A METHOD OF MAKING CAST SLABS

EMBEDDED WITH SEAMLESSLY INTEGRATED METAL SHEET INLAYS

DESCRIPTION

BACKGROUND

My invention relates to the process of creating solid slabs embedded with designed metal sheet, wherein slab and inlay are cast in unison and the inlay pieces are integral with the slab surface and there is no visible surface difference between the inlay metal sheet piece and the slab material. Any viscous compound which hardens can be used to produce the slab, while any type of metal or alloy can be used to produce the metal sheet.

THE DRAWINGS

Figl describe the process for manufacturing solid slabs embedded with designed thin sheet metal on the corner, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.lA Is a perspective view of a designed corner metal sheet inlay after cutting.

Fig. IB Is a perspective view of a designed corner metal sheet inlay after Folding.

Fig.lC Is a perspective exploded view of assembly of the lubricated mold with the folded metal sheet inlay placed.

Fig.lD Is a perspective view of the mold assembled with the folded metal sheet inlay. Fig.lE Is a perspective view of the mold after the viscous compound has been poured inside, flattened, leveled and air bubbles have been extracted from the compound. Plating tabs are left outside the mold.

Fig.lF Is a perspective view of the finished cast slab with metal sheet inlay after extraction from the mold, grinding and finish. Plating tabs sticking out of the slab's sides.

Fig.lG Is a perspective view of the cast slab with metal sheet inlay with or without plating/treatment applied, plating tabs have been removed, and sealer/ epoxy coating applied.

Fig3 Drawings describe the process for manufacturing solid slabs embedded with designed thin sheet metal on the center with the help of a fixing element, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.3A Is a perspective view of a designed center metal sheet inlay after cutting.

Fig.3B Is a perspective view of a designed center metal sheet inlay after Folding.

Fig.3C Is a perspective view of the fixing element

Fig.3D Is a perspective exploded view of assembly of the lubricated mold with the folded metal sheet inlay placed with the aid of the fixing element.

Fig.3E Is a perspective view of the mold assembled with the folded metal sheet inlay placed with the fixing element.

Fig.3F Is a perspective view of the mold after the viscous compound has been poured inside, flattened, leveled and air bubbles have been extracted from the compound. Plating tabs are sticking outside the slab. Fig.3G Is a perspective view of the finished cast slab with metal sheet inlay after extraction from the mold, grinding and finish. Metal sheet inlay with or without plating/treatment applied, plating tabs have been removed, and sealer/ epoxy coating applied.

Fig5 Drawings describe the process for manufacturing solid slabs embedded with designed thin sheet metal that covers most of the slabs surface, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.SA Is a perspective view of a designed metal sheet inlay after cutting.

Fig.5B Is a perspective view of a designed metal sheet inlay after Folding.

Fig.SC Is a perspective exploded view of assembly of the lubricated mold with the folded metal sheet inlay placed.

Fig.5D Is a perspective view of the mold assembled with the folded metal sheet inlay.

Fig.5E Is a perspective view of the mold after the viscous compound has been poured inside, flattened, leveled and air bubbles have been extracted from the compound. Plating tabs are left outside the mold.

Fig.5F Is a perspective view of the finished cast slab with metal sheet inlay after extraction from the mold, grinding and finish. Plating tabs sticking out the sides of the slab.

Fig.5G Is a perspective view of the cast slab with metal sheet inlay with or without plating/treatment applied, plating tabs have been removed, and sealer/ epoxy coating applied.

Fig7 Drawings describe "Alternative Process A" and "Alternative Process B" for manufacturing solid slabs embedded with designed thin sheet metal, wherein the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.7A Is a perspective view of a designed center metal sheet inlay after cutting.

Fig.7B Is a perspective view of a designed center metal sheet or a copy glued permanently or temporarily to the mold center.

Fig.7C Is a perspective view of the mold after the viscous compound has been poured inside, flattened, leveled and air bubbles have been extracted from the compound.

