MANUFACTURED STONE VENEER SYSTEM AND METHOD OF USE
A system for providing a veneer for a surface, comprising a first plurality of veneer blocks, each having dimensions of 1N by 3N, where N is a unit of length. A second plurality of veneer blocks, each having dimensions of 1N by 4N. A third plurality of veneer blocks, each having dimensions of 2N by 3N. A fourth plurality of veneer blocks, each having dimensions of 2N by 4N, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks are provided as the veneer on the surface.
The present disclosure relates generally to manufactured block products, and more specifically to a manufactured veneer block system and method of use that provides a highly variable veneer block with decreased manufacturing, shipping and storage costs.
BACKGROUND OF THE INVENTIONStone veneers are used to allow a builder to provide a wall or other structure made from uniform structural components such as bricks with an appearance of customized natural stone. However, if manufactured veneer blocks are used, then repeated use of the same blocks will destroy that functionality.
SUMMARY OF THE INVENTIONA system for providing a veneer for a surface is provided that includes a first plurality of veneer blocks, each having dimensions of 1 N by 3 N, where N is a unit of length. A second plurality of veneer blocks are also provided, each having dimensions of 1 N by 4 N. A third plurality of veneer blocks are also provided, each having dimensions of 2 N by 3 N. A fourth plurality of veneer blocks are also provided, each having dimensions of 2 N by 4 N. The first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks are provided as the veneer on the surface, such as by arranging the veneer blocks in a random pattern.
Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.
Aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, and in which:
In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures might not be to scale and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness.
One of the advantages of system 100 is that a small predetermined number of manufactured veneer stones can be used to provide a veneer covering for a large section of wall that does not have a repeating pattern of adjacent veneer stones. For example, if the dimension N is 4 to 6 inches, then it is possible to design a veneer wall covering for most walls that will not noticeably repeat any patterns, as far as a casual observer can determine. As such, the veneer wall covering can be assembled and installed using only nine different pallets of manufactured veneer stone blocks, which would not be an unusually large number of pallets for a typical construction project. Likewise, the manufacturing equipment needed to manufacture nine different veneer blocks is not excessive, and can be implemented using a single press and nine different molds.
The veneer blocks can be made from concrete, masonry or other suitable materials, and can also be molded, stamped or otherwise formed. In one exemplary embodiment, a different mold can be used for each different veneer block, including blocks having the same size but a different surface finish. In another exemplary embodiment, the same perimeter mold can be used and can have a surface finish that is stamped onto the outer surface, so as to allow the same perimeter mold to be used to create veneer blocks having the same dimensions but different surface finishes. Other suitable processes can also or alternatively be used.
Module 712 includes one 3 N by 3 N block 106, one 2 N by 3 N block 112 and three 1 N by 3 N blocks 118. By using modules 702, 704, 706, 708, 710 and 712 to design a veneer for a structure, a designer can reduce the amount of work that is needed to create a veneer pattern that avoids repetition and which creates the appearance of a customized stone wall. Likewise, additional variability can be simulated using different surface textures, such as surface textures A, B and C of veneers 200 and 300 or other suitable numbers of different textures.
As used herein, “hardware” can include a combination of discrete components, an integrated circuit, an application-specific integrated circuit, a field programmable gate array, or other suitable hardware. As used herein, “software” can include one or more objects, agents, threads, lines of code, subroutines, separate software applications, two or more lines of code or other suitable software structures operating in two or more software applications, on one or more processors (where a processor includes a microcomputer or other suitable controller, memory devices, input-output devices, displays, data input devices such as a keyboard or a mouse, peripherals such as printers and speakers, associated drivers, control cards, power sources, network devices, docking station devices, or other suitable devices operating under control of software systems in conjunction with the processor or other devices), or other suitable software structures. In one exemplary embodiment, software can include one or more lines of code or other suitable software structures operating in a general purpose software application, such as an operating system, and one or more lines of code or other suitable software structures operating in a specific purpose software application. As used herein, the term “couple” and its cognate terms, such as “couples” and “coupled,” can include a physical connection (such as a copper conductor), a virtual connection (such as through randomly assigned memory locations of a data memory device), a logical connection (such as through logical gates of a semiconducting device), other suitable connections, or a suitable combination of such connections.
Surface size system 802 generates one or more user interface controls to allow a user to enter the dimensions of a surface for a veneer design, such as a wall, a barrier, a fence or other suitable surfaces. In one exemplary embodiment, surface size system 802 can generate one or more user prompts to enter a dimension of a surface, can include one or more user interface devices that allow a user to draw a surface, or can include other suitable user interface controls.
