Abstract:
A step form mold apparatus includes a support having an upper portion, a lower portion, and a middle portion disposed between, and interconnecting, the upper and lower portions, with the upper portion including a first mold mounting surface extending upwardly from the middle portion, and a first molding form being secured to the support such that the inner surface of the first molding form is disposed in face-to-face relationship with the first mold mounting surface, the outer surface of the first molding form being uneven so as to impart a textured appearance upon materials molded thereagainst.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application claims priority from U.S. Provisional application Serial No. 60/296,699 filed Jun. 7, 2001, the contents of which are herein incorporated by reference. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to decorative concrete molds generally, and more particularly to concrete molds for creating decorative concrete steps. The present invention also relates to methods for producing decorative concrete steps.  
         BACKGROUND OF THE INVENTION  
         [0003]    Concrete and other formable materials are often times utilized to create permanent structures reflecting desired configurations. Such moldable materials are particularly useful in creating walkways, decorative walls, and other decorative formations. A particularly common application for such moldable materials is in exterior steps formed along a walkway or the like. The formable material most commonly used in creating such steps is concrete, which has proven to be a durable material that is desirable in exterior applications.  
           [0004]    In creating concrete steps, an appropriately-sized mold box is formed for containing flowable and curable cement therewithin until cured and hardened concrete is formed. Such mold boxes are typically constructed of a plurality of planks secured to one another through various means. Typical planks are wood or light weight metal, and are preferably relatively rigid for maintaining a desired configuration even when the weight of flowable cement is placed thereagainst.  
           [0005]    Respective mold boxes are configured to form the flowable cement into a desired shape. For ease of design and quick construction, such mold boxes typically reflect standard geometrical formations incorporating right angles. As a result, steps or other structures formed by such mold boxes are typically more functional than they are aesthetic.  
           [0006]    For many applications, however, decorative patterns or other aesthetically pleasing configurations are desired. For example, walkways, patios, steps, and other exterior structures are often times desired to have a “natural” appearance. To that end, natural materials such as stone are commonly utilized in exterior applications. However, such natural materials are typically much more expensive than the corresponding amount of moldable material such as concrete. Therefore, a natural or uneven appearance has heretofore been unreachable and overly expensive for many consumers.  
           [0007]    The present invention overcomes this drawback by providing a means for forming moldable materials such as concrete into an aesthetically pleasing “natural” appearance. The present invention finds particular application in desirably configuring exterior surfaces of concrete steps to substantially replicate the appearance of stone placed upon concrete pads, or stone placed upon stone pads. To achieve such an appearance, a mold form of the present invention is utilized simultaneously with a concrete step-forming mold box, whereby certain surfaces of the molded steps reflect surface characteristics of the mold form of the present invention.  
           [0008]    To obtain a stone “cap” appearance to the concrete steps, a recess is preferably provided in the mold form of the present invention whereby a portion of the molded concrete extends beyond an associated step riser positioned immediately below the cap portion. It has been determined by the present invention that the thickness dimension of this cap portion is directly dependent upon the overhang dimension of the same. As a result, the height of the recessed portion of the mold form of the present invention is preferably modified to meet weight bearing requirements of particular applications.  
           [0009]    It is therefore a principle object of the present invention to provide a means for obtaining a natural or uneven appearance to steps fabricated from moldable materials such as concrete.  
           [0010]    It is another object of the present invention to provide a step form mold apparatus having one or more uneven surfaces against which moldable material may be cured and formed.  
           [0011]    It is a further object of the present invention to provide a step form mold apparatus having a recessed portion including an uneven surface against which moldable material can form and cure, which recessed portion provides an overhang portion in the resulting moldable form.  
         SUMMARY OF THE INVENTION  
         [0012]    By means of the present invention, moldable material such as concrete may be formed into configurations replicating stone or other natural material. In that connection, the step form mold is preferably provided having at least one uneven or mottled surface for creating a desired natural appearance in the molded material.  