Fig.7D Is a perspective view of the finished cast slab with sunken hollowed area in the shape of the metal plate after finish.

Fig.7E Is a perspective view of the cast slab with metal sheet inlay copy or the temporarily bonded inlay extracted from the mold with or without plating/treatment applied, inlay has been bonded inside the sunken hollow area, and sealer/ epoxy coating applied to the slab surface.

Fig9 drawings describe "Alternative Process C" for manufacturing solid slabs embedded with designed thin sheet metal, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.9A Is a perspective view of a designed metal sheet inlay after cutting. Fig.9B Is a perspective view of a designed metal sheet inlay after Folding. Fig.9C Is a perspective view of the mold with insertion holes for the folded metal sheet.

Fig.9D Is a perspective view of the mold with the folded metal sheet placed upward in the insertion holes.

Fig.9E Is a perspective view of the mold after the viscous compound has been poured inside, flattened, leveled and air bubbles have been extracted from the compound. Metal sheet may be partially hidden by the compound.

Fig.9F Is a perspective view of the finished cast slab with metal sheet inlay after extraction from the mold, grinding and finish.

Fig.9G Is a perspective view of the back of the slab with the plating tabs visible.

Fig.9H Is a perspective view of the back of the slab with the plating tabs extracted for the plating/ treatment process.

Figll Drawings describe "Alternative Process D" for manufacturing solid slabs embedded with designed thin sheet metal cast, wherein the inlay is cast on the slab, the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab's material.

Fig.llA Is a perspective view of the mold with the desired metal cast sheet pattern shape elevated and small poles sticking from the pattern up to the height of the mold upper border

Fig.1 IB Is a perspective view of the cast slab with a slightly sunken hollowed area in the shape of the desired metal cast sheet and small holes that pass through the slab.

Fig.llC Is a perspective view of the cast slab and the dedicated surface that has holes that continue the slab holes. Fig.llD Is a perspective view of the slab laid on top of the dedicated surface, dedicated surface holes position matching the slab's holes.

Fig. HE Is a perspective view of the slab laid on top of the dedicated suiface,molten metal (or molten alloy) in the sunken area and holes, metal level is slightly above the slab's surface level.

Fig.llF Is a perspective view of the slab's and cast metal sheet after been grind and finished together.

Fig.llG Is a perspective view of the slabs bottom with extended cast poles used for plating/ treatment.

Fig.llH Is a perspective view of the slab's bottom with metal cast sheet inlay with or without plating/treatment applied, extended cast poles have been removed, and sealer/ epoxy coating applied.

Fig.13 Is a flow chart describing the production process for manufacturing solid slabs embedded with designed thin sheet metal, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.15 Is a flow chart describing "Alternative Process A" for manufacturing solid slabs embedded with designed thin sheet metal, wherein the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.17 Is a flow chart describing "Alternative Process B" for manufacturing solid slabs embedded with designed thin sheet metal, wherein the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.19 Is a flow chart describing "Alternative Process C" for manufacturing solid slabs embedded with designed thin sheet metal, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.21 Is a flow chart describing "Alternative Process D" for manufacturing solid slabs embedded with designed thin sheet metal cast, wherein the inlay is cast on the slab and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

I HAVE INCLUDED 32 DRAWING SHEETS THE INVENTION

The finished slab embedded with the metal sheet inlay is handled as one cohesive unit during the process of plating or treating of the metal sheet, using the extended plating tabs that are left to pop out of the sides or the back of the slab, after the slab casting, to be used as the contact point for the electrode or electrical charge used in the plating or treatment process of the metal sheet.

ADVANTAGES

Usage of thin metal sheets considerably reduces amount of metal used.

Usage of a thin metal sheet allows for various cutting methods allowing for easy, quick and highly effective metal sheet production such as die-cutting or punching or other effective techniques for mass production which are not possible with thicker metal inlays commonly used.

Eliminates / brings to a minimum the need for use of adhesives and silicones.

