Inorganic Hydraulic Settable Material Shaping Patents (Class 264/333)
  • Patent number: 5833907
    Abstract: A patterned shaped article is produced on a given surface by a method including the steps of disposing a partition body on the given surface, temporarily fixing a plurality of cut pattern pieces to the upper surface of the partition body or the upper surface of a mesh member disposed on the partition body so that the cut pattern pieces are disposed adjacent to each other to constitute a pattern to be formed, unfixing one of the cut pattern pieces from a portion of the upper surface to which a pattern-course material is to be supplied, supplying the pattern course material to the portion, repeating the unfixing and supplying steps until the partition body is filled with a prescribed amount of pattern-course materials, removing the partition body alone or together with the mesh member from the pattern-course materials, and allowing the pattern-course materials to set into the patterned shaped article on the given surface.
    Type: Grant
    Filed: May 5, 1997
    Date of Patent: November 10, 1998
    Assignee: CCA Inc.
    Inventors: Hiroshi Uchida, Mituhiro Onuki, Hideo Watanabe
  • Patent number: 5814146
    Abstract: The invention concerns a MDF cement material showing better impact strength meant as an increase in the breaking total energy, by fibers addition.
    Type: Grant
    Filed: December 31, 1996
    Date of Patent: September 29, 1998
    Assignee: Italcementi S.P.A.
    Inventors: Rosa Di Maggio, Marcello Franchini, Gianluca Guerrini, Claudio Migliaresi, Stefano Poli
  • Patent number: 5814253
    Abstract: The invention relates to a process of making a light weight, cementitious, three dimensional structure such as a building panel which includes the steps of measuring a quantity of water, measuring about 425 kilograms of cement, and between approximately 40 to 60 grams of ferric chloride in 40% solution by volume per approximately 278 liters of water, mixing the quantity of water, the cement and the ferric chloride, measuring between approximately 0.620 kilograms and 1.347 kilograms of substantially pure powdered aluminum, between approximately 0.230 kilograms and 0.710 kilograms of Hexafluorosilicate, between approximately 0.560 and 0.
    Type: Grant
    Filed: March 14, 1995
    Date of Patent: September 29, 1998
    Assignee: Thermoflex, Inc.
    Inventors: Faiz Sikaffy, Osvaldo Moran, Eugene Berger
  • Patent number: 5804003
    Abstract: The object of the present invention is to prevent delamination of an inorganic board. To attain this object, a method of manufacturing an inorganic board comprising forming a single mat by the paper making method by using slurry of raw material mixture substantially consisting of cement material, fiber material and inorganic filler inside of which is empty wherein said empty inorganic filler is effected on an alkali treatment; laminating the plural number of said single mats to form a laminated mat; and molding, incubating and curing said laminated mat.
    Type: Grant
    Filed: December 2, 1996
    Date of Patent: September 8, 1998
    Assignee: Nichiha Corporation
    Inventor: Kazuhide Nishizawa
  • Patent number: 5800756
    Abstract: Methods and systems for readily and economically manufacturing hydraulically settable articles, particularly containers, from microstructurally engineered hydraulically settable mixtures. The mixture is pressed between a male die of a desired shape and a female die having a substantially complimentary configuration of the male die shape to immediately fashion a portion of the mixture into a form stable shape for the desired article. To assist in imparting form stability, the dies can be heated or cooled. Once the article has obtained form stability, the article is removed from the dies and dried under heated air to gain strength. The article can then receive printing or a coating, if desired, prior to packaging, shipping, and use.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: September 1, 1998
    Assignee: E. Khashoggi Industries, LLC
    Inventors: Per Just Andersen, Simon K. Hodson
  • Patent number: 5798010
    Abstract: Fiberboards are provided containing at least about 65 wt. % calcium sulfate dihydrate derived from hemihydrate or anhydrous gypsum, and at least about 7 wt. % pulped paper fibers. The boards are capable of being formed into structural members having superior mechanical properties and/or fire resistance, including screw-holding capacities in excess of 650 lbs.
    Type: Grant
    Filed: December 5, 1994
    Date of Patent: August 25, 1998
    Assignee: Georgia-Pacific Corporation
    Inventors: Turner W. Richards, Hubert C. Francis, George F. Fowler
  • Patent number: 5795515
    Abstract: At the method of producing formed articles of a fiber reinforced, hydraulically setting material the organic fibers are mineralized by aluminum sulfate and silica, the mixture processed with excess water to multilayered products, the laminates arrived therewith are then set in two steps and finally the formed articles produced treated by CO.sub.2 for a pre-carbonization.
    Type: Grant
    Filed: July 8, 1996
    Date of Patent: August 18, 1998
    Assignee: Nueva AG
    Inventor: Hans Fischer
  • Patent number: 5795380
    Abstract: A roof tile which is lightweight and yet strong has a dry component that includes cement, gypsum, perlite aggregate, lava stone and a powder that may be perlite powder or volcanic ash. Water and a styrene acrylic catalyst are mixed with the dry constituents. The composition can be formed into the shape of roof tiles by conventional equipment.
