US20160244976A1

US20160244976A1 - Simulated stone structures, insulative assemblies including the simulated stone structures, and related methods

Info

Publication number: US20160244976A1
Application number: US15/018,282
Authority: US
Inventors: Steve Gehring
Original assignee: Summit Stone Solutions LLC
Current assignee: Summit Stone Solutions LLC
Priority date: 2015-02-19
Filing date: 2016-02-08
Publication date: 2016-08-25

Abstract

A simulated stone structure comprises a simulated stone body, and at least one attachment structure embedded within and protruding from the simulated stone body. In addition, an insulative assembly comprises an insulative structure, an adhesive material overlying the insulative structure, and at least one simulated stone structure partially overlying the adhesive material and comprising a simulated stone body and at least one attachment structure embedded within the simulated stone body and extending from the simulated stone body, through the adhesive material, and into the insulative structure. A method of forming an insulative assembly is also described.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/118,356, filed Feb. 19, 2015, the disclosure of which is hereby incorporated herein in its entirety by this reference.

FIELD

The disclosure, in various embodiments, relates generally to simulated stone structures, to insulative assemblies including the simulated stone structures, and to related methods. More specifically, embodiments of the disclosure relate to simulated stone structures including embedded attachment structures, to insulated assemblies including such simulated stone structures, and to related methods.

BACKGROUND

Simulated stone (also referred to as “artificial stone” and “manufactured stone”) generally comprises a shaped concrete material including a hydraulic binder and at least one aggregate material (e.g., rock, gavel, sand, crushed fines, etc.). Simulated stone can be attached to one or more surface(s) of a structure (e.g., a building structure, such as a building wall) to provide the structure desirable properties, such as desirable aesthetic properties and/or desired structural properties. To improve the energy efficiency of the structure to be covered by the simulated stone, the simulated stone can be attached to insulative structures (e.g., insulative panels, such as polymeric foam panels) to form insulative assemblies, which may be secured (e.g., attached, coupled, etc.) to a surface of the structure.
Simulated stone has conventionally been secured to structures (e.g., building walls, insulative panels, etc.) using at least one adhesive (e.g., an adhesive mortar). Unfortunately, the weight of simulated stone often results in movement (e.g., settling, sliding, shifting, etc.) and/or detachment of the simulated stone before the adhesive completely cures, especially when environmental conditions (e.g., cold temperatures, moisture, etc.) prolong the cure time of the adhesive. To alleviate such problems, separate fixtures (e.g., clamps, through-bolts, lath, etc.) have been fastened to such structures (e.g., such building walls, such insulative panels, etc.) at predetermined locations and have then been used to hold and secure the simulated stone in position until the adhesive cures. However, such fixtures can require a significant amount of time and skilled labor to position and assemble on site, making it difficult to cover large areas of such structures with the simulated stone in a simple, efficient, and cost-effective manner.
Accordingly, there remains a need for new structures, assemblies, and methods facilitating the simple and efficient means of securing simulated stone to another structure.

BRIEF SUMMARY

In accordance with one embodiment described herein, a simulated stone structure comprises a simulated stone body, and at least one attachment structure embedded within and protruding from the simulated stone body.
In additional embodiments, an insulative assembly comprises an insulative structure, an adhesive material overlying the insulative structure, and at least one simulated stone structure partially overlying the adhesive material. The at least one simulated stone structure comprises a simulated stone body, and at least one attachment structure embedded within the simulated stone body and extending from the simulated stone body, through the adhesive material, and into the insulative structure
In additional embodiments, a method of forming an insulative assembly comprises forming a simulated stone structure comprising a simulated stone body and an attachment structure embedded within and protruding from the simulated stone body. An adhesive material is formed over at least one of an insulating structure and the simulated stone structure. The simulated stone structure is positioned over the insulating structure, the adhesive material and at least a portion of the attachment structure of the simulated stone structure intervening between the simulated stone structure and the insulating structure. The attachment structure of the simulated stone structure is driven into the insulating structure to form a preliminary insulative assembly. The preliminary insulative assembly is subjected to at least one curing process to substantially cure the adhesive material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a transverse cross-sectional view illustrating a simulated stone structure, in accordance with an embodiment of disclosure.

FIG. 2 is a bottom-up view of the simulated stone structure shown in FIG. 1.

FIG. 3 is a transverse cross-sectional view illustrating an insulative assembly, in accordance with an embodiment of disclosure.

