Natural rock panel, natural rock veneer panel and panel support apparatus

An architectural finish element operable to be placed adjacent similar architectural finish elements to form a finished surface on an architectural structure includes a body formed of a rock-based composite material comprising a low density solid particle additive, a plurality of unitary real stone veneer elements bonded to the body in courses extending in a first direction and in a random non-repetitive pattern, the real stone veneer elements having respective face surfaces generally lying in a plane to form an overall face surface of the architectural finish element. The low density solid particle additive is provided in an amount suitable to cause the architectural finish element to have a density of between about 10 to 15 pounds per square foot. The architectural finishing element may be mounted by mounting a portion of a body of at least one dual architectural finish element support to a surface of an architectural structure.

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention relates to architectural finish elements and supporting apparatus therefor, and more particularly to architectural finish elements that employ real rock configured in a lightweight panel form. The invention also relates to apparatus for supporting architectural finish panels including the type that employ real rock configured in a lightweight panel form.

2. Description of Related Art

Various architectural finish elements have been used over the years to clad architectural structures such as buildings. Some of these architectural finish elements involve individual stone elements, individually secured to the architectural structure. Installation of this type of element is time-consuming, and such elements can be susceptible to release from the surface due to thermal expansion and contraction, which can loosen mortar adhesion systems that secure such elements to an architectural structure for example. Further, such individually secured stone elements are often joined by mortar joints having thicknesses of about ⅜ inches or more, and such mortar joints may have an undesirable appearance.

Some inventors have overcome the mortar adhesion problem by cutting grooves into the individual stone elements and using a support clip that cooperates with the groove to support the individual stone element, but this tends to secure the stone elements rather rigidly to the surface of the architectural structure, which can still be a problem due to wind loading and seismic loading. Forces due to these conditions can result in displacement of the individual stone elements from the clips, resulting in release of one of more of the stone elements from the structure.

The appearance of dry-stacked individual stone elements (i.e. where there are no readily apparent joint lines between adjacent stone elements) is a highly desirable and attractive finish and is generally achieved only by actually dry stacking individual stone elements. Generally, individual stone elements are not aggregated together into unitary collections to form an architectural finish element because the stone elements themselves are generally relatively heavy such that any unitary collection of stone elements is generally too heavy to be lifted by a single person and would be too heavy to meet many building codes. To reduce weight, individual stone elements may sometimes be secured to a foam backing for example, but the foam can deform over time if subjected to point loading and can be susceptible to ultraviolet radiation degradation and can present challenges for fire proofing.

Artificially formed surfaces comprised of concrete painted and molded to look like a dry-stacked arrangement of individual stone elements have been used on foam to form building blocks but are still too heavy and therefore not suitable for cladding a building. Patio and walkway surfaces have been paved by masonry panels comprising a reinforced series of masonry elements such as stone or brick pavers bound together by a cement or mortar-like material, but these too are too heavy for cladding an architectural structure.

SUMMARY OF THE INVENTION

In accordance with one aspect of the invention, there is provided an architectural finish element operable to be placed adjacent similar architectural finish elements to form a finished surface on an architectural structure. The architectural finish element includes a body formed of a rock-based composite material including a low density solid particle additive. The architectural finish element also includes a plurality of unitary real stone veneer elements bonded to the body in courses extending in a first direction and in a random non-repetitive pattern, the real stone veneer elements having respective face surfaces generally lying in a plane to form an overall face surface of the architectural finish element. The low density solid particle additive is provided in an amount suitable to cause the architectural finish element to have a density of between about 10 pounds per square foot to about 15 pounds per square foot.

The real stone veneer elements may have a density of between about 8 pounds per square foot to about 11 pounds per square foot.

The solid particle additive may include at least one of recycled waste, non-toxic waste, post manufacturing waste, and post consumer waste.

The solid particle additive may include lightweight synthetic particles.

The lightweight synthetic particles may include polymer particles.

The body may include about 25% to about 50% of the low density solid particle additive by volume.

The rock-based composite material may include pumice and cement.

The rock-based composite material may have a density of no more than about 4 pounds per square foot.

The body may have top, bottom and left and right edges and the left and right edges may have complementary shapes for engaging with corresponding right and left edges of left and right adjacent similar architectural finish elements respectively.

