U.S. patent application number 14/982795 was filed with the patent office on 2016-05-12 for concrete-mosaic.
The applicant listed for this patent is LITHOCRETE, INC.. Invention is credited to Robin Brailsford, Ronald D. Shaw.
Application Number | 20160130807 14/982795 |
Document ID | / |
Family ID | 48279317 |
Filed Date | 2016-05-12 |
United States Patent
Application |
20160130807 |
Kind Code |
A1 |
Brailsford; Robin ; et
al. |
May 12, 2016 |
CONCRETE-MOSAIC
Abstract
Provided is a method of installing a tile mosaic upon a vertical
concrete surface. The method includes providing a plurality of
tiles, a tile support, and a concrete form. The plurality of tiles
are adhered to the tile support to define a mosaic assembly. The
tiles are positioned on the tile support corresponding to the
mosaic. The mosaic assembly is connected to the concrete form, and
concrete is poured within the concrete form such that a portion of
the tiles become embedded within the concrete. The tile support is
subsequently detached from the concrete form and the concrete form
is removed from the cured concrete. The tile support is
additionally removed from the plurality of tiles to reveal the
mosaic on vertical surface of the concrete structure.
Inventors: |
Brailsford; Robin; (Dulzura,
CA) ; Shaw; Ronald D.; (Corona Del Mar, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LITHOCRETE, INC. |
Costa Mesa |
CA |
US |
|
|
Family ID: |
48279317 |
Appl. No.: |
14/982795 |
Filed: |
December 29, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14062144 |
Oct 24, 2013 |
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14982795 |
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13294434 |
Nov 11, 2011 |
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14062144 |
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Current U.S.
Class: |
264/35 |
Current CPC
Class: |
B44C 1/28 20130101; E04F
13/142 20130101; E04B 2/02 20130101; E04F 13/08 20130101; E04B 2/84
20130101; E04F 13/00 20130101; E04F 13/0862 20130101 |
International
Class: |
E04B 2/02 20060101
E04B002/02; E04B 2/84 20060101 E04B002/84; E04F 13/08 20060101
E04F013/08 |
Claims
1. A method of forming a mosaic upon a concrete surface, the method
comprising the steps of: a) providing a plurality of tiles, a tile
support, and a concrete form; b) adhering the plurality of tiles to
the tile support to define a mosaic assembly, the tiles being
positioned on the tile support corresponding to the mosaic; c)
connecting the mosaic assembly to the concrete form; d) pouring the
concrete within the concrete form such that a portion of the tiles
become embedded within the concrete; and e) removing the concrete
form from the concrete.
2. The method as recited in claim 1, wherein the tile support is
formed from a porous material.
3. The method as recited in claim 2, wherein the tile support is
formed from mesh.
4. The method as recited in claim 1, wherein step b) includes
adhering the plurality of tiles to the tile support using a
water-soluble adhesive.
5. The method as recited in claim 4, wherein step e) includes
spraying water on the tile support to dissolve the adhesive to
allow separation of the tile support from the tiles when the
concrete form is removed.
6. The method as recited in claim 1, wherein step b) includes
applying adhesive to mesh and then placing the plurality of tiles
on the mesh to secure the tiles thereto.
7. The method as recited in claim 1, wherein step b) includes
applying adhesive to the plurality of tiles and then placing the
tiles on the mesh to secure the tiles to the mesh.
8. The method as recited in claim 1, wherein the tile support
includes a visual template corresponding to mosaic to facilitate
placement of the tiles thereon.
9. The method as recited in claim 1, wherein step c) includes
stapling the tile support to the form.
10. The method as recited in claim 1, further comprising the step
of sand blasting the cured concrete.
11. The method as recited in claim 1, further comprising the step
of acid washing the cured concrete.
12. The method as recited in claim 1, further comprising the step
of washing the cured concrete with a surface retarder.
