Modular natural stone wall system and method of making

Abstract

The present invention provides a modular natural stone wall system and method of making that provides a modular solution that is able to build true natural stone walls in an efficient manner. The invention dramatically reduces the cost, time, and labor resources needed to build natural stone walls. It makes natural stone walls more affordable to consumers, more efficient for contractors to install, and eases the concerns surrounding skilled masonry labor shortages. In one particular embodiment, the present invention is created by first pre-designing multiple unit surfaces, natural stones are pre-cut; design is laid out on template; the back of pre-cut natural stone pieces and multiple block surfaces are preferably roughed out, bonding material is added and the natural stones are affixed to the block. As a result, the surface of the modular blocks are covered with natural stone prior to installation.

1 . A modular method of making a natural stone wall system comprising the steps of:
 creating at least one block with various face shells; cutting at least one natural stone to make a face for adhesion to the at least one block; selecting at least one natural stone for adhesion to the at least one block; adhering at least one natural stone to the at least one block by a bonding material.   
   
   
       2 . The method of  claim 1  wherein the at least one block is a concrete block. 
   
   
       3 . The method of  claim 2  wherein the creating at least one block step is accomplished by using a concrete block machine. 
   
   
       4 . The method of  claim 3  wherein the cutting at least one natural stone step is accomplished by using diamond blades. 
   
   
       5 . The method of  claim 4  wherein the selecting at least one natural stone step is done by following a design pattern. 
   
   
       6 . The method of  claim 5  wherein the at least one natural stone is selected from the group consisting of slate, limestone, sandstone, lava stone and coral stone. 
   
   
       7 . The method of  claim 6  wherein the adhering of at least one natural stone step is accomplished by coating the block with a first bonding material. 
   
   
       8 . The method of  claim 7  wherein the adhering of at least one natural stone step is accomplished by coating the at least one natural stone with a second bonding material. 
   
   
       9 . The method of  claim 8  wherein the first bonding material and the second bonding material are the same compound. 
   
   
       10 . The method of  claim 8  wherein the first bonding material and the second bonding material are a different compound. 
   
   
       11 . The method of  claim 9  wherein the bonding material does not deteriorate. 
   
   
       12 . The method of  claim 10  wherein the first bonding material and the second bonding material do not deteriorate. 
   
   
       13 . The method of  claim 10  wherein the first bonding material and the second bonding material are both selected from the group consisting of Latex, Acrylic, Polymer, Polyurethane, Epoxy, and Silicone. 
   
   
       14 . The method of  claim 11  wherein the first bonding material and the second bonding material are a cement-based inorganic bonding material. 
   
   
       15 . The method of  claim 14  wherein the at least one natural stone ranges in thickness from 10 mm to 50 mm. 
   
   
       16 . The method of  claim 15  wherein the at least one natural stone ranges in thickness from 10 mm to 50 mm. 
   
   
       17 . The method of  claim 16  further comprising the steps of washing and drying the natural stones prior to the adhering step. 
   
   
       18 . The method of  claim 17  wherein the natural stone is further cut by hand with hammer, after using the concrete block machine, to create pieces of stones unique in shape and color.