DETAILED DESCRIPTION

Simulated stone structures are disclosed, as are insulative assemblies including the simulated stone structures, and related methods of forming the simulated stone structures and the insulative assemblies. In some embodiments, a simulated stone structure includes a simulated stone body, and at least one attachment structure embedded in and extending from the simulated stone body. The attachment structure is configured and positioned to secure the simulated stone body to another structure (e.g., an insulative structure) during and after formation of an assembly (e.g., an insulative assembly) including the simulated stone body and the other structure. The structures, assemblies, and methods of the disclosure may provide enhanced efficiency, reduced costs, energy code compliance, and/or increased durability relative to conventional structures, assemblies, and methods associated with siding operations.
The following description provides specific details, such as material compositions and processing conditions, in order to provide a thorough description of embodiments of the present disclosure. However, a person of ordinary skill in the art would understand that the embodiments of the disclosure may be practiced without employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional simulated stone structure fabrication techniques employed in the industry. In addition, the description provided below does not form a complete process flow for manufacturing a simulated stone structure or insulative assembly. Only those process acts and structures necessary to understand the embodiments of the disclosure are described in detail below. Additional acts to form a complete insulative assembly from the structures described herein may be performed by conventional fabrication processes.
Drawings presented herein are for illustrative purposes only, and are not meant to be actual views of any particular material, component, structure, device, or system. Variations from the shapes depicted in the drawings as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments described herein are not to be construed as being limited to the particular shapes or regions as illustrated, but include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as box-shaped may have rough and/or nonlinear features, and a region illustrated or described as round may include some rough and/or linear features. Moreover, sharp angles that are illustrated may be rounded, and vice versa. Thus, the regions illustrated in the figures are schematic in nature, and their shapes are not intended to illustrate the precise shape of a region and do not limit the scope of the present claims. The drawings are not necessarily to scale. Additionally, elements common between figures may retain the same numerical designation.
As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” and grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements or method steps, but also include the more restrictive terms “consisting of” and “consisting essentially of” and grammatical equivalents thereof. As used herein, the term “may” with respect to a material, structure, feature or method act indicates that such is contemplated for use in implementation of an embodiment of the disclosure and such term is used in preference to the more restrictive term “is” so as to avoid any implication that other, compatible materials, structures, features and methods usable in combination therewith should or must be, excluded.
As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
As used herein, “and/or” includes any and all combinations of one or more of the associated listed items.
As used herein, spatially relative terms, such as “beneath,” “below,” “lower,” “bottom,” “above,” “upper,” “top,” “front,” “rear,” “left,” “right,” and the like, may be used for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Unless otherwise specified, the spatially relative terms are intended to encompass different orientations of the materials in addition to the orientation depicted in the figures. For example, if materials in the figures are inverted, elements described as “below” or “beneath” or “under” or “on bottom of” other elements or features would then be oriented “above” or “on top of” the other elements or features. Thus, the term “below” can encompass both an orientation of above and below, depending on the context in which the term is used, which will be evident to one of ordinary skill in the art. The materials may be otherwise oriented (e.g., rotated 90 degrees, inverted, flipped, etc.) and the spatially relative descriptors used herein interpreted accordingly.
As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0% met, at least 95.0% met, at least 99.0% met, or even at least 99.9% met.
As used herein, the term “about” in reference to a given parameter is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the given parameter).
FIG. 1 is a transverse cross-sectional view illustrating a simulated stone structure 100, in accordance with an embodiment of the disclosure. The simulated stone structure 100 includes a simulated stone body 102 and attachment structures 108 embedded within and extending from the simulated stone body 102. In some embodiments, the attachment structures 108 longitudinally extend from the simulated stone body 102. As used herein, each of the terms “longitudinal” and “vertical” means and includes extending in a direction substantially perpendicular to the simulated stone body 102, regardless of the orientation of the simulated stone body 102. Accordingly, as used herein, each of the terms “lateral” and “horizontal” means and includes extending in a direction substantially parallel to the simulated stone body 102, regardless of the orientation of the simulated stone body 102. In additional embodiments, one or more of the attachment structures 108 may extend both longitudinally and laterally from the simulated stone body 102 (e.g., one or more of the attachment structures 108 may extend diagonally from the simulated stone body 102). FIG. 2 is a bottom-up view of the simulated stone structure 100.
The simulated stone body 102 may be formed of and include a material suitable for use as a siding (e.g., an exterior siding, an interior siding) for at least one of a building (e.g., a domestic building, a commercial building, etc.) and an interior structure (e.g., hearth, mantle, backsplash, etc.) of a building. The simulated stone body 102 may, for example, be formed of and include a composite material including a cement matrix, aggregate (e.g., rock, gavel, sand, crushed fines, etc.), and, optionally, one or more additional materials (e.g., pigments, curatives, hardeners, other additives, etc.). In some embodiments, the composite material is a relatively light density (e.g., within a range of from about 1 pound per square foot to about 30 pounds per square foot) cement aggregate material.
The simulated stone body 102 may exhibit any desired geometric configuration (e.g., shape and size). The simulated stone body 102 may, for example, exhibit a shape and a size that resembles (e.g., imitates, simulates, emulates, etc.) brick, fieldstone, slate, or any type of natural stone that may be used as an exterior building material and/or as an interior building material. By way of non-limiting example, referring collectively to FIGS. 1 and 2, the simulated stone body 102 may exhibit a generally rectangular shape including a top surface 104, a bottom surface 106 (FIG. 1), opposing sides 105, and opposing ends 107 (FIG. 2). In additional embodiments, the simulated stone body 102 may exhibit a different shape, such as a conical shape, a pyramidal shape, a cubic shape, a cuboidal shape, a spherical shape, a hemispherical shape, a cylindrical shape, an annular shape, a semi-cylindrical shape, truncated versions thereof (e.g., a frusto-conical shape), or an irregular shape. Irregular shapes include complex shapes, such as complex shapes exhibited by natural stone.
