Stone Veneer with Mounted Supports

Abstract

The present invention relates to a stone veneer with mounts providing a drainage plane. The mounts are affixed to the rear face of the stone and the height of the mount defines the height of the drainage plane behind the stone body. The mount may include an upper extension, extending beyond the upper surface of the stone body and a lower extension, extending from the mount body and beyond the lower surface of the stone body. The upper extension being spaced from the stone such that the lower extension fits between the stone and the upper extension. A second mount is also shown that extends above the stone to support the lower end of the stone above in the wall.

Description

CROSS-REFERENCES TO RELATED APPLICATION

This application claims priority to U.S. Prov. App. No. 62/846,093, filed May 10, 2019, entitled, “Stone Veneer with Mounted Supports”, currently pending, which application is incorporated herein by reference.

FIELD

This description relates to stone veneer

BACKGROUND

Manufactured and natural stone veneers have become more and more desirable. The stone veneer is generally affixed to a prepared surface with mortar. In practice, substantial preparation of the wall is required because the manufactured stone does not form a proper barrier to moisture.

SUMMARY

The present invention relates to a stone veneer with mounts providing a drainage plane. The mounts are adhered or otherwise affixed to the rear face of the stone and the height of the mount defines the height of the drainage plane behind the stone body. The mount may include an upper extension, extending beyond the upper surface of the stone body and a lower extension, extending from the mount body and beyond the lower surface of the stone body. The upper extension being spaced from the stone such that the lower extension fits between the stone and the upper extension. A second mount is also show that extends above the stone to support the lower end of the stone above in the wall.

In one exemplary embodiment, a stone veneer with support provides a drainage plane. The stone veneer with support comprises a stone body, the stone body comprising a rear stone body face, a front stone body face, opposed left and right stone body surfaces, and opposed upper and lower stone body surfaces. The stone veneer with support further comprises at least one mount body, the mount body having a height defined by an upper face and a lower face, the mount body affixed to the rear stone body face, the mount body being narrower than the rear face, the mount configured to provide a drainage plane behind the stone body.

In a further exemplary embodiment, a stone veneer with support provides a drainage plane. The stone veneer with support comprises a stone body, the stone body comprising a rear stone body face, a front stone body face, opposed left and right stone body surfaces, and opposed upper and lower stone body surfaces. The stone veneer with support further comprises at least one mount body, the mount body having a height defined by an upper face, and a lower face, the mount body affixed to the rear stone body face, said mount body being narrower than the rear face, the mount providing a drainage plane behind the stone body, an upper mount extension, the upper mount extension having a height defined by an upper face and a lower face, the upper extension extending from the mount body and beyond the upper surface of the stone body, the lower face of the upper mount extension being coplanar with the lower face of the mount body, a lower mount extension, the lower mount extension having a height defined by an upper face and a lower face, the lower mount extension extending from the mount body and beyond the lower surface of the stone body, the upper face of the lower mount extension being coplanar with the upper face of the mount body.

In a further exemplary embodiment, a stone veneer with support provides a drainage plane. The stone veneer with supports comprises a stone body, the stone body comprising a rear stone body face, a front stone body face, opposed left and right stone body surfaces, and opposed upper and lower stone body surfaces. The stone body with support further comprises at least one mount body, the mount body having a height defined by an upper face and a lower face, the mount body affixed to the rear stone body face, the mount body being narrower than the rear face, the mount body extending beyond the upper stone body surface, the mount body configured to provide a drainage plane behind the stone body.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and the many embodiments thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings. The drawings are incorporated in, and constitute part of, this specification, illustrate several embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention.

FIG. 1A illustrates a side plan view of a veneer stone including a mount on the back side of the stone, in accordance with an embodiment of the present invention.

FIG. 1B illustrates a side plan view of a veneer stone including a mount on the back side of the stone, in accordance with the present invention.

