORATIVE STONES
SPESIFICATION
FIELD OF INVENTION
The present invention relates to a method for producing a wall, vertical or
to horizontal precast concrete article, walkway and roadway which is faced
with
stones or bricks of water containing materials.
BACKGROUND OF INVENTION
There are two main methods for producing a construction element which
1s is faced with separate stones or bricks of water containing materials.
According to the first method the individual stones are created and packed
at the factory, and are shipped to the construction site. Each stone is
attached
separately to an existing construction element. According to the second
method all the individual stones are attached to concrete forms. While
2o casting, the said stones are attached together by the freshly poured
concrete.
The said methods are expensive since it is very time consuming and has to be
done by skilled workers. As the individual stone is smaller and the design is
more complicated the cost of the construction element is higher. Over the
years some stones can pill off the exterior wall which can be dangerous.
DISCLOSURE OF THE INVENTION
I have found that the disadvantages, described above, may be overcome
by producing a modular construction element which is faced with at least one
construction article, here in after referred to as decorative article. The
3o modular decorative article including a plurality of separate stones or
bricks
CA 02307039 2000-03-15
- WO 99125933 PCT/IL98/0052~ .
2
which are connected together with a plurality of rods, wires or ropes here in
after referred to as rods while a space separate between all the adjacent
stones. The said stones and bricks here in after referred to as stones are
made
of water containing materials such as concrete, gypsum, mortar, silicate or
any other material which can be transferred from liquid to a solid state, here
1o in after referred to as hardened material. The said stones can be produced
in
various sizes, shapes and colors. The rods are made of rigid or flexible
material such as steel, aluminum, plastic or cotton and can be created in a
different cross section and bent to a desire geometrical shape.
The modular decorative article is produced in at least one mold
including(a) an exterior mold frame that comprises a horizontal bottom and
vertical perimeter walls and (b) an interior form that comprises a plurality
of
vertical interconnected beams with grooves. The mold is created of rigid or
flexible material such as metal, wood ,plastic, rubber or polyurethane.
The said rods are mounted inside the said mold which after the pouring of the
2o hardened material and the curing process, become an inseparable part of the
modular decorative article.
The present invention introduce two main methods for producing the
modular decorative article.
According to the first method of production, the modular decorative article is
produced in a mold wherein exterior mold frame and the interior form are
created as at least two separate components. The exterior mold frame
comprises the said horizontal bottom which has even or uneven top surface
and the perimeter walls. In order to enable easier striping the perimeter
walls
are usually created in at least two separate pieces which are erected and tied
3o together. The perimeter walls are erected around the said horizontal bottom
CA 02307039 2000-03-15
- WO 99/25933 PCT/IL98/00527_ .
3
or on top of it. The interior form comprises a plurality of interconnected
beams which have a plurality of grooves at the bottom edge to accommodate
the said rods. The rods are mounted and tied inside the exterior mold frame in
a distance above the said horizontal bottom. Following the mounting of the
rods, the said interior form is positioned adjacent to the horizontal bottom
1o and to the said perimeter walls . The said vertical interconnected beams,
the
perimeter walls and the horizontal bottom circumscribe together a plurality of
stone shaped openings. The hardened material is poured into the stone shaped
openings. Following the pouring of the hardened material and prior to the
hardening, the said form is lifted and removed. The modular decorative article
is created as the said rods are anchored inside the cured hardened material.
According to the first method of production it is possible pour the
hardened material inside the exterior mold frame prior to the placing of the
interior form. Following the pouring the said interior form is pushed inside
the hardened material and cut it to a plurality of stone shaped segments.
2o According to the second method of production the modular decorative
article is usually produced in at least two modular molds which are placed
adjacent each other. Each modular mold is usually created as one inseparable
component including the said horizontal bottom, perimeter walls and the said
vertical interconnected beams which circumscribe together a plurality of
stone shaped openings. The perimeter walls and the vertical interconnected
beams have a plurality of grooves at the top edge. In order to enable the
placing the said modular molds adjacent each other and to obtain equal
distance between all the adjacent stones it is necessary to create the said
vertical perimeter walls thinner than the interior vertical interconnected
3o beams. The present method is useful for producing a large modular
CA 02307039 2000-03-15
WO 99/25933 PCT/IL9$/00527. .
4
decorative article while using relatively small size modular molds. The said
rods are mounted on top of the interior vertical interconnected beams inside
the said grooves. The rods are stretched along the molds which after pouring
and curing of the hardened material connect all the stones of the modular
decorative article.
