US2012247045A1PendingUtilityA1

System and method of stonework installation

43
Individually held — no corporate assignee on recordPriority: Mar 4, 2011Filed: Mar 1, 2012Published: Oct 4, 2012
Est. expiryMar 4, 2031(~4.6 yrs left)· nominal 20-yr term from priority
Inventors:Thomas L. Schlough
E04F 13/0864Y10T29/49826Y10T156/10E04F 2203/06E04F 13/144E04F 13/0891Y10T29/49947B23P 19/04E04F 13/0801B32B 37/12E04F 13/09
43
PatentIndex Score
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Cited by
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References
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Claims

Abstract

A system and method of attaching a natural stone to a wall surface includes attaching a piece of natural stone to a base plate so as to leave at least a portion of the base plate uncovered by the piece of natural stone and attaching the base plate to the wall surface with a fastener extending through the uncovered portion of the base plate.

Claims

exact text as granted — not AI-modified
1 . A method of attaching a natural stone to a wall surface, the method comprising:
 attaching a first piece of natural stone to a first base plate so as to leave at least a portion of the first base plate uncovered by the first piece of natural stone;   attaching the first base plate to the wall surface with a fastener extending through the uncovered portion of the first base plate.   
     
     
         2 . A method according to  claim 1 , further comprising attaching a second piece of natural stone to a second base plate so as to leave at least a portion of the second base plate uncovered by the second piece of natural stone and attaching the second base plate to the wall surface so as to overlap the uncovered portion of the first base plate with a portion of the second base plate that is covered by the second piece of natural stone. 
     
     
         3 . A method according to  claim 2 , further comprising providing a sealant between the first piece of natural stone and the second piece of natural stone once the pieces of natural stone have been attached to the wall surface. 
     
     
         4 . A method according to  claim 3 , wherein the sealant includes grout. 
     
     
         5 . A method according to  claim 2 , wherein the second piece of natural stone defines a different configuration than the first piece of natural stone. 
     
     
         6 . A method according to  claim 3 , wherein the second piece of natural stone defines a different peripheral size than the first piece of natural stone. 
     
     
         7 . A method according to  claim 1 , further comprising providing at least one fastener hole through the uncovered portion of the first base plate. 
     
     
         8 . A method according to  claim 1 , further comprising attaching the first piece of natural stone to the first base plate with an adhesive. 
     
     
         9 . A method according to  claim 1 , wherein the first base plate includes a metallic material. 
     
     
         10 . A method according to  claim 1 , wherein the first piece of natural stone defines a top end, a bottom end, a right end, and a left end, wherein the first base plate defines uncovered portions that extend out away from at least one of the ends of the first piece of natural stone. 
     
     
         11 . A method according to  claim 10 , wherein the first base plate defines uncovered portions that extend out away from at least two of the ends of the first piece of natural stone. 
     
     
         12 . A method according to  claim 11 , wherein the at least two of the ends of the first piece of natural stone includes one of the top end and the bottom end and one of the right end and the left end. 
     
     
         13 . A method according to  claim 1 , wherein the first base plate defines a greater overall outer peripheral dimension than that of the first piece of natural stone. 
     
     
         14 . A method according to  claim 1 , further comprising attaching a second piece of natural stone to the first base plate so as to leave at least a portion of the first base plate uncovered by the second piece of natural stone. 
     
     
         15 . A method of manufacturing a stone veneer configured for attachment to a wall surface, the method comprising:
 attaching at least one piece of natural stone to a base plate so as to leave at least a portion of the base plate uncovered by the at least one piece of natural stone.   
     
     
         16 . A method according to  claim 15 , further comprising attaching a second piece of natural stone to the base plate so as to leave at least a portion of the base plate uncovered by the second piece of natural stone. 
     
     
         17 . A method according to  claim 15 , further comprising providing at least one fastener hole through the uncovered portion of the base plate. 
     
     
         18 . A method according to  claim 15 , further comprising attaching the at least one piece of natural stone to the base plate with an adhesive. 
     
     
         19 . A method according to  claim 15 , wherein the base plate includes a metallic material. 
     
     
         20 . A method according to  claim 15 , wherein the at least one piece of natural stone defines a top end, a bottom end, a right end, and a left end, wherein the base plate defines uncovered portions that extend out away from at least one of the ends of the at least one piece of natural stone. 
     
