Abstract: During the manufacture of slabs of stone or stone-like material using the technology which envisages preparation of a mix formed by a granular product and by a binder consisting of a hardening synthetic resin, vacuum vibrocompression of a layer of said mix and hardening of the resultant rough slab by means of a catalytic action and by heating, the slab is cooled to room temperature by directing onto both its surfaces a flow of cooling fluid, in particular air at room temperature, while controlling the flowrate of the air, so as to ensure gradual and controlled cooling, and supporting the slab in a static and perfectly flat condition. The device consists of a flat structure provided with a plurality of spacers (20) which keep the slab in a perfectly flat condition and allow the flow of cooling fluid to perform its action.

Abstract: In order to manufacture articles in the form of sheets or blocks of conglomerate stone or stone-like material, single mixes are prepared in mixers (18a,b,c,) arranged in a line and at intervals along a conveyor belt (12), each mixer depositing on said conveyor belt a layer of single mix which is arranged on top of the mix deposited by the mixer immediately upstream, forming a multiple mix which is then fed in an axially offset position to a rotating support (24) provided with homogenizing means and then passes to the vacuum vibrocompression section, after a deaeration step. A crushing device (32) is inserted between each mixer and the underlying belt so as to control the size of the agglomerations in each mix. Means (34) are envisaged for cleaning the upper surface (12a) of the conveyor belt (12) and the crushing devices (32) between the cycles for preparation of the multiple mix.

Abstract: In a method for manufacturing conglomerate articles in sheet form, a mix comprising the following is prepared: an expanded inert granular material; a filler consisting of hollow inorganic microspheres and a plasticizer (clay, quartz or other powder mineral, cellulose); an aqueous silicon-containing binder. A layer of mix, where necessary coated with a fibreglass meshwork in order to increase the mechanical strength thereof, is deposited on a temporary support and subjected to vacuum vibrocompression. The resultant rough-formed sheet is heated at a controlled temperature so as to cause evaporation of the water present in the mix. A light, sound-absorbing, heat-insulating sheet, rated in Class 0 in terms of fire reaction, suitable to be plastered or painted superficially and used for forming panels and partitions for internal and external use, is obtained.

Abstract: A method for manufacturing decorative concrete blocks for decorative garden walls is presented, along with a machine suitable for practicing the method.

Abstract: Methods and apparatuses for combining raw fibrous and binding materials in single mixing step (Step S3), followed by consolidation (Step S5) to greatly shorten overall cycle time to finished fiber-reinforced composite part. Chopped fibrous materials and binder materials are deposited sequentially onto belt conveyor (Step S2) so that materials are successively layered on top of one another in predetermined ratio and subsequently mixed (Step S3) to achieve uniform dispersion throughout. Mixed materials are deposited into rotating mold (Step S4), which further ensures uniform dispersion of fibrous and binder materials. Impregnation of fibrous materials with the binder material occurs in situ as uniformly mixed materials are heated and subsequently compacted in mold (Step S5) to obtain desired shape of fiber-reinforced composite part. Rotation device including: turntable for rotating mold; and actuator for supporting turntable and providing reciprocating motion to mold.

Abstract: Systems and methods for forming patterns and structures in target materials are described. The method produces a pattern or structure in a target material by contacting a stamp including one or more features with a target material using a normal load sufficient for keeping the one or more features in contact with the target material, and providing a cyclic shear force in an amount sufficient to extrude the target material and form a negative relief of the one more features in the target material. The systems and methods can be used to produce a variety of articles including, but not limited to, semiconductor integrated electrical circuits, integrated optical, magnetic, mechanical circuits and microdevices.

Abstract: In a method for manufacturing slabs which are thin (10-30 mm) and broad, a cement mix comprising water, cement and a fluidizer is mixed with inert stone aggregrate having a controlled particle size. The resultant mix is deposited in a predetermined thickness onto a temporary support and subjected to vacuum vibrocompression. The slab thus formed is subjected to the steps of setting and hardening by means of curing, enclosing it between two thin sheets of plastic impermeable to water vapour which are hermetically sealed along their edges. The method envisages specific measures as regards the method of mixing performed during the steps of preparation of the cement mix and mixing of the cement paste with the stone aggregrate. Other improvements concern the components of the cement paste as well as the order of introduction of the aggregate during mixing with the latter.

