A method of manufacturing a stony product, a stony product and a mould

Abstract

A method of manufacturing a stony product (1) which has a front side (2) and a back side (3), wherein the back side (3) is provided with a cavity (4) which widens in a direction from the back side (3) to the front side (2), the method comprising the steps of either providing a mould (8) comprising a bottom (9) and a surrounding wall (10) projecting upwardly from the bottom (9), wherein the bottom (9) is provided with an upwardly directed elastic protrusion (11) which widens in a direction away from the bottom (9), filling the mould (8) with a liquid mixture which is curable to a stony product, then curing the mixture and subsequently demoulding the resulting stony product (1) from the mould, or providing a mould comprising a bottom and a surrounding wall projecting upwardly from the bottom, wherein a rigid element (12) is placed on the bottom, which rigid element (12) has a cavity (4) that opens to the bottom and widens in upward direction from the bottom, filling the mould with a liquid mixture which is curable to a stony product, then curing the mixture and subsequently demoulding the resulting stony product (1) including the rigid element (12) from the mould.

Description

[0001] A method of manufacturing a stony product , a stony product and a mould

[0002] The present invention relates to a method of manufacturing a stony product which has a front side and a back side , wherein the back side is provided with a cavity which widens in a direction from the back side to the front side .

[0003] The cavity in such a stony product serves to easily mount the stony product to a support , for example a wall of a building, which is provided with a snap- fit connector which cooperates with the cavity . A stony product is defined as a product which is not a natural stone as such, but is manufactured arti ficially and comprises stone particles which provide the stony product an appearance and characteristics of natural stone . It may also be as hard as stone . Because of its hardness it is quite challenging to create the cavity .

[0004] An obj ect of the invention is to provide a method of manufacturing a stony product as described hereinbefore .

[0005] This obj ect is accomplished with the method according to the invention, which comprises the steps of either providing a mould comprising a bottom and a surrounding wall proj ecting upwardly from the bottom, wherein the bottom is provided with an upwardly directed elastic protrusion which widens in a direction away from the bottom, filling the mould with a liquid mixture which is curable to a stony product , then curing the mixture and subsequently demoulding the resulting stony product from the mould, or providing a mould comprising a bottom and a surrounding wall proj ecting upwardly from the bottom, wherein a rigid element is placed on the bottom, which rigid element has a cavity that opens to the bottom and widens in upward direction from the bottom, filling the mould with a liquid mixture which is curable to a stony product , then curing the mixture and subsequently demoulding the resulting stony product including the rigid element from the mould .

[0006] In the latter case a moulding cavity is defined by the surrounding walls , the bottom and the rigid element , whereas in the former case a moulding cavity is defined by the surrounding walls , the bottom and the protrusion . Furthermore , in the latter case the rigid element is integrated in the resulting stony product , whereas in the former case the cavity is surrounded by the cured mixture of the resulting stony product . In both cases the cavities may be ready for receiving a snap- fit connector without applying a mechanical treatment after the casting process in order to create the cavity . This means that the method according to the invention provides an ef ficient manufacturing process . The step of curing the mixture may be performed at room temperature , for example by leaving the curable mixture in the mould during a day before demoulding, but the time period depends on the composition of the curable mixture .

[0007] The bottom, the surrounding walls and the protrusion may be made of a rubber, an elastomer or an elastic polymer . The liquid mixture may comprise sand, cement , water, glass fibres and acrylic, but numerous alternative curable mixtures are conceivable . In order to provide the front side of the stony product with a natural appearance , stony particles such as granite granules may be spread onto the liquid mixture after it is applied into the mould and before it is cured . The resulting stony product may be a panel . The mould may be elongated, having a length to width ratio which is larger than 5 , preferably larger than 10 or 15 . This means that the resulting stony product is elongated, for example having the form of an elongated strip .

[0008] The protrusion or the rigid element may be elongated in a direction along the bottom .

[0009] When the mould is elongated, the protrusion or the rigid element may be elongated in longitudinal direction of the mould .

[0010] Preferably, the bottom and the surrounding wall are made of an elastic material , since this facilitates the step of demoulding and minimi zes the risk of damage to the cured stony product .

