U.S. patent number 3,683,579 [Application Number 05/067,515] was granted by the patent office on 1972-08-15 for artificial stone facing construction and method therefor.
Invention is credited to Jack M. Beardsley.
United States Patent |
3,683,579 |
Beardsley |
August 15, 1972 |
ARTIFICIAL STONE FACING CONSTRUCTION AND METHOD THEREFOR
Abstract
The disclosure comprises sheets of thin, porous, compressible
backing material stapled to an underlying structure. The backing
sheets butt up against each other to completely cover the surfaces
which are to be covered by the artificial bricks. A coat of
mortar-colored paint is applied to the outer surface of the backing
sheets. While the coat of mortar-colored paint is still wet,
imitation bricks are secured in rows to the backing sheet by nails
with T-heads which are driven through the imitation bricks, through
the backing sheet, and into the underlying structure. The nails are
driven so that their heads are flush with the outer surface of the
imitation bricks. The heads of the nails are covered with brick
colored paint. The imitation bricks are spaced so that they cover
the staples used to hold the backing sheet to the underlying
structure. In this manner, the backing sheet is compressed beneath
the imitation bricks and projects outwardly beyond the inner
surfaces of the imitation bricks so that the junctions between the
inner surfaces of the imitation bricks of the backing sheet are
concealed, thus creating the appearance of real bricks set into
real mortar.
Inventors: |
Beardsley; Jack M. (Glendale,
CA) |
Family
ID: |
22076501 |
Appl.
No.: |
05/067,515 |
Filed: |
August 27, 1970 |
Current U.S.
Class: |
52/389; 52/385;
428/15; 52/746.12; 52/391; 52/311.1 |
Current CPC
Class: |
E04F
13/147 (20130101) |
Current International
Class: |
E04F
13/14 (20060101); E04f 013/14 () |
Field of
Search: |
;52/309,311,314,384-389,390,391,746 ;156/71 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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|
|
|
|
860,319 |
|
Feb 1961 |
|
GB |
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925,198 |
|
May 1963 |
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GB |
|
Primary Examiner: Perham; Alfred C.
Claims
The invention claimed is:
1. An artificial stone construction to be applied to an underlying
structure, comprising:
a compressible backing sheet supported against the underlying
structure; and
artificial stones secured in place by nail-like means extending
from the interior of said artificial stones through said backing
sheet and into said underlying structure, said artificial stones
being spaced apart to form free spaces between adjacent sides of
said stones whereby the backing sheet is compressed beneath the
artificial stones and relatively uncompressed portions of said
backing sheet project substantially outward beyond the inner
surfaces of the artificial stones around the sides of the stones
and to a position short of the outer surfaces of said stones
thereby concealing the junctions between the inner surfaces of said
stones and said backing sheet from view and simulating a raked
joint.
2. An artificial stone construction as defined in claim 1 wherein
paint has been applied to the outer surface of said backing sheet
thereby partially securing the artificial stones to said backing
sheet and providing coloring to the uncompressed portions of said
backing sheet.
3. An artificial stone construction as defined in claim 2 wherein
said artificial stones are composed of a binding material, a
lightening compound, and a coloring material.
4. An artificial stone construction as defined in claim 3 wherein
said backing sheet is about one-eighth inch thick when uncompressed
and about one-sixteenth inch thick when compressed and said
artificial stone is about one-half inch thick.
5. An artificial stone construction as defined in claim 1 wherein
said artificial stones are artificial bricks in which said binding
material is green tag casting plaster, said lightening compound is
expanded vermiculite and said coloring material is red iron
oxide.
6. An artificial stone construction as defined in claim 1 wherein
said compressible backing sheet is composed of sponge-like
material.
7. In an artificial brick construction to be applied to an
underlying structure having a backing sheet secured to the
underlying structure, said backing sheet having the appearance of
mortar, and a plurality of spaced-apart imitation bricks secured to
said backing sheet and to the underlying structure, the combination
with the above designated parts wherein said backing sheet
comprises a compressible material which is compressed beneath the
imitation bricks and projects outward in relatively uncompressed
condition beyond the inner surfaces of the imitation bricks and
into the spaces between adjacent bricks whereby the junctions
between the inner surfaces of the bricks and the backing sheet are
concealed.
