United States Patent 19
`Kawasaki
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`73)
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`METHOD FOR PRODUCING CONCRETE
`PRODUCTS PROVIDED WITH INLAD
`PATTERNS
`Masaki Kawasaki, Fukuoka, Japan
`Inventor:
`Assignee:
`Kabushiki-Kaisha Yamau, Fukuoka,
`Japan
`Appl. No.: 240,993
`Fied:
`Sep. 6, 1988
`Int, Cl* ....................... B28B 1/16; B29C 39/12;
`B32B 31/00
`U.S. C. ...................................... 264/22; 264/139;
`264/162; 264/221; 264/226; 264/227; 264/246;
`264/251; 264/317
`Field of Search ................. 264/22, 139, 162, 163,
`264/256, 261, 221, 226, 227,317, 246, 25, 219,
`236, 14, 132, 251; 156/272.2, 273.3, 273.5
`References Cited
`U.S. PATENT DOCUMENTS
`36,821 10/1862
`Poitevin
`Cousins.
`488,541 12/1892
`731,254 6/1903 Whitman ............................. 264/162
`827,287 7/1906 Bidtel ........
`... 264/246X
`1,557,723 10/1925 Pearson ............................... 249/19
`1,666,232 4/1928 Boynton .............................. 264/246
`1,792,486 2/1931 Feinberg......................... 264/227 X
`1,816,915 8/1931 Scott ............................... 264/139 X
`2,193,586 3/1940 Fischett ............................... 264/139
`3,739,051 6/1973 Smith .............................. 264/226X
`
`
`
`[11] Patent Number:
`(45) Date of Patent:
`
`4,889,666
`Dec. 26, 1989
`
`3,798,134 3/1974 Hynes ............................. 264/227 X
`4,133,369
`/ 1979 Maire et al. ..................... 264/317 X
`4,595,543 6/1986 Williams ............................... 264/22
`Primary Examiner-Jan H. Silbaugh
`Assistant Examiner-Karen D. Kutach
`Attorney, Agent, or Firm-Jordan and Hamburg
`57
`ABSTRACT
`A method for producing concrete products provided
`with inlaid patterns includes (a) preparing a reusable
`mold provided with recessed patterns by applying ultra
`violet rays on the surface of an ultra-violet-ray setting
`resin plate, (b) preparing a waste mold provided with
`recessed patterns from the reusable mold, the waste
`mold being made of a soluble material which can be
`dissolved by water, solution or heat, (c) casting con
`crete into the waste mold and solidifying the concrete
`to provide a concrete block on the waste mold, (d)
`dissolving and removing the waste mold from the con
`crete block and providing recessed patterns on the sur
`face of the concrete block, (e) filling a coloring material
`into the recessed patterns on the surface of the concrete
`block and solidifying the coloring material, and (f)
`grinding the surface of the concrete block to produce
`concrete products provided with inlaid patterns on the
`surface thereof. Due to this construction, the fine and
`delicate recessed patterns on the original can be accu
`rately and vividly reproduced on the surface of the
`concrete products as the inlaid patterns.
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`2 Claims, 2 Drawing Sheets
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`5
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`KYKYSSA.
`3-1, SSN
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`NS
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`Metromont Ex-1016, p. 1
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`U.S. Patent Dec. 26, 1989
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`Sheet 1 of 2
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`4,889,666
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`FIG.
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`FIG2 4
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`5
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`4
`3
`essess
`8 2
`7a
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`(SASA
`3-1 sis
`C C C C C C C C/O C. C. C. C.
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`5
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`FIG 3 Y,
`M %. FIG.4
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`8b
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`Metromont Ex-1016, p. 2
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`U.S. Patent Dec. 26, 1989
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`Sheet 2 of 2
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`4,889,666
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`Metromont Ex-1016, p. 3
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`1
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`METHOD FOR PRODUCING CONCRETE
`PRODUCTS PROVIDED WITH NLAD
`PATTERNS
`
`O
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`4,889,666
`2
`the recessed patterns on the surface thereof which are
`substantially as fine and delicate as patterns on the origi
`nal. Using this reusable mold, the waste mold is pro
`duced from a plastic material such as paraffin which is
`soluble by water, solution or heat so that the fine and
`delicate recessed patterns on the reusable mold can be
`accurately reproduced on the surface of the waste
`mold. Making use of this waste mold, the concrete
`block provided with recessed patterns can be produced,
`wherein the fine and delicate recessed patterns on the
`waste mold can be accurately reproduced on the sur
`face of the concrete block. By filling the coloring mate
`rial into the recessed patterns on the concrete block and
`grinding the surface of the concrete block after the
`coloring material is solidified, the concrete product
`provided with inlaid patterns can be produced, wherein
`the inlaid patterns can accurately reproduce the fine
`and delicate recessed patterns of the waste mold, and
`eventually the fine and delicate patterns of the original.
