Product of a method for manufacturing non-seamed stone corners for veneer stone surfaces

Abstract

A product of a method is disclosed, the method being for construction of non-seamed stone corners for use on outside edges formed by joining thin stone walls at right angles. Thin stone is used to lay the field of the walls. In the method, two cuts are made in a building stone, removing a residual piece and leaving a corner stone with sides ½ inch to 3 inch thick to match the thickness of the thin stone on the field of the walls. These corner stones are the product of the method and are laid on the corner formed by the right angle joint between the walls, giving the illusion of a thick building stone wall with nearly the low cost and easy laying of thin stone. Where the residual piece is large enough, it is used to cut a second corner stone in the same manner.

1 . A non-seamed stone corner for first and second thin stone walls of thickness T 1  and T 2 , respectively, said first and second walls being joined at right angles at an external edge, the corner created by a method comprising the steps of: 
 selecting a building stone having a height H, a depth D and a width W, said building stone having top and bottom surfaces H 1  and H 2 , respectively, front and back surfaces D 1  and D 2 , respectively, and left and right surfaces W 1  and W 2 , respectively;    orienting said building stone at the higher end of an inclined chute having perpendicular sides C 1  and C 2 , such that surface W 1  rests on side C 1  and surface H 2  rests on side C 2 ;    adjusting dual stone cutting saw blades B 1  and B 2  mounted perpendicularly to one another and parallel to respective sides C 1  and C 2  in said chute, such that the distance between blade B 1  and side C 1  is T 1  and the distance between blade B 2  and side C 2  is T 2 , and the cutting edges of blades B 1  and B 2  have a clearance of about one-eighth of an inch;    feeding said oriented building stone down said chute and through said saw blades; and    removing from said building stone a residual piece, said removal step of the method leaving said building stone remainder as a corner stone.    
   
   
       2 . A non-seamed stone corner created by a method as in  claim 1 , the method further comprising the steps of: 
 sandblasting said corner stone at surfaces formed by said first cut and said second cut; and    laying said corner stone on said external edge joining said first and second thin stone walls.    
   
   
       3 . A non-seamed stone corner created by a method as in  claim 1 , wherein the height H of said building stone is between three inches and ten inches, the width W of said building stone is between three inches and ten inches, the depth D of said building stone is between three inches and twenty-four inches, the thickness T 1  of said first thin stone wall is one and one-half inches, and the thickness T 2  of said second thin stone wall is one and one-half inches.  
   
   
       4 . A non-seamed stone corner created by a method as in  claim 1 , said method further comprising the steps of: 
 re-orienting said residual piece in preparation for cutting so that neither the surface facing side C 1  nor the surface facing side C 2  is formed by said first or second cuts, wherein the height H′ of said re-oriented residual piece is between three inches and ten inches, the width W′ of said re-oriented residual piece is between three inches and ten inches, the depth D′ of said re-oriented residual piece is between three inches and twenty-four inches, said re-oriented residual piece having top and bottom surfaces H′ 1  and H′ 2 , respectively, front and back surfaces D′ 1  and D′ 2 , respectively, and left and right surfaces W′ 1  and W′ 2 , respectively;    orienting said re-oriented residual piece at the higher end of said inclined chute, such that surface W′ 1  rests on side C 1  and surface H′ 2  rests on side C 2 ;    feeding said re-oriented residual piece down said chute and through said saw blades; and    removing from said residual piece a second residual piece, said removal step of the method leaving said residual piece remainder as a second corner stone.    
   
   
       5 . A non-seamed stone corner created by a method as in  claim 4 , the method further comprising the steps of: 
 sandblasting said second corner stone at surfaces formed by said third cut and said fourth cut; and    laying said second corner stone on said external edge joining said first and second thin stone walls.    
   
   
       6 . A non-seamed stone corner created by a method as in  claim 4 , wherein the thickness T 1  of said first thin stone wall is one and one-half inches, and the thickness T 2  of said second thin stone wall is one and one-half inches.  
   
   
       7 . A non-seamed stone corner created by a method as in  claim 2 , wherein said corner stone is oriented so that said surface W 1  of said corner stone is parallel to said first thin stone wall and said surface H 2  of said corner stone is parallel to said second thin stone wall.  
   
