Abstract:
A method of forming a decorative shape from a concrete block by cutting the block into a predetermined shaped piece, polishing all flat surfaces and then applying a coating of clear material to the surface of said piece.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     The present invention provides a method for cutting concrete in a manner whereby unique three-dimensional shapes are formed. 
     2. Description of the Prior Art 
     Apparatus for cutting concrete have been available in the prior art. For example, U.S. Pat. No. 5,579,753 to Chiuminatta et al discloses a saw for cutting grooves in the surface of wet concrete. The speed of a variable speed transmission device connected to the wheels used to propel the saw across the concrete during cutting is controlled, the speed being dependent upon whether the saw is cutting hard aggregate or soft concrete. 
     U.S. Pat. No. 5,223,200 to Schulz et al discloses a method for making concrete roof tiles. Specifically, a continuous layer of fresh concrete is deposited on pallets supplied in a continuous row and is subsequently compacted, the compacted layer of fresh concrete being cut into roof tile moldings of equal length with a front and a rear edge, the front edge also being trimmed. 
     Although the prior art exemplified above discloses various concrete cutting apparatus and techniques for forming particularly shaped concrete blocks, the prior art shaped blocks are utilized in construction related projects. 
     Processes for forming designs from various materials are also well known. For example, porcelain and glass bases for lamps have long been available. However, techniques for cutting formed concrete into designs that have consumer appeal are not currently available. What is thus desired is to provide a process for producing designs from formed concrete, the designs either having utilitarian features or created solely for its aesthetic appearance. 
     SUMMARY OF THE PRESENT INVENTION 
     The present invention provides a method of cutting formed concrete into shapes which can be used for specific functions, such as lamp bases, or solely for its aesthetic appearances. 
     The concrete is cut into the desired shaped piece using a diamond cutting tool. Flat surfaces that result from the cutting are polished using an abrasive disc wheel. An adhesive, clear coating is then applied to the cut aggregate and allowed to dry. Large pieces may have a core portion removed in order to reduce weight. The resulting piece is highly aesthetic and has many uses, such as lamp bases, paper weights and sculpture. 
     The process is simple and relatively inexpensive and provides a new form of decorative art having many uses. 
    
    
     DESCRIPTION OF THE DRAWINGS 
     For a better understanding of the invention as well as other objects and further features thereof, reference is made to the following description which is to read in conjunction with the accompanying drawing wherein: 
     FIG. 1A illustrates a block of concrete aggregate; and 
     FIG. 1B is a simplified plan view of a diamond concrete cutting tool; 
     FIG. 2A illustrates the concrete block of FIG. 1 cut to a desired shape; and 
     FIG. 2B is a simplified view of a abrasive grinding tool; 
     FIG. 3A illustrates the concrete block after the flat edges are ground; and 
     FIG. 3B is a view illustrating the application of a clear adhesive to the surfaces of the piece illustrated in FIG. 3A; and 
     FIG. 4 illustrates the piece of FIG. 3A, after application of the clear adhesive, formed as a lamp base. 
    
    
     DESCRIPTION OF THE INVENTION 
     Referring now to FIG. 1A, a concrete block  10  is illustrated. Formed concrete having aggregate therein is commonly available in block form, typically from sites whereat old buildings are being, or have been, demolished. As shown in FIG. 1B, a cutting tool  12  having a cutting surface  14  comprising diamonds is positioned to cut block  10  into a predetermined shape. A cutting tool which has been successfully utilized is the Meco  4  Speed Drill, manufactured by Meco Engineering Company, Prescott, Ariz. A cutting surface which has been utilized successfully is the Model PL10C 18×25 diamond cutting bit manufactured by Pro Link Diamond, Irvine, Calif. FIG. 2A illustrates one of numerous shapes that can be cut in accordance with the teachings of the invention. The particular shape illustrated is a wedge shaped piece  16  having flat surfaces  18 ,  20  and  22 . 
     In accordance with the teachings of the invention, a masonry type grinder device  24 , preferably using an abrasive disc wheel  26 , is used to polish flat surfaces  18 ,  20  and  22 . FIG. 3A illustrates polished piece  16 . The next step of the inventive method is to apply a coating of clear, shining material to the surfaces of piece  16 . As illustrated in FIG. 3B, a coating material (illustrated as stored in receptacle  26 ) is applied to the surfaces of piece  16  by brush  28 . A preferred material which has been successfully utilized is polyurethane. Polyurethane highlights the color of the aggregate and provides viewing depth. Three coats have been applied to provide the desired effect, the second coating being applied after the first coating dries, the third coating being applied after the second coating dries. The total drying time is approximately twenty-four hours (other coatings, such as lacquer, can be used although lacquer will require more than three coatings). 
     FIG. 4 illustrates one application of the present invention. In particular, a hole is formed in piece  16  and a lamp structure  30  is secured therein, piece  16  forming a unique lamp base. 
     Concrete material can be removed from the piece  16  to reduce the weight thereof. In this case, a Model D5246 bit (6 inches) manufactured by Cushion Cut, Torrance, Calif., has been used to remove core material from shaped concrete pieces for weight reduction purposes. 
     The present invention thus provides a simple and cost effective technique for forming unique and aesthetically pleasing designs from concrete. 
     While the invention has been described with reference to its preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its essential teachings.