Abstract:
A system for providing a veneer for a surface, comprising a first plurality of veneer blocks, each having dimensions of 1N by 3N, where N is a unit of length. A second plurality of veneer blocks, each having dimensions of 1N by 4N. A third plurality of veneer blocks, each having dimensions of 2N by 3N. A fourth plurality of veneer blocks, each having dimensions of 2N by 4N, wherein the first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks are provided as the veneer on the surface.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates generally to manufactured block products, and more specifically to a manufactured veneer block system and method of use that provides a highly variable veneer block with decreased manufacturing, shipping and storage costs. 
       BACKGROUND OF THE INVENTION 
       [0002]    Stone veneers are used to allow a builder to provide a wall or other structure made from uniform structural components such as bricks with an appearance of customized natural stone. However, if manufactured veneer blocks are used, then repeated use of the same blocks will destroy that functionality. 
       SUMMARY OF THE INVENTION 
       [0003]    A system for providing a veneer for a surface is provided that includes a first plurality of veneer blocks, each having dimensions of 1 N by 3 N, where N is a unit of length. A second plurality of veneer blocks are also provided, each having dimensions of 1 N by 4 N. A third plurality of veneer blocks are also provided, each having dimensions of 2 N by 3 N. A fourth plurality of veneer blocks are also provided, each having dimensions of 2 N by 4 N. The first plurality of veneer blocks, the second plurality of veneer blocks, the third plurality of veneer blocks and the fourth plurality of veneer blocks are provided as the veneer on the surface, such as by arranging the veneer blocks in a random pattern. 
         [0004]    Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0005]    Aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, and in which: 
           [0006]      FIG. 1  is a diagram of a system for providing a wall veneer in accordance with an exemplary embodiment of the present disclosure; 
           [0007]      FIG. 2  is a diagram of a veneer in accordance with an exemplary embodiment of the present disclosure; 
           [0008]      FIG. 3  is a diagram of a veneer that uses unequal numbers of different veneer blocks in accordance with an exemplary embodiment of the present disclosure; 
           [0009]      FIG. 4  is a diagram of 6 N by 6 N veneer modules in accordance with an exemplary embodiment of the present disclosure; 
           [0010]      FIG. 5  is a diagram of 6 N by 6 N veneer modules in accordance with an exemplary embodiment of the present disclosure; 
           [0011]      FIG. 6  is a diagram of 5 N by 6 N veneer modules in accordance with an exemplary embodiment of the present disclosure; 
           [0012]      FIG. 7  is a diagram of 4 N by 6 N veneer modules in accordance with an exemplary embodiment of the present disclosure; and 
           [0013]      FIG. 8  is a diagram of a system for designing a veneer for a surface in accordance with an exemplary embodiment of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0014]    In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures might not be to scale and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness. 
         [0015]      FIG. 1  is a diagram of a system  100  for providing a wall veneer in accordance with an exemplary embodiment of the present disclosure. System  100  includes nine different sizes of manufactured veneer blocks: 1) a 3 N by 6 N block  102 , 2) a 3 N by 4 N block  104 , 3) a 3 N by 3 N block  106 , 4) a 2 N by 6 N block  108 , 5) a 2 N by 4 N block  110 , 6) a 2 N by 3 N block  112 , 7) a 1 N by 6 N block  114 , 8) a 1 N by 4 N block  116  and 9) a 1 N by 3 N block  118 , where “N” refers to a suitable linear dimension value. By selecting the dimensions for the nine different veneer blocks as shown, the user is provided with substantial flexibility to arrange the blocks in different combinations, so as to avoid repeating a combination in a manner that will allow a casual observer to readily determine that the wall or other structure on which the veneer has been placed has been made from a manufactured stone veneer product. Although the nine exemplary dimensions as shown can be used to provide a system of manufactured veneer stones that allows a wall designer to create a wall veneer that does not appear to have been made from a manufactured veneer product, other suitable dimensions can also or alternatively be used in accordance with the present disclosure. 