1o A detailed process for producing the decorative article and the
construction elements according the present invention will be explain in the
detailed description of the invention and in the claims.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to methods for producing a wall, vertical or
horizontal precast concrete article, walkway and roadway which are faced
with a plurality of modular decorative articles. The modular decorative
articles are positioned adjacent each other.
FIG -1 illustrates a partial isometric view of a basic embodiment of the
2o modular decorative article generally indicated as 100 . The decorative
article
100 according to the present example comprises a plurality of separate
stones 1 which are connected together with a plurality of rods 7h and 7v .
The stones 1 which are made of cured hardened material can be produce in a
desired thickness, geometrical shape and color.
The present invention introduce two main methods for producing the
modular decorative article 100.
According to the first method of production, the modular decorative article
100 is created in a mold generally indicated as 200. FIG - 3 is a view of a
modular decorative article 100 which is created in a mold 200 as shows in
3o an isometric views in FIG - 2 and in FIG - 4. The mold 200 as illustrated
CA 02307039 2000-03-15
- WO 99/25933 PCT/IL98/00527_ .
5 in an isometric view in FIG - 2 including (a) an exterior mold frame,
indicated as 80, comprising a horizontal bottom 4 and vertical perimeter
walls 3 and (b) an interior form , indicated as 90, comprises a plurality of
vertical interconnected beams 10. The interconnected beams 10 have a top
edge lOt, a bottom edge lOb and a plurality of grooves 6 at the bottom
1o edge. The perimeter walls 3 according to the present example are created
with holes 15. FIG -4 illustrates the mold 200 according FIG -3 which
already erected and a plurality of the rods 7h and 7v. The interior form 90
is position inside the exterior mold frame 80 while the interconnected beams
are adjacent to the horizontal bottom 4 and to the perimeter walls 10
circumscribe together a plurality of stone shaped openings 2. The plurality of
rods 7h and 7v are positioned inside the grooves 6 in a distanced above the
horizontal bottom #4 and in a distance below the top edge lOt. 7e is part of
longer rod 7v which is placed inside the hole 15 and extends the outer face
of the perimeter wail 3. On the other side of the longer rod 7v is mounted a
2o receptacle 8 ,such as plastic pipe, for protruding the rod 7e of an
adjacent
decorative article 100. FIG - 5 is an enlarged cross sectional view along
a - a which illustrates the stone shaped openings 2 and the relative positions
of the horizontal bottom 4, the perimeter walls 3, the vertical beams 10 and
the rods. The present example shows the perimeter walls 3 that are
positioned around the horizontal bottom 4 which has even top surface 4t.
However, it is possible to position the perimeter walls 3 on top of the
horizontal bottom 4 which has uneven top surface 4t as illustrated in F1G -
6. According to the present example the rods 7h and 7v are tied together
and supported above the horizontal bottom 4 with the rods 7e inside the
3o holes 15. In order to enable the striping it is usually necessary to erect
the
CA 02307039 2000-03-15
- WO 99/25933 PCT/IL98/00527 .
6
perimeter walls 3 of at least two separate components. The perimeter walls 3
are connected together prior to the casting of the hardened material and are
striped separately from the decorative article 100 after the curing process.
FIG - 7 illustrates cross sectional view of mold 200 wherein the exterior
mold frame 80 is created as one inseparable component. In order to enable
to the removal of the mold frame 80 the rods 7v are not extending beyond the
perimeter walls and the rods are supported on top of spacers 16.
The hardened material is cast into the stone shaped openings 2 up to the
top edge lOt of the interconnected beams 10. The rods 7h and 7v are
anchored inside the hardened material which after the curing process become
inseparable part of the decorative article 100.
FIG - 8 and is an isometric view of different mold 200 which illustrates
the exterior mold frame 80 ,the plurality of rods 7h and 7v which are
mounted inside the mold frame and the interior form 90 including a plurality
of vertical interconnected beams 10 with a plurality of grooves 6
2o corresponding to the rods 7h and 7v. FIG - 9 is a cross sectional view
along b - b in FIG - 8. The exterior mold frame according to the present
example including (a) the perimeter walls 3 and (b) horizontal bottom 4
which has majority of even top surface and minority of uneven top surface 4t.
The minority of the uneven surface 4t comprises a plurality of interconnected
wall that extend upwardly beyond the said even top surface. The
interconnected walls 4t corresponding to the plurality of the vertical
interconnected beams 10.
The process for producing the modular decorative article according to the
first method of production is according to the following steps:
(a) preparing the hardened material 5;
CA 02307039 2000-03-15
- WO 99/25933 PGT/IL98/00527_ .