     
         21 . A method according to  claim 20 , wherein the base plate defines uncovered portions that extend out away from at least two of the ends of the at least one piece of natural stone. 
     
     
         22 . A method according to  claim 21 , wherein the at least two of the ends of the at least one piece of natural stone include one of the top end and the bottom end and one of the right end and the left end. 
     
     
         23 . A method according to  claim 15 , wherein the base plate defines a greater overall outer peripheral dimension than that of the at least one piece of natural stone. 
     
     
         24 . A natural stone veneer comprising:
 a piece of natural stone attached to a base plate so as to leave at least a portion of the base plate uncovered by the piece of natural stone.   
     
     
         25 . A natural stone according to  claim 24 , further comprising a second piece of natural stone attached to the base plate so as to leave at least a portion of the base plate uncovered by the second piece of natural stone. 
     
     
         26 . A natural stone veneer according to  claim 24 , wherein the piece of natural stone is attached to the base plate with an adhesive. 
     
     
         27 . A natural stone veneer according to  claim 24 , further comprising a fastener hole through the uncovered portion of the base plate. 
     
     
         28 . A natural stone veneer according to  claim 24 , wherein the base plate includes a metallic material. 
     
     
         29 . A natural stone veneer according to  claim 24 , wherein the piece of natural stone defines a top end, a bottom end, a right end, and a left end, wherein the base plate defines uncovered portions that extend out away from at least one of the ends of the piece of natural stone. 
     
     
         30 . A natural stone veneer according to  claim 29 , wherein the base plate defines uncovered portions that extend out away from at least two of the ends of the piece of natural stone. 
     
     
         31 . A natural stone veneer according to  claim 30 , wherein the at least two of the ends of the piece of natural stone include one of the top end and the bottom end and one of the right end and the left end. 
     
     
         32 . A natural stone veneer according to  claim 24 , wherein the base plate defines a greater overall outer peripheral dimension than that of the piece of natural stone. 
     
     
         33 . A wall comprising:
 a wall surface;   a first piece of natural stone attached to a first base plate so as to leave at least a portion of the first base plate uncovered by the first piece of natural stone, wherein the first base plate is attached to the wall surface with a fastener extending through the uncovered portion of the first base plate; and   a second piece of natural stone attached to a second base plate so as to leave at least a portion of the second base plate uncovered by the second piece of natural stone, wherein the second base plate is attached to the wall surface so as to overlap the uncovered portion of the first base plate with a portion of the second base plate that is covered by the second piece of natural stone, the second piece of natural stone defining a different configuration than the first piece of natural stone.   
     
     
         34 . A wall according to  claim 33 , wherein the second piece of natural stone defines a different peripheral size than the first piece of natural stone. 
     
     
         35 . A wall according to  claim 33 , wherein at least one of the first base plate and the second base plate includes at least one fastener hole through the uncovered portion of the base plate. 
     
     
         36 . A wall according to  claim 33 , wherein at least one of the first piece of natural stone and the second piece of natural stone is attached to the corresponding base plate with an adhesive. 
     
     
         37 . A wall according to  claim 33 , wherein at least one of the first base plate and the second base plate includes a metallic material. 
     
     
         38 . A method of installing stonework on a wall surface, the method comprising:
 creating a pattern of stonework to be applied to a wall surface;   providing a plurality of natural stone veneers associated with the pattern of stonework;   providing a physical guide on the wall surface that associates the plurality of natural stone veneers with the created pattern of stonework; and   attaching the plurality of natural stone veneers to the wall surface using the physical guide.   
     
     
         39 . A method according to  claim 38 , wherein the pattern of stonework to be applied to the wall surface is created using computer software. 
     
     
         40 . A method according to  claim 38 , wherein the guide defines horizontal and vertical grid lines defining installment locations for each of the plurality of natural stone veneers. 
     
     
         41 . A method according to  claim 38 , wherein the guide includes a substrate to be fastened to the wall surface. 
     
     
         42 . A method according to  claim 38 , wherein the guide is a projected pattern image. 
     
     
         43 . A method according to  claim 38 , wherein each of the natural stone veneers includes a piece of natural stone attached to a base plate so as to leave at least a portion of the base plate uncovered by the piece of natural stone. 
     
     
         44 . A method according to  claim 43 , wherein each of the natural stone veneers is attached to the wall surface via a fastener through the portion of the base plate uncovered by the piece of natural stone.

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