8. In an artificial brick construction to be applied to an
underlying structure, comprising:
a compressible backing sheet having the appearance of mortar held
onto the underlying structure;
a plurality of imitation bricks secured in rows to the outer
surface of the backing sheet by T-shaped nails projecting through
the bricks and into the underlying structure,
said backing sheet being compressed beneath the bricks and
projecting outwardly beyond the inner surfaces of the bricks so
that the junctions between the inner surfaces of the bricks and the
backing sheet are concealed.
9. An artificial brick construction to be applied to an underlying
structure, comprising:
a sheet of thin, porous, compressible backing material, stapled
lightly to the underlying structure, said backing sheet having a
rough textured surface facing outwardly;
a coat of mortar-colored paint applied to the outer surface of the
backing sheet; and
a plurality of porous imitation bricks secured in rows to the outer
surface of the backing sheet before the mortar-colored paint is dry
by T-shaped nails projecting through the imitation bricks, through
the backing sheet, and into the underlying structure so that the
heads of the nails project into the outer surfaces of the
bricks,
said imitation bricks being composed of a binding material, a
lightening compound, and a coloring material,
said backing sheet being compressed beneath the bricks and
projecting outwardly beyond the inner surfaces of the bricks around
the sides of the bricks so that the junctions between the inner
surfaces of the bricks and the backing sheet are concealed,
said artificial brick construction creating the appearance of real
bricks set into real mortar.
10. An artificial brick construction as defined in claim 9 further
comprising:
a coat of brick-colored paint applied to the head of each T-shaped
nail, and
wherein said imitation bricks are secured to said backing sheet in
positions to conceal said staples,
said backing sheet being about 1/8 inch thick when uncompressed and
about 1/16 inch thick when compressed and said imitation brick
being about 1/2 inch thick.
11. An artificial brick construction as defined in claim 10 wherein
said binding material is green tag casting plaster, said lightening
compound is expanded vermiculite, and said coloring material is red
iron oxide.
12. A method for applying an artificial brick construction to an
underlying structure comprising the steps of:
stapling a sheet of compressible backing material to the underlying
structure;
applying a coat of mortar-colored paint to the outer surface of the
backing sheet;
nailing a plurality of porous imitation bricks to the outer surface
of the backing sheet and to the underlying structure before said
coat of mortar-colored paint is dry, the heads of said nails being
driven into the outer surface of said imitation bricks,
said backing sheet being compressed beneath the bricks and
projecting outwardly beyond the inner surfaces of the bricks around
the sides of the bricks so that the junctions between the inner
surfaces of the bricks on the backing sheet are concealed,
said artificial brick construction creating the appearance of real
bricks set into real mortar to the full depth of real bricks.
13. A method for applying an artificial brick construction to an
underlying structure as defined in claim 12 wherein said staples
are concealed by nailing the artificial bricks over the staples,
and further comprising the step of:
applying a coat of brick-colored paint to the heads of the
nails.
14. A method for applying an artificial brick construction to an
underlying structure as defined in claim 12 further comprising the
step of:
removing any staples which are visible after the artificial bricks
have been nailed to the backing sheet.
15. A method for applying an artificial stone construction to an
underlying structure comprising the steps of:
holding a sheet of compressible backing material on the underlying
structure;
applying paint to the outer surface of the backing structure;
applying artificial stones to the backing sheet in spaced-apart
relation to each other and in said application stage pressing the
artificial stones against the backing sheet thereby compressing
said backing sheet beneath said artificial stones while maintaining
the portions of the backing sheet between the artificial stones in
relatively uncompressed state so that those portions of the backing
sheet extend substantially outwardly into the spaces between the
artificial stones and beyond the inner surfaces of the artificial
stones but short of the outer surfaces of the artificial stones
whereby the junctions between the inner surfaces of the artificial
stones and the backing sheet are concealed thereby simulating raked
joints between the artificial stones.
16. The method of applying an artificial stone construction to an
underlying structure as defined in claim 15 including the step of
driving nails through the artificial stones and through the backing
sheet and into the underlying structure.