Abstract: A concrete dispensing apparatus is used in a manufacturing process for producing pre-cast concrete structures, which are conventionally used to form a foundation for a residential or commercial building. The dispensing apparatus includes a hopper that funnels to a discharge opening extending along the entire transverse length of the dispensing apparatus. A plurality of individually controlled gates cover the entire discharge opening for selectively controlling the length and location of the discharge opening through which concrete is dispensed. The dispensing apparatus also includes a finishing mechanism including a vibratory screed and a rotational finishing roller. The form can be moved relative to the dispensing apparatus or vice versa. A form vibrator induces a vibratory motion into the form to remove air from the dispensed concrete mixture.

Abstract: There are provided a plasticizing-kneading step of plasticizing a reinforcement fiber and a resin in a cylinder having a screw, and a metering-injecting step of supplying a physical foaming agent to the resin and injecting them into a cavity of a mold, after metering the necessary amount of resin for molding, a foaming-agent supplying step of supplying the physical foaming agent to the resin passed through a nozzle after being plasticized, and a mixing-dispersion promoting step of promoting mixing and dispersion of the physical foaming agent in the resin in a resin flow path from a supply portion of the physical foaming agent to the cavity of the mold. Accordingly, any breakage of reinforcement fiber is prevented and the mixing and dispersion of the physical foaming agent is improved.

Abstract: The present invention relates to apparatus and methods of vibration. In particular, the present invention relates to apparatus and methods of vibration for tooling in a structure, such as, for example, a fuselage. In one implementation, the tooling comprises at least two conductors that create a force to vibrate the media in the tooling, which improves the compaction of the media in the tooling and the extraction of the media from the tooling. Other implementations may be used for compaction and/or extraction of the media in the tooling.

Abstract: A hybrid arched overfilled structure includes a combination of pre-cast side elements and at least one cast-in-place crown sector element. The side elements are pre-cast generally in a horizontal orientation and subsequently lifted into place. The crown sector element is cast in place between the side elements. In one form of the invention, each of the three sections makes up about one-third of the overall arch span.

Abstract: The present invention is a method of forming and heating a compressed composite wood product. The method includes introducing a mat assembly of resinated discrete wood elements into an oscillating compression press. Once the material is within the oscillating compression press, the compression/release oscillation is controlled to form the material. Specifically, the compression/release oscillation is controlled to heat the mat assembly to a to at least a cure temperature of the resin.

Abstract: A metallic receptacle is embedded in the concrete material of a burial vault. The receptacle contains archival quality paper that records information identifying the person interred in the burial vault and the precise location at which the vault was buried. The receptacle is sealed by a cap that may be removed to access the archival information without opening the vault.

Abstract: Methods and devices for vulcanizing or cross-linking under pressure and increased temperature shaped bodies that consist especially of rubber mixtures. The shaped body is first dipped into a bed of fine-grained pourable or free-flowing bulk material with the sections to be vulcanized and the bulk material is brought into evenly tight contact with the surfaces of the shaped body while the bulk material is pressurized and brought to the elevated temperature at least in the region adjoining the section of the shaped body to be vulcanized.

Abstract: A process for producing tablets comprising one or more active substances, in which pulverulent to granular starting components are shaped and then solidified, wherein the solidification takes place by reacting a component A and a component B with one another, components A and B being mixed with the starting components, applied to them or added after shaping.

Abstract: The present invention is a method of forming a compressed product. The method includes introducing a material into a press that is oscillating between a compression phase and a release phase. The material has a compression recovery response time when compressed and released. The compressed product is formed by repeatedly compressing the material during the compression phase and releasing the material during the release phase.

Abstract: An apparatus for manufacturing a transversely aligned web has a spinning device provided with a plurality of nozzles for extruding molten polymer as filaments, and a conveyor on which the filaments spun by the spinning device are piled and traveling in a direction cross to the direction of array of the nozzles. The spinning device is provided with a high-speed fluid blowing unit for blowing a high-speed fluid in a direction parallel with a direction in which the filaments are extruded from the nozzles so as to attenuate the filaments. Further, the apparatus for manufacturing the transversely aligned web has at least one air stream vibrating mechanism for cyclically changing the flowing direction of the high-speed fluid blown from the high-speed fluid blowing unit in a direction cross to the machine direction of the conveyor. The filaments are vibrated in a direction cross to the machine direction of the conveyor, owing to the high-speed fluid by the air stream vibrating unit.