    Type: Grant
    Filed: May 2, 1997
    Date of Patent: August 18, 1998
    Assignee: Earth Products Limited
    Inventors: Patricia Billings, Susan Michalski
  • Patent number: 5788996
    Abstract: An apparatus for manufacturing a building block by molding under pressure a mixture of a hydraulic binder such as plaster, an inert filler such as sand, and water, by passing a mold (50) through various stations, including a station (A) for filling the mold with a measured quantity of the mixture (56), a station (B) for installing a mold top plate (38), a station (C) for compressing the mixture in the mold, a station (D) for keeping the top and bottom plates (38, 40) in place in the mold, a station (E) for withdrawing the top plate (38), and an unmolding station (F).
    Type: Grant
    Filed: May 21, 1997
    Date of Patent: August 4, 1998
    Assignee: Tecfim
    Inventor: Jean Brouard
  • Patent number: 5766728
    Abstract: The invention relates to a method of patterning a concrete surface and a pattern transfer mat for use in the method. The pattern transfer mat has a transfer surface having three-dimensional irregularities and carrying a multiplicity of grains to be transferred to the substrate concrete. Concrete is cast against the transfer surface of the mat and cured in situ and the mat is then detached. The aesthetic grains are grains having a cement powder deposited thereon beforehand. The cement powder absorbs water to cause fine air cells therein to collapse. Thus, the finished surface of the case concrete structure is made smoother.
    Type: Grant
    Filed: May 31, 1994
    Date of Patent: June 16, 1998
    Assignee: Tokai Rubber Industries, Ltd.
    Inventor: Nobuo Iwaya
  • Patent number: 5753308
    Abstract: Containers use in the storing, dispensing, packaging, and/or portioning of food and beverage products. The disposable and nondisposable food and beverage containers are manufactured from aggregates held together by organic binders in order to be lightweight, insulative, inexpensive, and more environmentally compatible than those currently used for storing, dispensing, packaging, or portioning such products. The food and beverage containers of the present invention are particularly useful for dispensing hot and cold food and beverages in the fast food restaurant environment. The structural matrices of the food and beverage containers include a hydrated organic binder paste (formed by mixing the binder with water) in combination with appropriate aggregate materials, such as fibers to add flexibility and strength, glass spheres to make the product more lightweight and insulative, or clay to make the product extremely inexpensive yet strong.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: May 19, 1998
    Assignee: E. Khashoggi Industries, LLC
    Inventors: Per Just Andersen, Simon K. Hodson
  • Patent number: 5733494
    Abstract: Improvements relating to composite materials. In a first aspect of the invention a distinctive and a less costly RTM preform is provided, along with a method of making it. In a second aspect of the invention, a distinctive preheating of an RTM preform provide enhanced surfaces on RTM composite articles.
    Type: Grant
    Filed: December 30, 1996
    Date of Patent: March 31, 1998
    Assignee: APX International
    Inventor: John H. Moore
  • Patent number: 5728334
    Abstract: A form assembly for forming vertical concrete walls for prefabricated apartment and office modules. The form assembly has a wall form having a plurality of internal wall forms and corresponding external wall forms. The wall form is connected to a support structure, and a plurality of hydraulic lifting cylinders connect to the support structure to raise and lower the wall form. The form assembly may also have hydraulic open and close mechanisms, hydraulic form ties and a control console for the hydraulic system. External corner mechanisms may be provided for locking the external form corners in place prior to concrete pouring. An efficient method of manufacturing the modules includes several steps. Slab reinforcement bars and conduits are layed on a slab deck. Concrete is poured over the slab reinforcement bars and conduits to form a slab. Wall reinforcement bars and conduits are erected on the slab for vertical walls.
    Type: Grant
    Filed: February 6, 1996
    Date of Patent: March 17, 1998
    Assignee: Daewoo Hawaii Corporation
    Inventor: Ho Woo Lee
  • Patent number: 5728327
    Abstract: The manufacture of moldable concrete products with deferred mold release incorporates molding means bm1 into optimized rotary structures 1, 5, 7, 9, 12 in the form of modular cylinders having at least two faces, the cylinders being equipped and/or associated with means which group together the main work-stations MP, MT, B, D, NH so as to assign a rotary travel of more than 270.degree. and preferably equal to 360.degree. to the curing of the molded material with or without recourse to any means for accelerating the curing.