   
       8 . A non-seamed stone corner created by a method as in  claim 5 , wherein said second corner stone is oriented so that said surface W′ 1  of said second corner stone is parallel to said first thin stone wall and said surface H′ 2  of said second corner stone is parallel to said second thin stone wall.  
   
   
       9 . A non-seamed stone corner created by a method as in  claim 1 , wherein said clearance is obtained by adjusting a lateral position of a shaft F 1  of blade B 1  and a lateral position of shaft F 2  of blade B 2  such that a nearest distance X 1  along side C 1  between shaft F 1  and an edge joining sides C 1  and C 2  is determined by  
         X   1 = S   1 /2+ T   2 +α,  
     and a nearest distance X 2  along side C 2  between shaft F 2  and said edge is determined by  
         X   2 = S   2 /2 +T   1 +α,  
     where S 1  is the diameter of blade B 1 , S 2  is the diameter of blade B 2 , and α is about one-eighth of an inch.  
   
   
       10 . A non-seamed stone corner created by a method as in  claim 4 , wherein in said re-orienting step of the method the residual piece is rotated one hundred eighty degrees counterclockwise about an axis between and perpendicular to front and back surfaces of the residual piece.  
   
   
       11 . A non-seamed stone corner for first and second thin stone walls of thickness T 1  and T 2 , respectively, said first and second walls being joined at right angles at an external edge, the corner created by a method comprising the steps of: 
 selecting a building stone having a height H, a depth D and a width W, said building stone having top and bottom surfaces H 1  and H 2 , respectively, front and back surfaces D 1  and D 2 , respectively, and left and right surfaces W 1  and W 2 , respectively;    making a first cut in said building stone, the plane of said first cut being parallel to the plane of surface W 1  and extending to a uniform depth from surface H 1 , such that the distance between the plane of said first cut and the plane of surface W 1  is T 1 , and such that said uniform depth is equal to (H-T 2 );    making a second cut in said building stone, the plane of said second cut being parallel to the plane of surface H 1  and extending to a second uniform depth from surface W 2 , such that the distance between the plane of said second cut and the plane of surface H 2  is T 2 , and such that said second uniform depth is equal to (W-T 1 ); and    removing from said building stone a residual piece, said removal step of the method leaving said building stone remainder as a corner stone.    
   
   
       12 . A non-seamed stone corner created by a method as in  claim 11 , the method further comprising the steps of: 
 sandblasting said corner stone at surfaces formed by said first cut and said second cut; and    laying said corner stone on said external edge joining said first and second thin stone walls.    
   
   
       13 . A non-seamed stone corner created by a method as in  claim 11 , wherein the height H of said building stone is between three inches and six inches, the width W of said building stone is between three inches and six inches, the depth D of said building stone is between three inches and ten inches, the thickness T 1  of said first thin stone wall is one and one-half inches, and the thickness T 2  of said second thin stone wall is one and one-half inches.  
   
   
       14 . A non-seamed stone corner created by a method as in  claim 11 , said method further comprising the steps of: 
 re-orienting said residual piece in preparation for cutting so that neither the left surface nor the bottom surface is formed by said first or second cuts, wherein the height H′ of said re-oriented residual piece is between three inches and six inches, the width W′ of said re-oriented residual piece is between three inches and six inches, the depth D′ of said re-oriented residual piece is between three inches and ten inches, said re-oriented residual piece having top and bottom surfaces H′ 1  and H′ 2 , respectively, front and back surfaces D′ 1  and D′ 2 , respectively, and left and right surfaces W′ 1  and W′ 2 , respectively;    making a third cut in said residual piece, the plane of said third cut being parallel to the plane of surface W′ 1  and extending to a third uniform depth from top surface H′ 1 , such that the distance between the plane of said third cut and the plane of surface W′ 1  is T 1 , and such that said third uniform depth is equal to (H′-T 2 );    making a fourth cut in said residual piece, the plane of said fourth cut being parallel to the plane of surface H′ 1  and extending to a fourth uniform depth from surface W′ 2 , such that the distance between the plane of said fourth cut and the plane of bottom surface H′ 2  is T 2 , and such that said fourth uniform depth is equal to (W′-T 1 ); and    removing from said residual piece a second residual piece, said removal step of the method leaving said residual piece remainder as a second corner stone.    
   
