Simulated stone or brick column and method of fabricating same

Abstract

A simulated stone or brick column which is fabricated by a method which involves providing a hollow closed mold which has an inner face in the form of a reverse image of the desired stone or brick surface. Two casting materials are sequentially introduced into the mold and in each case the mold is rotated about two perpendicular axes so that the casting material coats the inner face of the mold and results in the formation of a hollow column having the external appearance of the desired stone or brick surface. The two casting materials form an outer layer which has a texture and contour which simulate a stone or brick surface, and an inner layer which is adheredt to the outer layer and imparts high strength with minimal weight. A standard mailbox and newspaper tube can be integrally molded within the column.

1 . A method of fabricating a simulated stone or brick column, comprising the steps of
 providing a hollow closed mold having a peripheral side wall and opposite end plates, with at least the peripheral side-wall having an inner face which comprises a reverse image of a stone or brick surface,   introducing a first liquid casting material into the mold,   rotating the mold about two different axes to cause the first casting material to coat the inner face of the side wall and the opposite end plates of the mold,   allowing the first liquid casting material to cure and harden,   introducing a second liquid casting material into the mold,   rotating the mold about said two different axes so as to cause the second casting material to coat the hardened first casting material,   allowing the second liquid casting material to cure and harden, and   opening the mold so as to permit removal of the resulting molded column, and such that the resulting molded column comprises a peripheral side wall and upper and bottom end walls, with at least the peripheral side wall of the molded column having an exterior surface in the form of a positive image of the stone or brick surface.   
   
   
       2 . The method of  claim 1  wherein the peripheral side wall and upper and lower end walls of the resulting molded column each comprise an outer layer formed by the first casting material and an inner layer which is adhered to the outer layer and is formed by the second casting material. 
   
   
       3 . The method of  claim 2  wherein the first casting material comprises a composition which is formulated to provide the realistic look and texture of stone or brick in the outer surface of at least the peripheral side wall of the resulting molded column. 
   
   
       4 . The method of  claim 3  wherein the second casting material comprises a mixture of a polymeric resin and fiber strands which is formulated to provide tensile strength while adding minimal weight to the walls of the resulting molded column. 
   
   
       5 . The method of  claim 1  wherein the peripheral side wall and at least one of the end plates of the hollow closed mold comprise a relatively rigid outer panel and a liner releasably secured to the inside of the rigid outer panel, and wherein the liner is provided with said reverse image of a stone or brick surface. 
   
   
       6 . The method of  claim 5  wherein the peripheral side wall of the mold comprises four generally flat side wall members which are releasably interconnected to define a rectangular configuration in horizontal cross section. 
   
   
       7 . The method of  claim 6  comprising the further step of assembling a standard mailbox in one of the side wall members of the mold so that the openable end portion of the mailbox extends through at least a portion of the liner of the side wall member of the mold and so that the openable end lies closely adjacent the outer panel of the side wall member. 
   
   
       8 . The method of  claim 7  comprising the further subsequent step of partially filling the interior of the resulting molded column with an expandable foam product so as to form a foam which surrounds and supports the mailbox in the interior of the resulting molded column. 
   
   
       9 . The method of  claim 1  wherein the two different axes about which the mold is rotated are in each rotating step substantially perpendicular to each other. 
   
   
       10 . The method of  claim 9  wherein the rotational speed about each axis in each rotating step is between about 2 and 20 rotations per minute. 
   
   
       11 . The method of  claim 1  wherein one of the end plates of the mold is configured to form a closed bottom end wall of the resulting column having a smooth exterior surface, and wherein the method comprises the further subsequent step of mounting the molded column on the ground and including securing a flat footer on the surface of the ground, applying an adhesive to the exterior surface of the bottom end wall of the molded column and/or to the footer plate, and mounting the molded column upon the footer plate so that the exterior surface of the bottom end wall rests upon the footer plate and the adhesive secures the molded column thereupon. 
   