    Type: Grant
    Filed: July 8, 1994
    Date of Patent: March 17, 1998
    Inventors: Mircea Borcoman, M. Calin Borcoman
  • Patent number: 5725652
    Abstract: An improved lightweight cementitious product made up of an aqueous cementious mixture using cement and expanded shale, clay and slate mix, that can incorporate fly ash, lime, and the weight saving component, which is micronized polystyrene particles having particle sizes in the range of 50 to 2000 microns, and characterized by having water contents in the range of from about 0.5% to 50% v/v. The ultra low water compositions can be extruded and can be molded under high pressure.
    Type: Grant
    Filed: August 21, 1996
    Date of Patent: March 10, 1998
    Inventor: David M. Shulman
  • Patent number: 5709739
    Abstract: A composition useful as a release agent for hydraulic binders is provided. The composition comprises water, an oil component comprising a water-immiscible monohydric alcohol component liquid at temperatures of 5.degree. to 15.degree. C. and selected from the group consisting of unsaturated fatty alcohols containing 12 to 22 carbon atoms and having iodine values of 40 to 170, Guerbet alcohols containing 16 to 28 carbon atoms, oxoalcohols containing 8 to 15 carbon atoms, and saturated alcohols containing 6 to 10 carbon atoms, and 0.5 to 5% by weight of an emulsifier, based on the oil component. The release agent is particularly useful for the treatment of formwork material in concrete construction.
    Type: Grant
    Filed: August 16, 1996
    Date of Patent: January 20, 1998
    Assignee: Henkel Kommanditgesellschaft auf Aktien
    Inventors: Leonhard Wittich, Stephan Heck, Lothar Friesenhagen, Guenther Demmering, Horst-Dieter Komp, Michael Koehler, Ingo Wegener, Hans-Juergen Sladek
  • Patent number: 5707179
    Abstract: A method and apparatus for optimizing the curing of concrete poured under hostile ambient temperature conditions. The apparatus includes a liquid reservoir and pumping system and a number of spaced-apart tube segments overlaid into the forms for receiving the concrete with respective ends of the tubes positioned outside the concrete forms. A liquid manifold is connected to one set of tube ends and a second liquid manifold is connected to the other set of tube ends. The temperature of the liquid in the reservoir is adjusted for optimum curing of concrete, and the liquid is pumped through the tubes after the concrete has been poured; when the concrete hardens the liquid is disconnected, and the tubes are disconnected from the manifolds without removing the tubes from the hardened concrete.
    Type: Grant
    Filed: March 20, 1996
    Date of Patent: January 13, 1998
    Inventor: Mark Bruckelmyer
  • Patent number: 5704972
    Abstract: The present invention provides a method and mixture for use in forming strong light-weight aggregate and includes by weight about; 68% to 95% fly-ash, 2% to 10% hydrated lime, and 3% to 12% alkali hydroxide such as Sodium Hydroxide. While many types of fly-ash may be used, Type F or Type C fly-ash are preferred. The admix is mixed with water to form a slurry including water in a range of 10% to 25% by weight of the dry mixture and the slurry is then compacted. The compacted slurry is then cured such as by using a rotary kiln or by in situ open air curing. The cured slurry is then allowed to hydrolyzed to form a hard material which then may be crushed and optionally screened to form an aggregate having a particular size or range of sizes.
    Type: Grant
    Filed: January 23, 1997
    Date of Patent: January 6, 1998
    Assignee: Trans Ash, Inc.
    Inventor: Daniel P. Ivkovich
  • Patent number: 5698240
    Abstract: A compression molding apparatus adaptable for instantaneously applying a large pressurizing force in the final stage of compression molding having a simple design and at low cost. A gear is provided to a screw shaft for rotating through a pair of pinions by a pair of hydraulic motors, and a plunger compresses a composite material. In the final stage, by using a pair of pressure-mounting actuators provided in a pressure-mounting system, a compressed deformation takes place to instantaneously apply pressurizing force through the gear to the screw shaft by a torque arm and a lock-piece respectively.
    Type: Grant
    Filed: May 14, 1996
    Date of Patent: December 16, 1997
    Assignee: Kabushiki Kaisha Mitsuishi Fukai Tekkosho
    Inventor: Hisoshi Haguchi
  • Patent number: 5690729
    Abstract: A method of reinforcing cement/concrete mixtures with alkali-intolerant reinforcements and/or aggregate, such as uncoated, common glass filament, plastic filament, fabric and roving made therefrom by reducing the pH of the mixture while in its plastic state, and/or after it has set and cured, to about 7. With a neutral pH, the alkali-intolerant reinforcements need not be coated to protect them from degradation. In the absence of alkalinity, the reinforcement and/or aggregate material bonds with the cement mixture to form a relatively stronger mixture, which can be shaped as desired, made part of permanently poured structures, cement boards and many other small and large products. By selecting appropriate and, if desired, different materials for the reinforcements and/or aggregate, the strength, flexibility, etc. characteristics of the product can be readily changed to adapt the product to the intended use. The pH is reduced by migrating such materials as CO.sub.2 and/or CO and O.sub.