Abstract: The invention concerns a product and the relative manufacturing process, said product, including at least a precast support (2) of expanded material and at least a layer (3) of agglomerated stone material in form of granulates bound by a binding phase, over at least one surface of said expanded support (2). According to suitability, the product (1) is made by a sandwich structure with an intermediate layer of expanded material and two surface coatings of stone material. The product (1) can also have a complex or modular shape, from which it is possible to cut and eventually to work finished pieces of predetermined dimensions. The main advantage of the invention consists in obtaining a finished product (1, 10, 100) lighter than a product made of agglomerated stones homogeneous in the thickness.

Abstract: In an apparatus and process for manufacturing a detergent bar, the bar comprises a first distinct zone comprising a first component and at least a second distinct zone comprising a second component. In an injection step, the first and second components are injected into the mold cavity via nozzle means having a first orifice through which the first component is injected. The second component is injected through a second orifice of the nozzle means. The first and second components solidify in the cavity to form the bar. The interface between the zones may be non-planar and/or such that the zones cannot be separated by a unidirectional cut. The first and second zones may respectively comprise detergent and a benefit agent. The first and second zones may differ in texture.

Abstract: Cure and consolidation of a viscous thermoplastic resin, especially one that softens and melts at a high temperature, is improved by assisting autoclave pressurized momentum transport for compaction of the composite using high frequency, low amplitude acoustic vibration within the resin. The vibration induces shear thinning in the resin which promotes resin flow, achieves filling or collapse of voids, and assists consolidation of the composite preform.

Abstract: Apparatus for molding blocks with laterally projecting, undercut side features includes a mold box having split mold parts defining a mold cavity open at the top and bottom. A top plate having an opening aligned with a cavity overlies the mold parts. Moldable block material is charged into the cavity from a feed box, and the material is compacted and shaped between a lower pallet and upper stripper head. The mold parts are retractable beneath the top plate to release the block for stripping through the bottom of a mold. A plurality of fluid outlets in the top plate cleanse the mold surfaces of the block material between mold cycles.

Abstract: A method for producing a rail substructure for railroad tracks, for which a rail bed is concreted and dowels are anchored positively in the concrete in order to fasten the rails, such that the dowels are inserted into the still deformable concrete during the concreting of the track bed.

Abstract: An article and method of preparing a synthetic solid surface material having a simulated burled wood effect in a pattern formed by preparing a resin matrix with iron oxide pigments and pearlescent mica pigments, adding a darker mica pearlescent pigment and/or an iron oxide pigment composition with a slightly less specific gravity than the matrix for the creation of a burling effect, pouring into a flat substrate in paths, and applying vibration or agitation which generally allows or speeds the darker pigment to rise and bubble to create a burling effect on the back side of the solid surface. The back side of the slab, the surface generally not in contact with the mold, is then sanded to the desired thickness on a wide belt sander.

Abstract: The invention relates to a process for the production of marble conglomerate slabs, starting from marble sand and/or granulates, additivated with binders, of the kind comprising a step of mixing the raw materials, a step of placing the mixture on a conveyor belt or on moulds, an under vacuum vibro-compaction step and a following step of polymerisation of the binder, further comprising a step of placing a protective sheet on said conveyor belt or on the base of said moulds, before pouring the mixture, and on said mixture, said protective sheet being comprised of hydrosoluble plastic material in such a way to coat the mixture above and at the bottom before the vibro-compaction step, said hydrosoluble material sheet beeing automatically removed, after the binder polymerisation step, from the water of the slab finishing workings.

Abstract: A method of finishing concrete using a vibrating tool to consolidate a “dry shake” aggregate into the upper layer of the concrete. The use of the vibrating tool causes moisture within the concrete mass to migrate into the surface layer where the moisture may hydrate the aggregates in the dry shake mixture. The ability to cause upward migration of water in the concrete mass provides a larger window of finishability for the concrete. The vibrations also provide thorough consolidation of aggregates in the upper layer of the concrete mass helping to prevent delamination.

