Title:
Simulated stone veneer architectural trim assembly
Kind Code:
A1


Abstract:
An architectural trim assembly includes a receptacle and a stone veneer trim piece having an orifice that is configured to hold the receptacle within the orifice.



Inventors:
Heath, Robert W. (Napa, CA, US)
Ferguson, Donald W. (Napa, CA, US)
Application Number:
11/320032
Publication Date:
06/28/2007
Filing Date:
12/28/2005
Primary Class:
International Classes:
E04C2/52
View Patent Images:
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Primary Examiner:
FIGUEROA, LUZ ADRIANA
Attorney, Agent or Firm:
ALSTON & BIRD LLP (CHARLOTTE, NC, US)
Claims:
What is claimed is:

1. An architectural trim assembly adapted for being secured against an opening in a wall having a junction box mounted in the opening, the architectural trim assembly comprising, in combination: a receptacle, and a simulated stone veneer trim piece having a simulated stone textured front face, a back face, and at least one orifice, the orifice being configured for allowing the receptacle to be mounted within the orifice.

2. The architectural trim assembly of claim 1, wherein the orifice has a geometry that substantially conforms to an exterior perimeter of the receptacle.

3. The architectural trim assembly of claim 3, wherein a passageway within the receptacle has a geometry suitable for receiving the junction box, and provides about a ⅛-inch gap or less between a perimeter of the orifice and the exterior perimeter of the receptacle.

4. The architectural trim assembly of claim 1, wherein the orifice has a depth sufficient to allow the receptacle to at least be temporarily held therein at least during the installation thereof.

5. The architectural trim assembly of claim 1, wherein a rear edge of the receptacle extends beyond the back face of the simulated stone veneer trim piece.

6. The architectural trim assembly of claim 1, wherein a front edge of the receptacle is adjacent to the front face of the simulated stone veneer trim piece, and a rear edge of the receptacle extends beyond the back face of the simulated stone veneer trim piece.

7. The architectural trim assembly of claim 1, in which receptacle is configured to enhance a load-carrying capability of the junction box.

8. The architectural trim assembly of claim 1, wherein the simulated stone veneer trim piece has a shape configured to allow for installation of the architectural trim assembly adjacent to additional simulated stone veneer products.

9. The architectural trim assembly of claim 8 in which the simulated stone veneer trim piece has a rectangular shape.

10. An architectural trim assembly adapted for being secured with mortar against an opening in a wall having a junction box mounted in the opening, the architectural trim assembly comprising, in combination: a receptacle, and a simulated stone veneer trim piece having a simulated stone textured front face, a back face, and at least one orifice, the orifice being configured for allowing the receptacle to be mounted within the orifice, wherein a top of the orifice is configured to hold the simulated stone veneer trim piece in place while the mortar cures.

11. The architectural trim assembly of claim 10 wherein the receptacle is configured to enhance a load-carrying capability of the junction box.

12. A method for installing an architectural trim assembly to a wall, the wall having an opening containing a junction box therein and having mortar applied to the wall and substantially surrounding the opening; the architectural trim assembly comprising a receptacle and a simulated stone veneer trim piece having an orifice therein; the method comprising: positioning the receptacle within the orifice of the simulated stone veneer trim piece, and temporarily holding the receptacle in place within the orifice; moving the simulated stone veneer trim piece to the wall, with the receptacle held in place in the orifice, and positioning a rear edge of the receptacle within the opening in the wall, with at least the rear edge of the receptacle substantially surrounding the junction box; positioning the simulated stone veneer trim piece against the mortar; and, allowing the mortar to set.

13. The method of claim 12, wherein the orifice substantially holds the receptacle in position within the simulated stone veneer trim piece as the architectural trim assembly is mounted adjacent the opening in the wall.

14. The method of claim 12, in which the receptacle assists in aligning and setting the simulated stone veneer trim piece against the wall.

15. The method of claim 12, in which the receptacle holds the simulated stone veneer trim piece in position against the wall while additional simulated stone veneer materials are installed on the wall adjacent to the architectural trim assembly.

16. The method of claim 12 in which a top of the orifice is positioned against a top of the receptacle to hold the simulated stone veneer trim piece in place while the mortar cures and/or other adjacent simulated stone veneer materials are placed in position.

17. The method of claim 12, wherein a front edge of the receptacle is adjacent to a front face of the simulated stone veneer trim piece, and the rear edge of the receptacle extends beyond a back face of the simulated stone veneer trim piece.

18. The method of claim 12, in which receptacle is configured to enhance a load-carrying capability of the junction box.

19. The method of claim 12, further including positioning the receptacle in the opening by resting a top of the receptacle against a top of the junction box and allowing a top of the orifice to rest against a top of the receptacle, whereby substantially no additional support is needed to hold the receptacle within the orifice while the mortar sets.