[0011] At least the surrounding wall may be enveloped by a rigid support in order to prevent the elastic surrounding wall from bulging outwardly when filling the mould with the liquid mixture . The rigid support may have a receiving space for receiving the mould from which receiving space the mould including the cured mixture is removable before demoulding the resulting stony product from the mould .

[0012] In a preferred embodiment the elastic modulus of the surrounding wall and the bottom are higher than the elastic modulus of the protrusion, since the higher flexibility of the protrusion appears to facilitate the step of demoulding . The mould may be made of a polyurethane , a silicone , a rubber or the like .

[0013] The elastic modulus of the surrounding wall and the bottom may be substantially equal . The surrounding wall and the bottom may be made in one piece .

[0014] The hardness of the surrounding wall and the bottom may be higher than the hardness of the protrusion .

[0015] The hardness of the surrounding wall and the bottom may be in the range of Shore 40-70 and the hardness of the protrusion may be in the range of Shore 5-25 , for example on the scales Shore A or Shore D, as measured according to ASTM D2240 or ISO 7619- 1 .

[0016] Preferably, the protrusion is fixed to the bottom which creates a fixed position within the moulding space . Although the bottom and the protrusion may be made of di f ferent materials , they may be integrated in one piece or adhered to each other . It is advantageous when the protrusion is fixed to the bottom, since it provides the opportunity to use the mould repeatedly . Besides , the method is very ef ficient , since removal of the protrusion from the cavity in the resulting stony product after demoulding, such as in a lost-wax moulding process for example , can be omitted .

[0017] The rigid element may be made of an extruded material , preferably aluminium .

[0018] The rigid element may have an outer shape which forms a hook . This serves to create a strong bond between the cured material of the stony product and the rigid element . When the rigid element is plate shaped, the outer shape of the rigid element at the cavity may be hook-shaped . The step of demoulding the resulting stony product from the mould may comprise bending the mould away from the resulting stony product , or the step of demoulding the resulting stony product including the rigid element from the mould may comprise bending the mould away from the resulting stony product including the rigid element .

[0019] When the mould is elongated the bending may be started at one end of the mould in its longitudinal direction and continued in a direction towards an opposite end thereof . In this case the stony product may be gradually loosened from the mould .

[0020] The invention is also related to a stony product which is manufactured by means of the method as described hereinbefore .

[0021] The invention is also related to a mould for manufacturing a stony product comprising an elastic bottom and an elastic surrounding wall proj ecting upwardly from the bottom, wherein the bottom is provided with an upwardly directed elastic protrusion which widens in a direction away from the bottom, wherein the elastic modulus of the surrounding wall and the bottom are higher than the elastic modulus of the protrusion and / or wherein the hardness of the surrounding wall and the bottom are higher than the hardness of the protrusion .

[0022] The invention will hereafter be elucidated with reference to very schematic drawings showing embodiments of the invention by way of example .

[0023] Fig . 1 is a perspective view of an embodiment of a stony product which is manufactured by means of an embodiment of a method of manufacturing according to the invention .

[0024] Fig . 2 is an enlarged cross-sectional view of the stony product as shown in Fig . 1 .

[0025] Fig . 3 is a side view of a snap- fit connector which cooperates with the stony product as shown in Fig . 1 .

[0026] Fig . 4 is a perspective view of an embodiment of a mould according to the invention, which mould is used in an embodiment of a method of manufacturing according to the invention . Fig . 5 is an enlarged cross-sectional view of the mould as shown in Fig . 4 .

[0027] Fig . 6 is a similar view as Fig . 2 , but showing a stony product which is manufactured by means of an alternative embodiment of a method of manufacturing according to the invention .

[0028] Figs . 1 and 2 show an embodiment of a stony strip 1 which is made by means of an embodiment of a method of manufacturing according to the present invention . The stony strip 1 is made of a curable mixture which contains stony material . The stony strip 1 has a front side 2 and a back side 3 . A plurality of such stony strips 1 may be mounted next to each other on a wall of a building (not shown) , for example , wherein their back sides 3 face the wall of the building . Therefore , the front side 2 may have an esthetical surface , for example a raw surface formed by grains of stone or the like , such that the stony strip 1 imitates real stone . The stony strip 1 as shown in Fig . 1 has a block-shape , but numerous alternative shapes are conceivable . It may have a width of 60 mm, a thickness of 20 mm and a length of 2400 mm, for example , but numerous alternative dimensions are conceivable .

