Abstract:
An architectural finish attachment assembly ( 100  and  700 ) formed in accordance with the present invention for coupling an architectural finish ( 102 ) to a building structure ( 104 ). The architectural finish attachment assembly includes a base structure ( 110  and  710 ) having a first surface ( 124  and  752 ) adapted to engage the building structure and a second surface ( 126  and  753 ) disposed opposite the first surface and a spike ( 114, 214, 314, 414, 514, 614 , and  714 ) extending outward at an incline from the second surface, the spike adapted to impale the architectural finish for removably coupling the architectural finish to the building structure.

Description:
FIELD OF THE INVENTION  
       [0001]     The illustrated and described embodiments of the present invention relate generally to architectural finish attachment assemblies and, more particularly, to architectural finish attachment assemblies used for attaching architectural finishes to building structures and to the methods of attaching architectural finishes to building structures using architectural finish attachment assemblies.  
       BACKGROUND OF THE INVENTION  
       [0002]     An architectural finish in the form of moldings can transform a standard doorway into a grand archway and a fireplace mantle into a room&#39;s centerpiece. Or, an architectural finish in the form of wall cladding can provide a wall with an aesthetically pleasing finish, such as a stucco styled finish. Architectural finishes, such as moldings, cornices, and wall claddings, are widely used in the homebuilding industry as a way to increase the aesthetic and economic value of a home. To obtain market share and to establish a reputation, builders are seeking out variations on classic architectural finishes.  
         [0003]     In the recent past, architectural finishes were typically formed from stone/concrete, wood, or stucco. With a number of advancements made within the foam industry, many builders are now utilizing pre-coated foam architectural finishes. One reason for their popularity is that they have a similar look and feel to precast, natural stone products, wood, or stucco, at the same time providing a significant reduction in raw material and installation costs. The foam based architectural finishes are also being used to accommodate climates adverse to wood and to offset rising wood costs.  
         [0004]     In a typical construction, a mesh is applied to a foam core, which is in turn coated and topped with a stone like or other finish to create a product that is strong and aesthetically pleasing. The resulting product may be one-tenth the weight of precast stone. Further, the resultant product is easier and costs less money to install. It can be made in any shape and size. The manufacturing time is considerably less as well, and the cost is around 40 percent less for the installation of a foam product versus a precast product.  
         [0005]     The foam base is easily formed into any shape, allowing designers wide latitude in designing the shape of the architectural finishes. The design aspects for coated foam products are infinite and have become extremely popular with architects and interior designers alike. The foam is dimensionally stable, resistant to expansion, contraction, warping, rotting, and twisting. Additionally the foam is not a nutrient source for insects, which is important in humid and termite-prone climates.  
         [0006]     Although previously developed foam-based architectural finishes are effective, they are not without their problems. It has been discovered that previously developed architectural finishes are not well adapted for easy attachment to a building structure. In previously developed attachment methods, a permanent adhesive was applied to a back of the architectural finish, such as a stucco styled finish panel, in a prescribed pattern. A hot melt glue gun was then used to apply holt melt glue to the back of the finish panel. The finish panel was then quickly applied to the wall. The holt melt glue temporarily held the finish panel to the building structure while the permanent adhesive cured.  
         [0007]     Although effective, this process has several drawbacks. For example, the method requires the installer to purchase hot melt glue guns and carry them around the job site, and locate power sources and rig extension chords between the hot melt glue guns and the power sources. Further, the installer is subject to injury from burns received from the hot melt glue gun. Additionally, the installer has very little time to set and position the finish panel before the hot melt glue dries. Further still, the installer has only one shot at correctly installing and positioning the panel, since once the hot melt glue dries, the panel often cannot be removed for realignment without damaging the panel. Also, due to the large size of the finish panel, it can take the installer a while to apply a sufficient amount of the hot melt glue to the finish panel such that the hot melt glue first applied starts to cure by the time the last of the hot melt glue is applied and the panel installed. For at least these reasons, previously developed application methods and attachment assemblies are cumbersome, labor intensive, costly, increase a potential of injury to the installer, do not permit realignment of the architectural finish, and decrease the quality of the installation of the product.  
         [0008]     Thus, there exists a need for a method and an architectural finish attachment assembly which permits an architectural finish to be more easily attached to a building structure, that is reliable, permits realignment of the panel during initial installation, and/or is inexpensive to manufacture.  
       SUMMARY OF THE INVENTION  
       [0009]     One embodiment of a method performed in accordance with the present invention for attaching an architectural finish to a building structure using an architectural finish attachment assembly having a spike is disclosed. The method includes attaching the architectural finish attachment assembly to the building structure with the spike facing outward from the building structure and applying an adhesive to the architectural finish. The method further includes impaling the architectural finish upon the spike such that the architectural finish is attached to the building structure with the adhesive in contact with the building structure and permitting the adhesive to permanently cure to adhere the architectural finish to the building structure.  