20. The method of claim 12, further including installing additional stone veneer materials adjacent to the architectural trim assembly.

Description:

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

The present invention relates to an architectural trim assembly made of a simulated stone veneer material.

BACKGROUND OF THE INVENTION

Simulated stone veneer products are manufactured, precast artificial stones that are similar in size, shape, texture and color to natural stone. The simulated stone veneer products are used as a lightweight veneer facing on masonry, and on metal framed or wood framed construction. The simulated stone veneer products can be used both for exterior applications such as building walls and for interior applications such as fireplaces.

The simulated stone veneer product is made from Portland cement, aggregate and mineral oxide colors, which is then cured. The simulated stone veneer products are usually lower in cost than the natural stones that they replace, yet provide an aesthetically pleasing appearance. One type of especially aesthetically pleasing simulated stone veneer product are the CULTURED STONE® products manufactured by the Cultured Stone Corporation, a division of Owens Corning, Napa, Calif. The CULTURED STONE® product line includes hundreds of precast simulated stone veneer products that replicate an extensive variety of sizes, shapes, textures, and colors of natural stone. The simulated stone veneer products are manufactured using molds taken from natural stones.

In the past, the architectural trim pieces made from simulated stone veneer materials have been difficult to install. The architectural trim pieces have been especially difficult to mount over electrical boxes already installed in walls. In particular, both the ease of installation and the stability of the architectural trim piece once positioned on the wall are critical. In the past, the installation process has been accompanied by excessive installer time, expense and inconvenience. Furthermore, in order to install the architectural trim piece in the field, the installers are often required to order special electrical box configurations, thereby adding installation time and cost to the installation process. Alternatively, the installers must carry a large inventory of specialty boxes and fittings at considerable inventory cost.

Thus, it is desirable to have a minimum number of universally useful architectural trim pieces on hand for immediate installation onto different electrical box systems. A minimal number of such architectural trim pieces is thus desirable from the logistics and inventory cost viewpoint in order to effectively and inexpensively install a reasonable amount of architectural trim pieces in a reasonable time.

While the others have attempted to develop architectural trim pieces capable of a comprehensive range of utilities, they have been deficient in providing effective architectural trim pieces as a convenience to the installers and as a quality product to the consumers.

SUMMARY OF THE INVENTION

An architectural trim assembly includes a simulated stone veneer trim piece and a receptacle mounted therein. The simulated stone veneer trim piece has a stone textured front face, a back, and one or more orifices for receiving the receptacle.

The architectural trim assembly is suitable for being secured against an opening in a wall having a junction box mounted therein.

Various advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view of one embodiment of an architectural trim assembly including a simulated stone veneer architectural trim piece having a receptacle mounted therein.

FIG. 2 cross-sectional view of the embodiment of the architectural trim assembly shown in FIG. 1 mounted to a wall having a junction box affixed thereto.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The architectural trim assembly 10 improves the installation of architectural trim pieces.

The architectural trim assembly 10 includes, in combination, a simulated stone veneer trim piece 20 and a receptacle 40. The architectural trim assembly 10 accordingly provides an installer with an assembly constructed with a minimum number of components, i.e., the simulated stone veneer trim piece 20 and the receptacle 40. The architectural trim assembly 10 reduces both material and labor costs which, in turn, also reduces installation and inventory costs both in initial installations and in lifetime use of the architectural trim assembly 10.

In one embodiment, the simulated stone veneer trim piece 20 comprises a lightweight concrete material having a mixture of Portland cement, lightweight aggregates and mineral oxides. In certain embodiments, the simulated stone veneer trim piece 20 is manufactured by introducing a castable material into a flexible layer having a mold cavity section and a support section. The castable material substantially fills the mold cavity section and is allowed to harden to form the simulated stone veneer trim piece. In order to remove the simulated stone veneer trim piece, the support section is restrained to prevent the support section from being flexed or stretched. Pressure is applied to the mold cavity section sufficient to cause the mold cavity section to be flexed or stretched, thereby causing the simulated stone veneer trim piece to be at least partially dislodged from the mold cavity section. It is to be understood that the trim veneer piece can be made in any suitable manner.

The simulated stone veneer trim piece 20 has an aesthetically pleasing appearance. The simulated stone veneer trim piece 20 can made to have various sizes, shapes, textures and colors, providing an appearance of various natural construction materials such as sandstone, limestone, bricks, stucco, masonry and other natural material finishes. The simulated stone veneer trim piece 20 is relatively thinner and lighter as compared to the natural stones that the trim piece replaces.

In certain embodiments, the simulated stone veneer trim piece 20 includes suitable mineral oxide colors to give the stone veneer material a desired color such as, for example, a taupe or gray color. Also, the simulated stone veneer trim piece can also be stained using a suitable concrete or masonry stain.

