Patent EA-000269-B1 (EA)
Title: Method and apparatus for creating patterns in cast materials
Inventor: AUSTIN MARK
IPC: G03G21/04
Filed: 1996-12-27
Abstract: 1. A method for creating multicolor designs and patterns in cast materials comprising the steps of: a) preparing a mold to receive casting mixtures; b) preparing at least two wet casting mixtures of different colors at a viscosity to facilitate even pouring thereof; c) loading the casting mixtures into a container in a horizontal and vertical geometric arrangement according to a formula devised for a particular pattern; d) transferring the loaded mixtures from the container to the mold, and; e) consolidating the mixtures in the mold into a physically uniform mass and allowing the mass to set. 2. The method of Claim 1 wherein the consolidating step comprises applying low frequency, high amplitude shock waves to the mold. 3. The method of Claim 2 further comprising removing the set mass from the mold and finishing the surface. 4. The method of Claim 1 further comprising providing a removable matrix in said container which subdivides said container, and loading said casting mixtures into said subdivided container according to a predetermined formula wherein said formula is keyed to the subdivided arrangement provided by said matrix. 5. The method of Claim 4 further comprising removing said matrix after loading said container. 6. The method of Claim 5 wherein the loaded mixtures are transferred to said mold by pouring from said container. 7. The method of Claim 6 further comprising providing a pouring chamber removably attachable to said container and having a plurality of baffles defining a path through which said loaded mixtures pass upon pouring, and pouring said loaded mixtures from said container through said pouring chamber into said mold, whereby said geometrically loaded mixtures flow around said baffles in a predictable manner to create a pattern in said mold. 8. The method of Claim 5 wherein the loaded mixtures are transferred to said mold by extruding. 9. The method of Claim 5 wherein said loaded mixtures are transferred to said mold by spraying. 10. The method of Claim 4 comprising removing said matrix from said container, providing a nozzle at one end of said container and a driven piston at the other end of said container and driving said piston into said container whereby said loaded mixtures are extruded through said nozzle into said mold. 11. A method for casting multicolored cement based materials and controlling the patterning thereof, comprising: a) preparing a mold to receive wet cement based materials; b) preparing at least two wet cement based casting mixtures having different colors; c) providing a container having a removable matrix subdividing said container into at least two subchambers; d) loading said mixtures into said container in a geometric pattern according to said matrix and a repeatable formula devised therefor; e) removing said matrix from said container and attaching a baffled pouring aperture to said container, and; f) transferring said mixtures from said container to said mold through said pouring aperture whereby said baffled pouring aperture causes said mixtures to flow and combine in a predictable manner. 12. The method of Claim 11 further comprising consolidating the mixtures in said mold by application of low frequency, high amplitude shock waves to said mold. 13. The method of Claim 12 wherein said container comprises a flexible bladder from which said mixtures are extruded through said aperture. 14. The method of Claim 12 wherein said container comprises a rigid cylinder having a piston therein whereby said mixtures are extruded through said aperture. 15. The method of Claim 12 wherein said container comprises a tillable chamber with said baffled pouring aperture attached at one end whereby, when said matrix is removed, said chamber is tilted to pour said mixtures therefrom through said baffled pouring aperture. 16. A method for producing reproducible colored and patterned cement based castings, which simulate natural stone, comprising a) preparing two or more different colored wet cement based mixtures at a viscosity whereby the mixtures are pourable but resist combining when placed against each other; b) loading said mixtures in a container at geometrically determined positions both vertically and horizontally within said container and in specific amounts according to a formula corresponding to a particular pattern to be produced thereby forming a geometrically loaded bulk mix; c) transferring said geometrically loaded bulk mix from said container into a prepared form; and d) allowing said mixtures to set. 17. The method of Claim 16 further comprising applying low frequency, high amplitude shock waves to said form to consolidate said mixtures. 