Stone-look Architectural Blocks via Plaster Aggregate Finishing

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Solution Overview

Problem

Concrete blocks are often considered unsightly and industrial, making them less suitable for residential or business environments where a more aesthetic appearance is desired, despite their utility as a low-cost building material.

Innovation Solution

Architectural blocks are created by applying a plaster composition with a cementitious binder and aggregate components to a concrete block substrate, mimicking the appearance of cut stone, involving a manufacturing process that includes applying, leveling, curing, and finishing the plaster to expose crystal facets, and optionally sealing the surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If concrete blocks are used as building material, then cost is reduced and structural utility is provided, but aesthetic appearance deteriorates (industrial/unsightly appearance)

Engineering Contradiction:

ImprovecostVSAvoidappearance

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent applies composite materials by combining a concrete block substrate with a plaster composition coating. The concrete block provides structural integrity and cost-effectiveness, while the plaster composition with cementitious binder and aggregate materials provides the aesthetic appearance of cut stone. This composite structure resolves the contradiction by integrating both functional and aesthetic requirements in a single building element.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses copying by creating a plaster composition that replicates the appearance of natural cut stone on a concrete substrate. The plaster layer with specifically graded aggregate materials (limestone and silica) mimics the visual characteristics, texture, and crystal facets of real stone, allowing the building to achieve aesthetic goals without using expensive natural stone.

Inventive Principle:

Principle #26Copying

2Shape

If real cut stone is used to achieve aesthetic appearance, then appearance is improved, but cost increases and supply constraints arise

Engineering Contradiction:

ImproveappearanceVSAvoidcost

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent applies this principle by replacing expensive, limited natural stone with an affordable artificial plaster composition that can be mass-produced. The plaster coating on concrete blocks provides a cost-effective alternative that eliminates supply constraints associated with natural stone while maintaining the desired aesthetic appearance through careful formulation with aggregate materials.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent uses parameter changes by modifying the physical and chemical properties of the plaster composition, particularly the aggregate size distribution (D90 and D50 values for limestone and silica aggregates). By controlling these parameters, the plaster achieves the visual characteristics of cut stone including crystal facet appearance, while remaining a low-cost manufactured product.

Inventive Principle:

Principle #35Parameter changes

3Shape

If plaster composition is applied to concrete block, then aesthetic appearance is improved, but manufacturing process complexity increases

Engineering Contradiction:

ImproveappearanceVSAvoidmanufacturing process

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-mixing the plaster composition with specifically graded aggregate materials (limestone and silica aggregates in particular size ranges) before application. This pre-formulation ensures that when the plaster is applied to the concrete block and subsequently cured and finished, it automatically develops the desired cut stone appearance with crystal facets, reducing the need for complex post-processing steps.

Inventive Principle:

Principle #10Preliminary action

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 resulting architectural blocks provide a cost-effective, aesthetically pleasing alternative to real cut stone, offering the appearance of cut stone while reducing the limitations of cost, weight, and supply constraints associated with natural stone, while maintaining structural integrity.

Implementation Method 1

a cementitious binder component may include Portland cement, such as white cement or grey cement

Methodology Applied

Scientific EffectCement hydration: Chemical Bonding

Implementation Method 2

The finishing process beneficially abrades the coarse sand portion of the plaster to form and/or expose the crystal facets

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS11325279B2Architectural blocks with stone-like appearance and method of manufacture

Publication Date: 2022.05.10 TUSCAN STONEWORX USA LLC

AI summary

The present disclosure describes architectural blocks configured to give the appearance of real cut stone. A plaster composition may be applied to one or more surfaces of a block, such as a concrete masonry unit (CMU) to form an architectural block having the appearance of cut stone. The plaster composition includes a cementitious component, such as white Portland cement, a limestone aggregate component, and optionally an adhesive component. The limestone aggregate component includes a fine sand portion and a coarse sand portion that effectively enable the appearance of cut stone after finishing of the plaster surface via sanding and/or polishing.