Faux stone concrete panel and method for making same

Abstract

A wall or panel has a thin concrete layer with a cross-sectional contour having protrusions and indentations forming other objects, such as stone work, brick or wood. A reinforcement layer may be affixed to the concrete layer to provide tensile strength and impact resistance to the concrete layer. A foam layer is affixed to the reinforcement layer to further reinforce the concrete layer, and so that the wall or panel is light weight. A second concrete layer or a rigid backing layer may be disposed opposite the concrete layer so that the foam is disposed therebetween. A method for forming the wall or panel includes spraying the concrete onto a mold surface which has indentations and protrusions for forming the other objects. The reinforcement layer is sprayed onto the cured concrete layer. The mold is closed and foam is introduced into the mold.

What is claimed is:  
     
         1 . A panel comprising: 
 a) a concrete layer having interior and exterior surfaces, and a cross-sectional contour which (i) projects outwardly to form macro projections in the exterior surface and macro indentations in the interior surface, and (ii) projects inwardly to form macro indentations in the exterior surface and macro projections in the interior surface; and    b) a foam layer, coupled to the interior surface of the concrete layer, having protrusions mating with the indentations in the interior surface of the concrete layer.    
     
     
         2 . A panel in accordance with  claim 1 , wherein the projections and indentations are sized and shaped to appear as another object.  
     
     
         3 . A panel in accordance with  claim 1 , wherein the projections and indentations are sized and shaped to appear as another object selected from the group consisting of: rock, stone work, brick, and wood.  
     
     
         4 . A panel in accordance with  claim 1 , wherein the concrete layer has a substantially constant thickness at the projections and indentations.  
     
     
         5 . A panel in accordance with  claim 1 , further comprising: 
 a rigid backing layer, spaced-apart from the concrete layer, having an interior surface opposing the interior surface of the concrete layer; and    wherein the foam layer is disposed between the concrete layer and hacking layer.    
     
     
         6 . A panel in accordance with  claim 1 , wherein the concrete layer includes a first concrete layer, and further comprising: 
 a) a second concrete layer, spaced-apart from and opposite the first concrete layer, having interior and exterior surfaces, and a cross-sectional contour which (i) projects outwardly to form macro projections in the exterior surface and macro indentations in the interior surface, and (ii) projects inwardly to form macro indentations in the exterior surface and macro projections in the interior surface; and    wherein the foam layer is coupled to the interior surface of both of the first and second concrete layers, and has protrusions mating with the indentations in the interior surface of both of the first and second concrete layers.    
     
     
         7 . A panel in accordance with  claim 1 , further comprising: 
 a reinforcement layer, disposed between the concrete layer and foam layer, and directly affixed to the concrete layer, configured to provide impact resistance and tensile strength the concrete layer.    
     
     
         8 . A panel in accordance with  claim 7 , wherein the reinforcement layer includes an elastomer material.  
     
     
         9 . A panel in accordance with  claim 7 , wherein the reinforcement layer includes a urethane material.  
     
     
         10 . A panel in accordance with  claim 7 , wherein the reinforcement layer includes a high density foam, and the foam layer includes a low density foam.  
     
     
         11 . A panel in accordance with  claim 7 , wherein the reinforcement layer includes a high density foam of between approximately 10-20 lbs, and the foam layer includes a low density foam of between approximately 2-5 lbs.  
     
     
         12 . A panel in accordance with  claim 7 , wherein the reinforcement layer includes fiber reinforcement.  
     
     
         13 . A panel in accordance with  claim 1 , wherein the concrete layer has a thickness less than approximately 0.5 inches.  
     
     
         14 . A panel in accordance with  claim 1 , further comprising a plurality of voids formed in the foam layer and sized and shaped to reduce sound.  
     
     
         15 . A panel in accordance with  claim 1 , wherein the concrete layer and foam layer are configured to enable being affixed to an exterior wall of a building.  
     
     
         16 . A panel in accordance with  claim 1 , configured to be usable in a free-standing fencing structure.  
     
     
         17 . A panel comprising: 
 a) a concrete layer;    b) a elastomer layer, affixed to the concrete layer;    c) a rigid backing layer, spaced-apart from the elastomer layer; and    d) a foam layer, disposed between and affixed to the elastomer layer and backing layer.    
     
     
         18 . A panel in accordance with  claim 17 , wherein 
 the concrete layer has an exterior surface with protrusions and indentations, and an interior surface with indentations corresponding to the protrusions in the exterior surface, and protrusions corresponding to indentations in the exterior surface, the concrete layer having a substantially constant thickness at the projections and indentations; and    wherein the elastomer layer has an interior surface with indentations and protrusions corresponding to respective indentations and protrusions of the interior surface of the concrete layer, the elastomer layer having a substantially constant thickness at the projections and indentations.    
     
