Ornamental molding and method of manufacture

Abstract

An ornamental molding and method of manufacture have a positive molding ( 1 ) made of solidified foam material coated with predetermined cementitious-like material having a selected ornamental shape and predetermined resistivity to natural destructiveness. A negative molding ( 6 ) in which the positive molding is formed also is made preferably from solidified foam material that is coated with a release agent. The solidified foam material is preferred for its light weight, ease of forming and low cost. Additional advantages of the solidified foam material are long life with coating protection for the positive mold and contrastingly easy destruction and discard of the negative mold after being used to make the positive molding. For a wide selection of ornamental moldings, the positive and the negative moldings can be formed together by parting them from a single piece of solidified foam material with a cutting instrument ( 8 ) that can include a hot wire, a hot rod, a fluid jet stream or a laser beam. For moldings having compound curvature of interfaces, the positive and the negative moldings can be made from different pieces of solidified foam material that are shaped separately. Designs may be imprinted on the ornamental molding by attaching a layer of material, such as silicone rubber, bearing a design before injecting the cementitious-like material between the positive and negative molds.

What is claimed is:  
     
         1 . An ornamental molding comprising; 
 a positive molding made of solidified foam material;    the positive molding having an ornamental molding portion and an adhesional portion;    the ornamental molding portion having a selected ornamental size and shape for ornamenting an edifice predeterminedly;    the adhesional portion having a selected adhesional size and shape for adherence of the adhesional portion of the positive molding to the edifice;    the ornamental molding portion being coated with predetermined cementitious-like material having a selected coating shape;    the solidified foam material having predetermined lightness, ease of shaping, rigidity, material adherence and adhesive adherence;    the solidified foam material that is coated with the cementitious-like material having time durability for use as an ornamental component of the edifice predeterminedly; and    the cementitious-like material having predetermined weather resistance, impact resistance, biological resistance and thickness for the use of the positive molding as an ornamental component of the edifice predeterminedly.    
     
     
         2 . The ornamental molding of  claim 1  wherein: 
 the solidified foam material includes a compound of styrene.  
 
     
     
         3 . The ornamental molding of  claim 1  wherein: 
 the solidified foam material includes polyurethane.  
 
     
     
         4 . The ornamental molding of  claim 1  wherein: 
 the cementitious-like material includes predeterminedly fine sand.  
 
     
     
         5 . The ornamental molding of  claim 1  wherein: 
 the cementitious-like material includes predeterminedly colored stone.  
 
     
     
         6 . The ornamental molding of  claim 1  wherein: 
 the cementitious-like material includes predeterminedly sized stone.  
 
     
     
         7 . The ornamental molding of  claim 1  wherein: 
 the cementitious-like material includes pieces of predeterminedly shaped stone.  
 
     
     
         8 . The ornamental molding of  claim 1  wherein: 
 the cementitious-like material includes predeterminedly sized, shaped and colored stone substitute.  
 
     
     
         9 . The ornamental molding of  claim 1  wherein: 
 the cementitious-like material includes predeterminedly gypsum.  
 
     
     
         10 . The ornamental molding of  claim 1  wherein: 
 the cementitious-like material includes predeterminedly a polymer.  
 
     
     
         11 . The ornamental molding of  claim 1  wherein: 
 the cementitious-like material includes a predeterminedly smooth ornamental surface.  
 
     
     
         12 . The ornamental molding of  claim 1  wherein: 
 the cementitious-like material includes a predeterminedly colored ornamental surface.  
 
     
     
         13 . The ornamental molding of  claim 1  wherein: 
 the cementitious-like material includes a predeterminedly shaped ornamental surface.  
 
     
     
         14 . The ornamental molding of  claim 1  wherein: 
 the adhesional portion of the positive molding includes predetermined porosity for penetration of an adhesive predeterminedly.  
 
     
     
         15 . The ornamental molding of  claim 1  wherein: 
 the adhesional portion of the positive molding includes a surfacing material having predetermined material strength.  
 