FIG. 1C illustrates a side plan view of a veneer stone including a raised polymer mount formed on the back side of the stone, in accordance with the present invention.

FIG. 2A illustrates a bottom plan view of a stone affixed to mounts in accordance with the present invention.

FIG. 2B illustrates a bottom plan view of overlapping stones affixed on mounts in accordance with the present invention.

FIG. 2C shows a top view of a stone on mounts and demonstrates the height of drainage plane in accordance with the present invention.

FIG. 3A illustrates a side view of affixed stones in a wall assembly using adhesive, in accordance with the present invention.

FIG. 3B illustrates a side view of affixed stones in a wall assembly using fasteners, in accordance with the present invention.

FIG. 4A illustrates a side plan view of a veneer stone including a raised polymer mount on the back side of the stone, in accordance with an alternate embodiment of the present invention.

FIG. 4B illustrates a side plan view of a pair of veneer stones, each including a raised polymer mount on the back side of the stone, in accordance with an alternate embodiment of the present invention.

DETAILED DESCRIPTION

The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

As shown in FIG. 1A a veneer stone 10 is attached to a mount 24 for attachment to a wall without the use of a mortar layer. The veneer stone 10 includes a front face 12, a rear face 14, an upper face 16a and a lower face 16a. The veneer stone 10 may be a natural stone, a manmade stone, or a fired brick. The stone 10 is affixed to a mount 24 with an adhesive 20. The mount 24 includes an upper face 40 and a lower face 42. The mount 24 is preferably formed by injection molding but may be formed by machining and/or extruding a polymer or other suitable material. The mount 24 includes an upper extension 28. The upper extension 28 is adjacent lower face 42 of mount 24. The upper extension 28 includes an upper surface 48 that is recessed from the upper surface 40 by a mount wall 46 and shares lower surface 42. An orifice 30 is typically included in the upper extension 28 and extension 28 terminates at distal end 44. A lower extension 26 projects from the opposite end of the mount body 24. The lower extension 26 includes a lower surface 36 that is raised from the lower surface 42 by a mount wall 38 and shares the upper surface 40. An orifice is not typically included in the lower extension 26. The lower extension 26 terminates at a distal end 34. The stone 10 is preferably secured to the mount 24 using any suitable adhesive, for example, hot melt adhesives such as polyamides, EVAs, polyolefins, polyesters, or polyurethanes, epoxies such as Bisphenol A epoxy resin, Bisphenol F epoxy resin, Novolac epoxy resin, or cycloaliphatic epoxy resin. Other adhesives such as acrylic resin, polyurethane monomers, or styrene-butadiene rubber may be used.

An alternative mount 124 is shown in FIG. 1B where a veneer stone 110 is attached to the mount 124. The mount 124 includes keyways 140′ on an upper surface 140 and keyways 142′ on a lower surface 142. Keyways 140′ and 142′ allow an increased surface area and a mechanical connection for an adhesive 120 on the upper surface 140. The veneer stone 110 includes a front face 112, a rear face 114, an upper face 116A, and a lower face 116B. The mount 124 is preferably formed by injection molding but may be formed by machining and/or extruding a polymer material or other suitable material. The mount 124 includes an upper extension 128. The upper extension 128 is adjacent lower face 142 of the mount 124. The upper extension 128 includes an upper surface 148 that is recessed from the upper surface 140 by a mount wall 146 and shares the lower surface 142. An orifice 130 is typically included in the upper extension 128 and extension 128 terminates at distal end 144. A lower extension 126 projects from the opposite end of the mount 124. The lower extension 126 includes a lower surface 136 that is raised from lower surface 142 by a mount wall 138 and shares the upper surface 140. An orifice is not typically included in the lower extension 136 and the lower extension 126 terminates at a distal end 134.