Block select system 804 generates one or more user interface controls to allow a user to perform a block-by-block selection for veneer design. In one exemplary embodiment, the user can select from available veneer blocks, such as the blocks of veneer system 100 or other suitable blocks, and can view a simulation of a veneer surface formed from the selected veneer blocks. In another exemplary embodiment, the user can elect to have randomly-selected blocks automatically placed within the surface. Block select system 804 can also identify blocks that violate one or more user-selected or predetermined design rules, such as a rule that no identical blocks should be touching, a rule that no identical blocks should be within a predetermined distance of each other or other suitable design rules.
Module select system 806 generates one or more user interface controls to allow a user to perform a module-by-module selection for veneer design. In one exemplary embodiment, the user can select from available veneer modules and can view a simulation of a veneer surface formed from the selected veneer modules, such as where each module is formed from a predetermined group of separate veneer blocks. In another exemplary embodiment, the user can elect to have randomly-selected modules automatically placed within the surface. Module select system 806 can also identify modules that violate one or more user-selected or predetermined design rules, such as a rule that no identical modules should be touching, a rule that no identical modules should be within a predetermined distance of each other or other suitable design rules.
Material ordering system 808 receives veneer design data and generates order data for the materials needed to build the associated veneer design. In one exemplary embodiment, material ordering system 808 can increase a number of veneer blocks to account for expected breakage and rework, can include additional materials such as adhesives for installing the veneer, can arrange shipping and billing and can perform other suitable processes.
Install sequence system 810 receives veneer design data and generates installation sequence instructions, such as to facilitate the construction of a veneer for the veneer design. In one exemplary embodiment, install sequence system 810 can receive data that identifies a number of work crews and can generate installation instructions to allow each work crew to install veneer blocks in parallel. In another exemplary embodiment, install sequence system 810 can generate shipping instructions for shipment of material to a jobsite as it is needed, so as to reduce the amount of onsite storage space required.
Veneer design system 812 generates one or more user interface controls to allow a user to remotely interface with surface size system 802, block select system 804, module select system 806, material ordering system 808, install sequence system 810 and other suitable systems. In one exemplary embodiment, a user can access veneer design system 812 from a web browser, an application operating on a tablet computer or in other suitable manners and can design and order the veneer blocks and other materials that are needed to assemble a veneer on a surface.
In operation, system 800 allows a user to design a veneer for a surface from manufactured veneer blocks, and to create a veneer that makes the underlying surface appear to have been fabricated using custom-sized blocks of material. System 800 can be used with veneer block system 100 and the disclosed exemplary modules as discussed herein, or with other suitable veneer blocks or modules.
It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.
Claims
1. A system for providing a veneer for a surface, comprising:
- a first plurality of veneer blocks, each having dimensions of 1 N by 3 N, where N is a unit of length;
- a second plurality of veneer blocks, each having dimensions of 1 N by 4 N;
- a third plurality of veneer blocks, each having dimensions of 2 N by 3 N; and
- a fourth plurality of veneer blocks, each having dimensions of 2 N by 4 N, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks are provided as the veneer on the surface.
2. The system of claim 1 further comprising a fifth plurality of veneer blocks, each having dimensions of 1 N by 6 N, wherein the fifth plurality of veneer blocks are provided as the veneer on the surface.
3. The system of claim 1 further comprising a fifth plurality of veneer blocks, each having dimensions of 2 N by 6 N, wherein the fifth plurality of veneer blocks are provided as the veneer on the surface.
4. The system of claim 1 further comprising a fifth plurality of veneer blocks, each having dimensions of 3 N by 3 N, wherein the fifth plurality of veneer blocks are provided as the veneer on the surface.
5. The system of claim 1 further comprising a fifth plurality of veneer blocks, each having dimensions of 3 N by 4 N, wherein the fifth plurality of veneer blocks are provided as the veneer on the surface.
6. The system of claim 1 further comprising a fifth plurality of veneer blocks, each having dimensions of 3 N by 6 N, wherein the fifth plurality of veneer blocks are provided as the veneer on the surface.