`The degree of fineness of the inlaid patterns can be
`enhanced by utilizing concrete of fine grain size.
`Since the patterns on the concrete product are inlaid
`into the concrete product, the patterns will not fade for
`many years and the peeling off of the patterns can be
`prevented effectively.
`m
`Since many waste molds can be readily produced
`from a single reusable mold, and the concrete is cast on
`all waste molds simultaneously to produce concrete
`products, concrete products having the same patterns
`can be produced on a mass-production basis.
`Since the waste mold can be removed from the con
`crete block by dissolving the waste mold, the damage
`which may occur during the removing operation can be
`completely prevented thus the fine and clear patterns of
`the original can be reproduced on the surface of the
`concrete products.
`BRIEF EXPLANATION OF DRAWINGS
`FIGS. 1 through 4 are explanatory views showing
`the process of producing a reusable mold.
`FIG. 5 is an explanatory view showing the process of
`producing a waste mold.
`FIG. 6 is an explanatory view showing the process of
`casting concrete into the waste mold.
`FIG. 7 is an explanatory view showing the process of
`removing the waste mold from the concrete block.
`FIG. 8 is an explanatory view showing the process of
`charging a coloring material into the recessed patterns
`on the concrete block.
`FIG. 9 is an explanatory view showing the process of
`grinding the surface of the concrete block to produce a
`concrete product provided with inlaid patterns.
`BEST MODE FOR CARRYING OUT THE
`INVENTION
`The method for producing the concrete product pro
`vided with inlaid patterns is hereinafter explained in
`detail in conjunction with attached drawings.
`In FIGS. 1 through 4, the process of producing a
`reusable mold M is shown.
`As shown in FIG. 1, an original 2, such as a positive
`or negative photo film which is provided with a pattern
`8, is placed on a glass plate 1 and a covering film 3 is, in
`turn, placed on the original 2.
`A suitable amount of ultra-violet-ray setting resin is
`coated on the upper surface of the covering film 3 to
`
`FIELD OF ART
`The present invention relates to a method for produc
`ing concrete products provided with inlaid patterns.
`BACKGROUND OF INVENTION
`Conventionally, concrete products which are used
`for ornamental purposes are provided with various
`patterns including designed letters on the surface
`thereof for enhancing the aesthetic effects or the orna
`15
`mental effects.
`For providing patterns on the surface of such con
`ventional concrete products, several methods have been
`proposed, wherein one method applies a paint on the
`surface of the concrete products, another method uti
`lizes steel cores for providing patterns and still another
`method utilizes a wooden mold provided with protru
`sions and recesses on the surface thereof for providing
`patterns.
`The first method, however, cannot provide fine or
`delicate patterns on the surface of the concrete products
`since the surface is, in general, considerably rough.
`Furthermore, the painted patterns deteriorate in a short
`period and are peeled off from the concrete products
`and it is a time-consuming and laborious work to manu
`ally paint patterns on each concrete products.
`30
`The second method and the third method also are
`deficient for producing patterns made offine or delicate
`lines or designs.
`Accordingly, it is an object of the present invention
`to provide a method for producing concrete products
`which can overcome the drawbacks of the conventional
`methods, wherein the method can produce concrete
`products which are provided with inlaid patterns on the
`surface thereof and such inlaid patterns are capable of
`maintaining their aesthetic or ornamental effects vividly
`40
`for many years.
`It is another...object of the present invention to pro
`vide a method for producing concrete products pro
`vided with inlaid patterns, wherein the inlaid patterns
`are made of fine and delicate lines so that even patterns
`45
`made of complicated designs can be readily applied on
`the surface of the concrete products.