The overlap of adjacent stones 10 is shown in FIG. 1C. A lower veneer stone 10a and an upper stone 10b are shown. Each stone 10a, 10b is attached to a mount 24 for attachment to a wall without the use of a mortar layer. The veneer stones 10a, 10b are shown in detail but each includes a front face 12, a rear face 14, an upper face 16A and lower face 16B (as shown in FIG. 1A). The mounts 24a, 24b are substantially similar (typically only the length varies, dependent upon the height of the stones 10a, 10b). A lower stone 10a upper extension 28 is adjacent lower face 42 of mount 24. The upper extension 28 includes an upper surface 48 that is recessed from an upper surface 40 by a mount wall 46 and shares the lower surface 42. An orifice 30 is typically included in the upper extension 28 and the upper extension 28 terminates at a distal end 44. The upper stone 10b shows a lower extension 26 projecting from the mount body 24. The lower extension 26 includes a lower surface 36 that is raised from the lower face 42 by a mount wall 38 and shares an upper surface 40. The lower extension 26 on the upper stone 10b mates between the upper extension 28 on the lower stone 10a and the body of lower stone 10a. In use on a wall, the mounts 24a, 24b on adjacent stones 10a, 10b may or may not overlap. In any event, the lower extension 26 is retains the upper stone 10b on the wall beneath with the distal end 34 under the lower stone 10a.

FIG. 2A shows the rear face 14 of a veneer stone 10. The stone 10 includes a rear face 14 along with a top face 16A, a bottom face 16B, and opposed edges 16C. Two mounts 24 are affixed to the rear face 14. Each mount 24 includes an upper extension 28 on a mount wall 46 and shares a lower surface 42 (as shown in FIG. 1A). An orifice 30 is typically included in the upper extension 28. A lower extension 26 projects from the opposite end of mount body 24 and includes a lower surface 36 that is raised by mount wall 38. The rear stone face 14 is raised by mounts 24 to create a drainage plane between the stone 10 and the surface of the wall (not shown). Building codes vary by geography, Canadian codes recite a 10 mm drainage gap and U.S. codes vary but are typically 7/16″ (11 mm) or greater. The mounts 24 may include narrowed a upper extension 28 and lower extension 26 to improve the flow of liquid water or water vapor between the rear surface of the stone and the building wall.

FIG. 2B shows the rear face 14 of upper and lower veneer stones 10a, 10b. Stone 10a includes a rear face 14 along with a top face 16A, a bottom face 16B, and opposed edges 16C. Two mounts 24a, 24b are affixed to each rear face 14. Each mount 24a, 24b includes an upper extension 28 on a mount wall 46 and shares a lower surface 42 (as shown in FIG. 1A). An orifice 30 is typically included in the upper extension 28. A lower extension 26 projects from the opposite end of each mount body 24a, 24b and includes a lower surface 36 that is raised by mount wall 38. The upper stone 10b is placed above the lower stone 10b. Similar to FIG. 1C, the stones 10a, 10b may be stacked. The upper stone 10b shows lower extensions 26 projecting from each mount body 24b so that lower extensions 26 on the upper stone 10b, which includes a surface 36 that is raised by mount wall 38 and shares upper surface 40 (best seen in FIGS. 1A and 1C). The lower extensions 26 on the upper stone 10b mate between the upper extensions 28 on the lower stone 10a and the body of stone 10a. In use on a wall, the mounts 24a, 24b on adjacent stones 10a, 10b may or may not overlap. In any event, each lower extension 26 retains the upper stone 10b on the wall beneath with distal end 44 under lower stone 10a.

FIG. 2C shows a top view of a stone 10 on mounts 24 and demonstrates the height of a drainage plane D. The stone 10 includes a front face 12, a upper face 16b, and opposed side faces 16a, 16b. Two mounts 24 are affixed to a rear face 14 with adhesive 20. The mount wall 46 and distal end 44 are shown in FIG. 2C. The rear stone face 14 is raised by mounts 24 to create a drainage plane having a height D between the stone 10 and the surface of the wall 80 (FIG. 3A). Building codes vary by geography, Canadian codes recite a drainage plane having a height (D) of 10 mm and U.S. codes vary but typically recite 7/16″ (11 mm) or greater.