The attachment structures 108 are positioned (e.g., longitudinally positioned, laterally positioned, etc.) and configured to attach the simulated stone body 102 to at least one additional structure (e.g., a foam structure, such as a foam insulating panel), as described in further detail below. The attachment structures 108 may, for example, be configured and positioned to support the weight of the simulated stone body 102 and to secure the simulated stone body 102 to the additional structure at least for a sufficient period of time for an adhesive provided between the simulated stone body 102 and the additional structure to cure. Securing the simulated stone body 102 to the additional structure using the attachment structures 108 may prevent undesirable movement and/or detachment of the simulated stone body 102 that may otherwise occur if the attachment structures 108 were absent from (e.g., not included in) the simulated stone structure 100.
As shown in FIG. 1, portions of the attachment structures 108 may be embedded within the simulated stone body 102, and other portions of the attachment structures 108 may protrude (e.g., project, extend, etc.) beyond the bottom surface 106 of the simulated stone body 102. The depth to which each of the attachment structures 108 extends within the simulated stone body 102 at least partially depends on the configuration (e.g., material composition, size, shape, etc.), orientation, and lateral position of the attachment structure 108, on the configuration of the simulated stone body 102, and on the configuration, orientation, and lateral position of each other of the attachment structures 108. The attachment structures 108 may independently extend to one or more depths within the simulated stone body 102 ensuring that the attachment structures 108 will not undesirably separate (e.g., detach, dislodge, etc.) from the simulated stone body 102 during use and operation of the simulated stone structure 100. In some embodiments, each of the attachment structures 108 independently extends at least about 10 percent (e.g., at least about 25 percent, least about 33 percent, at least about 50 percent, at least about 66 percent, at least about 75 percent, etc.) of the way through a maximum thickness T of the simulated stone body 102. In additional embodiments, each of the attachment structures 108 independently extends to a depth at least about 0.25 inch (e.g., at least about 0.5 inch) from the bottom surface 106 of the simulated stone body 102.
Each of the attachment structures 108 may extend to substantially the same depth within the simulated stone body 102, or at least one of the attachment structures 108 may extend to a different depth within the simulated stone body 102 than at least one other of the attachment structures 108. For example, a first of the attachment structures 108 may extend to a shallower depth within the simulated stone body 102 than a second of the attachment structures 108 (i.e., the second of the attachment structures 108 may extend deeper into the simulated stone body 102 than the first of the attachment structures 108). In some embodiments, each of the attachment structures 108 extends to substantially the same depth within the simulated stone body 102.
Each of the attachment structures 108 may independently exhibit a desired orientation relative to the simulated stone body 102. Each of the attachment structures 108 exhibits substantially the same orientation relative to the simulated stone body 102, or at least one of the attachment structures 108 may exhibit a different orientation relative to the simulated stone body 102 than at least one other of the attachment structures 108. For example, a first of the attachment structures 108 may exhibit a first orientation (e.g., a perpendicular orientation) relative to the simulated stone body 102, and a second of the attachment structures 108 may exhibit a second, different orientation (e.g., a diagonal orientation) relative to the simulated stone body 102. In some embodiments, each of the attachment structures 108 is oriented substantially perpendicular to the simulated stone body 102. In additional embodiments, each of the attachment structures 108 is oriented diagonal to the simulated stone body 102. In further embodiments, some of the attachment structures 108 are oriented substantially perpendicular to the simulated stone body 102, and other of the attachment structures 108 are oriented diagonal to the simulated stone body 102.
Each of the attachment structures 108 may independently exhibit a shape and a size configured to attach and secure the simulated stone body 102 to at least one additional structure. For example, as shown in FIG. 1, one or more of the attachment structures 108 include a head region 110 and a stem region 112. The head region 110 may be completely embedded within the simulated stone body 102, and the stem region 112 may be partially embedded within the simulated stone body 102 and partially outside of the simulated stone body 102. The head region 110 and the stem region 112 may be integral and continuous with one another, and may each independently exhibit a desired shape (e.g., a cylindrical shape, a rectangular shape, a conical shape, a pyramidal shape, a cubic shape, a cuboidal shape, a spherical shape, a hemispherical shape, a semi-cylindrical shape, truncated versions thereof, an irregular shape, etc.) and a desired size. As shown in FIG. 1, the head region 110 may extend outwardly beyond a lateral periphery (e.g., outer sidewalls) of the stem region 112. In addition, as also shown in FIG. 1, an upper portion of the stem region 112 may extend upwardly and inwardly to an apex 114 (e.g., a pointed tip). The apex 114 may assist with driving the attachment structure 108 into another structure (e.g., an insulative structure), as described in further detail below. Furthermore, as depicted in FIG. 1, the stem region 112 may, optionally, exhibit at least one textured (e.g., grooved, ringed, threaded, spiraled, notched, barbed, etc.) section 115. The textured section 115 may assist with securing (e.g., anchoring) the attachment structure 108 (and, hence, the simulated stone body 102) to another structure. In some embodiments, the textured section 115 comprises a barbed tip of the stem region 112. In additional embodiments, the textured section 115 comprises at least one of a grooved region, a ringed region, a threaded region, a spiraled region, and a notched region of the stem region 112. In further embodiments, at least one of the textured section 115 of the stem region 112 (e.g., the steam region 112 may be substantially smooth), the apex 114 of the stem region 112, and the head region 110 may be absent (e.g., omitted) from one or more of the attachment structures 108. In some embodiments, the attachment structures 108 comprise at least one of nails, screws, rivets, bolts, studs, pins, and staples.
Each of the attachment structures 108 may independently be formed of and include a material capable of a retaining the attachment structure 108 (and, hence, the simulated stone body 102) in position against a surface of another structure. For example, each of the attachment structures 108 may independently be formed of and include at least one of a metal material (e.g., a metal, a metal alloy, etc.), polymer material (e.g., a plastic), and a ceramic material. In some embodiments, each of the attachment structures 108 is independently formed of and includes at least one of a metal and a metal alloy (e.g., steel).