    Type: Grant
    Filed: January 27, 1995
    Date of Patent: November 25, 1997
    Assignee: Materials Technology, Limited
    Inventor: Roger H. Jones, Jr.
  • Patent number: 5676905
    Abstract: Methods and systems for readily and economically manufacturing hydraulically settable articles, particularly containers, from microstructurally engineered hydraulically settable mixtures. The mixture is pressed between a male die of a desired shape and a female die having a substantially complimentary configuration of the male die shape to immediately fashion a portion of the mixture into a form stable shape for the desired article. To assist in imparting form stability, the dies can be heated or cooled. Once the article has obtained form stability, the article is removed from the dies and dried under heated air to gain strength. The article can then receive printing or a coating, if desired, prior to packaging, shipping, and use.
    Type: Grant
    Filed: August 10, 1993
    Date of Patent: October 14, 1997
    Assignee: E. Khashoggi Industries
    Inventors: Per Just Andersen, Simon K. Hodson
  • Patent number: 5672310
    Abstract: A method of manufacturing wood-cement board and an apparatus used in the method are provided in the present invention. The method of manufacturing wood-cement board comprising strewing a raw materials mixture of wood-cement board on a mold panel to form a mat, piling up a plural number of the mats with the mold panels, pre-pressing the piled mats to reduce the thickness of each mat, piling up a plural number of the pre-pressed mat, main-pressing the pre-pressed and piled mats and curing the piled mats being main-pressed and the apparatus used in the method consists of a piling up machine piling up a plural number of mats formed on a mold panel, a pre-press machine pre-pressing the piled mats to reduce the thickness of each mat, a main-piling up machine piling up a plural number of the pre-pressed mats, a main-pressing machine main-pressing the pre-pressed and piled mats, and a curing chamber curing the piled mats being main-pressed.
    Type: Grant
    Filed: November 30, 1995
    Date of Patent: September 30, 1997
    Assignee: Nichiha Corporation
    Inventor: Masaru Watanabe
  • Patent number: 5669969
    Abstract: A process for forming an ash aggregate is provided. The process involves mixing a cellulose sludge material with an ash component. The ash component may comprise fly ash or sanitary waste ash in combination with fly ash. The sludge component preferably comprises paper mill sludge or pulp mill sludge. The hard lightweight aggregate may be utilized in a variety of manners, for example, to provide lightweight concrete and lightweight concrete mixes.
    Type: Grant
    Filed: October 30, 1995
    Date of Patent: September 23, 1997
    Assignee: Greengrove Corporation
    Inventors: William Delbert Meade, John William Pearson
  • Patent number: 5670228
    Abstract: A tile having a desired pattern is provided. The pattern goes through the tile in the thickness direction. For manufacturing such a tile, e.g. a partition plate 84 is disposed in a pressure forming die 91 so as to divide its inside space into an outer forming space 95 and an inner forming space 96. Light black granules and light red granules are filled respectively in the outer and inner forming spaces 95, 96. Then, the partition wall 84 is taken out from the die 91, and lining granules are filled over the colored granules. Thereafter, they are pressed into one body and burned.
    Type: Grant
    Filed: November 3, 1995
    Date of Patent: September 23, 1997
    Assignee: Mino Ganryo Kagaku Corporation
    Inventors: Yoshinori Kakamu, Shinichi Kakamu, Shukichi Kakamu
  • Patent number: 5667200
    Abstract: A concrete building block (2) has complementary projections (10) and recesses (12) to cause it to interlock with other blocks (2). A T-shaped channel (16, 26) on the top surface (4) receives an anchor member (32). A projecting end (36) of the member (32) may be secured to an anchor cable (104). The ends of a metal cable (22) are embedded in the block (2) with an eye portion (24) projecting into an increased depth channel portion (20). The lower surface (6) of the block (2) has parallel channels (28) for receiving the tines of a forklift. The channels (16, 28) have breakaway walls (18, 30) at their outer ends, which are not broken away unless the channels (16, 28) are to be used. The walls (18, 30) prevent concrete from flowing out of the channels (16, 28) when reinforcing concrete is poured through vertical openings (14) in the block (2). In molding the block (2), slugs (86) are releasably attached to opposite mold walls to form the openings (14).
    Type: Grant
    Filed: January 5, 1995
    Date of Patent: September 16, 1997
    Inventor: Michael L. Kelley, Jr.
  • Patent number: 5648154
    Abstract: An inorganic constructional board for use as wall backing material or the like comprises a middle layer portion (1a) formed mainly of inorganic foamed material with an adequate quantity of fibrous material and binder added thereto, and outer layer portions (1b) placed on both surfaces of the middle layer portion (1a), the outer layer portion being formed mainly of mineral fiber material and inorganic powder material with binder added thereto. The middle layer portion (1a) has a specific gravity of less than 0.4, and the outer layer portions (1b) have a specific gravity of more than 0.7. Therefore, the board is more lightweight than a plaster board and has performance characteristics equivalent to or better than those of the plaster board.