Description
BACKGROUND OF THE INVENTION
This invention relates to an artificial stone construction for
application to an underlying structure, and more specifically, to
an artificial brick construction which consists of a backing sheet
composed of compressible material secured to an underlying
structure and imitation bricks secured to the backing sheet and
underlying structure. Wen the backing sheet is compressed beneath
the imitation bricks, it will project outwardly beyond the inner
surface of the bricks and be visible in its uncompressed state in
order to form a tight seal around the sides of the bricks, thus
eliminating any cracks between the sides of the bricks and the
backing sheet. This creates the impression of real bricks set into
real mortar.
Artificial brick walls and the like are presently constructed of
real or imitation bricks secured to a relatively in compressible
surface. For example, one artificial brick wall employs a cement
slab having intermittent indentations and projections in the slab
which define sockets the size of the bricks. The bricks are secured
in the indentations or sockets so that parts of the cement slab
project between the bricks. This construction avoids the necessity
for filling in mortar between the bricks. However, since the
underlying cement slab is dry and relatively rigid when the bricks
are placed in the indentations, cracks appear between the
projections of the slab and the sides of the bricks. These cracks
between the bricks and the slab betray the purpose of the bricks by
detracting from the attempted impression of real bricks set into
real mortar.
Another artificial brick construction presently in use consists of
imitation bricks secured to a wall by a coat of mortar-colored
mastic which is applied to the underlying structure and to the back
of the bricks. The cracks between the bricks and the underlying
mastic previously referred to do not appear in this construction.
However, this mastic construction usually requires about a 6 hour
wait for the mastic to set before imitation bricks can be applied.
A sealer is usually required to be applied to the mastic surfaces.
Also, the back of each individual brick must be coated with mastic.
This all requires additional time and expense. The construction of
my invention is much less expensive, can be completely installed in
much less time than is the case of the mastic construction, and is
easier and cleaner to install.
I have discovered that by employing a backing sheet of compressible
material, such as a thin, porous sheet of polyurethane foam or the
like, an artificial brick wall or the like may be constructed which
in appearance more closely resembles real bricks set into real
mortar than any of the artificial stone constructions heretofore
employed.
In the best embodiment of this invention, a 1/8-inch thick
polyurethane foam sheet is used as the backing sheet. In this type
of construction, the polyurethane sheet is compressed beneath the
imitation bricks to less than about one-half the thickness of the
uncompressed backing sheet. When the backing sheet is thus
compressed beneath an imitation brick, the backing sheet projects
outwardly away from the underlying structure alongside the
imitation brick so that the junction between the imitation brick
and the backing sheet is substantially concealed from view. To aid
in this illusion, a coat of mortar-colored paint is applied to the
backing sheet. The imitation bricks are then secured to the backing
sheet and to the underlying structure while the paint is still wet.
This wet paint aids in concealing cracks between the bricks and the
backing sheet, besides combining with the porous backing sheet to
create the impression of mortar. A portion of the imitation bricks
project beyond the backing sheet to give the appearance of real
bricks embedded into mortar with what are known as "combed" or
"raked" mortar joints between the bricks.
The bricks of this invention are composed of a binding or adhesive
material, such as green tag casting plaster or the like, a
lightening compound, such as perlite, expanded vermiculite or the
like, and a coloring compound, such as red iron oxide or the like.
Such imitation bricks are lightweight, fully color impregnated and
porous enough to allow nails to be driven through them without
cracking.
By employing this invention, a durable, lightweight, artificial
stone construction can be installed in less time and more
economically than the artificial stone constructions presently in
use.
Any color of brick and mortar can be represented by employing
appropriate coloring compounds and paints. Nails can be driven
through the bricks, thus obviating the necessity of forming nail
holes in the bricks as in other types of constructions. Because of
its light weight, the artificial stone construction of this
invention can be employed where ordinary bricks would be too heavy,
such as on ceiling beams and the like. This construction can be
employed both indoors and outdoors and presents the appearance of
real bricks embedded into real mortar, all without the use of
either real bricks or mortar of any kind.
SUMMARY OF THE INVENTION
This invention provides an artificial stone construction to be
applied to an underlying structure comprising a compressible
backing sheet which is held onto the underlying structure.
Artificial stones are secured to the backing sheet so that the
backing sheet is compressed beneath the artificial stones and
projects substantially outward beyond the inner surfaces of the
artificial stones around the sides of the stones and between
adjacent stones thereby concealing the junction between the inner
surfaces of the stones and the backing sheet and creating the
appearance of real stones set into real mortar.
