WO2008062226A1

WO2008062226A1 - Kit for forming a column comprising a decorative moulding

Info

Publication number: WO2008062226A1
Application number: PCT/GB2007/050701
Authority: WO
Inventors: Nicholas Shirtcliffe
Original assignee: Nick Shirtcliffe Mouldings Limited
Priority date: 2006-11-22
Filing date: 2007-11-21
Publication date: 2008-05-29
Also published as: GB0623291D0

Abstract

The present invention provides a kit for forming a column comprising a three-dimensional decorative moulding from a solidifiable material, the kit comprising a rigid column forming tube (1) and a mould insertable therein, wherein the mould comprises a plurality of portions (2a) which together form a substantially tubular mould and wherein the mould comprises an inner surface comprising a three-dimensional moulding (3). Kits of the invention are particularly suited to the formation of concrete columns comprising decorative mouldings.

Description

KIT FOR FORMING A COLUMN COMPRISING A DECORATIVE MOULDING

Field of the Invention

This invention relates to kits and methods for forming columns, in particular for forming concrete columns in situ.

Background to the Invention

Concrete columns may be constructed in situ using a suitable forming tube. Concrete column forming tubes are usually constructed from spirally-wound plies of paper adhered together, defining an inner wall surface of predetermined diameter. The inner surface of the tubes may be coated with a plastic material having concrete release properties. Plaster or concrete is poured into the tube, allowed to set, and the tube subsequently removed. The forming tube is then stripped away to yield a finished column, removal of the tube aided by the release properties of the plastic coating.

Due to the spirally-wound construction of forming tubes, spiral seam lines and other undesirable surface characteristics may be present on the inside wall surface of the tube, resulting in spiral seam lines and other irregularities on the surface of the finished column. From an aesthetic standpoint, these spiral seam lines and other irregularities are often undesirable and so sandblasting or other finishing techniques may be necessary to produce a smooth surface. In an effort to overcome these problems, separately-formed flexible cylindrical liners have been proposed; see, for example, the liners described in US 4595168 and US 4957270. These liners are inserted into the concrete column forming tube after manufacture of the tube and often at the concrete column forming site. While these separate liners improve the surface quality of the resulting concrete column, they often produce one vertical seam line running the length of the formed column. The liners are also expensive to manufacture, difficult to maintain and install, and present other problems in terms of their manufacture and use.

An alternative system is described in EP-A-0646685. This publication discloses a concrete column forming tube comprising a centrifugally-cast epoxy resin coating. The resin is sprayed onto the inside wall surface of the spirally-wound paper tube while the tube is rotating to produce a smooth inside coated surface on the forming tube to eliminate spiral seam lines and other undesirable characteristics on an outside surface of the formed concrete column.

While concrete column forming tubes have proved successful in the manufacture of plain concrete columns, they have limited utility in the manufacture of columns comprising decorative mouldings. Currently, a decorative moulding can only be imparted to a concrete column formed in situ by adding decorative portions to the top or bottom of the formed column. However, the resulting columns often look cheaply constructed and unsightly. Some lightweight decorative columns are known, but they are generally made from fibreglass and cannot be used as load-bearing columns. In many cases, a pre-cast column must be purchased, however pre-cast columns are extremely heavy and so transportation and labour costs can be high. There remains a need for a means of forming decorative columns in situ.

Summary of the Invention

The present invention is based on a realisation that decorative columns can be formed in situ using a suitable insert mould in conjunction with a column forming tube. The insert mould can be used with conventional column tubes and provides a cheap and simple means of forming decorative columns in situ.

In one aspect, the present invention provides a kit for forming a column comprising a three-dimensional decorative moulding from a solidifiable material, the kit comprising a rigid column forming tube and a mould insertable therein, wherein the mould comprises a plurality of portions which together form a substantially tubular mould and wherein the mould comprises an inner surface comprising a three-dimensional moulding. The mould forms a further aspect of the invention.

In another aspect, the present invention provides a method of forming a column comprising a three-dimensional decorative moulding, which comprises pouring a solidifiable material into a column forming tube and solidifying the material in situ, wherein the column forming tube comprises a mould inserted therein, wherein the mould comprises a plurality of portions which together form a substantially tubular mould and wherein the mould comprises an inner surface comprising a three-dimensional moulding.

Brief Description of the Drawings Fig. 1 is a plan view of a kit of the invention.

Fig. 2 is a side aspect of the kit of Fig. 1 .

Fig. 3 illustrates a kit of the invention comprising a securing collar.

Figs. 4 and 5 are cut-away views of a column forming tube and a mould portion comprising male and female locators.

Figs. 6 and 7 are cross-sectional views showing examples of columns which may be produced using a kit of the invention.