     
     
         16 . A method comprising the following steps for manufacturing the ornamental molding: 
 providing the solidified foam material for making the positive molding predeterminedly;    providing material for making the negative molding for receiving the positive molding predeterminedly;    providing the cementitious-like material for being affixed to the ornamental portion of the positive molding predeterminedly;    sizing and shaping the ornamental molding portion of the positive molding and a forming portion of the negative molding congruently;    sizing and shaping the adhesional portion of the positive molding and a base portion of the negative molding selectively;    structurally fortifying the negative molding selectively;    release-conditioning the forming portion of the negative molding;    positionally applying the cementitious-like material to the ornamental molding portion of the positive molding with the cementitious-like material being placed intermediate the ornamental molding portion of the positive molding and the forming portion of the negative molding;    allowing the cementitious-like material to set on the positive molding; and    removing the positive molding from the negative molding.    
     
     
         17 . The method of  claim 16  and further comprising: 
 adhering the adhesional portion of the positive molding to the edifice.  
 
     
     
         18 . The method of  claim 16  wherein: 
 the sizing and shaping of the ornamental molding portion of the positive molding and the forming portion of the negative molding include cutting them from a single piece of solidified foam material with a cutting instrument for producing the ornamental molding portion on a first side and the forming portion on a second side of a predetermined ornamental cutting configuration; and  
 the ornamental cutting configuration being bounded by a molding wall of the ornamental molding portion on the first side of the ornamental cutting configuration and by a forming wall of the forming portion that is oppositely disposed on the second side of the ornamental cutting configuration.  
 
     
     
         19 . The method of  claim 18  wherein: 
 the cutting instrument includes a cutting thickness for leaving a predetermined distance of separation between the molding wall and the forming wall for containing the cementitious-like material to form the ornamental molding portion of the positive molding.  
 
     
     
         20 . The method of  claim 19  wherein: 
 the cutting instrument includes a cutting wire having predetermined heat and thickness for heat-disintegrating the solidified foam material intermediate the molding wall and the forming wall by passage of the cutting wire congruously with the cutting configuration.  
 
     
     
         21 . The method of  claim 19  wherein: 
 the cutting instrument includes a resistance-heated rod having predetermined heat and thickness for heat-disintegrating the solidified foam material intermediate the molding wall and the forming wall by passage of the resistance-heated rod congruously with the cutting configuration.  
 
     
     
         22 . The method of  claim 19  wherein: 
 the cutting instrument includes a fluid stream having predetermined mass, flow speed and thickness for fluid-disintegrating the solidified foam material intermediate the molding wall and the forming wall by passage of the fluid stream congruously with the cutting configuration.  
 
     
     
         23 . The method of  claim 19  wherein: 
 the cutting instrument includes a laser beam having predetermined dimensions for laser-disintegrating the solidified foam material intermediate the molding wall and the forming wall by passage of the laser beam congruously with the cutting configuration.  
 
     
     
         24 . The method of  claim 16  wherein: 
 the sizing and shaping of the ornamental molding portion of the positive molding and the forming portion of the negative molding include structuring them separately from separate pieces of material having the ornamental cutting configuration being bounded by the molding wall of the ornamental molding portion on the first side of the ornamental cutting configuration and by a forming wall of the forming portion that is oppositely disposed on the second side of the ornamental cutting configuration.  
 
     
     
         25 . The method of  claim 16  wherein: 
 the positionally applying of the cementitious-like material to the ornamental molding portion of the positive molding includes removal of gaseous bubbles from the cementitious-like material.  
 
     
     
         26 . The method of  claim 25  wherein: 
 the removal of the gaseous bubbles includes vibrating the positive molding and the negative molding prior to allowing the cementitious-like material to set.  
 
     
     
         27 . The method of  claim 16  wherein sizing and shaping the ornamental molding portion of the positive molding and a forming portion of the negative molding further comprises attaching a layer of material bearing a design imprint to the forming portion of the negative molding.  
     
     
         28 . The method of  claim 27  wherein the material with the design imprint includes a polymer.