Artificial Lightweight Stone Corner Assembly
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Solution Overview
Problem
Traditional stone or manmade stone walls require mortar and lath materials for assembly, which add expense and time, and are difficult to manage at corners due to dimensional inconsistencies and the need for cutting, leading to variations in color, dimension, and manufacturing costs.
Innovation Solution
An artificial lightweight stone system comprising two stones with matching contours at the corner, one with a curved and one with a sharp corner, allowing for consistent dimensional tolerances and reduced cutting requirements, formed from cement and materials like expanded polystyrene or glass, which can be installed without mortar or lath, using a fixative for adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional stone or manmade stone walls are assembled with mortar and lath materials, then the wall structure is held together, but the expense and time for the project increases
Solution Approach 1:
The patent removes mortar and lath materials from the stone wall assembly system. The artificial stones are designed with interlocking features and recesses that allow them to be assembled directly without requiring mortar or lath, thereby eliminating the time-consuming application and drying processes associated with these traditional materials while maintaining structural integrity
Solution Approach 2:
The stone wall system is segmented into individual artificial stone units with standardized dimensions and interlocking features. Each stone is designed as a discrete module with specific geometric characteristics that enable direct assembly, allowing for faster installation compared to traditional monolithic stone construction that requires mortar bonding
2Strength
If traditional stone or manmade stone walls are assembled with mortar and lath materials, then the wall structure is held together, but the expense for the project increases
Solution Approach 1:
The patent eliminates the need for mortar and lath materials by designing artificial stones with self-interlocking features. This extraction of unnecessary materials directly reduces project costs while maintaining wall structure integrity through the engineered interlocking mechanisms built into the stone units themselves
Solution Approach 2:
The patent changes the physical parameters of the stone units by incorporating recesses and interlocking features that enable direct mechanical connection. This parameter change in the stone geometry allows the system to function without additional bonding materials, reducing both material costs and labor expenses
3Shape
If preformed sheet structures are used to face a wall, then the stone like appearance is achieved, but the dimensional changes of the wall are limited to multiples of the base dimension
Solution Approach 1:
The wall facing system is divided into individual artificial stone units with standardized base dimensions that feature interlocking mechanisms. These segmented units can be arranged in various configurations and combined in different sequences, enabling dimensional flexibility and adaptability while maintaining the desired stone-like appearance, overcoming the limitations of continuous preformed sheets
4Shape
If stones are arranged about a corner with traditional methods, then the corner configuration is achieved, but the manufacturing consistency varies in color, dimension or other features
Solution Approach 1:
The patent designs universal artificial stone units with standardized dimensions, colors, and interlocking features that can be used consistently across all wall sections including corners. The corner stones are not specially molded but are assembled from the same standardized units used elsewhere in the wall, ensuring manufacturing consistency in color, dimension, and material properties throughout the entire structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, aesthetically pleasing, and consistent stone arrangement at corners with minimal cutting, maintaining dimensional accuracy and reducing manufacturing complexity and labor costs, while eliminating the need for mortar and lath materials.
Implementation Method 1
formed of cement and at least one of expanded polystyrene or expanded glass
Data Source
AI summary
A stone arrangement for a corner is provided which includes two stones for positioning at the corner, wherein one of the stones is provided with a curved corner and the second stone is provided with a sharp corner and wherein the stones have matching contours at a location where they abut so that the stones have improved aesthetic appearance. Further, the stones are formed to provide consistent dimensions when arranged at a corner so that stones extending further from the corner maintain intended dimensional tolerances.