         [0016]    One of the advantages of system  100  is that a small predetermined number of manufactured veneer stones can be used to provide a veneer covering for a large section of wall that does not have a repeating pattern of adjacent veneer stones. For example, if the dimension N is 4 to 6 inches, then it is possible to design a veneer wall covering for most walls that will not noticeably repeat any patterns, as far as a casual observer can determine. As such, the veneer wall covering can be assembled and installed using only nine different pallets of manufactured veneer stone blocks, which would not be an unusually large number of pallets for a typical construction project. Likewise, the manufacturing equipment needed to manufacture nine different veneer blocks is not excessive, and can be implemented using a single press and nine different molds. 
         [0017]    The veneer blocks can be made from concrete, masonry or other suitable materials, and can also be molded, stamped or otherwise formed. In one exemplary embodiment, a different mold can be used for each different veneer block, including blocks having the same size but a different surface finish. In another exemplary embodiment, the same perimeter mold can be used and can have a surface finish that is stamped onto the outer surface, so as to allow the same perimeter mold to be used to create veneer blocks having the same dimensions but different surface finishes. Other suitable processes can also or alternatively be used. 
         [0018]      FIG. 2  is a diagram of a veneer  200  in accordance with an exemplary embodiment of the present disclosure. Veneer  200  is formed from the nine blocks of system  100 , plus an additional variation of three different surface finishes A, B and C. In this manner, veneer  200  can be assembled from 27 different pallets of veneer blocks, which is not an excessive number of pallets for large construction projects, and provides an additional amount of variability in design that makes it more difficult for a casual observer to determine that the structure is covered with a veneer that is formed from manufactured blocks instead of being built from more expensive custom-sized stones. 
         [0019]      FIG. 3  is a diagram of a veneer  300  that uses unequal numbers of different veneer blocks in accordance with an exemplary embodiment of the present disclosure. Veneer  300  is different from veneer  200  in that the number of large blocks  202 A and  202 C is greater as a percentage of the wall covering area in veneer  300 , and also because veneer  300  does not include any  202 B blocks. As shown, veneer  300  uses blocks having the size of 3 N by 6 N block  102  to provide 37.5% of the total surface area, while avoiding the placement of two blocks that have the same design in contact with each other. In this manner, veneer  300  can be made using a smaller number of pallets of material than veneer  200 , such 18 pallets instead of 27 pallets of material (for example, by omitting types A, B and C of each block size, or in other suitable manners). 
         [0020]      FIG. 4  is a diagram of 6 N by 6 N veneer modules  400  in accordance with an exemplary embodiment of the present disclosure. Veneer modules  400  allow a designer to use a small number of different modules for designing a veneer for a wall or other structure instead of designing a veneer from separate blocks, to simplify the design and ordering process. For example, module  402  includes one 3 N by 6 N block  102 , one 3 N by 4 N block  104  and one 2 N by 3 N block  112 . Module  404  includes one 3 N by 6 N block  102 , one 2 N by 6 N block  108  and one 1 N by 6 N block  114 . Module  406  includes one 3 N by 6 N block  102  and two 3 N by 3 N blocks  106 . Module  408  includes one 3 N by 6 N block  102 , one 2 N by 4 N block  110 , one 1 N by 4 N block  116  and two 1 N by 3 N blocks  118 . By using modules  402 ,  404 ,  406  and  408  to design a veneer for a structure, a designer can reduce the amount of work that is needed to create a veneer pattern that avoids repetition and which creates the appearance of a customized stone wall. Likewise, additional variability can be simulated using different surface textures, such as surface textures A, B and C of veneers  200  and  300  or other suitable numbers of different textures. 