[0029] The back side 3 of the stony strip 1 is provided with a cavity 4 . In this case the cavity 4 is an elongated groove which extends in longitudinal direction of the stony strip 1 . The cavity 4 widens in a direction from the back side 3 to the front side 2 . This provides the opportunity to receive a snap- fit connector 5 as shown in Fig . 3 . A base 6 of the snap- fit connector 5 can be fixed to a wall of a building . When moving the stony strip 1 to the snap- fit connector 5 such that flexible wings 7 of the snap- fit connector enter the cavity 4 the wings 7 are retracted and finally extended inside the cavity 4 . This provides the opportunity to install the stony strip 1 very quickly and easily . Fig . 2 shows that an outer portion of the cavity 2 at the back side 3 first narrows in a direction from the back side 3 to the front side 2 in order to guide and retract the wings 7 gradually during entering the cavity 4 .

[0030] The stony strip 1 is manufactured by means of introducing a liquid mixture which is curable to the stony material of the stony strip 1 into a mould 8 , which is shown in Figs . 4 and 5 . The mould 8 comprises a bottom 9 and a surrounding wall 10 which proj ects upwardly from the bottom 9 . The surrounding wall 10 and the bottom 9 are made in one piece of an elastic material . The bottom 9 is provided with an elongated and upwardly directed arrow-shaped protrusion 11 which widens in a direction away from the bottom 9 . The protrusion 11 is also made of an elastic material . The protrusion 11 is fixed to the bottom 9 , for example by means of adhesive . The outer shape of the protrusion 11 corresponds to the inner shape of the cavity 4 of the stony strip 1 as shown in Fig . 2 .

[0031] The elastic modulus of the surrounding wall 10 and the bottom 9 is higher than the elastic modulus of the protrusion 11 , i . e . the flexibility of the protrusion 11 is higher, whereas the elastic modulus of the surrounding wall 10 and the bottom 9 may be substantially equal .

[0032] In the method of manufacturing, the mould 8 is filled with a mixture which is curable to a stony product , after which the mixture is cured . Subsequently, the resulting stony strip 1 is demoulded from the mould 8 by bending the mould 8 away from the resulting stony product 1 . The bending is started at one end of the mould 8 in its longitudinal direction and continued in a direction towards an opposite end thereof . The material characteristics of the mould 8 are such that during the step of bending the protrusion 11 is removed from the resulting cavity 4 in the stony strip 1 without being detached from the bottom 9 of the mould 8 . After removal of the stony strip 1 the mould 8 can be used again for casting another stony strip 1 .

[0033] Fig . 6 shows a variant of the stony strip 1 which is manufactured by means of an alternative method of manufacturing according to the invention . The stony strip 1 is provided with a rigid element 12 , which may be made of aluminium, for example by means of extrusion . Nevertheless , alternative materials are also conceivable , for example a di f ferent metal or plastic . The rigid element 12 has the same cavity 4 as the stony strip 1 as shown in Fig . 2 . Casting of the stony strip 1 can be performed in a similar mould as shown in Fig . 5 , but wherein the bottom 9 is flat and the protrusion 11 is replaced by the rigid element 12 which in turn may rest on the bottom 9 without being permanently fixed thereto .

[0034] The rigid element 12 may also be elongated in longitudinal direction of the mould 8 . Its cavity 4 opens to the bottom and widens in upward direction from the bottom . The rigid element 12 has an arrow-shape at the cavity 4 , as seen in crosssection, which means that an outer shape thereof forms opposite hooks . This creates a strong bond between the cured material of the stony strip 1 and the rigid element 12 . It is noted that the rigid element 12 may have numerous alternative shapes and dimensions .

[0035] In the method of manufacturing, the mould 8 is filled with a mixture which is curable to a stony product , after which the mixture is cured . Subsequently, the resulting stony strip 1 including the rigid element 12 is demoulded from the mould 8 by bending the mould 8 away from the resulting stony strip 1 including the rigid element 12 . The bending is started at one end of the mould 8 in its longitudinal direction and continued in a direction towards an opposite end thereof .

[0036] The mould 8 may fit in a receiving space of a separate rigid support (not shown) which envelopes at least the surrounding wall 10 of the mould 8 in order to avoid bulging outwardly of the surrounding wall 10 after filling the mould with the curable mixture .