13. The method as recited in claim 1, further comprising the step
of sponging the cured concrete.
14. The method as recited in claim 1, further comprising the step
of applying a finishing coating to the cured concrete.
15. A method of forming a mosaic upon a concrete surface, the
method comprising the steps of: a) providing a plurality of tiles,
a tile support, and a concrete form; b) adhering the plurality of
tiles to the tile support to define a mosaic assembly, the tiles
being positioned on the tile support corresponding to the mosaic;
c) disposing mosaic assembly within pour area; d) pouring the
concrete within the concrete form such that a portion of the tiles
become embedded within the concrete; and e) removing the concrete
form from the concrete surface.
16. The method as recited in claim 15, wherein the tile support is
formed from a porous material.
17. The method as recited in claim 16, wherein the tile support is
formed from mesh.
18. The method as recited in claim 15, wherein step b) includes
adhering the plurality of tiles to the tile support using a
water-soluble adhesive.
19. The method as recited in claim 18, wherein step e) includes
spraying water on the tile support to dissolve the adhesive to
allow separation of the tile support from the tiles as the concrete
form is removed.
20. The method as recited in claim 15, wherein step b) includes
applying adhesive to mesh and then placing the plurality of tiles
on the mesh to secure the tiles thereto.
21. The method as recited in claim 15, wherein step b) includes
applying adhesive to the plurality of tiles and then placing the
tiles on the mesh to secure the tiles to the mesh.
22. The method as recited in claim 15, wherein the tile support
includes a visual template corresponding to mosaic to facilitate
placement of the tiles thereon.
23. A method of forming a mosaic upon a concrete surface, the
method comprising the steps of: a) providing a plurality of tiles,
a tile support, and a concrete form; b) adhering the plurality of
tiles to the tile support to define a mosaic assembly, the tiles
being positioned on the tile support corresponding to the mosaic;
c) disposing mosaic assembly within pour area; d) pouring the
concrete within the concrete form such that a portion of the tiles
become embedded within the concrete; e) detaching the tile support
from the concrete form; f) removing the concrete form; and g)
removing the tile support from the plurality of tiles.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND
[0003] 1. Field of the Invention
[0004] The present invention relates in general to concrete
products, and more particularly, to methods for creating a mosaic
concrete product, specifically, a method of fabricating a module
for use in creating a mosaic upon an uncured generally vertical
concrete surface and a method of installing the mosaic upon the
generally vertical concrete surface utilizing the module.
[0005] 2. Description of the Related Art
[0006] As is well known in the building and construction trade,
concrete is extensively utilized as a building material for
industrial, commercial and residential applications. Due to its
durability, water resistance, and cost economy, concrete has gained
wide spread use. With this widespread use, the public is currently
demanding variations in color, surface texture and overall
appearance of concrete so that the concrete possesses improved
aesthetics similar to more conventional and costly surfaces such as
stone, mosaic, and terrazzo.
[0007] In order to meet this demand, the concrete trade has
developed various coloring and surface finishing techniques to
enhance the aesthetics of concrete. Examples of such finishing
techniques include salt finish, multiple broom finish, form press
finish (e.g. stamped concrete), and exposed aggregate finish.
[0008] In addition to the extensive use of concrete in building and
construction, the use of mosaics in flooring, walls, and other
decorative structures and elements has also become significantly
widespread. Such products typically include a picture or decorative
design. The design is made by completing several steps. First, with
regard to flooring, for example, the flooring surface must be
prepared, which may include leveling the surface. Secondly, an
adhesive, such as mortar or a tile adhesive, is spread upon the
surface. After the adhesive is in place, small individual colored
mosaic pieces, such as stone or tile, are set into the surface.
Once the adhesive is substantially dried, a grouting product is
then set between the mosaic pieces to create a uniform surface and
further secure the mosaic pieces to the surface. The resultant
product is frequently very beautiful and may be very ornate and
detailed. However, due to the extensive amount of time and several
additional steps that such a product requires in comparison to
other flooring products, mosaic flooring are usually quite
expensive. Further, construction of mosaics in walls and other
decorative structures and elements may also be quite laborious and
expensive.