18. The method of Claim 17 comprising aiding the geometric placement of said mixtures in said container by providing a removable matrix temporarily subdividing said container into which said different colored mixtures are placed according to said recipe, and wherein said matrix is removed from said container after placement of said mixtures and prior to transferring said bulk mix into said form. 19. The method of Claim 17 further comprising providing a blending apparatus on said container and transferring said bulk mix by pouring from said container through said blending apparatus whereby said bulk mix is partially blended during pouring and wherein said partial blending is substantially predictable according to the viscosity of said mixtures and fluid characteristics thereof. 20. The method of Claim 19 wherein said blending apparatus comprises a pouring lip on said container, said pouring lip having a fixed geometry. 21. The method of Claim 19 wherein said blending apparatus comprises a pouring nozzle attachable to said container, said pouring nozzle comprising a plurality of baffles defining a specific flow pathway for said bulk mix. 22. The method of Claim 16 wherein said predetermined formula specifies the order, location and amount of each of said concrete mixtures to be placed in said container. 23. A simulated stone made by the method of Claim 17 and having a pattern resembling marble. 24. A simulated stone made by the method of Claim 17 and having a pattern resembling granite. 25. A simulated stone made by the method of Claim 17 and having a pattern resembling sandstone. 26. A simulated stone made by the method of Claim 17 and having a pattern resembling travertine. 27. A method for preparing multicolored mixes of castable materials for placement in a mold to produce a cast article having a pattern simulating natural stone, the method comprising loading individual colors of prepared castable materials into a container in a geometric, three dimensional, horizontal and vertical array according to a predetermined formula for said pattern. 28. The method of Claim 27 wherein a removable matrix is provided subdividing said container into an array of subchambers corresponding to said predetermined formula. 29. The method of Claim 28 further comprising removing said matrix from said container after loading with said castable materials. 30. The method of Claim 29 further comprising transferring said loaded, geometric, three dimensional array of castable material from said container to said mold in a manner calculated to produce a particular pattern. 31. The method of Claim 30 wherein the castable material is transferred by pouring from said container. 32. The method of Claim 30 wherein said castable material is transferred from said container by extruding. 33. The method of Claim 30 wherein said castable material is transferred from said container by spraying. 34. The method of Claim 31 whereby the pattern produced in the cast article simulates marble. 35. The method of Claim 32 whereby the pattern produced in the cast article resembles sandstone. 36. The method of Claim 33 whereby the pattern produced in the cast article resembles granite. 37. A kit for producing cast articles having a pattern simulating natural stone comprising: a plurality of packages of pre-measured and pre-mixed, colored, dry cementitious ingredients; a loading container and removable dividing matrix therefor; instructions for preparing individual wet mixes from said dry ingredients; a chart keyed to divisions of said matrix and designating an order for loading said container with said wet mixes to create a specific three-dimensional array in said container; and pouring criteria directing the manner for transfer of the loaded mixes from said chamber into a mold. 38. The kit of Claim 37 further comprising a combination pouring chamber and baffle removably mountable to said container and providing a pouring path for said loaded mixes from said container to said mold whereby said three-dimensional array is converted into a substantially linear pattern corresponding to a simulated natural stone pattern. 39. The kit of Claim 38 wherein said container comprises a flexible bladder and said combination pouring chamber and baffle comprises a nozzle mountable in said bladder, whereby said loaded mixes are extruded from said bladder through said nozzle in response to pressure exerted against the outside of said bladder. 40. The kit of Claim 38 wherein said container comprises a rigid cylinder, said combination pouring chamber and baffle comprise a nozzle structure mountable on one end of said cylinder, and said kit further comprises a piston assembly mountable to the other end of said cylinder whereby said piston fits within said cylinder and exerts a force against said loaded mixes to extrude said mixes through said nozzle. 41. A method for producing reproducible colored and patterned castings which simulate natural stone having a pattern which continues from piece to piece, comprising the steps of a) preparing at least one mold to receive casting mixtures by designating a pour design to be followed; b) preparing at least two different colored casting mixtures at a viscosity to facilitate even pouring; c) transferring the loaded mixtures to the molds in accordance