Patent ID: 7306757
Filing Date: 2007-12-11
Classification: B29C,B29K,B29L,B44C

Abstract:
1. A method for making a cast article replicating on a part of the surface thereof, a portion of a surface of one of a natural stone article or a brick article, said method comprising: making a first mold that replicates in a first negative reproduction at least said surface portion of the one stone or brick article; filling said first mold with a first castable material; curing the first castable material in the first mold to produce a master reproduction, the master reproduction including a first positive reproduction of the first negative reproduction, the first positive reproduction replicating said surface portion of the one stone or brick article; making a flexible second mold that replicates the first positive reproduction of the master reproduction as a second negative reproduction of said surface portion of the one stone or brick article, the second mold having a cavity which includes the second negative reproduction; placing said second mold in a closable support structure made from rigid material, the closable support structure comprising a bottom to support the second mold and a top to cover the cavity of the second mold, the bottom supporting the second mold with the cavity facing the top when closed; closing the top over the cavity of the second mold; filling said second mold between the cavity and the closed top with a second castable material; and curing the second castable material within the cavity while the top is closed to produce said cast article having a front exterior surface area formed as a second positive reproduction from the second negative reproduction, the front exterior surface area replicating said surface portion of the one stone or brick article.