   
       15 . A non-seamed stone corner created by a method as in  claim 14 , the method further comprising the steps of: 
 sandblasting said second corner stone at surfaces formed by said third cut and said fourth cut; and    laying said second corner stone on said external edge joining said first and second thin stone walls.    
   
   
       16 . A non-seamed stone corner created by a method as in  claim 14 , wherein the thickness T 1  of said first thin stone wall is one and one-half inches, and the thickness T 2  of said second thin stone wall is one and one-half inches.  
   
   
       17 . A non-seamed stone corner created by a method as in  claim 12 , wherein said corner stone is oriented so that said surface W 1  of said corner stone is parallel to said first thin stone wall and said surface H 2  of said corner stone is parallel to said second thin stone wall.  
   
   
       18 . A non-seamed stone corner created by a method as in  claim 15 , wherein said second corner stone is oriented so that said surface W′ 1  of said second corner stone is parallel to said first thin stone wall and said surface H′ 2  of said second corner stone is parallel to said second thin stone wall.  
   
   
       19 . A non-seamed stone corner created by a method as in  claim 11 , wherein said first and second cuts are made with a stationary saw and between said first and second cuts the building stone is rotated ninety degrees counterclockwise as viewed from the front face.  
   
   
       20 . A non-seamed stone corner created by a method as in  claim 14 , wherein in said re-orienting step of the method the residual piece is rotated one hundred eighty degrees counterclockwise about an axis between and perpendicular to front and back surfaces of the residual piece.  
   
   
       21 . A non-seamed stone corner for first and second thin stone walls of thickness T 1  and T 2 , respectively, said first and second walls being joined at right angles at an external edge, the corner created by a method comprising the steps of: 
 selecting a building stone having a height H, a depth D and a width W, said building stone having top and bottom surfaces H 1  and H 2 , respectively, front and back surfaces D 1  and D 2 , respectively, and left and right surfaces W 1  and W 2 , respectively;    making two cuts in said building stone, the plane of a first cut being parallel to the plane of surface W 1 , such that the distance between the plane of said first cut and the plane of surface W 1  is T 1 , the plane of a second cut being parallel to the plane of surface H 1 , such that the distance between the plane of said second cut and the plane of surface H 2  is T 2 ; and    removing from said building stone a residual piece, said removal step of the method leaving said building stone remainder as a corner stone.    
   
   
       22 . A non-seamed stone corner created by a method as in  claim 21 , wherein said two cuts are made sequentially by a single saw blade.  
   
   
       23 . A non-seamed stone corner created by a method as in  claim 22 , wherein said two cuts are made sequentially by reorienting the building stone after the first cut.  
   
   
       24 . A non-seamed stone corner created by a method as in  claim 22 , wherein said single saw blade is a circular saw.  
   
   
       25 . A non-seamed stone corner created by a method as in  claim 21 , wherein the two cuts are made simultaneously using two saw blades oriented at right angles.  
   
   
       26 . A non-seamed stone corner created by a method as in  claim 25 , wherein each of said two saw blades is a circular saw.  
   
   
       27 . A non-seamed stone corner created by a method as in  claim 21 , wherein at least one of said two cuts is comprised of a plurality of cuts in approximately the same plane, each of said plurality of cuts being of approximately the same depth.  
   
   
       28 . A non-seamed stone corner created by a method as in  claim 21 , wherein at least one of said two cuts is comprised of two separate cuts in approximately the same plane, each separate cut beginning at respective opposite ends perpendicular to the plane of the cut and being of approximately the same depth.  
   
   
       29 . A non-seamed stone corner created by a method as in  claim 21 , wherein said first cut extends to a uniform depth from surface H 1 , such that said uniform depth is equal to (H-T 2 ).  
   
   
       30 . A non-seamed stone corner created by a method as in  claim 21 , wherein said second cut extends to a second uniform depth from surface W 2 , such that said second uniform depth is equal to (W-T 1 ).