Endless design possibilities.

Wide variety of materials - any viscous compound which solidifies can be used as the base slab, while any kind of metal or alloy or combination thereof can be used to create the inlay metal sheet pieces. An innovative plating or treatment method by which the finished slab together with the metal sheet inlay is plated or treated en masse.

Finished slab can be comprised of a combination of finely finished top material and raw base material which can vary in thickness.

A repeatable industrial manufacturing process, ensuring consistent results.

Metal sheet firmly fixed during manufacturing process to withstand high pressure and vibrations.

Very simple and straightforward process does not require special machinery, can be handmade or industrialized for mass production purposes.

Can be used for decorative as well as functional purposes.

Eliminates the need for slab precutting or machining as commonly done.

Low cost of initial components that can be upgraded using various metals or platings.

COMPONENTS

METAL SHEET

Thin designed metal sheet 2 or multiple sheets per slab 26 (any metal or alloy can be used) with extended foldabie tabs.

Metal sheet 2 can be cut in one of the following methods: Die-cutting, Punching, Laser cutting, photochemical etching, water jet cutting or plasma cutting and any other method which allows cutting large amounts of metal sheet in identical forms. Metal sheet 2 design can serve for decorative as well as functional purposes.

FOLD ABLE TABS

Foldabie tabs come in varied lengths; some are used for fixing the sheet to the slab 6, some for placing the sheet in the mold 4 and some for plating or treatment purposes 12. Each tab can be used for any or all purposes. Each tab includes holes 8 which by interlacing with the viscous compound 24 act as a locking mechanism ¹ thus ensuring, after the compound 24 hardens, the metal sheet 2 is firmly fixed in place. Fixing tabs 6 are used to reinforce the metal sheet 2 firmly into the slab 26.

Placing tabs 4 are used for correctly placing the metal sheet 2 in the mold 22, are in essence an extension of the fixing tabs 6.

Plating tabs 12 are an additional extension of the placing tabs 4. The plating tabs 12 grasp the outer walls of the mold 22 and lock the metal sheet 2 into place. The plating tabs 12 are also used as the contact point for the electrode or electrical charge used in the plating or treatment process of the metal sheet 2.

SLAB

An initial viscous compound 24 which solidifies and hardens to form any of the following materials: cement, concrete, clay, terra cotta, epoxy, polyester, plaster and the various mixes in between with or without aggregates e.g. terrazzo. Finished slab 26 can also be comprised of a combination of finely finished top material and raw base material which can vary in thickness.

SLAB MOLD

Slab mold 22 which can be comprised of any non-absorbing material to which the metal sheet 2 is fixed into place by the metal sheets' 2 foldable metal tabs. Slab mold 22 walls are designed to accommodate the foldable tabs 4 and lock them in place, in order to prevent movement of the metal sheet 2 during the casting process.

FIXING ELEMENT

In cases where there is a need for extra-long metal tab, a fixing element 30 can be made of any rigid material to act as an extension for the foldable metal tabs and fix the metal sheet 2 into the desired place, thus reducing metal sheet 2 part size and saving raw material. PLATING METHOD

The finished slab 26 embedded with the metal sheet 2 inlay is handled as one cohesive unit during the process of plating or treating of the metal sheet 2, using the extended plating tabs 12 that are left to pop out of the sides or the back of the slab 26, after the slab 26 casting, to be used as the contact point for the electrode or electrical charge used in the plating or treatment process of the metal sheet 2.

PRODUCTION PROCESS

Graphic design of the metal sheet 2 includes the main graphic and the placement of all desired tabs, their layout and appropriate fold lines 10.

Application of the design to a thin metal sheet 2 (any metal or alloy can be used) with extended foldable tabs and fold lines 10. Metal sheet 2 is then cut in one of the following methods: Die-cutting, Punching, Laser cutting, photochemical etching, water jet cutting or plasma cutting and any other method which allows cutting large amounts of metal sheet into identical forms.

