Dimensionally compatible stone fabrication system

Abstract

A system for manufacturing stones for use in construction such that the manufactured stones may be easily used in conjunction and alongside compressed earth blocks. The manufactured stones have a plurality of surfaces, wherein at least one of the surfaces includes a simulated-stone appearance and a length and/or height which are determined based on dimension equations derived at least in part from compatibility factors, which may be based on the dimensions of a compressed earth block.

1 . A manufactured stone for use in building a wall, the stone having a plurality of surfaces, wherein at least one of the surfaces includes a natural stone appearance, the stone having a length and a height, at least one of which is determined based on a compatibility factor to insure dimensional compatibility of the stone in relation to contiguous stones of substantially different lengths and/or heights for being fittingly arranged in relation to one another and/or to non-stone building materials used in the construction of a wall therefrom. 
   
   
       2 . The manufactured stone of  claim 1  wherein the compatibility factor is used to derive at least one equation which substantially determines the dimension of at least one of the length or height. 
   
   
       3 . The manufactured stone of  claim 1  wherein the length dimension is substantially determined based on the following equation:
     L ( N )=( N/ 2)( CFL )+[( N/ 2)−1][ MW]     
     wherein L is the length of the manufactured stone and is a function of N, an integer variable ranging from one to about eight, CFL is the compatibility factor for the length, and MW is a mortar width. 
   
   
       4 . The manufactured stone of  claim 3  wherein the compatibility factor for the length is substantially equal to a length of a compressed earth block. 
   
   
       5 . The manufactured stone of  claim 3  wherein the compatibility factor for the length is substantially equal to eight inches. 
   
   
       6 . The manufactured stone of  claim 1  wherein the height dimension is substantially determined based on the following equation:
     H ( N )=( N/ 2)( CFH )+[( N/ 2)−1][ MW]     
     wherein H is the length of the manufactured stone and is a function of N, an integer variable ranging from one to about eight, CFH is the compatibility factor for the height, and MW is a mortar width. 
   
   
       7 . The manufactured stone of  claim 3  wherein the compatibility factor for the height is substantially equal to a height of a compressed earth block. 
   
   
       8 . The manufactured stone of  claim 3  wherein the compatibility factor for the height is substantially equal to 2.25 inches. 
   
   
       9 . The manufactured stone of  claim 1  wherein the manufactured stone comprises a crushed stone material, such that the manufactured stone has a substantially constant color and consistency throughout. 
   
   
       10 . A wall comprising a plurality of manufactured stone blocks each having a plurality of surfaces, wherein at least one of the surfaces includes a natural stone appearance, and a plurality of non-stone building units, wherein the plurality of manufactured stones are dimensionally compatible with and substantially adjacent to the plurality of non-stone building units. 
   
   
       11 . The wall of  claim 10 , wherein the manufactured stone blocks have a plurality of length and/or height dimensions, and further wherein the length and/or height dimensions are determined based on a compatibility factor which is derived from at least one of a length or a height of the non-stone building units. 
   
   
       12 . The wall of  claim 11  wherein the height dimensions of the manufactured stone blocks are substantially determined based on the following equation:
     H ( N )=( N/ 2)( CFH )+[( N/ 2)−1][ MW]     
     wherein H is the length of the manufactured stone blocks and is a function of N, an integer variable ranging from one to about eight, CFH is the compatibility factor for the height, and MW is a mortar width. 
   
   
       13 . The wall of  claim 11  wherein the length dimensions of the manufactured stone blocks are substantially determined based on the following equation:
     L ( N )=( N/ 2)( CFL )+[( N/ 2)−1][ MW]     
     wherein L is the length of the manufactured stone blocks and is a function of N, an integer variable ranging from one to about eight, CFL is the compatibility factor for the length, and MW is a mortar width. 
   
   
       14 . The wall of  claim 10 , wherein a portion of the plurality of manufactured stone blocks are interleaved with the non-stone building units. 
   
   
       15 . The wall of  claim 10 , wherein sections of manufactured stone blocks are interspersed with sections of non-stone building units to provide a variegated appearance to the wall. 
   
   
       16 . A method for building a wall using a plurality of manufactured stones the method comprising:
 (a) choosing at least one compatibility factor corresponding to at least one of a length or a height of a compressed earth block;   (b) deriving at least one dimension equation based at least in part on the compatibility factor;   (c) manufacturing a plurality of manufactured stones based at least in part on the derived dimension equation; and   (d) building a wall using the plurality of manufactured stones.   
   
   
       17 . The method of  claim 16  further comprising providing a plurality of compressed earth blocks, and wherein the step of building the wall comprises assembling the plurality of compressed earth blocks adjacent the manufactured stones. 
   
   
       18 . The method of  claim 16  wherein the lengths of the plurality of manufactured stones are substantially determined based on the following equation:
     L ( N )=( N/ 2)( CFL )+[( N/ 2)−1][ MW]     
     wherein L is the length of the manufactured stone and is a function of N, an integer variable ranging from one to about eight, CFL is the compatibility factor for the length, and MW is a mortar width. 
   
   
       19 . The method of  claim 16  wherein the heights of the plurality of manufactured stones are substantially determined based on the following equation:
     H ( N )=( N/ 2)( CFH )+[( N/ 2)−1][ MW]     
     wherein H is the length of the manufactured stone and is a function of N, an integer variable ranging from one to about eight, CFH is the compatibility factor for the height, and MW is a mortar width. 
   
   
       20 . The method of  claim 16  further comprising providing a plurality of compressed earth blocks, and wherein the step of building the wall comprises assembling the a portion of the plurality the manufactured stones interspersed among the plurality of compressed earth blocks.