The left and right edges of the body may have a complementary stepped-shape.

The plurality of unitary real stone veneer elements may be bonded to the body such that a spacing between adjacent courses is generally between 0 inches to about ¼ inches to cause the real stone veneer elements forming the overall face surface to have a dry-stacked appearance.

The body may have a bottom edge and the courses of the unitary real stone veneer elements may be bonded to the body such that upper and lower edges of left side veneer elements adjacent the left edge of the body are generally the same distance from the bottom edge of the body as corresponding upper and lower edges of right side veneer elements adjacent the right edge of the body such that when a left edge of a first similarly configured adjacent architectural finish element is engaged with the right edge of the architectural finish element, corresponding courses of real stone veneer elements are aligned to create the appearance of continuous courses of the real stone veneer elements across the architectural finish element and the similarly configured adjacent architectural finish element and such that when a right edge of a second similarly configured adjacent architectural finish element is engaged with the left edge of the architectural finish element corresponding courses of real stone veneer elements are aligned to create the appearance of continuous courses of the real stone veneer elements across the architectural finish element and the second architectural finish element.

The top and bottom edges may have top and bottom profiles respectively for cooperating with support apparatus to secure the architectural finish element to the architectural structure.

The body may have a rear portion disposed opposite the face surface and the rear portion may include an integral moisture path interference structure operably configured to interfere with seepage of moisture from between adjacent such architectural finish elements toward the architectural structure.

The moisture path interference structure may include a rear surface opposite the face surface, on the body, the rear surface including generally planar portions and a plurality of parallel spaced apart spacers extending between the top and bottom edges of the body.

The spacers may include dovetailed tenons.

At least some of the dovetailed tenons may have a recess to receive a portion of a mounting element.

At least some of the dovetailed tenons may be spaced apart between the top and bottom edges to form air passageways that may permit air to move in a direction generally parallel to the direction of the courses of the real stone veneer.

In accordance with another aspect of the invention, there is provided an architectural finishing method. The method involves mounting a mounting portion of a body of at least one dual architectural finish element support to a surface of an architectural structure, and causing a first holder on the body to hold a portion of a bottom edge of a first architectural finish element in a first holder. The method also involves causing a second holder on the body to hold a portion of a top edge of a second architectural finish element adjacent to the bottom edge of the first architectural finish element and in alignment with the bottom edge of the first architectural finish element such that finish surfaces of the first and second architectural finish elements are generally coplanar. The method also involves causing the body to absorb mechanical forces between the first and second architectural finish elements and the architectural structure.

The first and second holders may hold the bottom edge of the first architectural finish element and the top edge of the second architectural finish element within about ¼ inches of each other.

Mounting may involve causing a flat surface of a sheet portion of the body to rest against the surface of the architectural structure.

Absorbing mechanical forces may involve causing a force absorbing member to be held by a holder on the body, in a position to absorb the mechanical loads between the body and the surface of the architectural structure.

Causing a force absorbing member to be held may involve causing a portion of the force absorbing member to be held in an opening in the sheet portion and between the guides on opposite sides of the opening.

Causing the force absorbing member to be held may involve aligning the force absorbing member in the opening and aligning the force absorbing member between the guides.

Aligning the force absorbing member may involve causing a flat outer surface of a projection on the force absorbing member, having a shape complementary to a shape of the opening to bear against the surface of the architectural structure and a holding portion of the force absorbing member, adjacent the projection and having first and second opposite end portions extending outwardly on opposite sides of the projection to overlap with corresponding margins of the sheet portion on opposite sides of the opening when the projection is received in the opening.

Absorbing the forces may involve causing a fastening bar having a bearing surface having a shape corresponding to a shape of the holding portion of the force absorbing portion and an opening for receiving a fastener to receive a fastener through the opening and through the force absorbing member such that the fastener bears against the fastening bar to cause the bearing surface of the fastening bar to bear against the holding portion to press the opposite ends of the holding portion against the margins of the sheet portion, while holding the projection in contact with the surface of the architectural structure, such that differences in forces between the sheet portions and the surface of the architectural structure are absorbed by the force absorbing member.

Absorbing the force may involve causing a resilient body acting as the force absorbing member to resiliently deform in response to forces between the surface of the architectural structure and the mounting portion.