Abstract: A programmed material consolidation apparatus includes at least one fabrication site and a material consolidation system associated with the at least one fabrication site. The at least one fabrication site may be configured to receive one or more fabrication substrates, such as semiconductor substrates. A machine vision system with a translatable or locationally fixed camera may be associated with the at least one fabrication site and the material consolidation system. A cleaning component may also be associated with the at least one fabrication site. The cleaning component may share one or more elements with the at least one fabrication site, or may be separate therefrom. The programmed material consolidation apparatus may also include a substrate handling system, which places fabrication substrates at appropriate locations of the programmed material consolidation apparatus.

Abstract: The present invention is a method of forming a compressed product. The method includes introducing a material into a press that is oscillating between a compression phase and a release phase. The material has a compression recovery response time when compressed and released. The compressed product is formed by repeatedly compressing the material during the compression phase and releasing the material during the release phase.

Abstract: The present invention is a method of forming a compressed product. The method includes introducing a material into a press. The material has a flow direction through the press. The press is arranged to have at least one platen oscillating between a compression phase and a release phase. The at least one platen is configured to impart a compressive force onto the material during the compression phase such that the force is applied initially at an acute compression vector angle relative to the material flow direction. As a function of the angled compressive force, the material is transported a distance through the press and then released during the release phase.

Abstract: A cold isopressing method and mold for compacting a granular ceramic material in which the granular ceramic material is introduced into a cylindrical pressure bearing element of an isopressing mold. The cylindrical pressure bearing element is sufficiently rigid so as to maintain its shape during the introducing of the granular ceramic material. Such element is also sufficiently resilient in a radial direction thereof to deform and bear against the granular ceramic material upon the application of the hydrostatic pressure and to substantially return to its original shape upon the relaxation of the hydrostatic pressure, thereby to allow retraction of the cylindrical pressure bearing element from the granular ceramic material after compaction. In a further aspect, an isopressing method and mold is provided in which the cylindrical pressure bearing element thereof is provided with an enlarged end bore to form an enlarged end section in the finished ceramic tube for sealing purposes.

Abstract: A method of forming a concrete retaining wall block having a front face and an opposed back face in a front fact up position. The method includes inserting a plurality of tines of a horizontal core puller into a plurality of holes in the bottom of a mold such that the a plurality of tines are positioned to form a dovetail slot and chamfers in the back face of a concrete retaining wall block; and pressing and vibrating a semi-dry concrete mix feed into the mold with a head to form a concrete retaining wall block having a relief stamped in its front face and to form the dovetail slot and chamfers its back face. The method allows the dimensions of the concrete retaining wall block to be exact and consistent from cycle to cycle of the method.

Abstract: The method of producing slabs made of granulated stone and/or sand bound with a hardenable resin by compaction under vacuum and subsequent hardening in which before the vibratory compaction the mixture is spread to a uniform thickness on a support, the support being protected by highly resilient sheet material. A lower sheet material has a shaped configuration comprising a flat base and a peripheral frame projecting from the flat base for a predetermined height so as to define a seat of dimension corresponding in plan to those of the slab to be produced. The peripheral frame having a height which is lower by a predetermined amount than that of the final slab produced.

Abstract: A method and system of forming a fire door core. Hydraulic binder and resin are supplied from raw material bins and mixed to provide a submixture. Exfoliated vermiculite is then mixed with the submixture to provide a mixture that is deposited into a plurality of compression molds. Each of the filled molds are pressed in a press at a predetermined temperature at a predetermined pressure for a predetermined period of time sufficient to harden the mixture into a hardened slab. The hardened slabs are then removed from the molds, impregnated with water or steam in a water impregnation assembly and dried in a drying assembly.

Abstract: A concrete product molding machine supports a mold with a vertically extending mold cavity. A pallet support is mounted for lifting movement to dispose a pallet to close the cavity. Attachment structure extends from the mold to rest on frame surfaces prior to being moved upwardly to provide a clearance for vertical vibration of the mold. Mechanism vibrates the mold in a vertical path having lateral x and y axis vibration components. A guidance pin receiver is carried by the support attachment structure and a pin carrier assembly on the machine frame carries a vertically reciprocal guidance pin movable from a remote position up into the pin receiver. A vibration limiter is disposed laterally to the pin for limiting at least one of the lateral vibration components and a motor operated mechanism is coupled to the pin for moving the pin vertically.