7
(b) erecting the exterior mold frame 80;
(c) mounting the plurality of rods 7h and 7v inside the exterior mold
frame 80 a tying the rods to the mold frame;
(d) positioning the interior form 90 inside the exterior mold frame 80
adjacent to the horizontal bottom 4 and to the perimeter walls
io circumscribe together a plurality of stone shaped openings 2.
(e) pouring the hardened material 5 into the stone shaped openings 2;
(fJ vibrating the hardened material 5;
(g) lifting the interior form 90 and separating the form from the
hardened material 5;
(h) allowing the hardened material 5 to cure and the rods 7h and 7v
are anchored inside the cured hardened material 5, forming the modular
decorative article 100; and,
(i) separating and removing the exterior mold frame 80 from the
decorative article 100.
2o The process for producing the modular decorative article according to the
first method of production is according to the following steps:
(a) preparing the hardened material 5;
FIG - 10 is an isometric view which illustrates a different way of
production while using mold 200 which includes exterior mold frame 80 and
interior form 90. The hardened material 5 is poured into the mold frame 80
prior to the position of the interior form 90. The interior form 90 is pushed
into the hardened material 5 and cutting it to a plurality of stone shaped
segments.
According to the second method of production the modular decorative
3o article 100 is created in at least one mold generally indicated as 300.
CA 02307039 2000-03-15
WO 99/25933 PCT/IL98/00527_ _
s
FIG - 11 is an isometric view of a mold 300 including (a) an exterior
mold frame 80 comprises even or uneven horizontal bottom 4 and perimeter
walls 3 and (b) an interior form 90 comprises plurality of vertical
interconnected beams 10 which have a plurality of grooves 6 at the top edge.
The interconnected beams 10 together with the perimeter walls 3 and the
horizontal bottom 4 circumscribe a plurality of stone shaped openings 2.
FIG - 11 further illustrates a plurality of the rods 7h and 7v which are
mounted on top of the interconnected beams 10 inside the grooves 6. The
hardened material 5 is poured into the stone shaped openings 2. During the
curing process the plurality of rods are anchored inside the cured hardened
~5 material and become an inseparable part of the modular decorative article.
FIG - 12 is an isometric view of a modular mold 300 including (a) an
exterior mold frame 80 comprises even or uneven horizontal bottom 4 and
perimeter walls 3 which have a plurality of grooves 6a at the top edge and
(b) an interior form 90 comprises plurality of vertical interconnected beams
20 10 which have a plurality of grooves 6 at the top edge. The interconnected
beams 10 together with the perimeter walls 3 and the horizontal bottom 4
circumscribe a plurality of stone shaped openings 2. FIG - 13 and FIG - 14
are partial cross sectional views of the modular mold 300 along c - c
illustrating two different shapes of the perimeter walls 3 and the
25 interconnected beams 10. The modular mold 300 is usually created as one
inseparable component. The modular mold 300 is useful for producing large
modular decorative article while using a plurality of smaller size modular
molds 300 which are positioned adjacent each other. In order to be able to
attach two adjacent modular molds 300 it is necessary to create the thickness
CA 02307039 2000-03-15
WO 99/25933 PCT/II,98/00521 .
9
of the perimeter walls 3 less than half the thickness of the vertical
interconnected beams 3.
FIG -16 is an isometric view of two adjacent modular molds 300
according to FIG - 12. The rods 7h and 7v are positioned on top of the
interconnected beams 10 inside the grooves 6. The rods 7h are placed
1o inside the both molds 300 which after the pouring and curing are anchored
in
the hardened material producing one inseparable decorative article 100.
FIG - 15 is an isometric view of modular decorative article 100 which is
produced in the two adjacent modular molds 300 shown in FIG - 16.
The process for producing the modular decorative article according to the
~5 second method of production is according to the following steps:
(a) preparing the hardened material 5;
(b) erecting at least one regular or modular mold 300;
(c) mounting a plurality of rods 7h and 7v inside at least one mold 300;
(d) pouring the hardened material 5 into the stone shaped openings 2;
20 (e) vibrating the hardened material 5;
(f) allowing the hardened material 5 to cure and to anchor the rods 7h
and 7v, forming the modular decorative article 100; and,
(g) separating and removing the mold frame 300 from the decorative
article 100.
z5 FIG - 17 is an isometric view that illustrates the hardened material inside
the mold 200 or 300. The present example illustrates further additional
metal elements 11 which are useful for attaching the modular decorative
article 100 to a wall or for lifting the decorative article. The elements 11
are
anchored inside the hardened material and connected to the rods.