Each of the attachment structures 108 may be substantially the same, or at least one of the attachment structures 108 may be different than at least one other of the attachment structures 108. For example, each of the attachment structures 108 may have substantially the same shape, size, and material composition, or at least one of the attachment structures 108 may have a different shape, a different size, and/or a different material composition than at least one other of the attachment structures 108. In some embodiments, each of the attachment structures 108 is substantially the same as each other of the attachment structures 108. In additional embodiments, each of the attachment structures 108 exhibits substantially the same material composition, but at least one of the attachment structures 108 exhibits a different size and/or a different shape than at least one other of the attachment structures 108. In further embodiments, each of the attachment structures 108 exhibits substantially the same shape, but at least one of the attachment structures 108 exhibits a different material composition and/or a different size than at least one other of the attachment structures 108. In yet further embodiments, each of the attachment structures 108 exhibits a different shape, a different size, and a different material composition than each other of the attachment structures 108.
The simulated stone structure 100 may be formed of and include any quantity and any distribution (e.g., pattern) of the attachment structures 108 facilitating the at least temporarily attachment of the simulated stone body 102 to at least one additional structure (e.g., insulative structure, such as an insulative foam panel). The quantity and the distribution of the attachment structures 108 may at least partially depend on the configurations (e.g., material compositions, shapes, sizes, etc.) of the simulated stone body 102. The quantity and the distribution of the attachment structures 108 may also at least partially depend on the configurations of additional materials and structures (e.g., adhesive materials, insulative structures, etc.) to which the simulated stone structure 100 is to be attached, as described in further detail below. In some embodiments, the simulated stone structure 100 exhibits at least one of the attachment structures 108 for every two (2) square inches (in²) of the bottom surface 106 of the simulated stone body 102. The attachment structures 108 may be symmetrically distributed across the simulated stone body 102, or may be asymmetrically distributed across the simulated stone body 102. In some embodiments, the simulated stone structure 100 includes at least two attachment structures 108 symmetrically distributed across the simulated stone body 102. By way of non-limiting example, as shown in FIG. 2, the simulated stone structure 100 may include five (5) of the attachment structures 108 of symmetrically distributed across the simulated stone body 102 (e.g., four of the attachment structures 108 proximate four corners of the simulated stone body 102, and one of the attachment structures 108 proximate a center of the simulated stone body 102). In additional embodiments, the simulated stone structure 100 may include a different quantity of the attachment structures 108 (e.g., a different odd number of the attachment structures 108, or an even number of the attachment structures 108), and/or may exhibit an asymmetric distribution of the attachment structures 108. Moreover, while various embodiments herein describe the simulated stone structure 100 as including a plurality of attachment structures 108 (i.e., more than one attachment structure 108), the simulated stone structure 100 may, alternatively, include a single attachment structure 108 embedded in and protruding from the simulated stone body 102 at a desired lateral position along the simulated stone body 102.
As described in further detail below, the simulated stone structure 100 may be formed by forming a preliminary composition, forming (e.g., molding) the preliminary composition into an at least partially uncured simulated stone body exhibiting a desired geometric configuration, providing the attachment structures 108 into the at least partially uncured simulated stone body to form a preliminary simulated stone structure, and then curing (e.g., setting) the preliminary simulated stone body of the preliminary simulated stone structure to form the simulated stone structure 100. With the description as provided below, it will be readily apparent to one of ordinary skill in the art that the method described herein may be used in various applications. In other words, the method may be used whenever it is desired to form a simulated stone structure (e.g., the simulated stone structure 100) exhibiting a desired configuration (e.g., desired components, desired component arrangements, desired material compositions, desired shapes, desired sizes, etc.).
The preliminary composition may be a composition (e.g., mixture, slurry, etc.) formulated to provide the simulated stone body 102 to be formed therefrom with desired material properties. For example, the components (e.g., ingredients, such as cement matrix, aggregate, water, pigments, processing aids, etc.) and component ratios of the preliminary composition may be selected to provide the simulated stone body 102 with at least one of a pre-determined density, weight, hardness, compressive strength, tensile strength, flexural strength, absorptivity, and freeze thaw. Material properties of the simulated stone body 102 may, for example, be determined based on American Society for Testing and Materials (ASTM) standards, such as one or more of ASTM C567, ASTM C39, ASTM C190, ASTM C348, and ASTM C67. The preliminary composition may be formed using conventional processes (e.g., conventional material addition and mixing processes) and conventional processing equipment, which are not described in detail herein.
The preliminary composition may be formed into the at least partially uncured simulated stone body by providing (e.g., delivering, depositing, etc.) the preliminary composition into at least one mold structure having a geometric configuration complementary to a desired geometric configuration of the simulated stone body 102. For example, the preliminary composition may be delivered into a cavity of the mold structure having a shape and size that mirrors a desired shape and a desired size of the simulated stone body 102. In some embodiments, the preliminary composition may then be partially cured within the mold structure to form the at least partially uncured simulated stone body. The at least partially uncured simulated stone body exhibits material properties sufficient to facilitate the placement and suspension of the attachment structures 108 within the at least partially uncured simulated stone body. The material properties of the at least partially uncured simulated stone body also allow the attachment structures 108 to maintain a desired orientation within the at least partially uncured simulated stone body with or without the assistance of an additional support structure. The preliminary composition may be partially cured within the structure by subjecting the preliminary composition to at least one of elevated temperature(s) and elevated pressure(s) for a sufficient period of time to form the at least partially uncured simulated stone body exhibiting desired material properties. In additional embodiments, the preliminary composition may already exhibit material properties sufficient to facilitate the placement and suspension of the attachment structures 108 therein, and so the at least partially uncured simulated stone body may be formed from the preliminary composition without substantially employing a curing process (e.g., without subjecting the preliminary composition to at least one of elevated temperature(s) and elevated pressure(s)).
Next, the attachment structures 108 may be provided (e.g., embedded) into the at least partially uncured simulated stone body to form the preliminary simulated stone structure. The attachment structures 108 may each independently be provided into the at least partially uncured simulated stone body to any longitudinal depth, in any orientation (e.g., an orientation substantially perpendicular to the uncured simulated stone body, an orientation diagonal to the uncured simulated stone body, etc.), and in any lateral arrangement selected for the simulated stone structure 100 to be formed therefrom. At least one of an automated process (e.g., a process utilizing one or more apparatuses under computer number control) and a non-automated process (e.g., a hand placement process) may be used to provide the attachment structures 108 into the at least partially uncured simulated stone body.