Description of Various Embodiments

A column forming kit of the invention comprises a rigid column forming tube and a mould insertable therein. The term "column" as used herein includes reference to pillars, posts, poles, pilasters and the like. The column may be a supporting column or a non- supporting column.

The kit may be used for forming columns made from a solidifiable material, for example concrete, plaster or gypsum (especially hardened blends thereof). The solidifiable material may comprise one or more components selected from colouring additives, texturing additives and additives which provide a tough or waterproof finish to the formed column. Examples of such additives include crushed marble, crushed limestone and resins. The solidifiable material may comprise a purpose-made aggregate, for example Calmix ®.

The invention is particularly relevant to the formation of concrete columns. As mentioned above, concrete column forming tubes are well known in the art and typically comprise spirally-wound plies of paper adhered together which define an inner wall surface. Of particular mention are tubes of the type described in US 4595168, US

4957270 and EP-A-0646685, the contents of which are incorporated herein by reference. The column forming tube may be of the type described in EP-A-0646685, the column forming tube comprising a centrifugally-cast epoxy resin coating on the inner surface of the tube. In one embodiment, the column forming tube is a Sonotube® (Sonoco Products Company). The column forming tube may comprise a stripping filament (e.g. a "rip-cord") running along the length of the tube, whereby pulling of the filament facilitates removal of the forming tube from the finished column.

The column forming tube may comprise a substantially circular, semi-circular, square or rectangular cross-section. Typically, the column forming tube comprises a substantially circular cross-section, an example being a substantially cylindrical tube. In this case, the column forming tube may comprise an internal diameter ranging from about 20 cm to about 100 cm, e.g. from about 30 cm to about 90 cm. The length of the column forming tube may range from about 20 cm to about 400 cm, e.g. from about 100 cm to about 360 cm. The dimensions of the column forming tube can be tailored to the column in question. The tube may be a closed tube (e.g. a cylindrical tube) or an open tube (e.g. a semi-cylindrical tube). By way of example, an open tube may be obtained by cutting a closed tube lengthways. Open tubes are particularly useful for forming pilasters and the like.

The mould is capable of providing a decorative moulding in the formed column, the term "decorative moulding" as used herein including reference to three-dimensional mouldings. The mould may provide a fluting, channel, furrow, panel or Corinthian capital in the formed column. Decorative tops and bases may also be formed in the formed column. In one embodiment, the mould allows formation of a column comprising a Corinthian capital in an upper region of the column. Thus, the invention may allow columns of classical design to be produced in situ.

The mould comprises a plurality of portions which together form a substantially tubular mould. The dimensions of the mould and the forming tube may be such that the mould and the forming tube are in close contact when the mould is present in the tube. In embodiments, the dimensions of the mould are such that it presses against the inner wall of the forming tube. For example, this may be accomplished using a circular mould comprising an external circumference which corresponds to the internal circumference of a circular forming tube. A circular mould may comprise a diameter ranging from about 20 cm to about 100 cm, e.g. from about 30 cm to about 90 cm. The length of the mould will usually be no more than that of the forming tube. In one embodiment, the length of the mould ranges from about 20 cm to about 400 cm, e.g. from about 100 cm to about 360 cm. The dimensions of the mould can be tailored to the column forming tube in question. The mould comprises a plurality of portions, for example two, three or four portions. The use of a mould comprising a plurality of portions allows easier insertion and subsequent removal of the mould from the finished column. In addition, the risk of damage to the finished column is minimised. Of particular mention are moulds consisting of two portions, e.g. two semi-cylindrical portions. The kit may comprise a plurality of moulds, e.g. in order to obtain a variety of decorative effects.

The mould may be made from any suitable material known in the art, e.g. a rubber or plastics material. The mould is often substantially rigid. The mould may comprise a flexible or malleable material, for example a natural or synthetic rubber, e.g. a silicone or urethane rubber. Of mention are moulds comprising polystyrene, polyurethane or other polymeric materials. Expanded polystyrene is readily available and so may be preferable for mass-production of the mould. The mould may be reusable, particular reusable materials including silicone and urethane rubbers. A reusable mould may be particularly desirable where complex mouldings, e.g. Corinthian capitals, are to be formed numerous times.

By way of illustration, a kit of the invention is shown in Figs. 1 and 2. The kit comprises a substantially circular column forming tube 1 and mould portions 2a and 2b which together form a tubular mould. The mould has an external circumference similar to the internal circumference of the forming tube. The mould comprises one or more three- dimensional mouldings 3 on its inner surface, which result in formation one or more corresponding decorative mouldings in the finished column. The mould defines an internal region capable of receiving concrete or another solidifiable material.

