Patent GB-1396521-A (GB)
Title: Method for manufacturing surface decorated concrete panels
IPC: B28B11/04
Filed: 1972-03-30
Abstract: 1396521 Moulding decorated concrete building elements SKOMAKI 30 March 1972 [30 March 1971 (2) 21 May 1971 10 Sept 1971] 15127/72 Heading B5A [Also in Divisions E1 B8 and G3] A decorated concrete panel is manufactured by the folowing sequence of steps:-positioning a mould beneath a discharge nozzle; moving relatively the mould and nozzle whilst discharging surface decoration material from the nozzle, to deposit the material in the mould in a desired pattern; positioning a further discharge nozzle above the mould; and at least partially filling the mould from the further discharge nozzle with concrete of a colour contrasting with that of the surface decoration material. Moulds and mould supports.-The mould 114 (Fig. 8) comprises a glass or plastics bottom and removable inner and outer walls. The mould is supported by a rollway or conveyer belt 115 or a crane but during moulding is supported by side grippers, or is lowered by cam controlled rollers, bars or a flat plane (see Figs. 2, 3, not reproduced) on to a carriage 116. The carriage 116 is moved in a direction (a) by an endless chain 122, and in a direction (b) by a support frame 117 moved by an endless chain 119. This movement is controlled by a hand-operated lever, or by a pattern plate 38 (Fig. 6c) that is scanned by photo-electric detectors 41, 42. Material feeding.-In a first embodiment (Fig. 8) material is fed from a hopper 110 through a screw fed nozzle 112 supported on an arm 103. Further arms 103<SP>1</SP>, 10311 support other nozzles 112 for air and material feed. The arms 103, 103<SP>1</SP>, 103<SP>11</SP> extend radially from a cylinder 101 that rotates about a vertical axis to position successive nozzles above the mould; rotation is controlled by limit switches 108. In a second embodiment the arms B<SP>1</SP>, C<SP>1</SP> (Fig. 7) are mounted on a support 56 and slide horizontally and vertically over the support, which itself slides rectilinearly along the side of the mould. For a third embodiment, each arm supports several pivoted nozzles 21 (Fig. 4) controlled by electromagnetic valves 22. Operation.-The mould 114 (Fig. 8) is positioned on the carriage 116 and surface decoration material is deposited from a nozzle on the mould base while the mould is moved, to reproduce the pattern 37 (Fig. 6c) of the pattern plate 38. A second nozzle is positioned over the mould and air blown over the decoration to disperse it as required. A third nozzle is positioned over the mould and supplies the differently coloured concrete backing. First embodiment.-The surface decoration material comprises coloured cement, a dye, or coloured particles, each mixed with water glass, synthetic resin, a dispersion agent, water or granular stone. The backing concrete comprises mortar embedding lath and iron mesh. Inner walls are then positioned, spaced from the mould walls, and the space filled with ferrocement, steel bars and anchor bolts to form a frame. The inner walls are removed, and the frame filled with foamed or asphalt concrete (see Figs. 13, 14, not reproduced). Second embodiment.-The inner mould walls comprise a preformed lightweight concrete slab that is left as part of the article (see Figs. 15, 16, not reproduced). Third embodiment.-The backing concrete 235 (Fig. 22) with its surface decoration 231, is grooved, coated with adhesive, and receives a reinforced, precast concrete frame 234. Irons 236 are positioned and embedded in concrete 237. The decorated surface 231 is finished with water glass, an acryl group synthetic resin, or sodium alkyl benzene sulphonate. The panel can be convex, concave or wedge-shaped. The claims of the divisional Specification 1,396,522 are directed to the apparatus.