Title:
Decorative stone module
Kind Code:
A1


Abstract:
A decorative stone module comprising a backing panel having a peripheral contour, a decorative face and an opposing structure mounting face. The decorative stone is formed on the decorative face of the panel. The module is configured for mounting on a structure surface in a side-by-side fashion with other like modules thereby creating a decorative stone structure façade. The pre-cast artificial stone can have a cobblestone-like structure. Kits and methods for creating decorative stone structure façades using these modules are also disclosed.



Inventors:
Correia, Horacio (Quebec, CA)
Application Number:
11/190837
Publication Date:
02/01/2007
Filing Date:
07/28/2005
Primary Class:
International Classes:
E04F15/00
View Patent Images:



Primary Examiner:
EPPES, BRYAN L
Attorney, Agent or Firm:
Lavery, De Billy, LLP (Montreal, QC, CA)
Claims:
What is claimed is:

1. A decorative stone module comprising: a backing panel comprising a peripheral contour, a decorative face and an opposing structure mounting face; a decorative stone formed on said decorative face, wherein said module is configured to be mounted on a structure surface in a side by side fashion with other like said modules thereby creating a decorative stone structure façade.

2. A decorative stone module according to claim 1, wherein said backing panel comprises a generally rectangular configuration.

3. A decorative stone module according to claim 2, wherein said generally rectangular panel comprises two pairs of opposite sides, said opposite sides being configured to be mated with like opposite sides when assembling a plurality of like said module so as to create a decorative stone structure façade.

4. A decorative stone module according to claim 2, wherein said generally rectangular backing panel comprises at least one cut corner.

5. A decorative stone module according to claim 1, wherein said backing panel comprises a generally hexagonal configuration.

6. A decorative stone module according to claim 1, wherein when assembling a plurality of like said modules, said backing panels are positioned in a side-to-side fashion.

7. A decorative stone module according to claim 1, wherein said decorative stone covers at least a substantial portion of said decorative stone thereby providing for backing panel exposed portions.

8. A decorative stone module according to claim 1, wherein said decorative stone comprises a cross sectional relief comprising a first portion at one end thereof, a second portion at another end thereof and a generally downward sloped portion therebetween, said first portion having a height greater than the height of said second portion.

9. A decorative stone module according to claim 1, wherein said decorative stone emulates a cobblestone-like structure.

10. A decorative stone module according to claim 1, wherein said panel comprises an adhesive in said structure-engaging side.

11. A decorative stone module according to claim 7, wherein said panel is mountable to a structure via mounting elements drilled through said exposed portions.

12. A decorative stone module according to claim 1, wherein said structure surface is selected from the group consisting of a wall, a floor and ceiling.

13. A kit for covering a surface structure thereby creating a decorative stone façade, said kit comprising: a plurality of like decorative stone modules, each said module comprising: a backing panel comprising a peripheral contour and a decorative face and an opposing structure surface mounting face; and a decorative stone formed on said decorative face; and mounting elements for mounting said like modules to the surface structure wherein said like modules are configured to be mounted on the structure surface in a side-by-side fashion w thereby creating the decorative stone structure façade.

14. A kit according to claim 13, wherein said backing panel comprises a generally rectangular configuration.

15. A kit according to claim 14, wherein said generally rectangular panel comprises two pairs of opposite sides, said opposite sides being configured to be mated with like opposite sides when assembling a plurality of said like module so as to create the decorative stone structure façade.

16. A kit according to claim 15, wherein said generally rectangular backing panel comprises at least one cut corner.

17. A kit according to claim 13, wherein said backing panel comprises a generally hexagonal configuration.

18. A kit according to claim 13, wherein when assembling a plurality of like said modules, said backing panels are positioned in a side-by-side fashion.

19. A kit according to claim 13, wherein said decorative stone covers at least a substantial portion of said decorative stone thereby providing for backing panel exposed portions.

20. A kit according to claim 13, wherein said decorative stone comprises a cross sectional relief comprising a first portion at one end thereof, a second portion at another end thereof and a generally downward sloped portion therebetween, said first portion having a height greater than the height of said second portion.

21. A kit according to claim 13, wherein said decorative stone emulates a cobblestone-like structure.

22. A kit according to claim 13, wherein said, mounting elements comprise an adhesive spread on said panel structure surface engaging side.

23. A kit according to claim 19, wherein said mounting elements comprise surface engaging elements to be drilled through said exposed portions into said structure surface.

24. A kit according to claim 13, wherein said structure surface is selected from the group consisting of a wall, a floor and ceiling.