In certain embodiments, suitable simulated stone veneer trim pieces include the following types of materials that are made by Owens Coming: Cultured Brick® products, and Cultured Stone® products including Blended Textures, Carolina Ledgestone, Cobblefield®, Coral Stone, Country Ledgestone, Dressed Fieldstone, Driftstone, Drystack Ledgestone, European Castle Stone, Fieldstone, Limestone, Old Country Fieldstone, Pro-Fit® Ledgestone, River Rock, Rockface, Southern Ledgestone, Split Face, Stream Stone, Waterwash, Weather Edge Ledgestone, and other such products

In certain embodiments, the simulated stone veneer trim piece 20 has a rectangular or square shape to allow for easy installation of the architectural trim assembly 10 with surrounding simulated stone veneer products or other exterior surfaces. In other embodiments, the simulated stone veneer trim piece 20 can have other shapes including circular, or multi-sided such as hexagonal, octagonal and the like.

The simulated stone veneer trim piece 20 has a stone textured front face 22, a back face 24, and one or more orifices 26. In certain embodiments, the front face 22 can have additional aesthetically pleasing features such as chamfered edges 30 and a planar, or flat, recessed area 32 substantially surrounding the orifice 26. In certain embodiments, the front face 22 includes one or more inset grooved borders 36 which further provide an aesthetically pleasing appearance.

As shown in FIG. 2, the orifice 26 has a desired depth, or thickness, D which is defined as the distance between the front face 22 and the back face 24. In embodiments where the simulated stone veneer trim piece 20 includes the recessed area 32, the orifice 26 has a depth D which is defined as the distance between the recessed area 32 and the back face 24.

The orifice 26 can have any suitable geometric shape. In certain embodiments, the orifice 26 has a shape that generally conforms to standard receptacles 40, as further defined below. For example, the orifice 26 can have a square, rectangular or octagon shape. In the embodiment shown in the figures, the orifice 26 has a defined perimeter shape having a bottom B, sides S and top T. Also, in certain embodiments, the flat recessed area 32 surrounding the orifice is configured to accommodate any suitable receptacle covering 39.

In the embodiment shown in the figures, the one orifice 26 is substantially centered in the simulated stone veneer trim piece 20; however, in other embodiments, the simulated stone veneer trim piece 20 can include more than one orifice and/or the orifice(s) can be in a location other than the center of the simulated stone veneer trim piece 20.

Various types of receptacles 40 are useful in the architectural trim assembly 10 and can include most standard sized and shaped receptacles. In the embodiment shown in the figures, the receptacle 40 is generally depicted as an electrical extension box. The receptacle 40 includes a top 41, a bottom 42, and opposing sides 43 and 44 that define an exterior perimeter of the receptacle 40. The top 41, bottom 42, and sides 43 and 44 define a passageway 45 which allows the receptacle 40 to be axially positioned within the orifice 26, as further described below.

The passageway 45 in the receptacle 40 extends from a front edge 48 to a rear edge 49 of the receptacle 40 and has a geometry suitable for axially receiving a junction box 70, as shown in FIG. 2 and as further described below.

The receptacle 40 can include one or more tabs 46 which extend into the passageway 45 for allowing the junction box 70 to be secured to the receptacle 40. Each tab 46 can include a hole for receiving a screw 47 or other fastener for attaching the receptacle 40 to the junction box 70.

In certain embodiments, there is no more than about a ⅛-inch difference in the gap between the perimeter of the orifice 26 and the exterior perimeter of the receptacle 40. In certain embodiments, the receptacle 40 can be shimmed, if needed, to further hold the receptacle 40 in position within the orifice 26. The thickness, or depth, D of the orifice 26 is sufficiently thick so as to allow the receptacle 40 to be temporaily held in place within the orifice 26 at least during the installation thereof Once the receptacle 40 is positioned in the orifice 26, the receptacle 40 assists in aligning and setting the architectural trim assembly 10 in place against a wall 50.

FIG. 2 shows the architectural trim assembly 10 comprising, in combination, the simulated stone veneer trim piece 20 and the receptacle 40, secured against the wall 50. In certain embodiments, the wall 50 is shown as having a rigid back wall 52, a weather barrier material 54, a lath material 56, and a layer of mortar 58. In other embodiments, the wall can have a different suitable structure. The junction box 70 is then mounted within an opening 60 in the wall 50.

The receptacle 40 is held in position within the simulated stone veneer trim piece 20 as the architectural trim assembly 10 is mounted to the wall 50. The receptacle 40 is secured to the junction box 70 using a screw 47 extending through the tab 46. In the installed configuration, as shown in FIG. 2, the junction box 70 extends into the passageway 45 of the receptacle 40. A fixture 72 is operatively connected to the junction box 70. In certain embodiments, the fixture 72 can include, but is not limited to a light fixture, switch plate, security system, motion detection system, phone outlet, cable outlet, and the like.