Following the formation of the preliminary simulated stone structure, the preliminary simulated stone structure may be subjected to at least one curing process to form the simulated stone structure 100. The curing process may include subjecting the preliminary simulated stone structure to at least one of elevated temperature(s) and elevated pressure(s) (e.g., using a curing apparatus, such as a autoclave, a compression mold, etc.) for a sufficient period of time to provide the simulated stone structure 100 with desired material properties (e.g., density, weight, hardness, compressive strength, tensile strength, flexural strength, absorptivity, freeze thaw, etc.). The curing process may provide the simulated stone structure 100 sufficient mechanical integrity to be handled. As a non-limiting example, if the preliminary simulated stone structure is substantially uncured, the curing process may include exposing the preliminary simulated stone structure and the mold structure to at least one temperature less than or equal to about 175° C. and at least one pressure less than or equal to about 100 pounds per square inch (psi) for a sufficient period of time to form the simulated stone structure 100. The simulated stone structure 100 may then be removed from the mold structure and utilized as desired. The mold structure and the preliminary simulated stone structure may, optionally, be provided into a vacuum bag prior to performing the curing process. Alternatively, if the preliminary simulated stone structure exhibits sufficient mechanical integrity, the curing process may include removing the preliminary simulated stone structure from the mold structure, placing the preliminary simulated stone structure on a tool configured to hold the preliminary simulated stone structure, and then exposing the preliminary simulated stone structure and the tool to the aforementioned temperature and pressure for a sufficient period of time to form the simulated stone structure 100. The simulated stone structure 100 may then be removed from the tool and utilized as desired. The tool and the preliminary simulated stone structure may, optionally, be provided into a vacuum bag prior to performing the curing process.
FIG. 3 is a transverse cross-sectional view of an insulative assembly 200, in accordance with an embodiment of the disclosure. The insulative assembly 200 may include an insulating structure 202 (e.g., an insulating panel), an adhesive material 204 on or over the insulating structure 202, and simulated stone structures 206 on or over the adhesive material 204. One of more of the simulated stone structures 206 may be substantially similar to the simulated stone structure 100 previously described herein with reference to FIGS. 1 and 2. The insulative assembly 200 may, for example, comprise an insulative assembly for at least one of an exterior and an interior of a building (e.g., a domestic building, a commercial building, etc.).
The insulating structure 202 may be formed of and include at least one thermally insulative material, such as an insulative foam material. Suitable insulative foam materials include, but are not limited to, closed-cell polymeric foam materials, such as expanded polystyrene foam (EPS) (e.g., molded expanded polystyrene foam, extruded expanded polystyrene foam, etc.), polyisocyanurate (PIR) foam, polyethylene foam, polyurethane foam, polypropylene foam, polyester foam, polyvinyl chloride foam, polyacrylonitrile foam, polyamide foam, polyimide foam, a fluoropolymer foam, a polysilicon foam, or combinations thereof. In some embodiments, the insulating structure 202 is formed of and includes EPS.
The insulating structure 202 may exhibit any desired geometric configuration (e.g., shape and size). The insulating structure 202 may, for example, exhibit a shape and a size configured to at least partially cover at least one of an exterior surface and an interior surface of a building. The insulating structure 202 may exhibit a shape and a size commentary to (e.g., substantially similar to) a shape and a size of at least a portion of the exterior surface and/or the interior surface of the building. In some embodiments, the insulating structure 202 exhibits a generally rectangular shape. In additional embodiments, the insulating structure 202 may exhibit a different shape, such as a conical shape, a pyramidal shape, a cubic shape, a cuboidal shape, a spherical shape, a hemispherical shape, a cylindrical shape, an annular shape, a semi-cylindrical shape, truncated versions thereof (e.g., a frusto-conical shape), or an irregular shape. Irregular shapes include complex shapes, such as complex shapes exhibited by an exterior of a building and/or an interior of a building.
The insulating structure 202 may be forming using conventional processes (e.g., conventional molding processes, conventional extrusion processes, conventional machining processes, etc.) and conventional processing equipment, which are not described in detail herein.
The adhesive material 204 may be formed of at least one material formulated to adhere the insulating structure 202 and the simulated stone structures 206 to one another. The adhesive material 204 may be selected at least partially based on the material compositions of the insulating structure 202 and the components of the simulated stone structures 206 adjacent thereto. By way of non-limiting example, the adhesive material 204 may comprise at least one of a thinset cement (e.g., adhesive mortar) material, an acrylic adhesive material, and an epoxy adhesive material. In some embodiments, the adhesive material 204 comprises thinset cement.
Each of the simulated stone structures 206 may be configured at least partially based on the configurations of each other of the simulated stone structures 206 to provide the insulative assembly 200 with desired properties (e.g., aesthetic properties, structural properties, etc.). For example, each of the simulated stone structures 206 may be configured and positioned relative to each other of the simulated stone structures 206 to facilitate the formation of a simulated stone façade 214 that resembles (e.g., imitates, simulates, emulates, etc.) a wall formed of and including brick, fieldstone, slate, and/or any type of natural stone. The components and component arrangement of at least one of the simulated stone structures 206 may be substantially similar to components and component arrangement of the simulated stone structure 100 previously described with respect to FIGS. 1 and 2. For example, at least one of the simulated stone structures 206 may be formed of and include a simulated stone body 208 and attachment structures 212 configured, oriented, and positioned substantially similar to the simulated stone body 102 (FIGS. 1 and 2) and the attachment structures 108 (FIGS. 1 and 2), respectively.
As shown in FIG. 3, the attachment structures 212 of the simulated stone structures 206 may extend through the adhesive material 204 and into to the insulating structure 202. The attachment structures 212 may assist the adhesive material 204 in attaching (e.g., coupling, affixing, bonding, etc.) the simulated stone body 208 of each of the simulated stone structures 206 to the insulating structure 202. The depth to which each of the attachment structures 212 extends within the insulating structure 202 at least partially depends on the configuration, orientation, and lateral position of the attachment structure 212, on the configuration of the insulating structure 202, and on the configuration, orientation, and lateral position of each other of the attachment structures 212. The attachment structures 212 may independently extend to one or more depths within the insulating structure 202. In some embodiments, each of the attachment structures 212 independently extends at least about 10 percent (e.g., at least about 25 percent, at least about 33 percent, at least about 50 percent, at least about 66 percent, at least about 75 percent, etc.) of the way through a maximum thickness of the insulating structure 202. In additional embodiments, each of the attachment structures 212 independently extends to a depth at least about 0.25 inch (e.g., at least bout 0.5 inch) from the surface of the insulating structure 202 adjacent the adhesive material 204.