25. A method of building a decorative stone façade on a surface structure comprising: a) providing a plurality of decorative stone modules, each said module comprising: a backing panel comprising a peripheral contour and a decorative face and an opposing structure surface mounting face; and a decorative stone formed on said decorative face; and b) mounting the modules side-by-side on the structure surface.

26. A method according to claim 25, wherein said mounting comprises adding adhesive to the surface engaging side of the panel and then mounting the surface engaging side to the surface structure.

27. A method according to claim 25, wherein said panel comprises a generally rectangular configuration, said decorative stone covering a substantial part of said decorative face thereby providing baking panel exposed portions, said method further comprising cutting said exposed portions before said mounting.

Description:

FIELD OF THE INVENTION

The present invention relates to decorative structures for walls, floors and ceilings. More specifically, the present invention is concerned with a decorative stone module for building a decorative stone façade.

BACKGROUND OF THE INVENTION

Pre-fabricated panels that emulate natural stone surface structures are known in the art.

U.S. Pat. No. 4,218,496, issued to Savignac, teaches a laminated panel to be mounted to a surface; the panel is constructed from natural stone.

U.S. Pat. No. 4,325,177 issued to DePoorter teaches a panel having a main panel area that is randomly subdivided into smaller, variously sized and configured portions by grooves formed therein which are filled with solder.

International Patent Application having publication number WO 2004/033799 A1, teaches a decorative panel comprising a plurality of irregular shaped stone elements of the same or differing thickness embedded in a backing layer or base to form a tile or panel of a predetermined thickness. A flowable displacement material may be employed in the interstices between adjacent stone elements. The irregular space between adjacent stone elements of adjacent panels allows the formation of an optically seamless tiled surface.

A drawback with the prior art is that it does not provide a panel for a single stone element. Another drawback of the prior art is that it does not provide panels for pre-fabricated cobblestone like structures. A further drawback of the prior art is that the panels are not large enough to provide free spaces that can be worked on or that can receive materials thereon.

OBJECTS OF THE INVENTION

An object of the present invention is to provide an improved decorative stone module for building a decorative stone façade.

SUMMARY OF THE INVENTION

More specifically, in accordance with the present invention, there is provided a decorative stone module comprising:

a backing panel comprising a peripheral contour, a decorative face and an opposing structure mounting face; and

a decorative stone formed on the decorative face, wherein said module is configured to be mounted on a structure surface in a side by side fashion with other like said modules thereby creating a decorative stone structure façade.

In accordance with another aspect of the present invention, there is provided a kit for covering a surface structure thereby creating a decorative stone façade, the kit comprising:

a plurality of like decorative stone modules, each module comprising: a backing panel comprising a peripheral contour and a decorative face and an opposing structure surface mounting face; and a decorative stone formed on the decorative face; and

mounting elements for mounting the like modules to the surface structure

wherein said like modules are configured to be mounted on the structure surface in a side-by-side fashion thereby creating the decorative stone structure façade.

In an embodiment, the backing panel comprises a generally rectangular configuration. In an embodiment, the generally rectangular panel comprises two pairs of opposite sides, said opposite sides being configured to be mated with like opposite sides when assembling a plurality of like said module so as to create a decorative stone structure façade. In an embodiment, the generally rectangular backing panel comprises at least one cut corner backing panel comprises a generally hexagonal configuration. In an embodiment, when assembling a plurality of like said modules, the backing panels are positioned in a side-to-side fashion. In an embodiment, panel comprises an adhesive in said structure-engaging side.

In an embodiment, the decorative stone covers at least a substantial portion of said decorative stone thereby providing for backing panel exposed portions. In an embodiment, the decorative stone comprises a cross sectional relief comprising a first portion at one end thereof, a second portion at another end thereof and a generally downward sloped portion therebetween, said first portion having a height greater than the height of said second portion. In an embodiment, the decorative stone emulates a cobblestone-like structure. In an embodiment, the panel is mountable to a structure via mounting elements drilled through the exposed portions.

In an embodiment, the structure surface is selected from the group consisting of a wall, a floor and ceiling.

In accordance with a further aspect of the present invention, there is provided a method of building a decorative stone façade on a surface structure comprising:

a) providing a plurality of decorative stone modules, each module comprising: a backing panel comprising a peripheral contour and a decorative face and an opposing structure surface mounting face; and a decorative stone formed on the decorative face; and

b) mounting the modules side-by-side on the structure surface.

In an embodiment, the mounting step comprises adding adhesive to the surface engaging side of the panel and then mounting the surface engaging side to the surface structure. In an embodiment, the panel comprises a generally rectangular configuration, the decorative stone covering a substantial part of the decorative face thereby providing baking panel exposed portions, the method further comprising cutting these exposed portions before the mounting step.