Many other features of this invention will become evident to those
skilled in the art upon reading the following detailed description
of the drawings wherein:
FIG. 1 is a perspective view of the artificial stone construction
of this invention applied to an underlying structure;
FIG. 2 is a sectional elevational view of a portion of the
construction taken along the line 2--2 of FIG. 1, and
FIG. 3 is a perspective view of one of the bricks employed in the
best embodiment of this invention.
FIG. 1 shows the corner of a box form 10 such as an indoor planter
or the like, which forms the underlying structure of the best
embodiment of this invention. Typically, the underlying structure
is made of plywood or the like. However, the underlying structure
may be in any form and may be composed of any material which is
capable of having a backing sheet secured to it by some means such
as stapling, gluing, or the like, and which is capable of having
nails or the like driven into it. Typical underlying structures are
house walls, indoor house planters, ceiling beams, and the
like.
FIGS. 1 and 2 show the artificial stone construction of this
invention applied to the underlying structure 10. A backing sheet
14 composed of a spongy compressible material is secured to the
underlying structure 10 by staples 16 or the like. In the best
embodiment of this invention, the backing sheet 14 is composed of
polyurethane foam. The backing sheet may be composed of other
substances or materials which have characteristics similar to those
of polyurethane which will be described hereinafter.
One requirement for the backing sheet is that it be composed of a
highly compressible spongy material. In the best embodiment of the
invention, 1/8-inch thick sheets of porous polyurethane foam are
employed which are capable of being compressed between the
imitation bricks and the underlying structure, as will be explained
hereafter, to such an extent that the backing sheet beneath the
imitation bricks has a thickness of less than about one-sixteenth
inch.
In the best embodiment of this invention, the backing sheet also
has a rough surface which approximates the appearance of the rough
surface of real mortar such as is usually visible between bricks.
The backing sheet 14 is lightweight and easy to handle. Thus, it
can be easily held onto the underlying structure 10 either by hand
or by staples 16 while it is being painted and while the imitation
bricks 20 are being secured thereto, as will be explained
hereafter.
In the best embodiment of this invention, staples 16 are employed
to secure the backing sheet 14 to the underlying structure 10. The
backing sheets 14 are secured to the underlying structure 10 so
that their edges butt up against one another, thus forming a
continuous covering over the entire surface of the underlying
structure which is desired to be covered with the artificial stone
construction. The backing sheet 14 is flexible enough to follow the
contours of the underlying structure and may be secured around
corners and the like.
A coat of mortar-colored paint 18 is applied to the outer surface
of the backing sheet 14 while the backing sheet is held onto the
underlying structure 10 by staples 16. This coat of paint 18 may
consist of either textured or flat paint and may be varied in color
according to the color of the mortar desired to be represented.
The rough texture of the backing sheet 14 combined with the coat of
mortar-colored paint 18 creates the impression of real mortar
applied to the underlying structure 10.
Imitation stones 20 may be formed to have the appearance of either
man-made and natural occurring stones or construction materials,
such as flagstone, cement blocks, granite and the like. In the best
embodiment of the invention, the imitation stones 20 have the
appearance of red clay bricks.
These imitation bricks 20 are composed of a mixture of one part
adhesive or binder material, such as green tag casting plaster, one
part lightening compound, such as a lightweight aggregate or
expanded vermiculite or the like, and the desired amount of a
cement color, such as red iron oxide. The expanded vermiculite
employed is sold by the W.R. Grace Company under the name Zonolite.
I employ their grade No. 3 which satisfies the following
specifications regarding amounts retained by the respective
sieves:
Percent Retained Sieve Size Maximum Minimum
__________________________________________________________________________
8 10 0 16 60 20 30 95 65 50 98 75 100 100 90
__________________________________________________________________________
These materials are dry mixed and are then combined with one part
of water while the water is being agitated. After the mixture has
been agitated for about one minute, it is poured into brick molds
and allowed to set.
The result is a red imitation brick which is lightweight and fully
color impregnated throughout. This imitation brick 20 is solid and
durable while at the same time being porous enough to allow nails
to be driven through the brick 20 without cracking the bricks. Such
an imitation brick 20 may be cut in any desired lengths or widths
after it is formed in order to more easily adapt the brick to the
particular construction desired.
