Artificial Stone Siding with Integral Mounting Support
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Solution Overview
Problem
Existing artificial stone siding systems face challenges such as instability of larger stones, difficulty in outdoor installation due to weather conditions, and labor-intensive mortar application, requiring expertise and additional support methods like nails or screws.
Innovation Solution
An artificial stone siding product with a cement aggregate body and an integral mounting support that allows attachment to a wall using fasteners, eliminating the need for mortar and providing stability without the need for repositioning or additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mortar is used to attach artificial stones to the wall, then the stones can be held in place, but the installation becomes labor intensive and requires expertise in mixing and applying mortar
Solution Approach 1:
The patent extracts the attachment function from the mortar-based system and relocates it to an integrated metal support structure with built-in fastening mechanisms. The support structure includes pre-configured holes and anchoring features that eliminate the need for mortar application expertise and simplify the installation process while maintaining reliable stone attachment.
Solution Approach 2:
The patent introduces a metal support structure as an intermediary between the artificial stones and the wall. This support structure serves as a mediator that provides both mechanical attachment and structural stability, eliminating the need for direct mortar bonding and reducing installation complexity.
2Shape
If larger and heavier artificial stones are used, then the aesthetic appearance is improved, but the stones become unstable and may move or slide downward during installation
Solution Approach 1:
The patent employs metal support structures with anchoring mechanisms that counterbalance the weight of larger and heavier artificial stones. The support structure provides upward and lateral support forces that prevent the stones from sliding downward or moving during installation, regardless of their size or weight.
Solution Approach 2:
The patent replaces the gravity-dependent mortar bonding system with a mechanical fastening system. The metal support structure uses physical anchors, clips, or fasteners that mechanically secure the stones to the wall, providing stable positioning independent of the stones' weight or size.
3Reliability
If nails or screws are driven into the backing structure to hold stones in place, then additional support is provided, but the process becomes time-consuming and requires removal of fasteners after mortar sets
Solution Approach 1:
The patent incorporates fastening features directly into the metal support structure during manufacturing. The support structure includes pre-configured holes, anchoring points, or attachment mechanisms that are ready for immediate use during installation. This eliminates the need for separate fastening steps and removes the requirement to remove fasteners after mortar sets, as the integrated design allows for permanent attachment.
4Ease of manufacture
If mortar is used for outdoor wall construction, then the wall can be built, but cold, snowy, rainy, or damp weather interferes with mortar setting
Solution Approach 1:
The patent replaces the chemical curing process of mortar with a mechanical fastening system. The metal support structure with its integrated fastening mechanisms does not rely on chemical reactions that are sensitive to weather conditions. This allows for outdoor wall construction in cold, snowy, rainy, or damp weather without interfering with the attachment process.
Solution Approach 2:
The patent introduces a metal support structure as an intermediary that decouples the attachment process from weather-sensitive mortar curing. The support structure provides a weather-independent method for securing artificial stones to the wall, allowing installation to proceed regardless of outdoor weather conditions.
Data Source
AI summary
An artificial stone siding product for use as siding for homes, commercial buildings, and other structures, as well as for hearths, mantles, and other similar indoor structures, is provided. The artificial stone siding product includes a stone body cast of a cement aggregate and having an outer visible surface area shaped and colored to resemble real stone. An integral mounting support extends from at least one edge of the stone body. The mounting support allows the attachment of the artificial stone siding product to a surface of a wall using fasteners inserted through apertures defined by the support. The artificial stone siding product may be used to quickly and easily construct a stone wall by mounting a plurality of the artificial stone siding products to the exterior of a wall in much the same way as standard siding.