    Type: Grant
    Filed: February 2, 1994
    Date of Patent: July 15, 1997
    Assignee: Daiken Trade & Industry Co., Ltd.
    Inventors: Akio Koh, Hisashi Fujiwara, Kiyoshi Kurosaki, Shigezoh Masamoto, Keiji Shutoh
  • Patent number: 5645773
    Abstract: A method for placing concrete on a rock foundation to construct a massive concrete structure, such as a dam, a bridge pier or a foundation of a building, precludes development of cracks in the concrete by thermal stress.
    Type: Grant
    Filed: June 7, 1995
    Date of Patent: July 8, 1997
    Assignee: E.R.C. Co., Ltd.
    Inventor: Yasuaki Ichikawa
  • Patent number: 5643488
    Abstract: A form assembly is disclosed for forming vertical concrete walls for prefabricated apartment and office modules. The form assembly has a wall form having a plurality of internal wall forms and corresponding external wall forms. The wall form is connected to a support structure, and a plurality of hydraulic lifting cylinders connect to the support structure to raise and lower the wall form. The form assembly may also have hydraulic open and close mechanisms, hydraulic form ties and a control console for the hydraulic system. External corner mechanisms may be provided for locking the external form corners in place prior to concrete pouring. An efficient method of manufacturing the modules includes several steps. Slab reinforcement bars and conduits are layed on a slab deck. Concrete is poured over the slab reinforcement bars and conduits to form a slab. Wall reinforcement bars and conduits are erected on the slab for vertical walls.
    Type: Grant
    Filed: December 16, 1994
    Date of Patent: July 1, 1997
    Assignee: Daewoo Hawaii Corporation
    Inventor: Ho Woo Lee
  • Patent number: 5629033
    Abstract: A machine for pressing earth into blocks has a rectangular breech and a press foot vertically reciprocally drivable in the breech. A bucking block is horizontally reciprocally drivable into and out of registration with an open upper end of the breech. Portions of the upper surface of the bucking block are tapered upwardly from front to rear and a horizontal bucking bar extends across the breech and bears downwardly against the tapered upper portions of the bucking block when the bucking block is in registration with the breech. The bucking bar can be supported at selectively variable levels above the breech and assures a firm positioning of the block against the force of the earth being compacted by the press foot. A rod extending vertically from and movable with the press foot cooperates with a sight line device fixed to the machine to facilitate visual determination of the elevation of the press foot within the breech.
    Type: Grant
    Filed: October 16, 1995
    Date of Patent: May 13, 1997
    Inventor: David Lienau
  • Patent number: 5622556
    Abstract: An improved lightweight cementitious product made up of an aqueous cementious mixture that can incorporate fly ash, portland cement, sand, lime, and the weight saving component, which is micronized polystyrene particles having particle sizes in the range of 50 to 2000 microns, and characterized by having very low water contents, in the range of from about 0.5% to 5% v/v. The ultra low water compositions can be extruded and can be molded under high pressure.
    Type: Grant
    Filed: October 2, 1995
    Date of Patent: April 22, 1997
    Inventor: David M. Shulman
  • Patent number: 5614452
    Abstract: Asbestos cement may be converted to a harmless product by melting at a melt temperature of 1400.degree. to 1700.degree. C. a blend of 50 to 85% by weight asbestos cement with 15 to 50% by weight of additives that include naturally occurring silicate material such that the total blend has a CaO content of not more than 50%. The melt is discharged from the furnace, cooled and solidified and may be used as aggregate or, generally after solidification as regular units, may be used as part or all of the charge for producing MMV fibre material. It is of particular value for the production of man made vitreous fibre material that has low alumina content and is soluble in lung fluids.
    Type: Grant
    Filed: September 8, 1995
    Date of Patent: March 25, 1997
    Assignee: Rockwool International A/S
    Inventors: Anders U. Clausen, Vermund R. Christensen, Soren L. Jensen
  • Patent number: 5614009
    Abstract: Cement comprising hydraulic cement and polymer precursor such as alcohol-soluble phenol resin precursor that is substantially anhydrous and generates water by polymerization.
    Type: Grant
    Filed: June 5, 1995
    Date of Patent: March 25, 1997
    Assignee: Maeta Concrete Industry Ltd.
    Inventors: Tadashi Kobayashi, Game K. D. Pushpalal, Masaki Hasegawa
  • Patent number: 5612116
    Abstract: A decorative sheet for construction is disclosed. The decorative sheet for construction comprises a thermoplastic polyester resin foam forming a surface layer, a large number of inorganic aggregates scattered over the surface of the foam in the presence of an adhesive, said inorganic aggregates forming a decorative face layer by the medium of the adhesive, and a backing layer formed on the decorative face layer. The decorative sheet of the present invention enables its decorative face layer with a backing layer to be reliably and readily transferred to the surface of concrete construction or products, and yet which enables a foam layer as a protective layer for the decorative face layer with a backing layer to be readily removed after application. A decorative concrete product for construction using the same, and processes for preparing them are also disclosed.