CA 02307039 2000-03-15
- WO 99/25933 PCT/IL98/00527_ .
to
FIG - 18 is a partial isometric view of a mold according to the present
invention that illustrates the hardened material inside the mold 200 or 300.
FIG - 18 further shows form liner 12 which is positioned on top of the
hardened material 5. The form liner which has uneven bottom surface impart
to the hardened material 5 uneven top surface. FIG - 19 is an enlarged
to cross sectional view along d - d which shows the relative position of the
form liner 12, the hardened material 5, the rods 7h and the mold.
The rods 7h and 7v are made of flexible or rigid material and the can
bent horizontally whenever it is necessary. The rods are mounted inside the
mold 200 or 300 as a separate pieces or the rods are connected together
~ s and are mounted as an array of rods. FIG - 20 illustrates part of
decorative
article 100 which is useful for facing an oval shaped wall. The stones I are
connected with flexible rods 7h and with rigid rods 7v. The decorative
article I 00 can be bent to an oval shape as shown in FIG - 21.
FIG - 22, FIG - 24, FIG - 25 and FIG - 26 are an isometric views
2o which illustrate a production of vertical and horizontal decorative
elements
which are faced with a plurality of modular decorative articles 100. The
decorative article are produced are produced in small and large sizes. The
small size decorative article 100 is created up to 0.75 sq.m which can be
lifted and placed by hand. The large decorative article 100 has to be handled
25 by suitable crane or any other machinery. While the small decorative
articles
100 are usually created in the factory it is often more economical to produce
the large decorative
FIG - 22 is an isometric partial view of vertical wall 30 which is covered
with three modular decorative articles 100. Each decorative article 100 is
3o supported on top of foundation 20 or on top of another decorative article
CA 02307039 2000-03-15
- WO 99/25933 PCT/IL98/00527_ .
tt
100 below. while the hangers 14 prevent a horizontal movement. FIG - 23
is an enlarged cross-sectional view along a - e. The view illustrates the
hangers 14 that are attached to the wall 30 which is sealed with a mortar
13. The view illustrates also the decorative article 100 which is hung with
the horizontal rod 7h on top of the hangers 14 adjacent to the mortar 13
1o and supported on top of the foundation 20.
F1G - 24 is an isometric view of seven modular decorative articles 100
according to FIG - 17 and part of a stone la which are attached adjacent
each other to an exterior concrete form panel 21. The decorative articles 100
are supported on top of the foundation 20 and connected with nails or
~5 special brackets to the panel 21. FIG - 24 further shows the interior
concrete form panel 22 which is erected in a horizontal distance from the
unexposed surface of the decorative articles I OOu. The concrete is poured
into the concrete forms inside the space between the decorative articles 100
and the interior panel 22. Elements 11 which are part of the decorative
?o article 100 are anchored inside the concrete which after the curing process
attach the decorative articles I00 to the concrete. It is recommended to seal
the unexposed surface 100u with a mortar or with a layer of polyethylene.
The sealing prevent liquids that are normally discharged from the concrete to
penetrate through the space between the stones 1 and to damage the exposed
25 surface of the decorative article 100.
FIG - 25 is a partial isometric view that illustrates a production process of
decorative precast concrete element which is faced with four modular
decorative articles 100 according to FIG - 17 and few stones la. The
decorative articles 100 are positioned horizontally adjacent each other and
3o the concrete forms 23 are erected around the perimeter. The concrete is
CA 02307039 2000-03-15
- WO 99/25933 PCT/IL98/00527. .
~2
poured into the forms 23 on top of the decorative articles 100. The elements
11 are anchored inside the concrete and connect the decorative articles 100
to the concrete. In order to prevent the liquids that are normally discharged
from the concrete to damage the bottom decorative surface of the decorative
articles 100 it is recommended to seal the top surface prior to the pouring.
W FIG - 26 is a partial isometric view that illustrates a production process
of
a wall which is faced with modular decorative articles 100. Each decorative
article 100 is supported on top of a foundation 20 or on top of another
decorative article 100 below and connected to two columns. The walls 30a
are built between the columns only after the connection of the decorative
articles is finished. FIG - 27 is a cross sectional view along F - F showing
the position and the connection of the decorative article 100 prior to the
building of the wall 30a. The elements I 1 which are anchored inside the
decorative article 100 are connected to elements 15 that are anchored inside
the columns 16.
2o While the invention has been described in conjunction with various
embodiments, the are illustrative only. Accordingly, many alternatives,
modifications will be apparent to persons skilled in the art in light of the
foregoing detailed description, and it is therefore intended to embrace such
alternatives and variations as to fall within the spirit and board scope of
the
appended claims.