   
       12 . The method of  claim 1  wherein the peripheral side wall and at least one of the end plates of the mold have an inner face which comprises a reverse image of a stone or brick surface with grout lines between the individual stones or bricks, and so that the positive image which is imparted to the peripheral side wall and at least one end wall of the molded column includes grout lines. 
   
   
       13 . The method of  claim 12  comprising the further subsequent steps of covering the grout lines of the molded column with a removeable stencil, then spray painting the peripheral side wall and the at least one end wall of the molded column so that the stencil prevents the application of the paint to the grout lines, and then removing the stencil from the molded column. 
   
   
       14 . A method of fabricating a simulated stone or brick mailbox supporting column, comprising the steps of
 providing a hollow closed mold having four peripheral side wall members disposed in a rectangular configuration in cross section, and opposite end plates, with the side wall members and at least one of the end plates each comprising a relatively rigid outer panel and a relatively thick liner adhered to the inside of the panel, with the liner having an inner face which comprises a reverse image of a stone or brick surface,   assembling a standard mailbox in the mold so that the openable end portion of the mailbox extends into a close fitting opening in the liner of one of the side wall members and to a point adjacent the outer panel thereof,   introducing a first liquid casting material into the mold,   rotating the mold about two essentially perpendicular axes to cause the first casting material to coat the inner face of the liners of the four side wall members and the liner of the at least one end plate of the mold,   allowing the first liquid casting material to cure and harden,   introducing a second liquid casting material into the mold,   rotating the mold about said two axes so as to cause the second casting material to coat the hardened first casting material,   allowing the second liquid casting material to cure and harden, and   opening the mold so as to permit removal of the resulting molded column, and such that the resulting molded column comprises four peripheral side wall members and upper and bottom end walls, with the peripheral side wall members and at least one of the end walls of the molded column having an exterior surface in the form of a positive image of the stone or brick surface.   
   
   
       15 . The method of  claim 14  wherein the resulting molded column has a closed upper end wall and a closed bottom end wall, and comprising the further subsequent step of positioning the resulting molded column so that its upper end wall is below its bottom end wall, and then introducing an expandable foam material into the column so as to fill the bottom portion of the column and surround the mailbox, while causing the upper portion of the column to remain open. 
   
   
       16 . The method of  claim 14  wherein the first casting material comprises a gypsum based composition which generates an exothermic reaction when mixed and which is formulated to provide the realistic look of grout and stone or brick in the resulting molded column. 
   
   
       17 . The method of  claim 16  wherein the second casting material comprises a mixture of polyurethane and chopped fiberglass strands and which is formulated to provide tensile strength while adding minimal weight to the resulting molded column. 
   
   
       18 . A simulated stone or brick column configured to serve as a support for a plaque, light, mailbox, or the like, or a fence post, and comprising
 a molded column of elongate tubular configuration and which comprises a peripheral side wall, an upper end wall, and a bottom end wall which are joined together to form a hollow enclosure,   said peripheral side wall, said upper end wall, and said bottom end wall each comprising an outer layer of a material which is formulated to simulate the texture of stone or brick and grout in the molded column, and an inner layer which is adhered to the outer layer and comprises a mixture of a polymeric resin and fiber strands which is formulated to provide tensile strength while adding minimal weight to the molded column, and   said outer layer having an outer surface which is contoured to resemble a stone or brick surface with grout between the stones or bricks.   
   
   
       19 . The column of  claim 18  wherein the peripheral side wall comprises four generally flat side wall members which collectively form a rectangle in horizontal cross section. 
   
   
       20 . The column of  claim 19  further comprising a standard mailbox mounted to extend through one of the side wall members so that the openable end of the mailbox is accessible from the outside of the column and the rear end portion of the mailbox is within the hollow enclosure. 
   
   
       21 . The column of  claim 20  wherein the hollow enclosure is at least partially filled with a foam material so as to surround and support the rear end portion of the mailbox within the enclosure. 
   
   
       22 . The column of  claim 18  wherein the thickness of the outer layer and the inner layer is in each case between about 3/32 and 3/16 inches.