The resilient body may be comprised of Neoprene.

Causing the first holder on the body to hold a portion of a bottom edge of the first architectural finish element may involve causing a first projection on the first holder to be received in a groove in a bottom edge of the first architectural finish element.

The method may further involve causing the first holder to hold the edge of the first architectural finish element in a position spaced apart from the surface of the architectural structure.

The method may further involve receiving the edge of the first architectural finish element in a first receptacle defined by a first set of bent portions in a unitary piece of sheet metal acting as the body.

The method may further involve causing coplanar distal edges of the guides to touch a cooperating surface on a back side of the architectural finish element to position the first architectural finish element.

The method may further involve causing a second projection on the body to bear against a portion of the top edge of the second architectural finish element.

In accordance with another aspect of the invention, there is provided a dual architectural finish element support apparatus including a body. The body includes a mounting portion facilitating mounting the second body to a surface of an architectural structure, a first holder operably configured to hold a portion of a bottom edge of a first architectural finish element, a second holder operably configured to hold a portion of a top edge of a second architectural finish element adjacent to the bottom edge of the first architectural finish element and in alignment with the bottom edge of the first architectural finish element such that finish surfaces of the first and second architectural finish elements are generally coplanar, and a load absorber operably configured to absorb mechanical forces between the mounting portion and the architectural structure.

The first and second holders may hold the bottom edge of the first architectural finish element and the top edge of the second architectural finish element within about ¼ inches of each other.

The mounting portion may include a sheet portion having a flat surface for resting against the surface of the architectural structure.

The load absorber may include a force absorbing member, and the sheet portion may have a force absorbing member holder for holding the force absorbing member in a position to absorb the mechanical loads between the body and the surface of the architectural structure.

The force absorbing member holder may include a wall defining an opening in the sheet portion and guides extending from the wall and disposed adjacent the opening for holding a portion of the force absorbing member in the opening and between the guides.

The force absorbing member may include a first aligner operably configured to align the force absorbing member in the opening and a second aligner operably configured to align the force absorbing member against the guides.

The first aligner may include a projection on the force absorbing member. The projection may have a flat outer surface for bearing against the surface of the architectural structure and may have a shape complementary to a shape of the opening. The second aligner may include a holding portion on the force absorbing member adjacent the projection and having first and second opposite end portions extending outwardly on opposite sides of the projection such that the first and second opposite ends overlap with corresponding margins of the sheet portion on opposite sides of the opening when the projection is received in the opening.

The load absorber may further include a fastening bar having a bearing surface having a shape corresponding to a shape of the holding portion of the force absorbing portion, and the fastening bar may have an opening for receiving a fastener operable to extend through the fastening bar and through the force absorbing member such that the fastener bears against the fastening bar to cause the bearing surface of the fastening bar to bear against the holding portion to press the opposite ends of the holding portion against the margins of the sheet portion, while holding the projection in contact with the surface of the architectural structure, such that differences in forces between the sheet portions and the surface of the architectural structure may be absorbed by the force absorbing member.

The force absorbing member may include a resilient body resiliently deformable in response to forces between the surface of the architectural structure and the mounting portion.

The resilient body may be comprised of Neoprene.

The body of the architectural finish element support apparatus may be formed of a unitary piece of sheet metal bent into a form defining the mounting portion, the first holder and the second holder.

The first holder may include a first projection operably configured to be received in a groove in a bottom edge of the first architectural finish element.

The first holder may include a first receptacle spaced apart from the mounting portion, for holding the edge of the first architectural finish element in a position spaced apart from the surface of the architectural structure.

The first receptacle may be defined by a first set of bent portions of the unitary piece of sheet metal.

The guides may have coplanar distal edges lying in a plane spaced apart from the first projection by a distance enabling the coplanar distal edges to touch a cooperating surface on a back side of the first architectural finish element.

The second holder may include a second projection operably configured to bear against a portion of a top edge of the second architectural finish element.

