Abstract A structure defining an upwardly opening tray is provided and initially filled with a hardenable mixture compactable to at least a reasonable degree and a grid is thereafter introduced into the tray and depressed downwardly into the hardenable mixture to a level spaced above the bottom of the tray and with upper portions of the grid projecting above the mixture. A second hardenable mixture is thereafter introduced into the tray within the openings formed by the grid and on top of the first mixture to a level substantially flush with the upper surfaces of the grid. A male die including coplanar spaced die members snugly receivable within the voids or spaces defined by the grid is positioned with the spaced die members in registry with the openings or spaces defined by the grid and forced into the spaces or openings so as to compress both mixtures within the tray. The step of compression is continued and the entire assembly including the tray, the grid and the male die are vibrated to compact the mixtures within the tray after which the grid and male die are coupled together for simultaneous extraction and the same are extracted from the tray and the mixtures therein during continued virbration of the tray to assist in separation of the grid and the male die members from the hardenable mixtures within the tray. Subsequently, vibration of the tray is terminated and the mixtures are allowed to fully harden resulting in the formation of a substantially rigid sheet-like panel representing the face surfaces of a mortar and brick construction.
The method of forming a multi-ply building panel including a back ply and a face ply and with the face ply defining a relief pattern, said method including: (a) placing a first hardenable fluent mix layer material in an upwardly opening shallow receptacle; (b) supporting a grid in position over the first layer with the grid including intersecting members defining said pattern and the lower marginal portions of said intersecting members at least slightly downwardly depressed into said first layer while the latter is still fluent; (c) placing a second hardenable fluent mix layer material, of an appearance when hardened different than the appearance of the first mix material when hardened, on top of the first mix layer within the voids of the grid defined and bound by adjacent intersecting members of the grid; (d) vibrating and compressing said first and second layers thus causing the interface portions of the mix layer materials within the voids to intermix; and (e) allowing said mix layers to at least slightly harden.
Claim 2
Independent Claim
169 words
The method of forming a multi-ply building panel including a back ply and a face ply and with the face ply defining a relief pattern, said method including: (a) placing a first hardenable fluent mix layer material in an upwardly opening shallow receptacle; (b) supporting a grid in position over the first layer with the grid including intersecting members defining said pattern and the lower marginal portions of said intersecting members at least slightly downwardly depressed into said first layer while the latter is still fluent; (c) placing a second hardenable fluent mix layer material, of an appearance when hardened different than the appearance of the first mix material when hardened, on top of the first mix layer within the voids of the grid defined and bound by adjacent intersecting members of the grid; (d) vibrating and compressing said first and second layers thus causing the interface portions of the mix layer materials within the voids to intermix; and (e) allowing said mix layers to at least slightly harden.
Claim 3
Dependent Claim
15 words
The method of claim 1 wherein (d) includes: (1) vibrating said receptacle and grid together.
Claim 4
Dependent Claim
44 words
The method of claim 2 wherein (d) includes: (A) simultaneously registering and advancing male die members with and into said voids from the sides thereof remote from said first mix layer and (1) includes vibrating the male die members with said receptacle and grid.
Claim 5
Dependent Claim
25 words
The method of claim 3 wherein (e) includes: (2) withdrawing said male die members and grid, as a unit, from said mix layers during (1).
Claim 6
Dependent Claim
44 words
The method of claim 2 wherein (d) includes: (A) simultaneously registering and advancing male die members with and into said voids from the sides thereof remote from said first mix layer, in order to compress the mix layers between said receptacle and die members.
Claim 7
Dependent Claim
17 words
The method of claim 5 wherein (2) includes spraying the face layer with water prior to (A).