         [0010]     Another embodiment of a method performed in accordance with the present invention for attaching an architectural finish to a building structure using an architectural finish attachment assembly having a spike is disclosed. The method includes placing the architectural finish attachment assembly against the building structure and attaching the architectural finish attachment assembly to the building structure with the spike facing outward from the building structure by passing a fastener through a preformed fastener aperture in the architectural finish attachment assembly and into the building structure. The method also includes applying an adhesive to the architectural finish and impaling the architectural finish upon the spike such that the architectural finish is removably attached to the building structure with the adhesive in contact with the building structure. The method further includes permitting the adhesive to cure to permanently adhere the architectural finish to the building structure while the architectural finish attachment assembly holds the architectural finish in place.  
         [0011]     One embodiment of an architectural finish attachment assembly formed in accordance with the present invention for coupling an architectural finish to a building structure is disclosed. The architectural finish attachment assembly includes a base structure having a first surface adapted to engage the building structure and a second surface disposed opposite the first surface and a spike extending outward at an incline from the second surface, the spike adapted to impale the architectural finish for removably coupling the architectural finish to the building structure. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]     The foregoing aspects and many of the attendant advantages of this invention will become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:  
         [0013]      FIG. 1  is a perspective view of one embodiment of an architectural finish attachment assembly formed in accordance with the present invention;  
         [0014]      FIG. 2  is a cross-sectional view of the architectural finish attachment assembly of  FIG. 1  depicting the architectural finish attachment assembly in an installed state, coupling an architectural finish to a wall;  
         [0015]      FIG. 3  is an exploded isometric view of the architectural finish attachment assembly, architectural finish, and wall of  FIG. 2  showing the inner facing surfaces of the architectural finish attachment assembly, architectural finish, and wall;  
         [0016]      FIG. 4  is an exploded isometric view of the architectural finish attachment assembly, architectural finish, and wall of  FIG. 3  showing the outer facing surfaces of the architectural finish attachment assembly, architectural finish, and wall;  
         [0017]      FIG. 5  is a top view of an alternate embodiment of a spike formed in accordance with the present invention and suitable for use with the architectural finish attachment assembly of  FIGS. 1-4 ;  
         [0018]      FIG. 6  is an elevation view of the spike of  FIG. 5 ;  
         [0019]      FIG. 7  is a top view of an alternate embodiment of a spike formed in accordance with the present invention and suitable for use with the architectural finish attachment assembly of  FIGS. 1-4 ;  
         [0020]      FIG. 8  is an elevation view of the spike of  FIG. 7 ;  
         [0021]      FIG. 9  is a top view of an alternate embodiment of a spike formed in accordance with the present invention and suitable for use with the architectural finish attachment assembly of  FIGS. 1-4 ;  
         [0022]      FIG. 10  is an elevation view of the spike of  FIG. 9 ;  
         [0023]      FIG. 11  is a top view of an alternate embodiment of a spike formed in accordance with the present invention and suitable for use with the architectural finish attachment assembly of  FIGS. 1-4 ;  
         [0024]      FIG. 12  is an elevation view of the spike of  FIG. 11 ;  
         [0025]      FIG. 13  is a top view of an alternate embodiment of a spike formed in accordance with the present invention and suitable for use with the architectural finish attachment assembly of  FIGS. 1-4 ;  
         [0026]      FIG. 14  is an elevation view of the spike of  FIG. 13 ; and  
         [0027]      FIG. 15  is an isometric view of an alternate embodiment of an architectural finish attachment assembly formed in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0028]     Referring to  FIGS. 1-4 , one embodiment of an architectural finish attachment assembly  100  formed in accordance with the present invention is illustrated and described. Generally described, the architectural finish attachment assembly  100  may be used to couple an architectural finish  102  to a building structure  104 . For instance, the architectural finish attachment assembly  100  may be used to temporarily attach the architectural finish  102  to the building structure  104  while a permanent adhesive  106  cures, permanently attaching the architectural finish  102  to the building structure  104 .  
         [0029]     Turning to  FIGS. 1 and 2 , and in light of the above general description of the architectural finish attachment assembly  100 , the structural components of the architectural finish attachment assembly  100  will now be described in detail. The architectural finish attachment assembly  100  may include a retainment assembly  108 , a base structure  110 , and one or more fastener apertures  112 . The base structure  110  may be a planar base plate having a perimeter of any geometric shape or combination of shapes, one suitable example being a rectangular 2.5 inch×2.5 inch plate as illustrated. The base structure  110  may have a first or inner surface  124  adapted to engage or be in proximity to the building structure  104  and a second or outer surface  126  adapted to engage or be in proximity to the architectural finish  102 .  