           [0013]    In a particular embodiment, the step form mold apparatus of the present invention includes a support having an upper portion, a lower portion, and a middle portion disposed between, and interconnecting, the upper and lower portions. The upper portion is preferably substantially perpendicularly offset from the lower portion, and the upper portion includes a first mold mounting surface extending upwardly at least about three (3) inches from the middle portion. In addition, the step form mold apparatus includes a first molding form having an inner surface and a generally opposed outer surface, with the first molding form being secured to the support such that the inner surface of the first molding form and the first mold mounting surface are disposed in face-to-face relationship with one another. The outer surface of the first molding form is uneven so as to impart a textured appearance upon materials molded thereagainst.  
           [0014]    In some embodiments, the step form mold apparatus of the present invention includes a second molding form secured to a second mold mounting surface on the lower portion of the support, with the second mold mounting surface being substantially parallel to, spaced from, and facing substantially in the same direction as the first mold mounting surface. Preferably, the second molding form includes an uneven textured outer surface.  
           [0015]    Preferably, the first molding form is concave in a longitudinal direction, such that materials molded against the first molding form have an elongated convex profile along a length thereof. Preferably, the first and second molding forms are fabricated from a polymeric material. In other embodiments, however, the first and second molding forms are fabricated from a vulcanized rubber material.  
           [0016]    The support of the step form mold apparatus of the present invention is preferably an integral structure, and wherein the upper portion is offset from the lower portion by between about one-fourth inch and six inches. Further, the second mold mounting surface is preferably from about three inches and about ten inches in height. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    [0017]FIG. 1 is perspective view of the step form mold apparatus of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0018]    The objects and advantages enumerated above together with other objects, features and advances represented by the present invention will now be presented in terms of detailed embodiments described with reference to the attached drawing figure which is intended to be representative of various possible configurations of the inventions. Other embodiments and aspects of the invention are recognized as being within the grasp of those having ordinary skill in the art.  
         [0019]    Referring now by characters of reference to the drawing, step form mold  10  is shown having a support  12  and molding forms  14  secured thereto. Support  12  preferably includes an upper portion  18  and a lower portion  20 , which upper portion  18  is offset from, and connected to, lower portion  20 . In preferred embodiments, support  12  comprises a unitary structure having upper portion  18  offset from lower portion  20 . Preferably, upper portion  18  is perpendicularly offset from lower portion  20 , such that offset section  22  is oriented perpendicularly with respect to molding faces  16  of respective molding forms  14 .  
         [0020]    Molding forms  14  are preferably distinct pieces which are secured to support  12  through a suitable securement means. Such securement means include, for example, adhesives, fasteners, and the like. A particularly preferred securing means used in the present invention is a thermosetting epoxy adhesive. Molding forms  14  are preferably secured to respective molding surfaces of support  12 . In preferred embodiments, support  12  includes an upper mounting surface  24  and a lower mounting surface  26  upon which upper molding form  32  and lower molding form  34  mount respectively. Respective molding surfaces  33 ,  35  of upper and lower molding forms  32 ,  34  disposed away from mounting surfaces  24 ,  26  are preferably non-uniform and have a natural stone-like texture. Molding surfaces  33 ,  35  may have any desired texture, though a natural stone-like texture is most preferred.  
         [0021]    Molding forms  14  are preferably fabricated from a polymer-based material such as polyurethane. In some embodiments, molding forms  14  comprise a vulcanized rubber material. Molding forms  14  are preferably manufactured from durable and resilient materials, such that molding forms  14  may be reusable.  
         [0022]    In some embodiments of the present invention, molding forms  14  have a concave profile, and may be concave in one or more directions. Preferably, molding forms  14  are concave in a longitudinal direction, such that materials molded against molding forms have an elongated convex characteristic of relatively similar radius throughout an entire length of the molded material. Molding forms  14  may be linear or non-linear, and may be of varied surface dimension. Molding forms  14  are preferably configured to replicate a natural or stone look in material molded thereto.  