The metal sheet 2 includes foldable tabs which come in varied lengths; some are used for fixing 6 the metal sheet 2 to the slab 26, some for placing 4 the metal sheet 2 in the mold 22 and others for plating or treatment purposes 12.

Each tab includes holes 8 which by interlacing with the viscous compound 24 act as a 'locking mechanism ¹ thus ensuring, after the compound 24 hardens, the metal sheet 2 is firmly fixed in place

The foldable tabs are folded using their fold lines 10 according to their designated function:

Fixing tabs 6 that are used to reinforce the metal sheet 2 firmly into the slab 26, are folded using their fold lines 10 upwards in a 90 degree angle, thus perpendicular to the metal sheet 2. Placing tabs 4 are used for correctly placing the metal sheet 2 in the mold 22, they are in essence an extension of the fixing tabs 6 and are folded using their fold lines 10 again in a 90 degree angle thus being parallel to the metal sheet 2.

Plating tabs 12 are an additional extension from the placing tabs 4. The plating tabs 12 grasp the outer walls of the mold 22 to lock the metal sheet 2 in place. The plating tabs 12 also act as the contact point for the electrical procedures used in the plating or treatment process. The plating tabs 12 extensions are folded downwards using their fold lines 10 from their meeting point with the placing tabs 4 in a 90 degree angle thus perpendicular to the metal sheet 2.

Preparing a mold 22 for the slab compound 24, mold 22 is made by any non- absorbing material (flexible or rigid). Slab mold 22 walls are designed to accommodate the foldable tabs and lock them in place.

When the mold 22 is ready, lubricating its interior surfaces to allow for easy

extraction of the slab 26.

The metal sheet 2 is then fixed into place, face down, by the metal sheets ¹ foldable metal tabs.

In cases where there is a need for extra-long metal tab, a fixing element 30 with holes 32 in it to accommodate the placing tabs 4, acts as an extension for the foldable metal tabs and fixes the metal sheet 2 into the desired place, the fixing element 30 can be made of any rigid material (e.g. cardboard, wood, plastics, metal etc.).

The fixing element 30 remains inside the finished slab 26.

Pouring into the mold 22 any viscous compound 24 which can solidify into hardened materials to form any of the following materials: cement, concrete, clay, terra cotta, epoxy, polyester, plaster and the various mixes in between with or without aggregates e.g. terrazzo, or any other viscous compound 24 which can produce a hardened material of choice. Vibrating the mold 22 or its insides to extract air bubbles from the compound 24 before it dries, flattening the top surface, removing excess material, or alternatively pressing the slab compound 24 using industrial press, all according to the compound 24 of choice and desired production method.

Allowing the slab compound 24 to set and dry thoroughly for the required time

according to the type of compound 24 used.

Extracting the slab 26 from the mold 22 and allowing it to dry thoroughly.

If necessary grinding the top surface of the slab 26 to expose the metal sheet 2.

Fine finishing the surface of the metal sheet 2 together with the surface of the slab 26 in a way that both are polished and a homogenous smooth surface is received throughout.

Plating or treating the metal sheet 2 surface.

The novelty in the process is that the finished slab 26 embedded with the metal inlay 2 is handled for plating or treating of the metal sheet 2 as one cohesive unit, using the extended plating tabs 12 as the electrical contact point for the plating or treatment process.

After plating or treatment has been finished, removing the plating tabs 12 from the slab 26, either by breaking them off manually or sawing them off.

Applying a layer of sealer or epoxy coating to the slab 26 to protect the finished slab

26 and metal sheet 2 and prevent wear and tear. Alternatively, applying a thick layer of epoxy to achieve increased protection and longevity.

PROCESS ALTERNATIVES

Alternative methods can be used in the production of the slab to achieve same or similar results: ALTERNATIVE A:

Permanently bonding a designed metal sheet 2 (without tabs) to the floor surface of the mold 34 in the desired positioning,

Pouring the viscous compound 24 to the mold 34 creates the slab 26.