         [0030]     Although the base structure  110  is illustrated and described as being planar, it will be appreciated by those skilled in the art that the base structure may also be contoured so as to be other than a planar structure. For instance, the base structure may to be cooperatively shaped to match a specific building structure shape, a few suitable example being an L-shaped base structure  110  adapted to conform to a corner of a building structure  104  (a few suitable examples being a stucco, brick, cementitious, or wood wall) or a contoured base structure  110  adapted to cooperatively conform to a contoured portion of the building structure  104 . The base structure  110  may be made of a rigid or semi-rigid material, a few suitable examples being plastic or metal, such as 22 gauge galvanized steel.  
         [0031]     The base structure  110  may also include one or more fastener apertures  112 . The fastener apertures  112  pass through the base structure  110  and permit a fastener  116  to pass therethrough when the architectural finish attachment assembly  100  is coupled to the building structure  104 . The fastener apertures  112  also help in providing a template to aid an installer in correctly positioning and spacing the fasteners  116  when the architectural finish attachment assembly  100  is coupled to the building structure  104 . Although the base structure  110  is illustrated and described as having one or more fastener apertures  112 , it will be appreciated by those skilled in the art that the fastener apertures  112  are optional and may be eliminated. For instance, in one working embodiment, the base structure  110  is absent of fastener apertures  112  and the base structure  110  is simply adhered to the building structure  104  with an adhesive. In still another embodiment, the base structure  110  is absent of fastener apertures  112  and the fasteners  116  are simply driven through the base structure  110  without the aid of preformed fastener apertures  112 . Therefore, although fastener apertures  112  and fasteners  116  are illustrated and described with respect to the illustrated embodiment, it should be apparent to those skilled in the art that the fastener apertures  112  and fasteners  116  are illustrative in nature and non-limiting, and may be eliminated without departing from the spirit and scope of the present invention.  
         [0032]     The retainment assembly  108  may include one or more spikes  114 . The spikes  114  may extend substantially perpendicularly outward from the base structure  110 , or may extend at other angles relative to the base structure  110 , a few suitable examples being at angles exceeding about 45, 55, 65, 75, or 85 degrees relative to the base structure  110 . The spikes  114  may be integrally formed with the base structure  110  or may be a separate structure coupled to the base structure  110 . The spikes  114  may be made from any rigid or semi-rigid material, a few suitable examples being plastic or metal, such as galvanized steel or aluminum.  
         [0033]     In the illustrated embodiment, a perimeter shape of the spikes  114  is cut or stamped into the base structure  110 , and then the spikes  114  are bent from an orientation coplanar with the base structure  110  to an orientation wherein the spikes  114  are inclined relative to the base structure  110 , for instance so as to be substantially perpendicular to the base structure  110 . Once the spikes  114  are bent up as described, spike cut-out apertures  118  remain in the base structure  110 , the spike cut-out apertures  118  having a perimeter shape substantially identical to the perimeter shape of the spikes  114 .  
         [0034]     The spikes  114  may be shaped in any suitable manner having sufficient strength to puncture the architectural finish without collapsing or excessively bending. In  FIGS. 1-4 , spikes  114  are illustrated which are planar with a constant width base and a tip which tapers to a point. Preferably, the planar surface of each spike  114  is horizontally oriented to provide a “support shelf” for supporting the weight of the architectural finish  102  and to impede the architectural finish  102  from sliding downward as the adhesive securing the architectural finish  102  to the building structure  104  cures. Although the spikes  114  are illustrated and described as being horizontally oriented, it should be apparent to those skilled in the art that the planar surface of each spike may be oriented in any other direction, such as vertical, etc.  
         [0035]     In one embodiment, the illustrated spikes  114  are between about ¼ inch to ½ inch in height and about ⅛ inch to ½ inch in width. A few suitable alternate embodiments of spikes  114  suitable for use with and within the spirit and scope of the present invention are shown in  FIGS. 5-14 . For instance,  FIG. 5  shows a top view and  FIG. 6  is an elevation view of an alternate embodiment of a spike  214  which is arcuate in shape.  FIG. 7  shows a top view and  FIG. 8  is an elevation view of an alternate embodiment of a spike  314  which is in the form of a hollow cylinder.  FIG. 9  shows a top view and  FIG. 10  is an elevation view of an alternate embodiment of a spike  414  which is planar in shape and which has an arrow shaped distal end with a pair of barbs  490  to aid in retention of the architectural finish upon the spike  414 .  FIG. 11  shows a top view and  FIG. 12  is an elevation view of an alternate embodiment of a spike  514  which is formed of two planar panels intersecting each other at an incline to form a X-shaped spike.  FIG. 13  shows a top view and  FIG. 14  is an elevation view of an alternate embodiment of a spike  614  which is cylindrical in shape to form a spike that is in the form of a pin. The spikes may be treated to provide a more slip resistant exterior surface, a few suitable examples of surface treating include galvanizing, distressing, twisting, curling, and roughening of the surface.  