[0009] Although concrete and mosaic products have advanced
significantly over recent years to meet the demands of customers
and innovative builders, there is no current concrete product for
use in flooring, walls, or other decorative structures and elements
that makes the creation of mosaics more affordable or efficient
than the basic process described above.
[0010] Therefore, there exists a need in the art for an improved
process of creating mosaic products that is more cost and time
efficient, particularly for creating a mosaic upon a vertical
surface. Various aspects of the present invention are directed
toward addresses this particular need, as will be discussed in more
detail below.
BRIEF SUMMARY
[0011] According to various aspects of the present invention, there
is provided a method of installing a tile mosaic upon a vertical
concrete surface. In general, the method includes forming the
mosaic on a template and securing the template to a concrete form
used to frame the concrete surface. After the concrete has been
poured and cured, the form and template may be removed to reveal
the mosaic, which is embedded within the cured concrete. The method
advantageously provides a quick and easy process by which a
template may be formed on a generally vertical concrete surface.
Furthermore, it is contemplated that the template may be easily
constructed off-site and subsequently transported to the
construction site for implementation into the concrete surface. As
such, valuable space at the construction site may not be required
for construction of the mosaic template.
[0012] According to one embodiment, the method includes providing a
plurality of tiles, a tile support, and a concrete form. The
plurality of tiles are adhered to the tile support to define a
mosaic assembly. The tiles are positioned on the tile support
corresponding to the mosaic. The mosaic assembly is connected to
the concrete form, and concrete is poured within the concrete form
such that a portion of the tiles become embedded within the
concrete. The tile support is subsequently detached from the
concrete form and the concrete form is removed from the cured
concrete. The tile support is additionally removed from the
plurality of tiles to reveal the mosaic on vertical surface of the
concrete structure.
[0013] It is contemplated that the concrete form may be stripped or
removed while the concrete is in a semi-plastic state. A float may
be passed over the tile/concrete surface to create a more uniform
surface. Furthermore, a brush, sponge, power washer and/or surface
retarder may be used to expose the surface of the concrete.
[0014] The present invention is best understood by reference to the
following detailed description when read in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] These and other features and advantages of the various
embodiments disclosed herein will be better understood with respect
to the following description and drawings, in which like numbers
refer to like parts throughout, and in which:
[0016] FIG. 1 is an upper perspective view of a tile mosaic being
installed on a vertical concrete surface;
[0017] FIG. 2 is an upper perspective view of a plurality of tiles
which collectively define the mosaic, and a mesh tile support for
installing the tiles on the concrete surface;
[0018] FIG. 3A is a top view of a concrete form defining a pour
area, with the tile support and mosaic tiles disposed inside the
pour area adjacent the form, the tiles being secured to the tile
support via an adhesive;
[0019] FIG. 3B is a top view similar to FIG. 3A, with concrete
poured into the pour area defined by the concrete form;
[0020] FIG. 3C is a top view similar to FIG. 3B with the concrete
cured and the form and tile support removed from the cured concrete
and mosaic tiles; and
[0021] FIG. 3D is a top view similar to FIG. 3C with the adhesive
removed from the tiles.
[0022] Common reference numerals are used throughout the drawings
and detailed description to indicate like elements.
DETAILED DESCRIPTION
[0023] The detailed description set forth below is intended as a
description of the presently preferred embodiment of the invention,
and is not intended to represent the only form in which the present
invention may be constructed or utilized. The description sets
forth the functions and sequences of steps for constructing and
operating the invention. It is to be understood, however, that the
same or equivalent functions and sequences may be accomplished by
different embodiments and that they are also intended to be
encompassed within the scope of the invention.