Abstract: A method of installing a refractory lining in a coreless or channel electric induction furnace. For installation of a refractory lining in a furnace wall, the method comprises the steps of providing a dry refractory material between a liner form placed within the furnace and a furnace wall, placing at least one variable frequency/amplitude electric vibrator in operational communication with an element selected from a structural member of the furnace, the liner form, and a vibrator rig placed within the furnace, inducing flow of the dry refractory material by operating at least one variable frequency/amplitude vibrator in a first operational mode having a high amplitude, low frequency vibration, and compacting the dry refractory material by operating at least one variable frequency/amplitude vibrator in a second operational mode having low amplitude, high frequency vibration after inducing flow of the dry refractory material.

Abstract: A vibratory apparatus and method for agglomerating chopped bundles of wet fiberglass strands into uniform segments includes a container having a curved inner surface disposed about a generally horizontal axis where the container is mounted on a plurality of springs. The chopped bundles of wet fiberglass strands to be agglomerated are placed onto the curved inner surface at an input end of the container. A vibratory force is produced to cause the chopped bundles of wet fiberglass strands to be moved from the input end toward an output end of the container. The vibratory force causes the chopped bundles of wet fiberglass strands to be directed in a rising and falling path of rolling movement within the container. As a result of the rolling movement of the chopped bundles within the container which is produced by the vibratory force, the chopped bundles of wet fiberglass strands are converted into uniform segments by reason of agglomeration of the wet fiberglass strands.

Abstract: Magnetizable fibers dispersed in a viscous body, particularly reinforcing metal fibers dispersed in a wet cementitious material, is carried out by providing a fiber aligning member (15) having a nonmagnetic wall (17) including a first wall portion (17A) and a second wall portion (17B), moving the aligning member (15) relative to the viscous body with the first wall portion (17A) leading and the second portion (17B) trailing it and with the first and second wall portions (17A, 17B) contacting the viscous body, and directing a magnetic field into the viscous body through the first wall portion (17A) to subject the fibers (F) to a moving magnetic field.

Abstract: The invention relates to a method and device for the compression of granular materials. On compressing granular material to give prepared products e.g. concrete paving slabs, a resonance vibrator with an oscillating mass-spring system is applied, which may be energised by a controllable energiser to produce forced oscillation of a given frequency and oscillatory amplitude. The resonant effect, making use of the proximity of the inherent resonance frequency and the exciter frequency permits a reduction in the size of the exciter force. According to the invention, along with an adjustment of the exciter frequency the resonant frequency is also simultaneously co-adjusted by means of a suitable adjuster, in order to be able to g make use of the resonance effect throughout the whole spectrum of the exciter frequencies to be carried out.

Abstract: In the manufacture of slab-type products in which an initial mix-formed by a granulate and by a binder-is deposited on a temporary support and then subjected to vibrocompaction under vacuum and conveyed away for the hardening stages, before vibrocompaction a dye is deposited on the surface of the mix layer with a random and patch-like layout before the vibrocompaction step.

Abstract: A core puller/mold assembly includes a mold frame containing a block mold having a mold cavity. A pair of cylinders is present, with each cylinder fastened to an opposed, exterior side of the mold frame. The cylinders each have a rod that extends beyond the mold frame joining the opposed, exterior sides. A core bar mounting bracket is fastened between the cylinder rods. At least one core bar is secured to the mounting bracket, with the bar extending toward the mold cavity. The at least one core bar is removed from the mold cavity with the cylinder rods extended and traverses the mold cavity with the cylinder rods retracted.

Abstract: An initial process for preparing material to use in manufacturing fiber-reinforced structures. One embodiment envisions a method of manufacturing a cement board. The initial process includes providing an open mat of recycled carpet fibers in a container, placing a mortar mixture directly over the fiber mat, distributing the mortar through the fiber mat by moving a comb having bent tines through the mortar-fiber mixture, and vibrating the mortar-fiber mixture substantially simultaneously with the distribution of mortar through the fiber. Also provided is a method for making the final product.

Abstract: A method for the automatic production of hollow bodies from mixed material, particularly concrete. A mold assembled from a mold core comprising a shaking device, an exterior mold and a bottom sprue is positioned in a molding area, non-solidified bulk material, particularly unset concrete, is uniformly filled into the mold space between the mold core and the exterior mold, the mixed material is compressed by shaking, an upper centering end is formed by pressing an upper sprue into the unset concrete column and thereafter the so formed, still soft molded body is removed from the mold by extraction and is transported to a drying area. At least some of the mold components are automatically assembled in an assembly area previous to a mold exchange and moved into the molding area as a pre-mounted assembly. Previous to a renewed mold exchange they are reassembled in the molding area to form an independent assembly to be transported off.