Allowing the slab 26 to dry and set for the necessary amount of time according the compound 24 of choice.

Extracting the slab 26 produces a slab 26 with a slightly sunken hollowed area 36 in the exact shape of the designed metal sheet 2.

Finishing the surface of the slab 26 and bonding to the hollowed surface 36 the designed metal sheet 2 which may be treated or plated beforehand.

Coating or sealing the slab's 26 surface.

ALTERNATIVE B:

Temporarily bonding a designed metal sheet 2 (without tabs) using a non-permanent sealant or adhesive to the floor surface of the mold 34 in the desired positioning.

Pouring the viscous compound 24 to the mold 34 to create the slab 26.

Allowing it to dry and set for the necessary amount of time according the compound 24 of choice.

Extracting the slab 26 produces a slab 26 with a slightly sunken hollowed area 36 in the exact shape of the designed metal sheet 2.

Extracting the metal sheet 2 from the mold 34 and cleaning it thoroughly.

Finishing the surface of the slab 26 and bonding to the hollowed surface 36.

The extracted designed metal sheet 2 may be treated or plated beforehand.

Coating or sealing the slab's surface 26.

ALTERNATIVE C:

Preparing a mold 34 with insertion holes 38 for the foldable placing tabs 4 at its floor. Placing the designed metal sheet 2 upright and placing the placing tabs 4 into the holes 38. Pouring into the mold 34 the viscous compound 24 to produce a hardened material of choice.

Extracting the slab 26 from the mold 34 and allowing it to dry thoroughly.

Grinding the top surface to of the slab 26 expose the sheet metal 2.

Fine finishing the surface of the metal sheet 2 together with the surface of the slab 26 in a way that both are polished and a homogenous smooth surface is received throughout.

Extracting the plating tabs 12 from the bottom of the slab 26, and using them for plating or treatment purposes.

Optionally plating or treating the metal sheet 2 surface.

Breaking off the surplus of plating tabs 12 at the bottom of the slab 26.

Applying a layer of sealer or epoxy coating to the slab's 26 surface.

ALTERNATIVE D:

Preparing a mold 40 with the desired metal cast sheet pattern 52 shape elevated and small poles sticking from the pattern up to the height of the mold 40 upper border.

Pouring the viscous compound 24 to the mold 40 creates the slab 26.

Allowing it to dry and set for the necessary amount of time according the compound

24 of choice.

Extracting the slab 26 produces a slab 26 with a slightly sunken hollowed area 44 in the shape of the desired metal cast sheet pattern 52 and small holes 42 that pass through the slab 26.

Placing the slab 26 on a dedicated surface 46 that has holes 48 in a position matching the slab holes 42. Pouring the molten metal (or molten alloy) 50 into the sunken area 44 and holes 42 until the metal level is slightly above the slab's 26 surface level.

Grinding the molten metal cast 50 and the slabs 26 top surface until only the desired metal cast pattern 52 remains.

Fine finishing the slabs 26 top surface and the cast metal sheet 52.

Extracting the slab 26 from the dedicated surface 46.

Optional - Using the extended metal poles 54 sticking out of the slab 26 for the plating/ treatment process.

Removing extended metal poles 54.

Coating or sealing the slab's 26 surface.

SHORT DESCRIPTION OF DRAWINGS

DRAWING ELEMENTS:

2 Designed metal sheet

4 Placing tab

6 Fixing tab

8 Tab Holes

10 Tab fold lines

12 Plating Tab

14 Groove for plating tab

16 Upper mold frame

18 Mold Base

20 Mold Frame Groove for securing mold closure

22 Assembled mold

24 Slab viscous compound

26 Finished slab

28 Plating tab residue after removing sawing

30 Fixing element

32 Fixing element holes for the placing tabs

34 Slab mold

36 Slab's plate shaped sunken hollowed area 38 Slab's mold insertion holes for placing folded tabs

40 Mold with elevated pattern and poles

42 Slab holes

44 Slab's Sunken hollowed area for metal cast sheet

46 Dedicated surface for metal cast sheet

48 Continuing holes for extending metal poles

50 Molten metal cast sheet

52 Metal cast sheet and slab after grind and finish

54 Extended metal poles for plating treatment

56 Metal poles after cutting

I HAVE INCLUDED 32 DRAWING SHEETS

Figl Drawings describe the process for manufacturing solid slabs embedded with designed thin sheet metal on the corner, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.lA Is a perspective view of a designed corner metal sheet inlay after cutting.

Fig.lB Is a perspective view of a designed corner metal sheet inlay after Folding.

Fig.lC Is a perspective exploded view of assembly of the lubricated mold with the folded metal sheet inlay placed.

Fig. ID Is a perspective view of the mold assembled with the folded metal sheet inlay.

Fig. IE Is a perspective view of the mold after the viscous compound has been poured inside, flattened, leveled and air bubbles have been extracted from the compound. Plating tabs are left outside the mold. Fig. IF Is a perspective view of the finished cast slab with metal sheet inlay after extraction from the mold, grinding and finish. Plating tabs sticking out of the slab's sides.

Fig.lG Is a perspective view of the cast slab with metal sheet inlay with or without plating/treatment applied, plating tabs have been removed, and sealer/ epoxy coating applied.

Fig3 Drawings describe the process for manufacturing solid slabs embedded with designed thin sheet metal on the center with the help of a fixing element, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.3A Is a perspective view of a designed center metal sheet inlay after cutting.

Fig.3B Is a perspective view of a designed center metal sheet inlay after Folding.

Fig.3C Is a perspective view of the fixing element

Fig.3D Is a perspective exploded view of assembly of the lubricated mold with the folded metal sheet inlay placed with the aid of the fixing element.

Fig.3E Is a perspective view of the mold assembled with the folded metal sheet inlay placed with the fixing element.

Fig.3F Is a perspective view of the mold after the viscous compound has been poured inside, flattened, leveled and air bubbles have been extracted from the compound. Plating tabs are sticking outside the slab.

Fig.3G Is a perspective view of the finished cast slab with metal sheet inlay after extraction from the mold, grinding and finish. Metal sheet inlay with or without plating/treatment applied, plating tabs have been removed, and sealer/ epoxy coating applied. Fig5 Drawings describe the process for manufacturing solid slabs embedded with designed thin sheet metal that covers most of the slabs surface, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.5A Is a perspective view of a designed metal sheet inlay after cutting.

Fig.5B Is a perspective view of a designed metal sheet inlay after Folding.

Fig.5C Is a perspective exploded view of assembly of the lubricated mold with the folded metal sheet inlay placed.

Fig.5D Is a perspective view of the mold assembled with the folded metal sheet inlay.

Fig.SE Is a perspective view of the mold after the viscous compound has been poured inside, flattened, leveled and air bubbles have been extracted from the compound. Plating tabs are left outside the mold.

Fig.SF Is a perspective view of the finished cast slab with metal sheet inlay after extraction from the mold, grinding and finish. Plating tabs sticking out the sides of the slab.

Fig.SG Is a perspective view of the cast slab with metal sheet inlay with or without plating/treatment applied, plating tabs have been removed, and sealer/ epoxy coating applied.

Fig7 Drawings describe "Alternative Process A" and "Alternative Process B" for manufacturing solid slabs embedded with designed thin sheet metal, wherein the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material. Fig.7A Is a perspective view of a designed center metal sheet inlay after cutting.

Fig.7B Is a perspective view of a designed center metal sheet or a copy glued permanently or temporarily to the mold center.

Fig.7C Is a perspective view of the mold after the viscous compound has been poured inside, flattened, leveled and air bubbles have been extracted from the compound.

Fig.7D Is a perspective view of the finished cast slab with sunken hollowed area in the shape of the metal plate after finish.