`In summary, the present invention discloses a method
`for producing concrete products provided with inlaid
`patterns comprising (a) prepared a reusable mold pro
`50
`vided with recessed patterns by emitting ultraviolet
`rays on the surfaces of an ultra-violet-ray setting resin
`layer, (b) preparing a waste mold provided with re
`cessed patterns from the reusable mold, the waste mold
`being made of a soluble material which can be dissolved
`55
`by water, solution or heat, (c) casting concrete into the
`waste mold and solidifying the concrete to produce a
`concrete block on the waste mold, (d) melting or re
`moving the waste mold from the concrete block and
`providing recessed patterns on the surface of the con
`crete block, (e) filling a coloring materiai into the re
`cessed patterns on the surface of the concrete block and
`solidifying the coloring material, (f) grinding the sur
`face of the concrete block to produce concrete products
`provided with inlaid patterns on the surface thereof.
`According to this invention, the reusable mold can be
`produced by applying the ultraviolet rays on the ultra
`violet-ray setting resin, the reusable mold can exhibit
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`Metromont Ex-1016, p. 4
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`4,889,666
`4.
`3
`produce a coated resin layer 4 and a base film 5 is ad
`which further include silica fume, fly ash or limestone
`hered to the upper surface of the coated resin layer 4.
`which is pulverized to a grain size of less than 1 or an
`The ultra-violet-ray setting resin may preferably be
`expansion agent. Furthermore, the concrete may in
`urethane or polyester photopolymer. The covering film
`clude a material made of thermosetting resin such as
`3 may preferably be made of a polyester or polypropyl
`unsaturated polyester to which pulverized aggregate is
`ene film having the thickness of 30 um. The base film 5
`added.
`may preferably be made of a polyester film having the
`It is desirable to carry out a vacuum defoaming pro
`cess before the above-mentioned concrete casting oper
`thickness of 100 um.
`Subsequently, as shown in FIG. 2, a glass plate 6 is
`ation so that the damage on an inlaid pattern 8e pro
`placed on the base film 5 such that the original 2, the
`duced on a final concrete product B which may occur
`due to the impregnation of air can be prevented effec
`covering film 3 and the coated resin layer 4 are sand
`tively.
`wiched by the glass plates 1 and 6.
`A pair of ultra-violet-ray emitting lamps 7,7a are
`For preventing the impregnation of air into the con
`arranged below the glass plate 1 and above the glass
`crete 11, it is also possible to mount the mold frame 10
`plate 6 respectively, and these lamps 7, 7a are simulta
`on a centrifuge and to cast the concrete 11 under pres
`neously switched on to emit ultraviolet rays.
`Ste.
`The ultraviolet rays emitted from the lamp 7 pass
`Then, the block 12 is removed from the mold frame
`through the glass plate 1 and the pattern-made portion
`10 together with the waste mold W and the waste mold
`of the original 2 and reach the parts of the lower surface
`W is melted or removed from the block 12 by means of
`of the coated resin layer 4 which correspond to the
`hot water, solution or heat as shown in FIG. 7.
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`pattern-made portions of the original 2 and start solidi
`Finally, a coloring material 13 which is different in
`fying the parts gradually, while the ultraviolet rays
`color from the concrete 11 is filled in a recessed pattern
`emitted from the lamp 7a pass through the glass plate 6
`8d on the surface of the block 12 and the surface of the
`block 12 is ground or polished to produce the concrete
`and reach the entire upper surface of the coated resin
`products B provided with the inlaid pattern 8e.
`layer 4 and start the uniform solidifying of the entire
`upper surface of the coated resin layer 4.
`In the above embodiment, when paraffin is used as
`As a result of such emissions of the ultraviolet rays on
`the material of the waste mold W, the waste mold W
`the coated resin layer 4, the coated resin layer 4 is made
`can be readily melted and removed from the reusable
`of a solidified part 4a where the ultra-violet-ray setting
`mold M and the paraffin can be easily separated from
`water and used again.
`resin is solidified and an unsolidified part 4b where the
`ultra-violet-ray setting resin is not solidified.
`Furthermore, the removal of the waste mold W from
`As shown in FIG. 3, the unsolidified part 4b of the
`the block 12 is carried out by melting the waste mold W
`coated resin layer 4 is removed or washed out by using
`so that the fine and delicate pattern 8 of the original 2
`a washout liquid 9, such as a detergent including a sur
`can be accurately and vividly reproduced on the surface
`face active agent, and the solidified part 4a of the coated
`of the block 12 as the inlaid pattern 8e.
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`resin layer 4, which is provided with a downwardly
`Still furthermore, the coloring material 13 may be
`protruded pattern 8b on the lower surface thereof, re
`made of a material which has the same composition and
`the same grain size as those of the concrete 11 provided
`mains.