Abstract: A vibratory apparatus and method for agglomerating chopped bundles of wet fiberglass strands into uniform segments includes a container having a curved inner surface disposed about a generally horizontal axis where the container is mounted on a plurality of springs. The chopped bundles of wet fiberglass strands to be agglomerated are placed onto the curved inner surface at an input end of the container. A vibratory force is produced to cause the chopped bundles of wet fiberglass strands to be moved from the input end toward an output end of the container. The vibratory force causes the chopped bundles of wet fiberglass strands to be directed in a rising and falling path of rolling movement within the container. As a result of the rolling movement of the chopped bundles within the container which is produced by the vibratory force, the chopped bundles of wet fiberglass strands are converted into uniform segments by reason of agglomeration of the wet fiberglass strands.

Abstract: The present invention provides methods and devices for producing a subassembly for devices designed to receive particulate matter in a compartment of predetermined shape.

Abstract: A method forms a concrete block, particularly but not exclusively a composite block with a reflective fascia portion. The block is formed by a dry-cast technique, in which mixture for forming the block has a water/cement ratio less than or equal to 0.35, in combination with application of a compaction force so that the resultant block complies with compressive strength requirements set out in BS 6717: part 1: 1993.

Abstract: Cure and consolidation of a viscous thermoplastic resin, especially one that softens and melts at a high temperature, is improved by assisting autoclave pressurized momentum transport for compaction of the composite using high frequency, low amplitude acoustic vibration within the resin. The vibration induces shear thinning in the resin which promotes resin flow, achieves filling or collapse of voids, and assists consolidation of the composite preform.

Abstract: A process for forming molded articles from particulate thermoplastic material, the process comprising: (a) providing a track having a plurality of process stations, (b) providing a mold assembly comprising a base, at least one hollow mold upstanding from the base, and guide means on the base for moving the mold assembly on the track, (c) preheating the mold assembly at a preheat station on the track, (d) moving the mold assembly from the preheat station to a transfer station on the track, (e) transferring the mold assembly from the transfer station to a molding station, (f) forming the molded articles by fusing particulate material to the at least one mold at the molding station, (g) transferring the mold assembly with the molded articles thereon from the molding station back to the transfer station, (h) moving the mold assembly from the transfer station to a cooling station on the track, (i) moving the mold assembly from the cooling station to an unloading station on the track, (j) removing the mol

Abstract: A business model algorithm and an apparatus for forming landscape edging blocks in which preforms of a dry concrete mix is first formed into a preform after which the preform is formed under pressure into an edging block shaped so as to nest with like edging blocks in such manner that a continuous edging may be formed in linear or non linear shapes.

Abstract: A method is provided for rapidly forming a cementitious panel. A cementitious mixture is introduced into a mold configured to provide the desired surface appearance and profile of the cementitious panel. The cementitious mixture is then subject to an accelerated curing process by applying microwave energy to the cementitious mixture for a predetermined time period. After a relatively short resting or cooling period, the resulting cementitious panel is ready to be removed from the mold.

Abstract: The invention relates to a process for the cold transformation of urban solid refuses (USR) and/or sludge into inert materials including feeding USR and/or sludge from respective feeding lines; introducing the materials within a micronizer in order to reduce the granulometry and to recover water contained therein; adding CaO in an amount between 5 and 10% in weight of the main component; adding CaCO3 in an amount between 5 and 10% in weight of the main component; adding a polymeric additive in an amount between 3 and 10% in weight of the main component; conveying the product to the shaping and stocking step. The invention also relates to a plant for the realisation of the above process and to the products obtained.

Abstract: A process for manufacturing floor and wall coverings that produces a product a user may adhere to any wall or floor surface. The process begins by blending selected volumes of epoxy and aggregate into a vessel. A selected portion of the blended mixture is poured into a mold of selected geometry. A first piece of interlocking screening material is positioned over the first selected portion of the blended mixture. A second selected portion of the blended mixture is poured over the first interlocking screening material. A second piece of interlocking screening material is positioned over the second selected portion of the blended mixture. A selected portion of an adhering material is embedded into the top surface of the second interlocking screening material and the second selected portion of the blended molded mixture. The mold is cured and the product is released from the mold.