A wall assembly is shown in FIG. 3A, with adjacent stones 10a, 10b adhered to the wall 80 with adhesive 82, such that the adjacent mounts 24a, 24b overlap so that the stones 10a, 10b may abut or be adjacent. The wall 80 in FIG. 3A is typically masonry block or a poured wall. The wall 80 includes a layer of sealant such as paint, Loxon® (Sherwin Williams), or liquid Tyvec® (duPont). Local building codes vary by climate and location. An adhesive 82 is shown between the masonry wall and the mounts 24a, 24b. A flashing 60 is applied to the wall with a fastener 31. The flashing 60 provides a base for veneer stone 10a and also provides a kickout flashing 68 to direct water away from the foundation of the building. The flashing 60 includes an upright 62, which is attached to the wall 80, a base 64, a retaining edge 70, a spacer 66, and a kickout 68. The stone 10a is placed on the flashing 60 such that the distal edge 34 of the lower extension 26 engages the base 64 and the retaining edge 70 to support the stone 10a. The stone 10a is adjacent to the spacer 66, while the kickout 68 projects beyond the face 12 of the stone 10a. The stone 10a is affixed to the mount 24a, which includes the lower extension 26 and distal end 34 retained in the flashing 60. The veneer stone 10 includes a front face 12, a rear face 14, an upper face 16A, and a lower face 16B. The rear face 14 is adhered to the upper surface 40 of the mount 24a. The mount 24a includes an upper extension 28 which includes an upper surface 48 that is recessed from the upper surface 40 by the mount wall 46 and shares the lower surface 42. Fastening orifice 30 is unused since the stone 10a is adhered to the wall with adhesive 82. A space is created between the upper surface 48 and the rear face 14 of stone 10a. The upper stone 10b is subsequently applied to the wall 80 with adhesive 102. The front face 12, rear face 14, and lower face 16b of stone 10b are shown. The upper stone 10b is affixed to the mount 24b by the mount upper surface 40. A lower extension 26 projects from the lower end of the mount body 24b. The lower extension 26 includes a lower surface 36 that is raised by a mount wall 38 and shares the upper surface 40. The distal end 34 of mount 24b extends beyond the lower face 16b such that the upper mount surface 40 contacts the rear stone face 14 to retain the upper stone 10b on the wall 80. In the event the mounts 24a, 24b overlap, the distal end 34 is inserted between the upper surface 40 of the mount 24a and the rear stone face 14 of the stone 10a. On the wall 80, the upper face 16a abuts or approaches lower face 16b and leaves a small gap 16C between stones 10a, 10b. The assembly provides an aesthetically pleasing stone wall, which includes a drainage plane to inhibit water damage.

A wall assembly is shown in FIG. 3B, with adjacent stones 10a, 10b mechanically attached to a wall 80 with fasteners 31. FIG. 3B is substantially similar to FIG. 3A but includes mechanical fasteners 31 as well as optional barrier layers 72, 74. Adjacent polymer mounts 24a, 24b overlap so that the stones 10a, 10b may abut or approach one another while creating a drainage plane. The wall 80 is typically a framed wall 80, typically plywood or OSB (oriented strand board), and may include a layer of tar paper 72 or other sealant and a layer of house wrap 74 such as Tyvec® (duPont) or other available wrap. The barrier layers 72, 74 are optional and are generally applied to meet the requirements of local building codes, which vary by climate and location. A flashing 60 is applied to the wall 80 with a fastener 31. The flashing 60 provides a base for veneer stone 10a and also provides a kickout flashing 68 to direct water away from the foundation of the building. The flashing 60 includes an upright 62, which is attached to the wall 80, a base 64, a retaining edge 70, a spacer 66, and a kickout 68. The stone 10a is placed on the flashing 60 such that the distal edge 34 of the lower extension 26 engages the base 64 and the retaining edge 70 to support the stone 10a. The stone 10a is adjacent to spacer 66, while the kickout 68 projects beyond the front face 12 of the stone 10a. The stone 10a is affixed to the mount 24a, which includes a lower extension 26 and a distal end 34. The stone 10 includes a front face 12, a rear face 14, an upper face 16a, and a lower face 16b. The rear face 14 is adhered to the upper surface 40 of the mount 24a. The mount 24a includes an upper extension 28 and includes an upper surface 48 that is recessed from the upper surface 40 by a mount wall 46 and shares the lower surface 42. A space is created between upper surface 48 and the rear face 14 of the stone 10a. The upper stone 10b is subsequently applied to the wall 80 with the fastener 31. The front face 12, rear face 14, and lower face 16b of the stone 10b are shown. The upper stone 10b is affixed to the mount 24b by the mount upper surface 40. A lower extension 26 projects from the lower end of the mount body 24b. The lower extension 26 includes a distal end 36 that is raised by a mount wall 38 and shares the upper surface 40. The distal end 34 of the mount 24b extends beyond the lower face 16b such that the upper mount surface 40 contacts the rear stone face 14 to retain the upper stone 10b on the wall 80. In the event that mounts 24a, 24b overlap, the distal end 34 is inserted between the upper surface 40 of the mount 24a and the rear stone face 14 of the stone 10a.

An alternative mount 242 is shown in FIG. 4A, which illustrates a stone 210 with a front face 212, a rear face 214, a lower face 216a, and an upper face 216b. The stone 210 is attached to the mount 242 with adhesive 220. The mount 242 includes an upper surface 234, a lower surface 242, a distal end 244, and a proximal end 234, and may include an orifice 230 for use with a fastener (not shown). An upper surface 240 is adhered to the rear face 214 such that the mount 242 extends beyond the upper face 216b. The lower face 216a and the upper face 216b are formed at a complementary acute angle for use in constructing as shown in FIG. 4B.

FIG. 4B shows two stones 210a, 210b, each with a front face 212, a rear face 214, a lower face 216a, and an upper face 216b. The lower face 216a is not shown on the stone 210a and the upper face 216b is not shown on the stone 210b, however, the stones 210a, 210b are substantially similar and each includes a mount 242. The stone 210b is attached to the mount 242 with adhesive 220. The mount 242 includes an upper surface 234, a lower surface 242, a distal end 244, and a proximal end 234 and may include an orifice 230 for use with a fastener. The upper surface 240 is adhered to the rear face 214 such that the mount 242 extends beyond the upper face 216b. The lower face 216a and the upper face 216b are formed at a complementary acute angle such that when the stone 210a is affixed on a wall 80 (not shown), the upper face 216b is affixed in place and provides an anchor when a lower face 216a is placed against it and the mount 242 on the stone 210b (not shown) is affixed to the wall 80. The wall 80 is built similarly to that shown in FIGS. 3A and 3B, starting at the base of the wall 80 and applying subsequent rows up the wall 80. The interference fit of faces 216a, 216b proves a secure stone wall with a drainage plane.

The present invention provides and aesthetically pleasing stone wall while providing a drainage plane to inhibit water damage. The wall may be assembled with a cordless screwdriver or with a tube of adhesive so a modestly skilled installer can quickly and easily install a wall. Any arrangement of stones may be used and ashlar and dry-stacked walls are particularly suitable. For example, sets of stones of 2-in., 3-in., and 5-in. heights; 2in., 4-in., and 6-in. heights; 2-in., 3-in., 5in., and 7-in. heights may be grouped. The length of mounts correspond to the height of the stones. Any other grouping of stones that may be stacked in an attractive manner may be used, a grouping of stones having equal heights may also be used.

The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.

Claims

1. A stone veneer with support providing a drainage plane, comprising:

a stone body, the stone body comprising: a rear stone body face; a front stone body face; opposed left and right stone body surfaces; and opposed upper and lower stone body surfaces; and

at least one mount body, the mount body having a height defined by an upper face and a lower face, the mount body affixed to the rear stone body face, the mount body being narrower than the rear face, the mount configured to provide a drainage plane behind the stone body.

2. The stone veneer of claim 1, wherein the mount further comprises an upper extension, the upper extension having a height defined by an upper face and a lower face, the upper extension extending from the mount body and beyond the upper stone body surface of the stone body.

3. The stone veneer of claim 2, wherein the lower face of the upper extension is coplanar with the lower face of the mount body.

4. The stone veneer of claim 2, wherein the mount further comprises a lower extension, the lower extension having a height defined by an upper face and lower face, the upper extension extending from the mount body and beyond the lower surface of the stone body.

5. The stone veneer of claim 2, wherein the upper face of the lower extension is coplanar with the upper face of the mount body.

6. The stone veneer of claim 1, wherein the mount further comprises an upper extension, the upper extension having a height defined by an upper face and a lower face, the upper extension extending from the mount body and beyond the upper surface of the stone body, the height of the upper extension being less than the height of the mount.

7. The stone veneer of claim 6, wherein the mount further comprises a lower extension, the lower extension having a height defined by an upper face and lower face, the lower extension extending from the mount body and beyond the lower surface of the stone body, the height of the lower extension being less than the height of the mount.

8. The stone veneer of claim 7, wherein the upper face of the lower extension is coplanar with the upper face of the mount body.

9. The stone veneer of claim 7, wherein the upper extension and the rear stone body face define a gap, the gap being at least the height of the lower extension.

10. The stone veneer of claim 6, wherein the mount is polymer.

11. A stone veneer with support providing a drainage plane, comprising:

a stone body, the stone body comprising: a rear stone body face; a front stone body face; opposed left and right stone body surfaces; and opposed upper and lower stone body surfaces; and

at least one mount body, the mount body having a height defined by an upper face, and a lower face, the mount body affixed to the rear stone body face, said mount body being narrower than the rear face, the mount providing a drainage plane behind the stone body;

an upper mount extension, the upper mount extension having a height defined by an upper face and a lower face, the upper extension extending from the mount body and beyond the upper surface of the stone body, the lower face of the upper mount extension being coplanar with the lower face of the mount body; and

a lower mount extension, the lower mount extension having a height defined by an upper face and a lower face, the lower mount extension extending from the mount body and beyond the lower surface of the stone body, the upper face of the lower mount extension being coplanar with the upper face of the mount body.

12. The stone veneer of claim 11, wherein the height of the upper mount extension is less than the height of the mount.

13. The stone veneer of claim 11, wherein the height of the lower mount extension is less than the height of the mount.

14. The stone veneer of claim 11, wherein the upper mount extension and the rear stone body face define a gap, the gap being at least the height of the lower extension.

15. The stone veneer of claim 11, wherein the mount is polymer.

16. A stone veneer with support providing a drainage plane, comprising:

a stone body, the stone body comprising: a rear stone body face; a front stone body face; opposed left and right stone body surfaces; and opposed upper and lower stone body surfaces; and

at least one mount body, the mount body having a height defined by an upper face and a lower face, the mount body affixed to the rear stone body face, the mount body being narrower than the rear face, the mount body extending beyond the upper stone body surface, the mount body configured to provide a drainage plane behind the stone body.

17. The stone veneer of claim 16, wherein the upper stone body surface is at an acute angle to the rear stone body face.

18. The stone veneer of claim 16, wherein the lower stone body surface is a generally parallel to the upper stone body face.

19. The stone veneer of claim 16, wherein the lower stone body surface is at an acute angle to the rear stone body face.

20. The stone veneer of claim 16, wherein the mount is polymer.