     
         19 . A panel in accordance with  claim 17 , wherein the protrusions and indentations of the exterior surface of the concrete layer are sized and shaped to appear as another object selected from the group consisting of: rock, stone work, brick, and wood.  
     
     
         20 . The device of  claim 17 , wherein the concrete layer includes a first concrete layer, and the rigid backing layer includes a second concrete layer having an exterior surface with protrusions and indentations, and an interior surface with indentations corresponding to the protrusions in the exterior surface, and protrusions corresponding to indentations in the exterior surface, the second concrete layer having a substantially constant thickness at the projections and indentations, and a second elastomer layer including an interior surface with indentations and protrusions corresponding to respective indentations and protrusions of the interior surface of the second concrete layer, the elastomer layer having a substantially constant thickness at the projections and indentations.  
     
     
         21 . A panel in accordance with  claim 17 , wherein the reinforcement layer includes a urethane material.  
     
     
         22 . A panel in accordance with  claim 17 , wherein the elastomer layer includes fiber reinforcement.  
     
     
         23 . A panel in accordance with  claim 17 , wherein the concrete layer has a thickness less than approximately 0.5 inches.  
     
     
         24 . A panel in accordance with  claim 17 , configured to enable being affixed to a wall of a building.  
     
     
         25 . A panel in accordance with  claim 17 , configured to be usable in a free-standing fencing structure.  
     
     
         26 . A method for forming a panel, comprising the steps of: 
 a) providing a mold having an inner mold surface with macro indentations and macro protrusions;    b) applying a wet mixture of concrete material to the inner mold surface of the mold to form a concrete layer including a cross-sectional contour corresponding to the indentations and protrusions of the inner mold surface;    c) curing the concrete material until dry;    d) introducing foam into the mold to form a foam layer secured to the cement layer with the foam having protrusions mating with the concrete layer; and    e) removing the secured concrete and foam layers from the mold.    
     
     
         27 . A method in accordance with  claim 26 , wherein the step of providing the mold further includes providing a mold with indentations and protrusions sized and shaped to create another object selected from the group consisting of: rock, stone work, brick, and wood.  
     
     
         28 . A method in accordance with  claim 26 , wherein the step of applying the wet mixture of concrete mixture further includes applying the wet mixture of concrete material in a substantially constant thickness at the projections and indentations.  
     
     
         29 . A method in accordance with  claim 26 , further comprising the step of placing a rigid backing layer spaced-apart from the mold surface prior to introducing the foam into the mold.  
     
     
         30 . A method in accordance with  claim 26 , further comprising the step of applying a rigid backing layer to the foam layer.  
     
     
         31 . A method in accordance with  claim 26 , further comprising the steps of: 
 a) applying a layer of reinforcement material to the concrete layer prior to introducing the foam to form a reinforcement layer; and    b) wherein the step of introducing the foam further includes introducing the foam into the mold to form a foam layer secured to the reinforcement layer.    
     
     
         32 . A method in accordance with  claim 26 , further comprising the steps of: 
 a) applying a layer of elastomer material to the concrete layer prior to introducing the foam to form an elastomer layer; and    b) wherein the step of introducing the foam further includes introducing the foam into the mold to form a foam layer secured to the elastomer layer.    
     
     
         33 . A method in accordance with  claim 26 , further comprising the steps of: 
 a) applying a layer of high density foam to the concrete layer prior to introducing the foam to form a reinforcement layer; and    b) wherein the step of introducing the foam further includes introducing a low density of foam into the mold to form a low density foam layer secured to the reinforcement layer.    
     
     
         34 . A method in accordance with  claim 26 , wherein the step of applying a wet mixture of concrete material further includes applying the wet mixture of concrete material in a layer having a thickness less than approximately 0.5 inches.  
     
     
         35 . A method in accordance with  claim 26 , wherein the step of providing the mold further includes providing the mold in a vertical orientation.  
     
     
         36 . A method in accordance with  claim 26 , wherein the step of applying a wet mixture of cement material further includes spraying the wet mixture of cement material onto the inner mold surface.  
     
     
         37 . A method in accordance with  claim 26 , wherein the step of introducing foam into the mold further includes introducing an expandable foam into the mold which expands to fill the indentations in the inner mold surface.  
     