The color, weight, hardness, and size of the bricks may be varied
as desired. Typically, the imitation brick 20 is about 0.5 inches
thick, about 8.125 inches long, and about 2.5 inches wide.
Imitation bricks 20 may also be composed of rubber, polyesters,
concrete, or the like. Where a rubber, foam rubber, or other
bendable material is utilized, the bricks are capable of being bent
around corners for installation on curved surfaces. Where the
bricks 20 are composed of concrete or other similarly hard
material, it is common practice to perform nail holes in the bricks
to allow nails to be driven through the bricks without danger of
cracking the bricks.
While the cost of mortar-colored paint 18 is still wet, the bricks
20 are secured to the underlying structure 10 in rows 1/2 inch
apart by nails 22 or the like. The bricks 20 are placed by hand in
the positions desired and pressed firmly against the underlying
structure 10 thereby compressing the backing sheet 14 while the
nails 22 are being driven through the bricks 20, the backing sheet
14 and into the underlying structure 10. The nails 22 have T-heads
and are 1 inch long T-shaped finishing nails. Nails 22 are driven
into the bricks 20 so that their heads are completely embedded into
the bricks 20 and are flush with the outer surface of the
bricks.
When the bricks 20 are secured to the underlying structure 10 in
this manner, the backing sheet 14 projects outwardly along the
sides of the bricks. This outward projection or uncompressed
portion of the backing sheet 14 between the bricks 20 serves to
conceal the cracks which are normally seen between the inner
surface of the bricks and the backing material used in other types
of artificial stone construction. Furthermore, the coat of
mortar-colored paint 18 serves to fill in any cracks between the
side of the brick 20 and the backing sheet 14 which might otherwise
exist since the coat of paint 18 is wet when the bricks 20 are
pressed against and secured to the backing sheet 14.
In the best embodiment of the invention, the bricks 20 are secured
over the staples 16 so that the staples 16 are concealed by the
bricks 20. An alternative procedure for eliminating the staples 16
from view is to pull them out with pliers or the like after some
bricks have been secured to each backing sheet. The bricks will
retain the backing sheet in position on the underlying structure 10
while the staples are removed.
After the bricks 20 have been secured to the underlying structure
10 by nails 22 or the like, the heads of the nails 22 are covered
with a coat of brick colored paint, thus concealing the manner in
which the bricks are secured to the underlying structure.
FIG. 3 shows a corner brick 30 which is employed in this invention.
This particular corner brick 30, also shown in FIG. 1, is
constructed as one unit and employed in the same manner as has been
described above for bricks 20. However, this brick 30 has three
sides which illustrate all of the sides of imitation bricks which
are employed in this invention.
Brick 30 has a top panel 32, an end panel 34, and a side panel 36.
All three panels are molded integrally with one another. Any of
these panels 32, 34, 36 may be formed either by themselves or in an
integral combination with an other panel to simulate various bricks
20. The brick 30 shown in FIG. 3 is employed to simulate a brick
placed at the top corner of the wall shown in FIG. 1.
Top brick panel 32 would be used by itself, for example, to
simulate bricks on the top of a wall which are not adjacent to a
corner of the underlying structure. End brick panel 34 would be
used by itself, for example, to simulate the end of a brick which
is not adjacent to a corner of the underlying structure. Similarly,
side brick panel 36 would be employed by itself, for example, to
simulate the side of a brick which is not adjacent to one of the
corners of the underlying structure. It is also possible to mold
the panels 32, 34 and 36 in various combinations to simulate other
bricks 20. For example, a top-end brick would be composed of panels
32 and 34 molded together as one unit, a top-side brick would be
composed of panels 32 and 36, an end-side brick would be composed
of panels 34 and 36, and the mirror image of brick 30 shown in FIG.
3 would be composed of panels 32, 34 and 36.
It will be understood that other forms of artificial stones and
other backing sheets composed of other materials may be employed
which are similar to that disclosed above, all within the scope of
this invention.
Although this invention has been described with reference to a
particular embodiment and to particular applications, the
principles involved are susceptible to numerous other applications,
which will be apparent to those skilled in the art, and the scope
of the invention is not to be limited by the proceeding
embodiments.
* * * * *