The rear edge 49 of the receptacle 40 extends beyond the back face 24 of the simulated stone veneer trim piece 20 to allow the architectural trim product 10 to be aligned within the opening 60 in the wall 50. The receptacle 40 does not need to be separately held in place within the opening 60 while the simulated stone veneer trim piece 20 is mounted on the wall 50.

During certain installations, the top T of the orifice 26 rests against the top 44 of the receptacle 40 and the front edge 48 is adjacent to the front face 22 or recessed area 32, if present.

The simulated stone veneer trim piece 20 and the receptacle 40 are both held in a secure position adjacent the opening 60 by the mortar 58. The mortar 58 substantially surrounds the receptacle 40, thereby holding the receptacle 40 in a desired and aligned position against the wall 50 without the need for additional support while the mortar 58 cures or sets up. The mortar 58 also secures the simulated stone veneer trim piece 20 against the wall 50.

Also, in certain embodiments, the receptacle 40 holds the simulated stone veneer trim piece 20 in a desired position while adjacent simulated stone veneer materials 66 are installed on the wall 50. Optionally, the adjacent veneer materials 66 can rest on the simulated stone veneer trim piece 20 such that there is no need to plumb the adjacent simulated stone veneer materials 66.

The architectural trim assembly 10 is configured to accept standard punched-out, stamped electrical junction boxes 70. The architectural trim assembly 10 allows the mounted receptacle 40 to be directly attached at any desired mounting location. The architectural trim assembly 10 insures that the fixture 72 is installed in the wall 50 at the proper location and required distances and meets National Electrical Code (NEC) standards.

The architectural trim assembly 10 exploits the strength of the wall 50, including any fixture support studs (not shown), and the top wall and the side walls of the junction box 70. The receptacle 40 also enhances the load-carrying capability of the junction box 70. In certain embodiments, the receptacle 40, mounted within the simulated stone veneer trim piece 20, acts as an additional support for securing the fixture 72 to the wall 50. Thus, in certain embodiments, the architectural trim assembly 10 is configured to be able to carry at least some of the static and/or dynamic loading of the fixture 72; that is, the receptacle 40 is configured to carry at some of the static and dynamic loads that exist during the installation and throughout the useful life of the architectural trim assembly 10. The architectural trim assembly 10 has sufficient strength so that simulated stone veneer trim piece 20 and the receptacle 40 do not loosen when subjected to these static and/or dynamic loading forces.

The architectural trim assembly 10 is easily manufactured, has few components (i.e., the trim piece 20 and the receptacle 40), is easily assembled, and is easily installed with few steps required.

Mortar 58 is applied to the wall and substantially surrounding the opening 60 in the wall 50. The receptacle 40 is aligned within the orifice 26 in the simulated stone veneer trim piece 20 to form the architectural trim assembly 10. The architectural trim assembly 10 is moved to the wall and the receptacle 40 is brought into alignment with the junction box 70 that is within the opening 60 in the wall 50. The rear edge 49 of the receptacle 40 is axially moved over the junction box 70 until the front edge 48 of the receptacle 40 is substantially aligned with the front face 22 of the simulated stone veneer trim piece 20. The simulated stone veneer trim piece 20 is forced against the mortar 58. The mortar 58 is allowed to cure or set. In certain embodiments, the top T of the orifice 26 is positioned against the top 44 of the receptacle 40 to hold the simulated stone piece 20 in place while the mortar 58 cures and/or other adjacent simulated stone veneer materials 66 are placed in position.

EXAMPLES

Light Fixture Trim Assembly

A rectangular 8″×10″ light fixture stone veneer trim piece features a stone surface texture that is any one of the types of Cultured Stone® wall veneers, stucco, thin brick or other exterior finishes, as described herein. The Light Fixture Trim Assembly has chamfered edges and an inset grooved border design. The Light Fixture Trim Assembly accommodates both standard round fixture bases and rectangular bases up to 8″ height. In one embodiment, an octagon-shaped orifice is centered and accommodates a standard 3½″×1½″ octagon extension box-type receptacle. An extension box-type receptacle is used in aligning and setting the simulated stone veneer trim piece in place.

Single Outlet Trim Assembly

A Single Outlet Trim Assembly is a 6″×8″ outlet fixture stone veneer trim piece that features a stone surface texture that is any one of the types of Cultured Stone® wall veneers, stucco, thin brick or other exterior finishes, as described herein. The Single Outlet Trim Assembly has chamfered edges and an inset grooved border design. In one embodiment, a rectangular orifice within the Single Outlet Trim Assembly allows for insertion of a standard 2″×4″×1½″ electrical extension box-type receptacle. An extension box-type receptacle is used in aligning and setting the simulated stone veneer trim piece in place.

While the invention has been described with reference to a preferred embodiment, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the essential scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims.