U.S. patent number 3,811,909 [Application Number 04/889,851] was granted by the patent office on 1974-05-21 for method of making stone reliefs.
Invention is credited to Hermann Bertsch.
United States Patent |
3,811,909 |
Bertsch |
May 21, 1974 |
METHOD OF MAKING STONE RELIEFS
Abstract
Contaminants are removed from an exposed surface of a stone
element on which a relief is to be produced. The exposed surface is
covered with a self-adhesive foil which is intimately adhered
thereto in surface-to-surface contact and which is resistant to
etching fluid capable of attacking the stone element. An
illustration of the desired relief is provided on the exposed side
of the foil. Successive sections of the foil are removed, each
matching the outline of a portion of the illustration to thereby
expose corresponding portions of the surface. To the respectively
exposed portions of the surface etching fluid is applied of a
concentration and for a period of time requisite to etch the
respective exposed portion to desired depth, before another section
of the foil is removed and etching fluid is applied to the newly
exposed portion.
Inventors: |
Bertsch; Hermann
(Donaueschingen, DT) |
Family
ID: |
5716771 |
Appl.
No.: |
04/889,851 |
Filed: |
December 17, 1969 |
Foreign Application Priority Data
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Dec 19, 1968 [DT] |
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1815742 |
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Current U.S.
Class: |
427/270; 427/272;
428/3; 428/187; 428/207; 216/54; 216/100 |
Current CPC
Class: |
B44C
1/227 (20130101); C04B 41/72 (20130101); C04B
41/5353 (20130101); C04B 41/009 (20130101); C04B
41/009 (20130101); C04B 28/02 (20130101); Y10T
428/24736 (20150115); Y10T 428/24901 (20150115) |
Current International
Class: |
B44C
1/22 (20060101); C04B 41/72 (20060101); C04B
41/53 (20060101); C04B 41/60 (20060101); B44d
001/52 (); B65b 033/00 () |
Field of
Search: |
;117/8.5,5.5,6 ;156/2,12
;117/38 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
A Hopkins, The Scientific American Cyclopedia of Formulas, N.Y.
Scientific American Publishing Co., Munn & Co. Inc., 1925, pg.
393..
|
Primary Examiner: Rosdol; Leon D.
Assistant Examiner: Esposito; MIchael F.
Attorney, Agent or Firm: Stricker; Michael S.
Claims
1. A method of making stone reliefs, comprising the steps of
removing contaminants from an exposed surface of a stone element on
which a relief is to be produced; intimately adhering to said
exposed surface in surface-to-surface contact therewith an adhesive
provided on one side of a foil which is resistant to etching fluid
capable of attacking said stone element; providing on the other
side of said foil an illustration of the desired relief;
successively removing sections of said foil each matching the
outline of a portion of said illustration, to thereby expose
corresponding surface portions of said surface; applying to at
least some of said exposed surface portions an etching fluid of
requisite concentration for a predetermined period of time required
to produce a depressed surface portion which is bounded by edge
faces; removing the applied etching fluid; drying the depressed
surface portion; deflecting marginal zones of the foil which bound
said depressed surface portion, into tight overlying engagement
with said edge faces so as to cover the latter; and repeating at
least the steps of applying and removing while said marginal zones
cover said edge faces, to thereby obtain sharply defined edge faces
at the juncture between respective surface portions.
2. A method as defined in claim 1, wherein the step of applying
said etching fluid also comprises applying said etching fluid to
others of said exposed surface portions at least once and for a
period of time considerably shorter than said predetermined period
of time, removing the thus-applied etching fluid, and drying the
respective other exposed
3. A method as defined in claim 2; and further comprising the step
of applying coloring matter to said depressed surface portions
prior to removal of residual sections of said foil from still
covered portions of
4. A method as defined in claim 3, wherein said coloring matter is
a
5. A method as defined in claim 3, wherein the step of applying
said coloring matter comprises spraying said coloring matter onto
said
6. A method as defined in claim 3, wherein first ones of said
depressed surface portions are etched in form of narrow and shallow
grooves, and wherein second ones of said depressed surface portions
are etched in form of deeper recesses having relatively large
surface areas, and wherein the step of applying coloring matter
comprises applying said coloring matter
7. A method as defined in claim 3, wherein first ones of said
depressed surface portions are etched in form of narrow and shallow
grooves, and wherein second ones of said depressed surface portions
are etched in form
8. A method as defined in claim 3; and further comprising the
subsequent steps of removing said residual sections of said foil so
that said surface is again exposed with the desired relief provided
therein; and coating said surface and relief with a layer of
transparent material capable of protecting said surface and relief
against mechanical and atmospheric
9. A method as defined in claim 8, wherein said layer of protective
material is colorless and non-reflective.