Each of the attachment structures 212 may extend to substantially the same depth within the insulating structure 202, or at least one of the attachment structures 212 may extend to a different depth within the insulating structure 202 than at least one other of the attachment structures 212. For example, a first of the attachment structures 212 may extend to a shallower depth within the insulating structure 202 than a second of the attachment structures 212 (i.e., the second of the attachment structures 212 may extend deeper into the insulating structure 202 than the first of the attachment structures 212). The first of the attachment structures 212 and the second of the attachment structures 212 may be components of the same simulated stone structure 206 (e.g., may be each embedded in the same simulated stone body 208), or may be components of different simulated stone structures 206 (e.g., may be embedded in different simulated stone bodies 208). In some embodiments, each of the attachment structures 212 extends to substantially the same depth within the insulating structure 202.
Each of the attachment structures 212 may exhibit substantially the same orientation relative to the insulating structure 202, or at least one of the attachment structures 212 may exhibit a different orientation relative to the insulating structure 202 than at least one other of the attachment structures 212. For example, a first of the attachment structures 212 may exhibit a first orientation (e.g., a perpendicular orientation) relative to the insulating structure 202, and second of the attachment structures 212 may exhibit a second, different orientation (e.g., a diagonal orientation) relative to the insulating structure 202. The first of the attachment structures 212 and the second of the attachment structures 212 may be components of the same simulated stone structure 206 (e.g., may be each embedded in the same simulated stone body 208), or may be components of different simulated stone structures 206 (e.g., may be embedded in different simulated stone bodies 208). In some embodiments, each of the attachment structures 212 is oriented substantially perpendicular to the insulating structure 202. In additional embodiments, each of the attachment structures 212 is oriented diagonal to the insulating structure 202. In further embodiments, some of the attachment structures 212 are oriented substantially perpendicular to the insulating structure 202, and other of the attachment structures 212 are oriented diagonal to the insulating structure 202.
Each of the simulated stone structures 206 may be substantially the same, or at least one of the simulated stone structures 206 may be different than at least one other of the simulated stone structures 206. For example, each of the simulated stone structures 206 may have substantially the same shape, size, and material composition, or at least one of the simulated stone structures 206 may have a different shape, a different size, and/or a different material composition than at least one other of the simulated stone structures 206. In some embodiments, each of the simulated stone structures 206 is substantially the same as each other of the simulated stone structures 206. For example, the simulated stone body 208 of each of the simulated stone structures 206 may be substantially the same as (e.g., exhibit substantially the same shape, size, and material composition) each other of the simulated stone structures 206, and the attachment structures 212 of each of the simulated stone structures 206 may be substantially the same (e.g., exhibit substantially the same shape, size, material composition, orientation, lateral distribution, and embedded depth) as each other of the simulated stone structures 206. In additional embodiments, the simulated stone body 208 of at least one of the simulated stone structures 206 may be different than (e.g., exhibit a different shape, a different size, and/or a different material composition) than at least one other of the simulated stone structures 206, and/or at least one of the attachment structures 212 of at least one of the simulated stone structures 206 may be different than (e.g., exhibit a different shape, a different size, a different material composition, a different orientation, a different lateral position, and/or a different embedded depth) than at least one of the attachment structures 212 of at least one other of the simulated stone structures 206.
The insulative assembly 200 may be formed of and include any quantity and any distribution (e.g., pattern) of the simulated stone structures 206. The quantity and the distribution of the simulated stone structures 206 may at least partially depend on the configuration (e.g., material composition, shape, size, etc.) of the insulating structure 202. The simulated stone structures 206 may be symmetrically distributed across the insulating structure 202, or may be asymmetrically distributed across the insulating structure 202. In some embodiments, the simulated stone structures 206 are asymmetrically distributed across the insulating structure 202. In addition, while various embodiments herein describe the insulative assembly 200 as including a plurality of simulated stone structures 206 (i.e., more than one simulated stone structure 206), the insulative assembly 200 may, alternatively, include a single simulated stone structure 206 attached to the insulating structure 202 at a desired position along the insulating structure 202.
Optionally, as shown in FIG. 3, the insulative assembly 200 may also include at least one additional simulated stone structure 216 (e.g., in addition to the simulated stone structures 206) that does not include one or more attachment structure(s). The additional simulated stone structure 216 may, for example, include a simulated stone body 218 substantially free of attachment structures embedded within and projecting (e.g., protruding, extending, etc.) therefrom. In some embodiments, the simulated stone body 218 is substantially similar to (e.g., exhibits substantially the same shape, size, and material composition) the simulated stone body 208 of at least one of the simulated stone structures 206, except that the attachment structures 212 are not present in the simulated stone body 218. The simulated stone body 218 may, for example, be substantially similar to the simulated stone body 102 previously described with respect to FIGS. 1 and 2, except that the attachment structures 108 are not present in the simulated stone body 218. In additional embodiments, the simulated stone body 218 is different than (e.g., exhibits a different shape, a different size, and/or a different material composition) the simulated stone body 208 of each of the simulated stone structures 206. Furthermore, if the insulative assembly 200 includes a plurality of the additional simulated stone structures 216, the additional simulated stone structures 216 may be substantially the same as one another, or at least one of the additional simulated stone structures 216 may be different than at least one other of the additional simulated stone structures 216. One or more of the simulated stone structures 206 may be provided adjacent the additional simulated stone structure(s) 216. Providing one or more of the simulated stone structures 206 adjacent the additional simulated stone structure(s) 216 may provide at least some support for (e.g., at least partially impede movement of) the additional simulated stone structure(s) 216.