Other objects, advantages and features of the present invention will become more apparent upon reading of the following non restrictive description of embodiments thereof, given by way of example only with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the appended drawings where like elements are referenced by like reference numerals and in which:

FIG. 1 shows a perspective view of a plurality of modules in accordance with the present invention;

FIG. 2 is a lateral view of a module in accordance to the present invention;

FIG. 3 is a top plan view of two side-by-side modules in accordance with another object of the present invention;

FIG. 4 is a plan view of two side-by-side modules in accordance with a further embodiment of the present invention.

DESCRIPTION OF THE EMBODIMENT

With reference to the appended drawings an embodiment of the invention will be herein described so as to exemplify the invention and not limit its scope.

FIG. 1 shows a plurality 10 of side-by-side stone modules 12.

As shown in FIG. 2, the modules 12 have a backing panel 14. The panel 14 includes a decorative face 16 on which a decorative stone 18 has been formed and an opposite structure mounting face 20. Each panel 14 is bounded by a peripheral contour. In this example panel 14 has a generally rectangular configuration and the peripheral contour thereof comprises opposites top and bottom sides 22 (see FIG. 1) and 24 and opposites lateral sides 26 and 28.

As shown in FIG. 2, the pre-cast artificial decorative stone 18 comprises a wavy relief “W” that emulates cobblestone for example. The wavy like relief “W” of the decorative stone 16 defines a decorative stone having a larger portion “L” near panel lateral side 84, a smaller portion “S” near lateral side 22 and a curved, concave-like slope “P” there between. It should be understood that the decorative block 18 can be provided a variety of a precast artificial stones in order to emulate various natural stones.

When assembling modules 12 to form a plurality 10 on a wall, floor or ceiling structure, the panels 14 are placed in a side-by-side fashion, in a plurality of side-by-side rows such as 30A, 30B, 30C and 30D. The modules 12 are placed in a given row by placing the lateral edges 26 and 28 of two adjacent modules such as 12A and 12B of FIG. 1 in a side-by-side fashion with the aforementioned sides 26 and 28 being placed flush with each other. Rows 3OA, 30B, 30C and 30D positioned together by placing the top and bottom edges 22 and 24 of two adjacent modules 12 such as modules 12C and 12D of rows 30A and 30B respectively, flush with one another. For a decorative effect emulating a real stone structure, two adjacent modules 12C and 12D are placed together with the lateral edges 26 and 28 of module 12C being offset with the lateral sides 26 and 28 of module 12D. Thereby, the adjacent rows such as 30A and 30B, 30C, and 30D, are placed in an offset fashion as shown in FIG. 1. As such, the modules 12 when assembled create a decorative stone structure façade such as a wall, a ceiling or a floor.

It should be noted that the modules 12 are positioned with their respective relief W being in the same general direction, so as to create a structure having a wave-like surface emulating a surface made from cobblestones or like stones.

The structure engaging side 20 of a panel 14 may have an adhesive material or an adhesive material may be added thereto.

As shown in FIG. 1 and FIG. 2, a top portions 16A of the panel 14 are exposed and hence mounting elements such as screws and the like can be drilled thereto for mounting on a surface structure.

After having mounted a plurality of modules 12 as illustrated in FIG. 1 on a given surface structure, the space between the decorative stones 18 that is defined by adjacent exposed portions 16A of panels 14 can be filed with a variety of materials such as mortar and the like or be left exposed.

The panels 14 may be any type of variety of panels such as wood, plastic, metal or any other type of convenient material. In one embodiment, hard material such as wood is used which permits the user to quickly place panels 14 in a side-by-side fashion as shown in FIG. 1.

The corners of panels 14 may be cut as shown in FIG. 3 thus defining sides 32A, 32B, 32C and 32D. In this way, panels 14 can be positioned as shown in FIG. 3 in with the side 32B of module 12E in contact with the side 32D of module 12F.

In a further embodiment shown in FIG. 4, modules 34A and 34B comprise circular-like prefabricated stones 36 defined on a generally hexagonal backing panels 38 having sides 40, 42, 44, 46, 48 and 50. These modules 34A and 34B can be placed in a side-by-side fashion as shown in FIG. 4 and are assembled in a similar fashion as the modules 12.

The invention also includes kits for building stone structure façades using the modules of the present invention as well as mounting elements.

It is to be understood that the invention is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The invention is capable of other embodiments and of being practised in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation. Hence, although the present invention has been described hereinabove by way of embodiments thereof, it can be modified, without departing from the spirit, scope and nature of the subject invention as defined in the appended claims.