Description
BACKGROUND OF THE INVENTION
The present invention relates generally to stone reliefs, and more
particularly to a method of making such stone reliefs.
The use of reliefs--that is sculptures involving the projection of
figures, ornaments and the like from a background--for decorating
purposes dates back to antiquity. Many different types of relief
work have been developed, and a host of different materials have
been used. Thus, it is known to provide reliefs in pressed or cast
metal, in form of wood carvings and in stone. The latter material
is used especially where the relief is to be provided on a rough or
course-textured background, such as a wall, and for such
applications relief in natural stone or stone-like materials are
customary.
Reliefs can be made by modeling in plastic material, by forming
casts of original objects to which plastic materials are applied
and subsequently removed when they have hardened, or by the removal
of material from a blank to thereby obtain the desired appearance
of the relief. The latter approach is that which is historically
employed in the making of stone reliefs, particularly in the making
of natural stone reliefs. Material is removed manually by means of
suitable tools, such as chisels, drills, gouges and the like.
Reliefs produced in this manner in stone are the product of great
skill on the part of the artist. They are exceedingly
time-consuming to produce and concomitantly expensive. Moreover,
and particularly where lines in the relief are close together
and/or where the artisan has incorrectly evaluated the structure of
the stone, even a skilled artisan frequently cannot avoid
irreparable errors or damage.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the present invention to overcome
the aforementioned disadvantages with respect to the production of
stone relief.
More particularly it is an object of the present invention to
provide an improved method of making stone reliefs, particularly
reliefs in natural stone.
In pursuance of these objects, and others which will become
apparent hereafter, one feature of the invention resides in a
method of making stone reliefs which, briefly stated, comprises the
steps of removing contaminants from an exposed surface of a stone
element on which a relief is to be produced, and intimately
adhering to and covering said exposed surface in surface-to-surface
contact with a self-adhesive foil resistant to etching fluid
capable of attacking the stone element. On the exposed side of the
foil an illustration of the desired relief is provided. Now,
sections of the foil which each match the outline of a portion of
the illustration are successively removed, to thereby expose
corresponding underlying portions of the surface. To the
respectively exposed portions of the surface etching fluid is
applied of a concentration and for a period of time requisite to
etch the respective exposed portion to the desired depth, before
another section of the foil is removed and the etching process
repeated.
The treatment of the exposed surface of the stone element for
removal of contaminants is carried out in known manner, for
instance by washing with an acid--e.g., concentrated hydrochloric
acid--or a lye solution. Thereupon, the surface is thoroughly
washed--e.g., with water--to remove all traces of the lye or acid,
dried, and provided with the aforementioned self-adhesive foil. It
will be appreciated that at least one side of the foil--that is the
one which will be exposed after the foil has been applied to the
stone element--must be capable of accepting an illustration of the
desired relief, in form of a sketch or the like. This illustration
can be provided before the foil is applied or it can be provided
after the foil has been applied to the stone element. How the
illustration is applied to the foil is immaterial, and tracing,
free-hand sketching and printing are mentioned here only as
illustrative examples.
By resort to my invention it is possible to provide reliefs in
stone, particularly in natural stone, of the most varied figures,
ornaments or the like; moreover, these reliefs need not be produced
by highly skilled artisans, but only by persons who have been
trained in carrying out the novel method. If the method is carried
out with a reasonable amount of care it will almost invariably
result in the production of flawless reliefs, thereby eliminating
rejects, quite aside from the fact that it is of course less time
consuming and therefore less expensive than the conventional
method, particularly when considered in conjunction with the fact
that it is carried out not by highly skilled artists but by readily
trained production personnel. Some reliefs are in simple line form
while others are raised above and bordered by a free surface, that
is a surface portion which is not provided with relief. Again,
there are reliefs which have relatively large planar surface areas
within the outline of the relief configuration, and which are
offset from other portions of the relief by fine lines. These
latter possibilities are readily achievable by exposing the surface
portions corresponding to the large areas--that is by removing the
corresponding sections of foil--and treating each such surface
portion in successive stages of which each may last approximately 7
- 8 minutes, for example--each involving the application of an
etching fluid, the removal of the etching fluid and the drying of
the exposed surface area whereupon the marginal portions of the
foil bounding the surface area under treatment are tightly pressed
against the edge face of the gradually deepening depression whose
outline corresponds to the exposed surface area. This guarantees
the formation of sharply defined edges at the juncture between
surface portions which are etched to a differential depth. Of
course, the depth can be regulated at will by varying the
concentration of the etching fluid, varying the time period for
which the etching fluid is allowed to contact the respective
surface area of the stone element, and varying the number of times
for which the etching fluid is applied. The use of the marginal
portions of the foil in the aforedescribed manner prevents the
etching fluid from attacking the edge faces bounding the deepening
recess so that these edge faces will be sharp and clearly
defined.