[0037] The invention is not limited to the embodiments shown in the drawings and described hereinbefore , which may be varied in di f ferent manners within the scope of the claims and their technical equivalents . For example , the stony strip may have di f ferent shapes and dimensions . The cavity may be located at a di f ferent location at the back side and it may have di f ferent shapes and dimensions . It is also conceivable that the back side has more than one cavity .

Claims

CLAIMS1. A method of manufacturing a stony product (1) which has a front side (2) and a back side (3) , wherein the back side (3) is provided with a cavity (4) which widens in a direction from the back side (3) to the front side (2) , the method comprising the steps of either- providing a mould (8) comprising a bottom (9) and a surrounding wall (10) projecting upwardly from the bottom (9) , wherein the bottom (9) is provided with an upwardly directed elastic protrusion (11) which widens in a direction away from the bottom (9) , filling the mould (8) with a liquid mixture which is curable to a stony product, then curing the mixture and subsequently demoulding the resulting stony product (1) from the mould, or- providing a mould comprising a bottom and a surrounding wall projecting upwardly from the bottom, wherein a rigid element (12) is placed on the bottom, which rigid element (12) has a cavity (4) that opens to the bottom and widens in upward direction from the bottom, filling the mould with a liquid mixture which is curable to a stony product, then curing the mixture and subsequently demoulding the resulting stony product(1) including the rigid element (12) from the mould.

2. A method according to claim 1, wherein the mould (8) is elongated, having a length to width ratio which is larger than 5, preferably larger than 10 or 15.

3. A method according to claim 1 or 2, wherein the protrusion (11) or the rigid element (12) is elongated in a direction along the bottom (9) .

4. A method according to claim 2 and 3, wherein the protrusion (11) or the rigid element (12) is elongated in longitudinal direction of the mould (8) .

5. A method according to any one of the preceding claims, wherein the bottom (9) and the surrounding wall (10) are made of an elastic material.

6. A method according to claim 5, wherein at least the surrounding wall (10) is enveloped by a rigid support.

7. A method according to claim 5 or 6, wherein the elastic modulus of the surrounding wall (10) and the bottom (9) are higher than the elastic modulus of the protrusion (11) .

8. A method according to claim 7, wherein the elastic modulus of the surrounding wall (10) and the bottom (9) are substantially equal.

9. A method according to any one of the claims 5-8, wherein the hardness of the surrounding wall (10) and the bottom (9) are higher than the hardness of the protrusion (11) .

10. A method according to claim 9, wherein the hardness of the surrounding wall (10) and the bottom (9) are in the range of Shore 40-70 and the hardness of the protrusion (11) is in the range of Shore 5-25, as measured according to ASTM D2240 or ISO 7619-1.

11. A method according to any one of the preceding claims, wherein the surrounding wall (10) and the bottom (9) are made in one piece.

12. A method according to any one of the preceding claims, wherein the protrusion (11) is fixed to the bottom (9) .

13. A method according to any one of the preceding claims, wherein the rigid element (12) is made of an extruded material, preferably aluminium.

14. A method according to any one of the preceding claims, wherein the rigid element (12) has an outer shape which forms a hook.

15. A method according to any one of the preceding claims and to claim 5, wherein the step of demoulding the resulting stony product (1) from the mould (8) comprises bending the mould (8) away from the resulting stony product (1) , or wherein the step of demoulding the resulting stony product (1) including the rigid element (12) from the mould comprises bending the mould away from the resulting stony product including the rigid element.

16. A method according to claim 2 and claim 15, wherein the bending is started at one end of the mould (8) in its longitudinal direction and continued in a direction towards an opposite end thereof.

17. A stony product (1) which is manufactured by means of the method according to any one of the preceding claims.

18. A mould (8) for manufacturing a stony product (1) comprising an elastic bottom (9) and an elastic surrounding wall (10) projecting upwardly from the bottom (9) , wherein the bottom(9) is provided with an upwardly directed elastic protrusion (11) which widens in a direction away from the bottom (9) , wherein the elastic modulus of the surrounding wall (10) and the bottom (9) are higher than the elastic modulus of the protrusion (11) and / or wherein the hardness of the surrounding wall (10) and the bottom (9) are higher than the hardness of the protrusion (11) .

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