         [0036]     Referring to  FIGS. 2-4  and in light of the above description of the structure of the architectural finish attachment assembly  100 , the installation of the architectural finish attachment assembly  100  will now be described. One or more architectural finish attachment assemblies  100  may be coupled to the building structure&#39;s  104  waterproof and code-compliant face or to an approved water-resistant membrane  113  of the building structure  104  via passing the fasteners  112  through the fastener apertures. For instance, the fasteners  116  may be screws or nails which are driven through the fastener apertures  112 , such that a head of the screw or nail clamps the base structure  110  to the building structure  104 . An adhesive or sealant may be applied to and around the heads of the fasteners  116  to seal the heads to impede moisture infiltration. Alternately, the architectural finish attachment assemblies  100  may simply be adhered to the building structure  104  without the use of fasteners  112  as discussed above, through the use of an approved adhesive.  
         [0037]     A permanent adhesive  106  is strategically applied to a back surface  122  of the architectural finish  102  in accordance with well known techniques in the industry and upon the architectural finish attachment assemblies  100 . The architectural finish  102  is then pressed towards the building structure  104  such that the architectural finish  102  is impaled upon the spikes  114  and the permanent adhesive  106  contacts the building structure  104 . The spikes  114  of the architectural finish attachment assembly  100  hold the architectural finish  102  upon the building structure  104  until the permanent adhesive  106  cures, permanently adhering the architectural finish  102  to the building structure  104 .  
         [0038]     If the initial installation of the architectural finish  102  is for any reason misaligned and needs adjustment, the architectural finish  102  may be simply pulled outward from the building structure  104  (as long as the permanent adhesive  106  has not yet cured). This causes the spikes  114  to pull out of the architectural finish  102  to permit the architectural finish  102  to be realigned and re-impaled upon the architectural finish attachment assembly  100  to attach the architectural finish  102  in the correct position.  
         [0039]     Referring to  FIG. 15 , an alternate embodiment of an architectural finish attachment assembly  700  is shown. The architectural finish attachment assembly  700  of  FIG. 15  is substantially identical to the previously described embodiments in structure and use, and therefore, for the sake of brevity, only the aspects of the architectural finish attachment assembly  700  which depart from the previously described embodiments will be discussed herein. Generally stated, the architectural finish attachment assembly  700  of  FIG. 15  departs from the previously described embodiments in that the fastener apertures of the previous embodiments have been removed and replaced with permanently attached building structure spikes  750 .  
         [0040]     The building structure spikes  750  are adapted to be driven into a building structure to attach the architectural finish attachment assembly  700  to the building structure. The building structure spikes  750  may be shaped in any suitable manner permitting their attachment to a particular building structure. For instance, the building structure spikes  750  may be planar and triangular shaped as illustrated, or may take another form, such as the form of any of the above illustrated and described architectural finish spikes of the previously described embodiments. The building structure spikes  750  extend outward at an incline from an inner surface  752  of the base structure  710  of the architectural finish attachment assembly  700 , generally in an opposite direction of the architectural finish spikes  714 . In the illustrated embodiment, the building structure spikes  750  are oriented substantially perpendicular to the inner surface  752  of the base structure  710 , however other angles of inclination relative to the inner surface  752  are suitable for use with and within the spirit and scope of the present invention, such as angles exceeding about 45, 55, 65, 75, and 85 degrees. Preferably, the building structure spikes  750  are oriented parallel and in an opposite direction relative to the architectural finish spikes  714 .  
         [0041]     In the illustrated embodiment, the building structure spikes  750  are offset from the spikes  714  used in impaling the architectural finish, thereby permitting an installer to strike the outer surface  753  of the base structure  710  directly above the building structure spikes  750  without hitting the architectural finish spikes  714 . Although a specific number of building structure spikes  750  are illustrated and described, it should be noted to those skilled in the art that any number of building structure spikes  750  may be used, a few suitable examples being a single building structure spike  750 , two or more, three or more, four or more, etc.  
         [0042]     The building structure spikes  750  may be integrally formed with the base structure  710  or may be separate structures coupled to the base structure  710 . The spikes  750  may be made from any rigid or semi-rigid material, a few suitable examples being plastic or metal. In the illustrated embodiment, a perimeter shape of the building structure spikes  750  is cut or stamped into the base structure  710 , and then the spikes  750  are bent from an orientation coplanar with the base structure  710  to an orientation wherein the spikes  750  are inclined relative to the base structure  710 , for instance so as to be substantially perpendicular to the base structure  710 . Once the spikes  750  are bent up as described, spike cut-out apertures  754  remain in the base structure  110 , the spike cut-out apertures  754  having a perimeter shape substantially identical to the perimeter shape of the building structure spikes  750 .  
         [0043]     While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.