`The ultraviolet rays are again emitted to the solidified
`that the coloring material 13 includes the coloring agent
`part 4a of the coated resin layer 4 as shown in FIG. 4
`which is different from the color of the concrete 11 or
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`until the solidified part 4a is completely solidified or
`the coloring agent included in the concrete 11.
`hardened in its entirety and such a completely-solidified
`Still furthermore, it is possible to produce the waste
`part 4a is used as a reusable mold M.
`mold W from several parts which are different from
`As shown in FIG. 5, a plastic material such as paraffin
`each other in terms of the melting points. During the
`(the melting point being about 55° C) which is melted
`process of removing the waste mold W from the block
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`or fused by water, a solution or heat is applied on the
`12, the waste mold W can be melted part by part in
`sequence and the corresponding number of coloring
`surface of the reusable mold M to form a plastic mate
`rial layer on the reusable mold M.
`materials are filled in the recessed patterns in sequence
`After the plastic material layer is solidified or hard
`so that the concrete products provided with a plurality
`ened, the layer is removed from the reusable mold M
`of inlaid patterns in different colors can be readily pro
`50
`and such a solidified layer is used as a waste mold W
`duced.
`which is provided with a recessed pattern 8c and such a
`I claim:
`recessed pattern 8c accurately reproduced the pro
`1. A method for producing concrete products pro
`vided with inlaid patterns comprising:
`truded pattern 8b on the reusable mold M.
`(a) preparing a reusable mold provided with recessed
`As shown in FIG. 6, the waste mold W is set on an
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`patterns by:
`upper surface of a bottom plate of a mold frame 10 with
`the recessed pattern 8c directed in a an upward direc
`(i) providing a layer of an ultra-violet-ray setting
`tion and the concrete 11 is cast in the mold frame 10 and
`resin having at least two opposed surfaces between
`cured for a predetermined period and a block 12 is
`a pair of ultra-violet-ray emitting lamps;
`produced.
`(ii) emitting ultra-violet rays from said pair of ultra
`60
`violet-ray emitting lamps simultaneously on both of
`The grain size of the concrete 11 is determined in
`view of the fineness or the complicatedness of the pat
`said surfaces of said ultra-violet-ray setting resin
`tern 8 of the original 2. Namely, the finer or more com
`layer, whereby one of said lamps emits ultra-violet
`plicated the pattern of the original 2, the smaller the
`rays on one of said surfaces of said resin layer
`through means for selectively transmitting said
`grain size of the concrete 11 should be.
`In this invention, the term "concrete' means cement,
`ultra-violet rays onto said one surface in a predeter
`mined pattern to expose pedetermined portions of
`mortar or plastic or the mixture thereof which become
`solidified or hardened by hydration as well as materials
`said one surface to said ultra-violet rays while leav
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`4,889,666
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`ing other portions of said one surface unexposed
`(c) casting concrete into said waste mold and solidify
`and whereby the other of said lamps emits ultra-
`ing said concrete to produce a concrete block on
`violet rays non-selectively onto the other of said
`said waste mold;
`surfaces of said resin layer to expose said other
`(d) dissolving and removing said waste mold from
`said concrete block to provide recessed patterns on
`surface in its entirety tO said ultra-violet rays, such
`the surface of said concrete block which was in
`contact with said recessed patterns on said surface
`that those portions of said resin layer exposed to
`said rays become solidified while those portions of
`of said waste mold.
`said resin layer not exposed to said rays remain
`(e) filling a coloring material into said recessed pat
`unsolidified; and
`terns on said surface of said concrete block and
`(iii) washing out said unsolidified portions from said
`solidifying said coloring material; and then
`(f) grinding said surface of said concrete block to
`solidified portions to form said reusable mold hav
`remove excess coloring material from said surface
`ing said recessed patterns conforming to said pre
`of said block to thereby produce a finished con
`determined pattern of said selectively transmitting
`crete product provided with inlaid patterns on said
`eaS
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`O
`surface thereof.
`(b) preparing a waste mold provided with recessed
`2. A method according to claim 3, in which said
`patterns on its surface by casting paraffin in said
`selective transmitting means comprises negative photo
`reusable mold, thereby forming said waste mold of
`graphic film having a pattern thereon.
`paraffin;
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`Metromont Ex-1016, p. 6
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