As described in further detail below, the insulative assembly 200 may be fabricated (e.g., manufactured, formed, produced, etc.) by forming the simulated stone structures 206 (and, optionally, the additional simulated stone structure(s) 216), forming the adhesive material 204 over at least one surface of one or more of insulating structure 202 and the simulated stone structures 206 (and, optionally, the additional simulated stone structure(s) 216), positioning the simulated stone structures 206 (and, optionally, the additional simulated stone structure(s) 216) adjacent to the insulating structure 202 and driving (e.g., pushing, forcing, etc.) the attachment structures 212 of the simulated stone structures 206 into the insulating structure 202, and then substantially curing the adhesive material 204. With the description as provided below, it will be readily apparent to one of ordinary skill in the art that the method described herein may be used in various applications. In other words, the method may be used whenever it is desired to form an insulative assembly (e.g., the insulative assembly 200) exhibiting a desired configuration (e.g., desired components, desired component arrangements, desired material compositions, desired shapes, desired sizes, etc.).
Each of the simulated stone structures 206 may independently be formed according the methods previously described herein with reference to FIGS. 1 and 2. Each of the simulated stone structures 206 may be formed substantially simultaneously, or at least one of the simulated stone structures 206 may be formed after (e.g., in sequence with) at least one other of the simulated stone structures 206. Moreover, the additional simulated stone structure(s) 216, if any, may be formed using conventional processes and processing equipment, which are not described in detail herein.
The adhesive material 204 may be formed on or over one or more portions of at least one of the insulating structure 202 and the simulated stone structures 206 (and the additional simulated stone structures 216, if any). In some embodiments, the adhesive material 204 is formed on a surface of the insulating structure 202 and on surfaces of the simulated stone structures 206 (as well as on surfaces of the additional simulated stone structures 216, if any). The adhesive material 204 may be formed on the surface of the insulating structure 202 and on the surfaces of the simulated stone structures 206 simultaneously, sequentially, or a combination thereof. In additional embodiments, the adhesive material 204 is formed on a surface of the insulating structure 202, but is not formed on surfaces of the simulated stone structures 206 (or on surfaces the additional simulated stone structures 216, if any). In further embodiments, the adhesive material 204 is formed on surfaces of the simulated stone structures 206 (and on surfaces the additional simulated stone structures 216, if any), but is not formed on a surface of the insulating structure 202. The adhesive material 204 may be formed on or over one or more portions of at least one of the insulating structure 202 and the simulated stone structures 206 (and the additional simulated stone structures 216, if any) using at least one conventional deposition process. Suitable deposition processes include, but are not limited to, trowelling, spin coating, spray coating, brush coating, dip coating, immersion, soaking, and steeping. In some embodiments, the adhesive material 204 is trowelled on or over at least one surface of one or more of the insulating structure 202 and the simulated stone structures 206.
Next, the simulated stone structures 206 (and the additional simulated stone structures 216, if any) may be positioned relative to one or more locations along the insulating structure 202, and pressure may be applied to at least one of the insulating structure 202 and the simulated stone structures 206 to drive portions (e.g., pointed regions, parts of stem regions, etc.) of the attachment structures 212 of the simulated stone structures 206 into the insulating structure 202 and form a preliminary insulative assembly. The attachment structures 212 may each independently be provided (e.g., driven, forced, pushed, etc.) into the insulating structure 202 to any depth permitting the simulated stone structures 206 to remain attached to the insulating structure 202 during and after subsequent curing of the adhesive material 204 (described in further detail below). Providing the attachment structures 212 into the insulating structure 202 may form openings in the insulating structure 202 substantially filled by the attachment structures 212. The simulated stone structures 206 may be positioned and partially driven into the insulating structure 202 simultaneously, sequentially, or a combination thereof. At least one of an automated process (e.g., a process utilizing one or more apparatuses under computer number control) and a non-automated process (e.g., a hand placement process) may be used to position simulated stone structures 206 relative to locations along the insulating structure 202, and/or to the provide the attachment structures 212 of the simulated stone structures 206 into the insulating structure 202.
After forming the preliminary insulative assembly, the preliminary insulative assembly may be subjected to at least one curing process to form the insulative assembly 200. The curing process may include subjecting the preliminary insulative assembly to at least one of elevated temperature(s) and elevated pressure(s) for a sufficient period of time to cure the adhesive material 204. The curing process may enhance the bond strength between the insulating structure 202 and the simulated stone structures 206 (and the additional simulated stone structures 216, if any). As a non-limiting example, the curing process may include exposing the preliminary insulative assembly to at least one temperature less than or equal to about 175° C. and at least one pressure less than or equal to about 100 pounds per square inch (psi) for a sufficient period of time to form the insulative assembly 200. In some embodiments, the curing process is performed under ambient environmental conditions (e.g., ambient temperatures and ambient pressures). Following the curing process the insulative assembly 200 may be utilized as desired.
The simulated stone structures and methods of the disclosure may facilitate the fast, simple, and cost-effective production and customization of insulative assemblies for a wide variety of structures (e.g., buildings, such as domestic buildings and/or commercial buildings). For example, the simulated stone structures (including the embedded attachment structures thereof) and methods of the disclosure may provide a simple means of mitigating or even preventing undesirable movement of one of more components (e.g., simulated stone bodies) of an insulative assembly during formation and/or use of the insulative assembly relative to conventional simulated stone structures and methods. Embodiments of the disclosure may be used to quickly and reliably form an insulative assembly from an insulative structure and different simulated stone structures (e.g., simulated stone structures exhibiting different shapes, different sizes, and/or different material compositions than one another). The simulated stone structures and methods of the disclosure may improve the manufacturability and durability of insulative assemblies for a wide variety of structures as compared to conventional simulated stone structures and methods.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, the disclosure is not limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure as defined by the following appended claims and their legal equivalents.