[0024] Referring now to the drawings wherein the showings are for
purposes of illustrating a preferred embodiment of the invention
only, and not for purposes of limiting the same, FIGS. 1-3D show a
system and method of creating and installing a mosaic 10 upon a
concrete surface 12, particularly a vertical concrete surface 12.
The mosaic 10 includes a plurality of tiles 14 which are secured or
adhered to a template or tile support 16. The tile support 16 is
placed adjacent the concrete form used to define the vertical face
of the concrete structure. In a preferred embodiment, the tile
support 16 is connected to the concrete form. Concrete is then
poured into the form and is allowed to cure. As the concrete cures,
the tiles 14 become embedded within the concrete, while a portion
of the tile 14 remains exposed. After the concrete has cured, the
form is removed from the concrete and the tile support 16 is
separated from the tiles 14. The result is a vertical concrete
surface having a plurality of tiles embedded therein collectively
defining a mosaic 10.
[0025] As used herein, the word "vertical" refers to a direction
having a directional component aligned with an axis defined by the
force of gravity (i.e., the gravitational axis). A vertical face
may extend generally upward from a lower support, or generally
downward from an upper support. "Vertical" may also indicate a
direction that is substantially perpendicular to the horizontal.
Along these lines, a vertical surface is not limited to being
substantially upright or perpendicular to the horizontal. In this
regard, the vertical surface may be slightly offset from the
perpendicular to the horizontal.
[0026] Referring now to FIG. 3A, there is shown a concrete form 18
including form members 20a-20d for constructing a concrete
structure, such as a concrete wall similar to the concrete
structure shown in FIG. 1. The form members 20a-20d may be formed
from wood, plastic, or other materials known in the art. The form
18 is placed upon a base or ground surface, and defines a pour
cavity 22 corresponding to the concrete structure. The form 18
shown in FIGS. 3A and 3B includes four form members 20a-20d, which
collectively define the pour cavity 22. Each form member 20a-20d
defines an inner face and an outer face, with the inner faces of
the form members 20a-20d defining the pour cavity 22. Although the
form members 20a-20d shown in FIGS. 3A and 3B are planar, it is
additionally contemplated that other embodiments may include form
members 20a-20d that define other shapes and configurations, such
as arcuate or rounded sections. Furthermore, the form 18 shown in
FIGS. 3A and 3B defines a pour cavity 22 that is completely
circumscribed by the concrete form 18, however, it is understood
that the form 18 may only partially circumscribe the cavity 22. For
instance, the form 18 may be placed against an existing structure,
wherein a portion of the existing structure defines a portion of
the cavity 22. The form members 20a-20d defining the form are held
together by mechanical fasteners, such as nails or screws, to
define the cavity 22 within which the concrete is poured.
[0027] The mosaic 10 is comprised of a plurality of tiles 14 which
may collectively form an artistic or decorative pattern. The
transfer of the tiles 14 to the concrete structure is facilitated
by the use of a tile support 16 to which the tiles 14 are
preferably temporarily adhered to. The tile support 16 may include
a porous material, such as mesh, cloth or paper that is strong
enough to support the plurality of tiles 14 included in the mosaic
design. As will be described in more detail below, the tiles 14 are
adhered to the tile support to 16 maintain the tiles 14 in position
while the concrete is poured into the pour cavity 22, as well as
maintaining the tiles 14 in position during the curing process.
[0028] Referring now to FIGS. 3A and 3D each tile 14 includes an
exposed surface 24 (See FIG. 3D) and an embedded surface 26 (See
FIG. 3A). The tiles 14 are configured to be placed within the
concrete structure such that the embedded surface 26 is embedded
within the concrete, while the exposed surface 24 remains exposed
to contribute to the overall appearance of the mosaic 10. The tiles
14 may be formed of ceramic, glass, stone, shell, and/or brick tile
pieces, and any other variety of ornamental material or
combinations thereof. Furthermore, the tiles 14 are preferably
configured to withstand the environmental conditions associated
with the location of the concrete structure. For instance, if the
concrete structure is located outside, the tiles 14 should be
configured to endure extended periods of exposure to the sunlight,
as well as temperature changes, precipitation, or other conditions
commonly associated with the local environment. A protective
coating may be applied to the tiles 14 to provided added protection
from the environmental elements.