    Type: Grant
    Filed: March 13, 1996
    Date of Patent: March 18, 1997
    Assignees: Sekisui Kaseihin Kogyo Kabushiki Kaisha, Nippon Preston Kabushiki Kaisha, Eslen Chemical Co., Ltd.
    Inventors: Chitoshi Jinno, Hiroyuki Toyohara, Hikaru Mimura, Takashi Murohashi
  • Patent number: 5605570
    Abstract: The invention pertains to a cementious composition of a strong, light, foamed silicate binder or concrete made from ground, calcium-rich glassy silicates that are the major component of blast-furnace slag. The other materials used to create the material are sodium peroxide and water. The cementious mixture can include a volume modification foaming agent that substitutes a part of the mixture. These agents include sodium hydroxide, potassium hydroxide and hydrogen peroxide.
    Type: Grant
    Filed: July 20, 1995
    Date of Patent: February 25, 1997
    Assignee: U.S. Army Corps of Engineers as represented by The Secretary of the Army
    Inventors: Dennis L. Bean, Philip G. Malone
  • Patent number: 5603887
    Abstract: The invention relates to a process of making fiber structures in the form of refractory light-weight moldings. These fiber structures exhibit the advantage that they do not contain, or contain virtually no harmful fibers, and/or that such fibers that might still exist in the fiber structures can be readily decomposed by water or body fluids. Nevertheless, the fiber structures exhibit the advantageous thermal and mechanical properties of conventional light-weight moldings. The fiber structures according to the invention are manufactured using inorganic fibers, wherein at least 90% by weight of each fiber comprises 20-50% by weight of CaO and 50-80% by weight of Al.sub.2 O.sub.3. The rest comprises a maximum of 10% by weight of typical impurity oxides. Water or a water-containing liquid is used as the charge liquid, and conventional refractory additives may also be added to the mixture of fibers and water to be molded.
    Type: Grant
    Filed: December 6, 1995
    Date of Patent: February 18, 1997
    Assignee: Didier-Werke AG
    Inventor: Axel Eschner
  • Patent number: 5603878
    Abstract: A decorative sheet for construction is disclosed. The decorative sheet for construction comprises a thermoplastic polyester resin foam forming a surface layer, a large number of inorganic aggregates scattered over the surface of the foam in the presence of an adhesive, said inorganic aggregates forming a decorative face layer by the medium of the adhesive, and a backing layer formed on the decorative face layer. The decorative sheet of the present invention enablesits decorative face layer with a backing layer to be reliably and readily transferred to the surface of concrete construction or products, and yet which enables a foam layer as a protective layer for the decorative face layer with a backing layer to be readily removed after application. A decorative concrete product for construction using the same, and processes forpreparing them are also disclosed.
    Type: Grant
    Filed: May 17, 1995
    Date of Patent: February 18, 1997
    Assignees: Sekisui Kaseihin Kogyo Kabushiki Kaisha, Nippon Preston Kabushiki Kaisha, Eslen Chemical Co., Ltd.
    Inventors: Chitoshi Jinno, Hiroyuki Toyohara, Hikaru Mimura, Takashi Murohashi
  • Patent number: 5595698
    Abstract: A method of making the tile dispenses wet concrete having two different colors into a partitioned pug box for disposition onto opposite sides of a pallet, so that, the two different colors reside on opposite sides of the pallet in side-by-side relation. The wet concrete is metered and compressed by a roller and shaped by a slipper to provide the concrete tile with a desired cross-sectional shape, following which the concrete is then chopped by a knife assembly to form the individual tiles with desired edge configurations. The concrete is cured and then removed from the pallets to form the completed tiles. The method may be incorporated into a continuous process in which a succession of the pallets are passed by a conveyor beneath a making head assembly containing the partitioned pug box and the roller and slipper and then beneath a knife assembly to form a succession of the concrete tiles.
    Type: Grant
    Filed: September 13, 1994
    Date of Patent: January 21, 1997
    Assignee: Monier Roof Tile, Inc.
    Inventors: Thomas G. Nicholas, Scott W. Fechner
  • Patent number: 5589124
    Abstract: A method of using a masonry block mold includes the steps of loading the mold with block fill through the top of a cavity formed in the mold, drawing excess block fill from the top of the cavity, compressing the block fill within the mold with a compression head moving into the cavity from top to bottom of the cavity. The mold includes opposing sidewalls which each have at least one step formed on their respective top edge to retain additional block fill proximate thereto and assist in the formation of a flange or other structural feature on the formed masonry block.