Claims

What is claimed is:

1. A simulated stone structure, comprising:

a simulated stone body; and

at least one attachment structure embedded within and protruding from the simulated stone body.

2. The simulated stone structure of claim 1, wherein the at least one attachment structure is oriented substantially perpendicular to the simulated stone body.

3. The simulated stone structure of claim 1, wherein the at least one attachment structure partially extends through the simulated stone body, the at least one attachment structure extending at least about 10 percent of the way through a maximum thickness of the simulated stone body.

4. The simulated stone structure of claim 1, wherein the at least one attachment structure comprises:

a head region completely embedded within the simulated stone body; and

a stem region integral and continuous with the head region and partially embedded within the simulated stone body, the head region extending beyond a lateral periphery of the stem region.

5. The simulated stone structure of claim 4, wherein an upper portion of the stem region distal from the head region extends upwardly and inwardly to an apex.

6. The simulated stone structure of claim 4, wherein the stem region exhibits at least one textured section.

7. The simulated stone structure of claim 6, wherein the at least one textured section comprises at least one of a grooved section, a ringed section, a threaded section, a spiraled section, a notched section, and a barbed section.

8. The simulated stone structure of claim 4, wherein the stem region exhibits a barbed tip.

9. The simulated stone structure of claim 1, wherein the at least one attachment structure comprises a plurality of attachment structures.

10. The simulated stone structure of claim 9, wherein each of the plurality of attachment structures exhibits substantially the same geometric configuration, the same material composition, the same orientation, and the same embedded depth within the simulated stone body as each other of the plurality of attachment structures.

11. The simulated stone structure of claim 9, wherein at least one of the plurality of attachment structures exhibits at least one of a different geometric configuration, a different material composition, a different orientation, and a different embedded depth within the simulated stone body than at least one other of the plurality of attachment structures.

12. An insulative assembly, comprising:

an insulating structure;

an adhesive material overlying the insulative structure; and

at least one simulated stone structure partially overlying the adhesive material and comprising:

a simulated stone body; and

at least one attachment structure embedded within the simulated stone body and extending from the simulated stone body, through the adhesive material, and into the insulative structure.

13. The insulative assembly of claim 12, wherein the insulative structure comprises a closed-cell polymeric foam material.

14. The insulative assembly of claim 12, wherein the at least one attachment structure extends only partially through each of the simulated stone body and the insulating structure.

15. The insulative assembly of claim 12, wherein the at least one attachment structure comprises at least one of a nail, a screw, a rivet, a bolt, a stud, a pin, and a staple.

16. The insulative assembly of claim 12, wherein the at least one simulated stone structure comprises a plurality of simulated stone structures.

17. The insulative assembly of claim 16, wherein the at least one attachment structure of at least one of the plurality of simulated stone structures exhibits substantially the same geometric configuration, material composition, orientation, and embedded depth within the simulated stone body of the at least one of the plurality of simulated stone structures as the at least one attachment structure of at least one other of the plurality of simulated stone structures.

18. The insulative assembly of claim 16, wherein the at least one attachment structure of at least one of the plurality of simulated stone structures exhibits at least one of a different geometric configuration, a different material composition, a different orientation, and a different embedded depth within the simulated stone body of the at least one of the plurality of simulated stone structures than the at least one attachment structure of at least one other of the plurality of simulated stone structures.

19. The insulative assembly of claim 12, further comprising at least one additional simulated stone structure overlying the adhesive material and comprising another simulated stone body substantially free of attachment structures embedded therein.

20. A method of forming an insulative assembly, comprising:

forming a simulated stone structure comprising a simulated stone body and an attachment structure embedded within and protruding from the simulated stone body;

forming an adhesive material over at least one of an insulating structure and the simulated stone structure;

positioning the simulated stone structure over the insulating structure, the adhesive material and at least a portion of the attachment structure of the simulated stone structure intervening between the simulated stone structure and the insulating structure;

driving the attachment structure of the simulated stone structure into the insulating structure to form a preliminary insulative assembly; and

subjecting the preliminary insulative assembly to at least one curing process to substantially cure the adhesive material.