         [0021]      FIG. 5  is a diagram of 6 N by 6 N veneer modules  500  in accordance with an exemplary embodiment of the present disclosure. Veneer modules  500  allow a designer to use a small number of different modules for designing a veneer for a wall or other structure instead of designing a veneer from separate blocks, to simplify the design and ordering process. For example, module  502  includes one 3 N by 6 N block  102  and three 2 N by 3 N blocks  112 . Module  504  includes two 3 N by 3 N blocks  106 , one 1 N by 6 N block  114  and two 2 N by 3 N blocks  112 . Module  506  includes one 2 N by 4 N block  110 , one 3 N by 4 N block  104 , one 1 N by 4 N block  116  and one 2 N by 6 N block  108 . Module  508  includes one 1 N by 6 N block  114 , four 1 N by 3 N blocks  118 , two 2 N by 3 N blocks  112  and one 1 N by 6 N block  114 . By using modules  502 ,  504 ,  506  and  508  to design a veneer for a structure, a designer can reduce the amount of work that is needed to create a veneer pattern that avoids repetition and which creates the appearance of a customized stone wall. Likewise, additional variability can be simulated using different surface textures, such as surface textures A, B and C of veneers  200  and  300  or other suitable numbers of different textures. 
         [0022]      FIG. 6  is a diagram of 5 N by 6 N veneer modules  600  in accordance with an exemplary embodiment of the present disclosure. Veneer modules  600  allow a designer to use a small number of different modules for designing a veneer for a wall or other structure instead of designing a veneer from separate blocks, to simplify the design and ordering process. For example, module  602  includes one 3 N by 6 N block  102  and two 2 N by 3 N blocks  112 . Module  604  includes two 2 N by 3 N blocks  112 , one 1 N by 6 N block  114  and four 1 N by 3 N blocks  118 . Module  606  includes one 2 N by 4 N block  110 , one 1 N by 4 N block  116 , two 2 N by 3 N blocks  112  and two 1 N by 3 N blocks  118 . Module  608  includes one 3 N by 4 N block  104 , two 1 N by 6 N blocks  114  and one 2 N by 3 N block  112 . By using modules  602 ,  604 ,  606  and  608  to design a veneer for a structure, a designer can reduce the amount of work that is needed to create a veneer pattern that avoids repetition and which creates the appearance of a customized stone wall. Likewise, additional variability can be simulated using different surface textures, such as surface textures A, B and C of veneers  200  and  300  or other suitable numbers of different textures. 
         [0023]      FIG. 7  is a diagram of 4 N by 6 N veneer modules  700  in accordance with an exemplary embodiment of the present disclosure. Veneer modules  700  allow a designer to use a small number of different modules for designing a veneer for a wall or other structure instead of designing a veneer from separate blocks, to simplify the design and ordering process. For example, module  702  includes one 3 N by 6 N block  102  and two 1 N by 3 N blocks  118 . Module  704  includes one 3 N by 3 N block  106 , one 1 N by 6 N block  114 , one 2 N by 3 N block  112  and one 1 N by 3 N block  118 . Module  706  includes one 3 N by 6 N block  102  and one 1 N by 6 N block  114 . Module  708  includes two 3 N by 3 N blocks  106  and two 1 N by 3 N blocks  118 . Module  710  includes one 1 N by 6 N block  114 , two 1 N by 3 N blocks  118  and two 2 N by 3 N blocks  112 . 
         [0024]    Module  712  includes one 3 N by 3 N block  106 , one 2 N by 3 N block  112  and three 1 N by 3 N blocks  118 . By using modules  702 ,  704 ,  706 ,  708 ,  710  and  712  to design a veneer for a structure, a designer can reduce the amount of work that is needed to create a veneer pattern that avoids repetition and which creates the appearance of a customized stone wall. Likewise, additional variability can be simulated using different surface textures, such as surface textures A, B and C of veneers  200  and  300  or other suitable numbers of different textures. 
         [0025]      FIG. 8  is a diagram of a system  800  for designing a veneer for a surface in accordance with an exemplary embodiment of the present disclosure. System  800  includes surface size system  802 , block select system  804 , module select system  806 , material ordering system  808 , install sequence system  810  and veneer design system  812 , each of which can be implemented in hardware or a suitable combination of hardware and software, and which can be one or more software systems operating on one or more processors. 