    Type: Grant
    Filed: June 6, 1995
    Date of Patent: December 31, 1996
    Assignee: Block Systems, Inc.
    Inventors: Michael E. Woolford, Dick J. Sievert
  • Patent number: 5587035
    Abstract: A filled hollow structure, such as a fence post, which is constructed with a hollow member filled with a core to increase its strength. One aspect of the structure is that the core material normal expands upon setting, so that, when hardening within the hollow member, the expansion is restrained by the hollow member and the core is formed into an integral structure with the hollow member. Further strength is added by constructing the hollow member of reinforced fiberglass with the fiberglass rovings oriented at an angle to the axis of the pipe and by using a hard coating on the outside of the pipe.
    Type: Grant
    Filed: December 8, 1994
    Date of Patent: December 24, 1996
    Inventor: Robert H. Greene
  • Patent number: 5580409
    Abstract: Compositions and methods for manufacturing containers from sheets having a hydraulically settable matrix. Suitable compositions are prepared by mixing together a hydraulic binder, water, and appropriate additives (such as aggregates, fibers, and rheology-modifying agents) which impart predetermined properties so that a sheet formed therefrom has the desired performance criteria. Hydraulically settable sheets are formed from the mixture by extrusion, then calendering the sheets using a set of rollers and then drying the sheets in an accelerated manner to substantially harden the sheets. The resulting hydraulically settable sheets may have properties substantially similar to sheets made from presently used materials like paper, cardboard, polystyrene, or plastic. The sheets can be laminated, corrugated, coated, printed on, scored, perforated, cut, folded, rolled, spiral wound, molded, assembled and seamed to mass produce articles of manufacture from the sheets such as food and beverage containers.
    Type: Grant
    Filed: December 7, 1993
    Date of Patent: December 3, 1996
    Assignee: E. Khashoggi Industries
    Inventors: Per J. Andersen, Simon K. Hodson
  • Patent number: 5571464
    Abstract: A mold box is flexibly mounted to a product forming machine having upper and lower vertically displaceable beams. A feed drawer dispenses concrete material into the mold box while a vibration system vertically vibrates the mold box while dampening horizontal vibration. The vibration system is driven by a single drive shaft that actuates first and second vibrator rods while at the same rotating a counter-weight in a counter-rotating direction. A set of alignment brackets lock the mold box into a predetermined aligned relationship while being mounted in the product forming machine. The bottom side of each mold box is mounted to the product forming machine in the same relative position to reduce machine readjustments. A set of telescoping legs hold the feed drawer assembly variable distances above the mold box. A unitized pallet feeder quickly moves pallets one at a time from an "on-deck" position to a "receiving" position underneath the mold box.
    Type: Grant
    Filed: July 28, 1994
    Date of Patent: November 5, 1996
    Inventors: Allen Aaseth, Robert A. Schmitt
  • Patent number: 5567446
    Abstract: A slip supply system for supplying slip to one or more casting molds includes a slip supply pipe 2 to which the base ends of pouring hoses 3 each having a pouring valve 4 are connected. The ends of the pouring hoses 3 are detachably connected to casting molds 1. A slip discharge pipe 20 having communicating holes 22 is laid in the vicinity of the slip supply pipe 2. The ends of the pouring hoses 3 are removed from the casting molds 1 and connected to the communicating ports 22 before supplying slip to the casting molds 1. Slip is fed in this condition, so that the solid matters attached to the interior of the slip supply pipe 2 and the interiors of the pouring hoses 3 are washed away to the slip discharge pipe 20. Thereafter, the ends of the pouring hoses 3 are connected to the casting molds 1 to feed slip to the casting molds 1.
    Type: Grant
    Filed: June 1, 1995
    Date of Patent: October 22, 1996
    Assignee: Toto Ltd.
    Inventors: Takeo Enomoto, Toshiya Abe, Hironobu Murakami, Shinichi Hiraki
  • Patent number: 5558823
    Abstract: A method for the production of substantially vertical walls, and specifically, walls made of concrete, includes a single sided concrete form used, for example, to form a concrete wall against a preexisting wall or embankment, by pumping concrete into a gap between the form and the preexisting wall or embankment, and raising the form vertically as the pumped concrete settles and drys. The method enables the construction of vertical walls of superior strength in less time as compared to currently available systems.
    Type: Grant
    Filed: August 12, 1994
    Date of Patent: September 24, 1996
    Inventor: Leroy D. Gray
  • Patent number: 5549859
    Abstract: Hydraulically settable mixtures and methods for extruding such mixtures into a variety of objects which are form-stable in the green state. High green strength is achieved by increasing the yield stress of the mixture while maintaining adequate extrudability. Optimizing the particle packing density while including a deficiency of water yields a hydraulically settable mixture which will flow under pressures typically associated with the extrusion of clay or plastic. In addition, a rheology-modifying agent can be added to increase the yield stress of the mixture while not significantly increasing the viscosity. The desired strength properties and other performance criteria of the final hardened extruded product are controlled by adding aggregates, fibers, a hydraulically settable binder, water, and other admixtures.