         [0023]    Support  12  may be fabricated from a variety of materials, so long as support  12  is relatively strong and durable. In some embodiments, support  12  is fabricated from wood, and may comprise a single sculpted piece of wood or a combination of multiple pieces of wood secured to one another. In embodiments utilizing multiple distinct pieces for creating support  12 , securement of the distinct pieces may be permanent or temporary, whichever is desired. In some embodiments, temporary securement of multiple distinct pieces forming supports  12  is desired for interchanging respective upper portions  18  and lower portions  20 , which respective portions may have similar or dissimilar molding form patterns  14  secured thereto. In still other embodiments, respective upper and lower portions of support  12  may be interchanged such that one or more molding forms  14  are absent.  
         [0024]    In preferred embodiments, step form mold  10  is utilized for creating decorative or custom-designed concrete steps by pouring uncured concrete against step form mold  10 . One or more step form molds  10  may be utilized in combination with mold box sides (not shown) to form one or more concrete steps of desired dimensions. In such embodiments, step form mold  10  is preferably disposed between mold box sides to create a negative mold in which uncured concrete is poured to form the desired concrete steps. In the embodiment illustrated in FIG. 1, lower portion  20  serves as the support for molding riser portions of respective steps, while upper portion  18  constitutes support for a decorative “cap” portion of the desired step.  
         [0025]    In use, uncured concrete is poured to a level substantially equal to upper surface  42  of upper molding form  32 , wherein step form mold  10  is bounded on respective sides by mold box sides (not shown). The concrete therefore assumes the configuration of step form mold  10 , in that the riser portion and the cap portion of the concrete step will reflect the surface characteristics of the respective molding forms  14 . Thus, the finished concrete step displays a decorative riser portion and cap portion having a desired customized texture.  
         [0026]    In some embodiments of the present invention, only one of upper molding form  32  or lower molding form  34  is used in creating the desired concrete step. For example, steps having a non-textured riser portion with a desirably textured cap portion may be created by either eliminating lower molding form  34  from step form mold  10  or providing lower molding form  34  with a non-textured outer surface  35 . Step form mold  10  is preferably sized and configured to create steps of desired dimensions. Though step form mold  10  is particularly configured for molding uncured concrete, other curable materials useful in step structures may be utilized in combination with the present invention.  
         [0027]    In preferred configurations, offset portion  22 , which forms the “overhang” of the cap portion of the step, is between one-quarter inch and six inches in depth. Upper molding form  32 , which forms the thickness of the step cap portion is preferably at least three inches in height, such that sufficient strength is provided for the overhang portion of the cap. Such a dimension for upper molding form  32  is an important aspect of the present invention so that the concrete poured against step form mold  10  forms a cap portion of sufficient thickness to bear a significant amount of weight when cured. In practice, the cap portion of the step typically bears a significant amount of weight in supporting users stepping thereon. The cured concrete thickness is also important to the strength of the cap portion, in that unique torque moments are created when downward force is applied on the overhanging cap portion, particularly at distal edges of the cap portion.  
         [0028]    Step form mold  10  may be fabricated in a variety of sizes, such that customized concrete steps may be created therewith. In preferred embodiments, step form mold  10  may be fabricated in length of up to 12 feet, though longer lengths are certainly possible.  
         [0029]    Molding forms  14  preferably include at least one surface having a customized or “natural” texture disposed thereon. Molding forms  14  are preferably fabricated through a thermal molding process, such as insert molding. The desired texture is formed upon a respective molding form surface by inserting the polymerizable material adjacent to a structure having the desired texture characteristic. The molding material is then polymerized and removed from the mold apparatus as a finished molding form. In some embodiments of the present invention, the molding material is polymerized while in intimate contact with a stone of desired surface texture. In such a manner, the finished molding form assumes the texture of the natural stone. Through such a technique, any desired surface texture for respective molding forms  14  can be obtained.  
         [0030]    The invention has been described herein in considerable detail in order to comply with the patent statutes, and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use embodiments of the invention as required. However, it is to be understood that the invention can be carried out by specifically different devices and that various modifications can be accomplished without departing from the scope of the invention itself.