7. The system of claim 1, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks are manufactured veneer blocks.
8. A system for providing a veneer for a surface, comprising:
- a first plurality of veneer blocks, each having dimensions of 1 N by 3 N, where N is a unit of length;
- a second plurality of veneer blocks, each having dimensions of 1 N by 4 N;
- a third plurality of veneer blocks, each having dimensions of 2 N by 3 N;
- a fourth plurality of veneer blocks, each having dimensions of 2 N by 4 N;
- a fifth plurality of veneer blocks, each having dimensions of 1 N by 6 N;
- a sixth plurality of veneer blocks, each having dimensions of 2 N by 6 N;
- a seventh plurality of veneer blocks, each having dimensions of 3 N by 3 N;
- an eighth plurality of veneer blocks, each having dimensions of 3 N by 4 N;
- a ninth plurality of veneer blocks, each having dimensions of 3 N by 6 N, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks, the fourth plurality of veneer blocks, the fifth plurality of veneer blocks, the sixth plurality of veneer blocks, the seventh plurality of veneer block, the eight plurality of veneer blocks and the ninth plurality of veneer blocks are each manufactured veneer blocks and are provided as the veneer on the surface.
9. The system of claim 1, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks are provided as the veneer on the surface in a non-repeating surface pattern.
10. The system of claim 1, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish; and
- wherein the first set of veneer blocks and the second set of veneer blocks are arranged on a wall surface in a pattern that is not visibly repeating.
11. The system of claim 1, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish;
- a third set of veneer blocks having a third veneer surface finish; and
- wherein the first set of veneer blocks, the second set of veneer blocks and the third set of veneer blocks are arranged on a wall surface in a pattern that is not visibly repeating.
12. The system of claim 2, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks, the fourth plurality of veneer blocks and the fifth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish; and
- wherein the first set of veneer blocks and the second set of veneer blocks are arranged on a wall surface in a pattern that is not visibly repeating.
13. The system of claim 2, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks, the fourth plurality of veneer blocks and the fifth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish;
- a third set of veneer blocks having a third veneer surface finish; and
- wherein the first set of veneer blocks, the second set of veneer blocks and the third set of veneer blocks are arranged on a wall surface in a pattern that is not visibly repeating.
14. The system of claim 2, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks, the fourth plurality of veneer blocks, the fifth plurality of veneer blocks, the sixth plurality of veneer blocks, the seventh plurality of veneer blocks, the eighth plurality of veneer blocks and the ninth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish; and
- wherein the first set of veneer blocks and the second set of veneer blocks are arranged on a wall surface in a pattern that is not visibly repeating.
15. The system of claim 2, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks, the fourth plurality of veneer blocks, the fifth plurality of veneer blocks, the sixth plurality of veneer blocks, the seventh plurality of veneer blocks, the eighth plurality of veneer blocks and the ninth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish;
- a third set of veneer blocks having a third veneer surface finish; and
- wherein the first set of veneer blocks, the second set of veneer blocks and the third set of veneer blocks are arranged on a wall surface in a pattern that is not visibly repeating.
16. The system of claim 1, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish; and
- wherein the first set of veneer blocks and the second set of veneer blocks are arranged on a wall surface in a non-repeating pattern.
17. The system of claim 1, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish;
- a third set of veneer blocks having a third veneer surface finish; and
- wherein the first set of veneer blocks, the second set of veneer blocks and the third set of veneer blocks are arranged on a wall surface in a non-repeating pattern.
18. The system of claim 2, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks, the fourth plurality of veneer blocks and the fifth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish; and
- wherein the first set of veneer blocks and the second set of veneer blocks are arranged on a wall surface in a non-repeating pattern.
19. The system of claim 2, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks, the fourth plurality of veneer blocks and the fifth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish;
- a third set of veneer blocks having a third veneer surface finish; and
- wherein the first set of veneer blocks, the second set of veneer blocks and the third set of veneer blocks are arranged on a wall surface in a non-repeating pattern.
20. The system of claim 2, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks, the fourth plurality of veneer blocks, the fifth plurality of veneer blocks, the sixth plurality of veneer blocks, the seventh plurality of veneer blocks, the eighth plurality of veneer blocks and the ninth plurality of veneer blocks each comprise a single set of veneer blocks, and further comprising:
- a first set of veneer blocks having a first veneer surface finish;
- a second set of veneer blocks having a second veneer surface finish; and
- wherein the first set of veneer blocks and the second set of veneer blocks are arranged on a wall surface in a non-repeating pattern.
Type: Application
Filed: May 2, 2014
Publication Date: Nov 5, 2015
Applicant: VENEERSTONE, LLC (McKinney, TX)
Inventor: Bobby L. Staten (Carrollton, TX)
Application Number: 14/269,031