    Type: Grant
    Filed: June 7, 1994
    Date of Patent: August 27, 1996
    Assignee: E. Khashoggi Industries
    Inventors: Per J. Andersen, Simon K. Hodson
  • Patent number: 5545297
    Abstract: Methods and apparatus for continuously extruding a hydraulically settable mixture and simultaneously placing continuous filaments within the extruding mixture to yield articles having a filament-reinforced, hydraulically settable matrix. The filaments can be placed within the mixtures in a parallel configuration, a helical configuration, or combinations thereof, in order to yield an article having the desired properties of, e.g., tensile strength, flexural strength, hoop strength, burst strength, toughness, and elongation ability. The desired properties of the hydraulically settable mixture, as well as of the cured hydraulically settable matrix of the hardened article, may also be adjusted by including varying amounts and types of aggregates, discontinuous fibers, binders, rheology-modifying agents, dispersants, or other admixtures within the hydraulically settable mixture.
    Type: Grant
    Filed: October 4, 1994
    Date of Patent: August 13, 1996
    Assignee: E. Khashoggi Industries
    Inventors: Per J. Andersen, Simon K. Hodson
  • Patent number: 5540771
    Abstract: A concrete product which uses 100% of the melt slags and pulverizes the melt slags into aggregates and fine powders, grinds the aggregates so that the percentage of absolute volume of the aggregates is over 60%, mixes the aggregates, fine powders, water and cement, and forms the mixture into the concrete product by vibration or press molding.
    Type: Grant
    Filed: July 24, 1995
    Date of Patent: July 30, 1996
    Assignees: Keihan Concrete Co., Osaka Gas Co., Ltd., Obayashi Corporation
    Inventors: Minoru Hata, Takeshi Tsunemi, Tohru Okui
  • Patent number: 5540869
    Abstract: A mold box is flexibly mounted to a product forming machine having upper and lower vertically displaceable beams. A feed drawer dispenses concrete material into the mold box while a vibration system vertically vibrates the mold box while dampening horizontal vibration. The vibration system is driven by a single drive shaft that actuates first and second vibrator rods while at the same rotating a counter-weight in a counter-rotating direction. A set of alignment brackets lock the mold box into a predetermined aligned relationship while being mounted in the product forming machine. The bottom side of each mold box is mounted to the product forming machine in the same relative position to reduce machine readjustments. A set of telescoping legs hold the feed drawer assembly variable distances above the mold box. A unitized pallet feeder quickly moves pallets one at a time from an "on-deck" position to a "receiving" position underneath the mold box.
    Type: Grant
    Filed: July 28, 1994
    Date of Patent: July 30, 1996
    Assignee: Columbia Machine, Inc.
    Inventors: Allen Aaseth, Robert A. Schmitt
  • Patent number: 5534292
    Abstract: A process for producing and curing hydraulic material to reduce its hydrophilic characteristics and increase its strength. By preventing water loss and by adding water, efflorescence is controlled and the number of and size of voids created by water evaporation and hydration are reduced. Controlling the cure environment, humidity, temperature and pressure and using fluid barriers and water, control the physical and chemical composition formed during curing. The controls can be used before and/or after the initial set or shape formation of the hydraulic material.
    Type: Grant
    Filed: October 14, 1992
    Date of Patent: July 9, 1996
    Inventor: Koji Mitsuo
  • Patent number: 5534214
    Abstract: A concrete coloring material and a process for coloring concrete by means of such a concrete coloring material capable of permitting concrete to exhibit natural color or aesthetic properties while preventing concrete from being substantially discolored. Polyethylene oxide is used as a water-soluble adhesive or gIue. The oxide is mixed with a composition such as dye, pigment, a mixture thereof or the like, to thereby permit the composition to penetrate into the concrete.
    Type: Grant
    Filed: December 7, 1994
    Date of Patent: July 9, 1996
    Assignees: Toyoko Giken Co., Ltd., Nikko Chemical Institute Inc.
    Inventors: Nobuyuki Sakamoto, Takehiko Kobayashi, Takashi Horiguchi
  • Patent number: 5531946
    Abstract: Production of plasterboard includes spreading of a mixture formed of gyps fibers and water onto a continuously moving belt to form a spread layer subsequently precompressed to 110% to 180% of a final board thickness and successively wetted from both sides and thereafter compressing the wetted layer to the final board thickness.
    Type: Grant
    Filed: March 2, 1994
    Date of Patent: July 2, 1996
    Assignee: Babcock BSH Aktiengesellschaft Vormals Buttner-Schilde-Haas AG
    Inventor: Jorg Bold