Fine contours within the outline of the relief can be provided by
removing narrow strip-like portions of the foil corresponding to
the respective fine contour to be produced, whereupon the
underlying exposed portion of the stone element surface is
subjected to one or several relatively short--for instance 2-3
minutes--treatments with etching fluid which in addition may have a
reduced concentration if desired. Subsequently the etching fluid is
removed by washing with water or the like in conventional manner.
Here, again, the depth to be achieved can be varied at will.
When the various etching steps are completed, but before the
residual sections of the foil are removed which still cover those
portions of the stone element surface which are not at all to be
etched, the washed and dried element with the residual foil
sections still adhering thereto may have applied to it suitable
coloring matter, for instance a dispersion dye, and this may be
accomplished by spraying the coloring matter onto the stone
element. By varying the colors and their concentration, as well as
varying application time, a great variety of different effects can
be produced without having to depart from the simple application
procedure. It is possible, for instance, to provide more coloring
matter in the narrower grooves of the relief than on the larger
surface areas thereof to thereby obtain special effects.
Evidently, a variety of different etching fluids is suitable for
carrying out the novel method. The selection will depend largely
upon the type of stone to be etched. Thus, hydrochloric acid has
been found particularly suitable for use with limestone, such as
marble and shell lime. Mixtures of acids and concentrated lyes are
also usable.
In some circumstances it is desirable to apply a layer of a
protective substance on the finished relief. This is not ordinarily
necessary if the relief is to be mounted within a closed room,
unless damaging gases, smoke or the like can be expected to be
present in such room. However, the application of such protective
substance is almost invariably advisable where the relief is to be
exposed to the ambient atmosphere, for instance at the outside of
buildings or the like. Naturally, different materials are suitable
for such protective coatings and they are well-known to those
having skill in the art. Their selection will depend to a large
extent upon the deleterious contents in the ambient atmosphere
against which the relief is to be protected. Generally speaking,
however, such a protective coating must not detract from the
appearance of the material, which means that it should be
colorless, transparent and reflection free.
The novel features which are considered as characteristic for the
invention are set forth in the appended claims. The invention
itself, however, both as to its construction and its method of
operation, together with additional objects and advantages thereof,
will be best understood from the following description of specific
embodiments when read in connection with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary top-plan view of a stone element provided
with a relief in form of a raised cross;
FIG. 2 is a section on the line A--A of FIG. 1 showing the stone
element with the protective foil applied, before initiation of the
work;
FIG. 3 is a fragmentary section on the line B--B of FIG. 1 showing
the prepared stone element of FIG. 2 in a first operational
stage;
FIG. 4 is a view similar to FIG. 3 showing the element in a further
operational stage;
FIG. 5 is a view similar to FIG. 4 showing an additional
operational stage;
FIG. 6 is a view similar to FIG. 5 showing the next-following
operational stage;
FIG. 7 is a view similar to FIG. 6 showing a succeeding operational
stage;
FIG. 8 is a view similar to FIG. 7 showing the final operational
stage;
FIG. 9 is a view similar to FIG. 2 but showing the completed stone
relief; and
FIG. 10 shows the stone relief of FIG. 9 in the same view but with
a protective layer applied.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Discussing now the drawing in detail, it will be seen that in FIG.
1 I have illustrated a stone relief in form of a raised cross which
is provided on a stone element 1. The cross 2 is surrounded by a
marginal surface portion 3a of the stone element 1, and within the
outlines of the cross 2 there is an inner planar surface portion 4
which is recessed below the highest level of the cross 2, but not
to the extent of the surface portion 3a (compare FIG. 9).
To produce the stone relief shown in FIG. 1, an exposed surface of
the stone element 1 is first cleaned of contaminants by washing
with an acid or a lye, and subsequent removal of the acid or lye
and drying of the exposed surface. Thereupon a self-adhesive foil 5
is applied and tightly pressed onto this surface, as shown in FIG.
2. The foil 5 must be resistant to the acid or lye which is to be
used for removing material from the stone element 1; this acid or
lye will hereinafter be referred to as the etching fluid for the
sake of convenience. The outer exposed side of the foil 5 is
previously or subsequently provided with an illustration of the
desired relief. It is also possible to provide the illustration on
a separate sheet, for instance a so-called "decal" and to apply it
to the outer side of the foil 5.
Thereupon, the foil 5 is severed along the outer line 2a of the
cross 2, as shown in FIG. 3, and the outer portions 5a of the foil
5 are removed. This exposes the underlying surface portions of the
stone element 1. This surface portion 3 is now thoroughly cleaned
in conventional well-known manner, and any residual adhesive from
the foil 5 which might still adhere, is removed. Now the stone
element 1 is exposed repeatedly to the influence of etching fluid,
i.e., hydrochloric acid, for respective periods of approximately
7-8 minutes, in order to remove material from the surface portion 3
until the level 3a is reached as shown in FIG. 4. During each such
etching stage, the etching fluid penetrates slightly below the
marginal portion of the foil 5 into the stone and thus produces
along and substantially below the marginal portion 5' of the foil a
groove 9. After each etching stage, the respective marginal portion
5' is bent inwardly and tightly pressed against the inner edge face
6 of the respective groove 9 whereby the thus-covered edge face 6
is protected against further attack by the etching fluid during the
next etching stage so that sharply delineated outer contours are
obtained for the relief.
After the surface portion 3 has been etched to the desired depth to
thereby obtain the level 3a of FIG. 4, the foil 5 is severed along
the interior contour line 2b of the cross 2, and the foil portion
5b is removed. This exposes the underlying surface portion 4 of the
stone element 1, and in the same manner as before this surface
portion 4 is subjected to one or several etching stages. The inner
marginal portions 5" of the remaining foil sections are again bent
over into the developing etching groove (compare FIG. 6) in the
same manner in which this has been illustrated and described with
reference to FIG. 5. This results in sharp internal contours for
the cross 2, also.
In FIG. 1, I have shown thin lines 8 intermediate the inner and
outer contours of the cross 2. To produce these lines 8 a narrow
foil strip 7 is removed as shown in FIG. 7. The thus-exposed
surface portion is now subjected for a short period of time to
treatment with the etching fluid whereby a narrow groove 8 is
etched into the surface of the stone element 1 along the cutout 7
and constitutes the intermediate line 8. Depending upon the desired
depth for the groove 8 the application of etching fluid may be
shorter or longer. The groove 8 is shown in FIG. 8 and it will be
seen to be shallower when the etching grooves 9, 9' which bound the
outer and inner contours of the relief.
After all etching steps are completed the residual foil sections
are removed--that is those still present in FIG. 8--and the now
exposed stone element 1 is provided with the relief visible in FIG.
9 in section. If desired the element 1 may now have applied to it,
for instance by spraying, a dispersion dye which settles more
strongly in the etching grooves than on the planar surfaces and
which provides a particularly good three-dimensional appearance.
Finally, and as shown in FIG. 10, the exposed side of the stone
element 1 which is provided with the relief may now be coated with
a layer 10 of a suitable material which protects against attack by
deleterious agents present in the ambient atmosphere, and
which--while its particular composition is selected in dependence
upon deleterious agents to which the element 1 is expected to be
exposed--should meet the requirements that it be colorless,
transparent and non-reflective so as not to conceal the texture of
the stone element.
It will be understood that each of the elements described above, or
two or more together, may also find a useful application in other
types of embodiments differing from the types described above.
While the invention has been illustrated and described as embodied
in a method of making stone reliefs, it is not intended to be
limited to the details shown, since various modifications and
structural changes may be made without departing in any way from
the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the
gist of the present invention that others can by applying current
knowledge readily adapt it for various applications without
omitting features that, from the standpoint of prior art, fairly
constitute essential characteristics of the generic or specific
aspects of this invention and, therefore, such adaptations should
and are intended to be comprehended within the meaning and range of
equivalence of the following claims.
What is claimed as new and desired to be protected by Letters
Patent is set forth in the appended claims.
* * * * *