[0029] According to one embodiment, the exposed surfaces 24 of the
tiles 14 are temporarily adhered to the tile support 16. When the
exposed surfaces 24 of the tiles 14 are adhered to the tiles
support 16, the tiles 14 are arranged on the tile support 16 in a
"reverse image" configuration, such that when the tiles 14 are
placed onto the vertical surface 12, the tiles 14 appear in the
correct configuration.
[0030] An adhesive 28 may be disposed between the tiles 14 and the
tile support 16 to temporarily adhere the tiles 14 to the tile
support 16. The adhesive 28 is preferably a water soluble adhesive
28 to facilitate separation of the tile support 16 from the tiles
14 after the concrete cures and the tiles 14 are embedded within
the concrete structure.
[0031] In one particular implementation, the adhesive 28 is
disposed on the tile support 16 prior to placing the tiles 14 on
the tile support 16 in the mosaic arrangement. In this regard, it
may be easier to apply the adhesive 28 to the tile support 16,
rather than applying the adhesive 28 to each tile individually.
After the adhesive 28 is completely disposed on the tile support
16, the tiles 14 are then placed on the tile support 16.
[0032] According to another implementation, the adhesive 28 is
applied to the exposed surface 24 of the tiles 14 before the tiles
14 are placed on the tile support 16. Applying the adhesive 28 to
each individual tile 14 may result in a more efficient use of the
adhesive 28 (i.e., less adhesive 28 may be used). After the
adhesive 28 has been placed on the tiles 14, the tiles 14 may be
placed upon the tiles support 16, with the adhesive 28 being
disposed between the exposed surface 24 of the tiles 14 and the
tile support 16.
[0033] The tile support 16 and the tiles 14 placed on the tile
support 16 collectively define a mosaic assembly 30 (See FIG. 2).
The mosaic assembly 30 is connected to the inner face of the form
18 to dispose the mosaic assembly 30 within the pour cavity 22. The
mosaic assembly 30 is arranged with the embedded surfaces 26 of the
tiles 14 facing into the cavity 22 and the exposed surfaces 24 of
the tiles 14 facing out of the cavity 22 (i.e., toward the adjacent
form member). The tile support 16 is disposed between the tiles 14
and the concrete form 18. According to one implementation, the tile
support 16 may be secured to the concrete form 18 via mechanical
fasteners, such as nails, screws, rivets, staples, adhesives, etc.,
or may be tied to the form 18, or otherwise secured thereto using
techniques known in the art.
[0034] The concrete 32 is poured into the pour cavity 22 and is
allowed to settle and cure. During the curing process, the mosaic
assembly 30 remains adjacent the inner surface of the form 18. It
is contemplated that the exposed surface 24 of the tiles 14 may
become partially or completely embedded within the concrete 32 when
the concrete 32 is poured into the cavity 22. However, as discussed
in more detail below, a finishing process may be performed to
remove a portion of the concrete 32 and thereby uncover the exposed
surfaces 24.
[0035] After the concrete 32 has been poured, the form 18 and tile
support 16 are removed from the concrete structure and the tiles
14. According to one implementation, the form 18 is removed while
the concrete is in a semi-plastic state. The tile support 16 may be
configured to peel away from the tiles 14 when the form 18 is
removed from the concrete structure. In other words, the tile
support 16 and the form 18 may be removed at the same time. In an
alternate embodiment, the concrete form 18 and tile support 16 are
removed separately. Along these lines, the concrete form 18 is
first removed from the concrete structure by separating the tile
support 16 from the form 18, and then removing the form 18 from the
concrete structure. Subsequently, the tile support 16 may be
removed from the tiles 14. To this end, the adhesive 28 binding the
tile support 16 to the tiles 14 may be dissolved or otherwise
rendered inoperable by spraying water or applying another agent
onto the tile support 16. After the adhesive 28 has been dissolved,
the tile support 16 may be separated from the tiles 14, leaving the
tiles 14 embedded within the concrete 32.