         [0026]    As used herein, “hardware” can include a combination of discrete components, an integrated circuit, an application-specific integrated circuit, a field programmable gate array, or other suitable hardware. As used herein, “software” can include one or more objects, agents, threads, lines of code, subroutines, separate software applications, two or more lines of code or other suitable software structures operating in two or more software applications, on one or more processors (where a processor includes a microcomputer or other suitable controller, memory devices, input-output devices, displays, data input devices such as a keyboard or a mouse, peripherals such as printers and speakers, associated drivers, control cards, power sources, network devices, docking station devices, or other suitable devices operating under control of software systems in conjunction with the processor or other devices), or other suitable software structures. In one exemplary embodiment, software can include one or more lines of code or other suitable software structures operating in a general purpose software application, such as an operating system, and one or more lines of code or other suitable software structures operating in a specific purpose software application. As used herein, the term “couple” and its cognate terms, such as “couples” and “coupled,” can include a physical connection (such as a copper conductor), a virtual connection (such as through randomly assigned memory locations of a data memory device), a logical connection (such as through logical gates of a semiconducting device), other suitable connections, or a suitable combination of such connections. 
         [0027]    Surface size system  802  generates one or more user interface controls to allow a user to enter the dimensions of a surface for a veneer design, such as a wall, a barrier, a fence or other suitable surfaces. In one exemplary embodiment, surface size system  802  can generate one or more user prompts to enter a dimension of a surface, can include one or more user interface devices that allow a user to draw a surface, or can include other suitable user interface controls. 
         [0028]    Block select system  804  generates one or more user interface controls to allow a user to perform a block-by-block selection for veneer design. In one exemplary embodiment, the user can select from available veneer blocks, such as the blocks of veneer system  100  or other suitable blocks, and can view a simulation of a veneer surface formed from the selected veneer blocks. In another exemplary embodiment, the user can elect to have randomly-selected blocks automatically placed within the surface. Block select system  804  can also identify blocks that violate one or more user-selected or predetermined design rules, such as a rule that no identical blocks should be touching, a rule that no identical blocks should be within a predetermined distance of each other or other suitable design rules. 
         [0029]    Module select system  806  generates one or more user interface controls to allow a user to perform a module-by-module selection for veneer design. In one exemplary embodiment, the user can select from available veneer modules and can view a simulation of a veneer surface formed from the selected veneer modules, such as where each module is formed from a predetermined group of separate veneer blocks. In another exemplary embodiment, the user can elect to have randomly-selected modules automatically placed within the surface. Module select system  806  can also identify modules that violate one or more user-selected or predetermined design rules, such as a rule that no identical modules should be touching, a rule that no identical modules should be within a predetermined distance of each other or other suitable design rules. 
         [0030]    Material ordering system  808  receives veneer design data and generates order data for the materials needed to build the associated veneer design. In one exemplary embodiment, material ordering system  808  can increase a number of veneer blocks to account for expected breakage and rework, can include additional materials such as adhesives for installing the veneer, can arrange shipping and billing and can perform other suitable processes. 
         [0031]    Install sequence system  810  receives veneer design data and generates installation sequence instructions, such as to facilitate the construction of a veneer for the veneer design. In one exemplary embodiment, install sequence system  810  can receive data that identifies a number of work crews and can generate installation instructions to allow each work crew to install veneer blocks in parallel. In another exemplary embodiment, install sequence system  810  can generate shipping instructions for shipment of material to a jobsite as it is needed, so as to reduce the amount of onsite storage space required. 
         [0032]    Veneer design system  812  generates one or more user interface controls to allow a user to remotely interface with surface size system  802 , block select system  804 , module select system  806 , material ordering system  808 , install sequence system  810  and other suitable systems. In one exemplary embodiment, a user can access veneer design system  812  from a web browser, an application operating on a tablet computer or in other suitable manners and can design and order the veneer blocks and other materials that are needed to assemble a veneer on a surface. 
         [0033]    In operation, system  800  allows a user to design a veneer for a surface from manufactured veneer blocks, and to create a veneer that makes the underlying surface appear to have been fabricated using custom-sized blocks of material. System  800  can be used with veneer block system  100  and the disclosed exemplary modules as discussed herein, or with other suitable veneer blocks or modules. 
         [0034]    It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.