     
         38 . A method in accordance with  claim 26 , wherein the step of providing a mold further includes providing a mold with a second mold surface opposing the inner mold surface; and wherein the step of introducing foam into the mold further includes introducing an expandable foam between the concrete layer and second mold surface.  
     
     
         39 . A method in accordance with  claim 26 , wherein the step of providing a mold further includes providing a mold with a second mold surface pivotally coupled to the inner mold surface such that the inner mold surface and second mold surface pivot between an open position and a closed position in which the mold surfaces oppose one another; and further including the steps of: 
 opening the mold prior to applying the wet mixture of cement material; and    closing the mold prior to introducing the foam.    
     
     
         40 . A method in accordance with  claim 26 , wherein the step of providing the mold further includes providing a mold with a second mold surface having indentations and protrusions; and 
 wherein applying the wet mixture of concrete material further includes applying a wet mixture of concrete to both the inner mold surface to form a first cement layer and the second mold surface to form a second cement layer; and    wherein introducing the foam into the mold further includes introducing the foam between the first and second foam layers to form a foam layer secured to both concrete layers.    
     
     
         41 . A method in accordance with  claim 26 , further comprising the step of: 
 moving the mold with a transfer system through a plurality of different stations for applying the concrete mixture, curing the concrete mixture, and introducing the foam.    
     
     
         42 . A method for forming a panel, comprising the steps of: 
 a) providing a mold having an inner mold surface with macro indentations and macro protrusions;    b) applying a wet mixture of concrete material to the inner mold surface of the mold to form a concrete layer;    c) curing the concrete material until dry;    d) applying a layer of reinforcement material to the cured concrete layer to form a reinforcement layer;    e) introducing foam into the mold to form a foam layer secured to the reinforcement layer; and    f) removing the secured concrete, reinforcement and foam layers from the mold.    
     
     
         43 . A method in accordance with  claim 42 , wherein applying the wet mixture of concrete further includes applying the wet mixture of concrete in a substantially constant thickness at the indentations and protrusions; and wherein applying the reinforcement material further includes applying the reinforcement material in a substantially constant thickness at the indentations and protrusions.  
     
     
         44 . A method in accordance with  claim 42 , wherein the step of providing the mold further includes providing a mold with indentations and protrusions sized and shaped to create another object selected from the group consisting of: rock, stone work, brick, and wood.  
     
     
         45 . A method in accordance with  claim 42 , further comprising the step of placing a rigid backing layer spaced-apart from the mold surface prior to introducing the foam into the mold.  
     
     
         46 . A method in accordance with  claim 42 , further comprising the step of applying a rigid backing layer to the foam layer.  
     
     
         47 . A method in accordance with  claim 42 , wherein applying the reinforcement material further includes applying a layer of elastomer material to the cement layer to form an elastomer layer.  
     
     
         48 . A method in accordance with  claim 42 , wherein the step of applying the wet mixture of concrete material further includes applying the wet mixture of concrete material in a layer having a thickness less than approximately 0.5 inches.  
     
     
         49 . A method in accordance with  claim 42 , wherein the step of applying the wet mixture of cement material further includes spraying the wet mixture of cement material onto the inner mold surface.  
     
     
         50 . A method in accordance with  claim 42 , wherein the step of applying the reinforcement material further includes spraying the reinforcement material onto the cured cement layer.  
     
     
         51 . A method in accordance with  claim 42 , wherein the step of introducing foam into the mold further includes introducing an expandable foam into the mold which expands to fill the indentations in the inner mold surface.  
     
     
         52 . A method in accordance with  claim 42 , wherein the step of providing a mold further includes providing a mold with a second mold surface opposing the inner mold surface; and wherein the step of introducing foam into the mold further includes introducing an expandable foam between the concrete layer and second mold surface.  
     
     
         53 . A method in accordance with  claim 42 , wherein the step of providing a mold further includes providing a mold with a second mold surface pivotally coupled to the inner mold surface such that the inner mold surface and second mold surface pivot between an open position and a closed position in which the mold surfaces oppose one another; and further including the steps of: 
 opening the mold prior to applying the wet mixture of concrete material; and    closing the mold prior to introducing the foam.    
     
     
         54 . A method in accordance with  claim 42 , wherein the step of providing the mold further includes providing a mold with a second mold surface having indentations and protrusions; and 
 wherein applying the wet mixture of cement material further includes applying a wet mixture of cement to both the inner mold surface to form a first concrete layer and the second mold surface to form a second concrete layer; and    wherein introducing the foam into the mold further includes introducing the foam between the first and second concrete layers to form a foam layer secured to both concrete layers.