The mould may be held in position in the column forming tube by frictional forces, e.g. between an outer surface of the mould and an inner surface of the column forming tube. In use, it may be preferable to secure the mould in place using a collar to minimise "floating" or other movement of the mould in the tube. An example of such a collar is illustrated in Fig. 3. Collar 4 may be made from cardboard and may be attached to the column forming tube by, for example, one or more screws or adhesive tape.

The mould portions may comprise male and female locators which allow coupling of the portions. In one embodiment, the mould is a tubular mould consisting of two semi- cylindrical portions, the portions comprising male and female locators which allow coupling of the portions. Examples of moulds of this type are illustrated, without limitation, in Figs. 4 and 5. Fig. 4 is a cut-away view of a column forming tube 1 containing a mould portion 2a comprising decorative mouldings 3. The mould portion comprises male and female locators 5 and 6 respectively, which engage the corresponding locators on a further mould portion (not shown). The male and female locators are shown in more detail in Fig. 5.

In use, the column forming tube is usually placed in a substantially upright position, however a substantially horizontal orientation may be adopted if necessary. The forming tube may be held in place by tying or using light lumber or scaffolding. If necessary, the base of the column may be secured using a collar. Once the column forming tube is secured, the user may then position the decorative mould in the column forming tube. When the mould is in position, concrete or other solidifiable material is poured into the tube so that the solidifiable material fills the internal space defined by the mould. One or more reinforcing or securing rods may be incorporated into the structure prior, during or after the solidifiable material has been added. The solidifiable material is then allowed to set thereby forming a solid column. When the material has set, the column forming tube is removed, e.g. by cutting or pulling a stripping filament as described above. The decorative mould can then be removed. The use of a mould comprising a plurality of portions is particularly desirable because it facilitates removal of the mould and minimises the risk of damaging the formed column.

Figs. 6a to 6c illustrate examples of columns that may be formed in this manner, namely gate posts (Fig. 6a), fluted columns (Fig. 6b) and square columns (Fig. 6c). The finished columns 7 are shown surrounded by the column forming tube 1 and mould 2.

Fig. 7 illustrates the use of a kit comprising a plurality of moulds to form a column comprising a Corinthian capital. The kit comprises a column forming tube 8, lower mould 9 and upper mould 10. In this embodiment, the lower mould is used to create a fluted effect in the finished column 1 1 , while the upper mould is used to create a Corinthian capital in an upper region of the finished column. The lower and upper moulds may be made of polystyrene and silicone or urethane rubber respectively.

Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of the words, for example "comprising" and "comprises", means

"including but not limited to", and is not intended to (and does not) exclude other additives, components, integers or steps. Features, integers and characteristics described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.

Claims

1 . A kit for forming a column comprising a three-dimensional decorative moulding from a solidifiable material, the kit comprising a rigid column forming tube and a mould insertable therein, wherein the mould comprises a plurality of portions which together form a substantially tubular mould and wherein the mould comprises an inner surface comprising a three-dimensional moulding.

2. A kit according to claim 1 , for forming a concrete column.

3. A kit according to claim 1 or claim 2, wherein the column forming tube comprises a substantially circular cross-section.

4. A kit according to claim 3, wherein the column forming tube comprises spirally- wound plies of paper adhered together.

5. A kit according to any preceding claim, wherein the column forming tube comprises a centrifugally-cast epoxy resin coating on an inner surface of the tube.

6. A kit according to any preceding claim, wherein the decorative moulding is a fluting, channel, furrow, panel or a Corinthian capital.

7. A kit according to any preceding claim, wherein the mould comprises a substantially circular cross-section.

8. A kit according to any preceding claim, wherein the mould comprises a pair of elongate, semi-cylindrical portions.

9. A kit according to any preceding claim, wherein the mould comprises a flexible or malleable material.

10. A kit according to claim 9, wherein the mould comprises a rubber or other polymeric material.

1 1 . A kit according to claim 10, wherein the mould comprises a material selected from silicone rubber, urethane rubber, polystyrene and polyurethane.

12. A mould for forming a column comprising a three-dimensional decorative moulding from a solidifiable material, wherein the mould comprises a plurality of portions which together form a substantially tubular mould and wherein the mould comprises an inner surface comprising a three-dimensional moulding.

13. A mould according to claim 12, wherein the mould is as defined in any of claims 7 to 1 1 .

14. A method of forming a column comprising a three-dimensional decorative moulding, which comprises pouring a solidifiable material into a column forming tube and solidifying the material in situ, wherein the column forming tube comprises a mould inserted therein, wherein the mould comprises a plurality of portions which together form a substantially tubular mould and wherein the mould comprises an inner surface comprising a three-dimensional moulding.

15. A method according to claim 14, wherein the solidifiable material is concrete.

16. Use of a kit of any of claims 1 to 1 1 or a mould of claim 12 or claim 13, for forming a column from a solidifiable material.

17. Use according to claim 16, wherein the solidifiable material is concrete.