[0036] An optional finishing step may be performed to the concrete
structure and the tiles 14 after the form 18 has been removed. For
instance, a float may be passed over the tiles 14 and concrete
before the concrete completely cures to create a more uniform
surface. The concrete structure may be sandblasted, acid washed,
brushed, sponged, or power washed to remove the top layer of
concrete 32, which may further uncover the tiles 14 to more
prominently display the mosaic 10, as well as to expose the cement
fines to produce a more aesthetic appearance. In addition, a
surface retarder may be applied to the form 18 or concrete directly
to more prominently display the mosaic 10.
[0037] The foregoing describes a method of connecting the tiles 14
to the tile support 16 wherein the exposed surfaces 24 of the tiles
14 are connected to the tile support 16 (referred to as an "outer
support" method because the "outer" portion of the tiles 14 are
connected to the tile support 16). The following describes an
alternative method wherein the embedded surface 26 of the tiles 14
are connected to the tile support 16 (referred to as an "inner
support" method because the "inner" portion of the tiles 14 are
connected to the tile support 16).
[0038] According to the inner support method, the embedded portions
26 of the tiles 14 are coupled to the tile support 16. The tiles 14
may be more permanently adhered to the tile support 16 because the
tile support 16 may be embedded within the concrete structure with
the tiles 14 in the finished product. In other words, the tile
support 16 may not be separated from the tiles 14 after the
concrete structure has cured. However, the adhesives 28 described
above in relation to the outer support method may also be used for
the inner support method.
[0039] Given that the embedded portion 26 of the tiles 14 are
connected to the tile support 16, the tiles 14 may be placed on the
tile support 16 in the configuration which they are to be displayed
on the vertical surface 12. In other words, the tiles 14 do not
need to be placed in the "reverse" configuration as discussed above
in relation to the outer support method. Rather, the tiles 14 can
be placed as they will appear in the mosaic 10 on the vertical wall
12.
[0040] After the tiles 14 are adhered to the tile support 16 to
define the mosaic assembly 30, the mosaic assembly 30 is disposed
within the pour cavity 22 adjacent the inner surface of the
concrete form 18. The tile support 16 may be attached to the
concrete form 18, or to another readily available anchor point.
Alternatively, the tile support 16 may have enough rigidity to
support itself, i.e., without being anchored to a separate
structure. For instance, the tile support 16 may be formed from a
wire mesh having an internal rigidity sufficient for supporting the
mosaic assembly 30 in an upright, standing configuration.
[0041] After the mosaic assembly 30 is disposed within the pour
cavity 22, the concrete 32 is poured and is allowed to cure. The
mosaic assembly 30 is positioned within the pour cavity 22 such
that when the concrete 32 cures, the exposed surfaces 24 of the
tiles 14 are exposed and the embedded portions 26 of the tiles 14
are embedded within the concrete 32. After the concrete 32 cures,
the concrete form 18 is removed and the finishing steps described
above may be performed to the concrete structure.
[0042] The above description is given by way of example, and not
limitation. Given the above disclosure, one skilled in the art
could devise variations that are within the scope of the invention
disclosed herein, including various ways of creating different
textures, colors, patterns, utilizing various types of mosaic
pieces, etc. Further, the various features of the embodiments
disclosed herein can be used alone, or in varying combinations with
each other and are not intended to be limited to the specific
combination described herein. Thus, the scope of the claims is not
to be limited by the illustrated embodiments.
* * * * *