Fig.7E Is a perspective view of the cast slab with metal sheet inlay copy or the temporarily bonded inlay extracted from the mold with or without plating treatment applied, inlay has been bonded inside the sunken hollow area, and sealer/ epoxy coating applied to the slab surface.

Fig9 drawings describe "Alternative Process C" for manufacturing solid slabs embedded with designed thin sheet metal, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.9A Is a perspective view of a designed metal sheet inlay after cutting.

Fig.9B Is a perspective view of a designed metal sheet inlay after Folding.

Fig.9C Is a perspective view of the mold with insertion holes for the folded metal sheet.

Fig.9D Is a perspective view of the mold with the folded metal sheet placed upward in the insertion holes. Fig,9E Is a perspective view of the mold after the viscous compound has been poured inside, flattened, leveled and air bubbles have been extracted from the compound. Metal sheet may be partially hidden by the compound.

Fig.9F Is a perspective view of the finished cast slab with metal sheet inlay after extraction from the mold, grinding and finish.

Fig.9G Is a perspective view of the back of the slab with the plating tabs visible.

Fig.9H Is a perspective view of the back of the slab with the plating tabs extracted for the plating treatment process.

Figll Drawings describe "Alternative Process D" for manufacturing solid slabs embedded with designed thin sheet metal cast, wherein the inlay is cast on the slab, the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab's material.

Fig.llA Is a perspective view of the mold with the desired metal cast sheet pattern shape elevated and small poles sticking from the pattern up to the height of the mold upper border

Fig.llB Is a perspective view of the cast slab with a slightly sunken hollowed area in the shape of the desired metal cast sheet and small holes that pass through the slab.

Fig.llC Is a perspective view of the cast slab and the dedicated surface that has holes that continue the slab holes.

Fig.llD Is a perspective view of the slab laid on top of the dedicated surface, dedicated surface holes position matching the slab's holes.

Fig.llE Is a perspective view of the slab laid on top of the dedicated surface,molten metal (or molten alloy) in the sunken area and holes, metal level is slightly above the slab's surface level.

Fig.llF Is a perspective view of the slab's and cast metal sheet after been grind and finished together.

Fig.llG Is a perspective view of the slabs bottom with extended cast poles used for plating treatment.

Fig.llH Is a perspective view of the slab's bottom with metal cast sheet inlay with or without plating/treatment applied, extended cast poles have been removed, and sealer/ epoxy coating applied.

Fig.13 Is a flow chart describing the production process for manufacturing solid slabs embedded with designed thin sheet metal, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.15 Is a flow chart describing "Alternative Process A" for manufacturing solid slabs embedded with designed thin sheet metal, wherein the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.17 Is a flow chart describing "Alternative Process B" for manufacturing solid slabs embedded with designed thin sheet metal, wherein the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

Fig.19 Is a flow chart describing "Alternative Process C" for manufacturing solid slabs embedded with designed thin sheet metal, wherein the slab and inlay are cast in unison and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material. Fig.21 is a flow chart describing "Alternative Process D" for manufacturing solid slabs embedded with designed thin sheet metal cast, wherein the inlay is cast on the slab and the inlay pieces are integral and have no visible surface difference between the inlay piece and the slab material.

POSSIBLE EMBODIMENTS AND APPLICATIONS OF THE INVENTION

There are many decorative and practical alternatives to the implementation of the slab with metal sheet inlays (such as but not limited to):

Floor tiles

Wall Tiles

Pavers

Building blocks

Signage

Headstones / Tombstones

Furniture

Lighting / Lamps

Decorative objects

Plaques

While I have shown, described and pointed out fundamental novel features my invention as applied to the preferred embodiments described above, it will be understood that various omissions and substitutions and changes in the form and details of the devices/methods illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of my invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same manner to achieve the same results are within the scope of my invention.

My invention is not limited by the embodiments described above which are presented as examples only but can be modified in various ways.