In accordance with another aspect of the invention, there is provided an architectural finishing system. The system includes first and second architectural finish elements of the type described above, and at least one dual architectural finish element support system including a second body. The second body includes a mounting portion facilitating mounting the second body to a surface of an architectural structure, a first holder operably configured to hold a portion of a bottom edge of the first architectural finish element, and a second holder operably configured to hold a portion of a top edge of the second architectural finish element adjacent to the bottom edge of the first architectural finish element and in alignment with the bottom edge of the first architectural finish element such that finish surfaces of the first and second architectural finish elements are generally coplanar. The at least one dual architectural finish element support system also includes a load absorber operably configured to absorb mechanical forces between the mounting portion and the architectural structure.

The first and second holders may hold the bottom edge of the first architectural finish element and the top edge of the second architectural finish element within about ¼ inches of each other.

The mounting portion may include a sheet portion having a flat surface for resting against the surface of the architectural structure.

The load absorber may include a force absorbing member, and the sheet portion may have a force absorbing member holder for holding the force absorbing member in a position to absorb the mechanical loads between the mounting portion and the surface of the architectural structure.

The force absorbing member holder may include a wall defining an opening in the sheet portion and guides extending from the wall and disposed adjacent the opening for holding a portion of the force absorbing member in the opening and between the guides.

The force absorbing member may include a first aligner operably configured to align the force absorbing member in the opening and a second aligner operably configured to align the force absorbing member against the guides.

The first aligner may include a projection on the force absorbing member. The projection may have a flat outer surface for bearing against the surface of the architectural structure and may have a shape complementary to a shape of the opening. The second aligner may include a holding portion on the force absorbing member adjacent the projection and having first and second opposite end portions extending outwardly on opposite sides of the projection such that the first and second opposite ends overlap with corresponding margins of the sheet portion on opposite sides of the opening when the projection is received in the opening.

The load absorber may further include a fastening bar having a bearing surface having a shape corresponding to a shape of the holding portion of the force absorbing portion, and the fastening bar may have an opening for receiving a fastener operable to extend through the fastening bar and through the force absorbing member such that the fastener bears against the fastening bar to cause the bearing surface of the fastening bar to bear against the holding portion to press the opposite ends of the holding portion against the margins of the sheet portion, while holding the projection in contact with the surface of the architectural structure, such that differences in forces between the sheet portions and the surface of the architectural structure are absorbed by the force absorbing member.

The force absorbing member may include a resilient body resiliently deformable in response to forces between the surface of the architectural structure and the mounting portion.

The resilient body may be comprised of Neoprene.

The body of the architectural finish element support system may be formed of a unitary piece of sheet metal bent into a form defining the mounting portion, the first holder and the second holder.

The first holder may include a first projection operably configured to be received in a groove in a bottom edge of the first architectural finish element.

The first holder may include a first receptacle spaced apart from the mounting portion, for holding the edge of the first architectural finish element in a position spaced apart from the surface of the architectural structure.

The first receptacle may be defined by a first set of bent portions of the unitary piece of sheet metal.

The guides may have generally coplanar distal edges lying in a plane spaced apart from the first projection by a distance enabling the coplanar distal edges to touch a cooperating surface on a back side of the architectural finish element.

The second holder may include a second projection operably configured to bear against a portion of a top edge of the second architectural finish element.

In accordance with another aspect of the invention, there is provided an architectural finish element operable to be placed adjacent similar architectural finish elements to form a finished surface on an architectural structure. The architectural finish element includes a body formed of a plurality of unitary real stone elements adhesively secured together in courses, the real stone elements having respective face surfaces generally lying in a front plane to form an overall face surface of the architectural finish element and having respective rear surfaces generally lying in a rear plane facing in a direction opposite the face surface. The plurality of unitary real stone elements are arranged to form left and right edges each having complementary stepped-shapes and generally parallel top and bottom edges. The courses are parallel with the top and bottom edges and the stone elements at the left edge are of similar thickness and are disposed at the same distance from the bottom edge as corresponding stone elements at the right edge so that courses on left and right adjacently placed similar architectural finish elements are aligned with the courses of the real stone elements of the body.

The body may have a density of no more than about 15 pounds per square foot.

The rear surface may be flat planar, and may support a mesh backing or have grooves cut therein to cooperate with mortar to secure the architectural finish element to said architectural structure.

DETAILED DESCRIPTION

Referring toFIG. 1, an architectural finish element operable to be placed adjacent similar architectural finish elements to form a finished surface on an architectural structure is shown generally at10. The architectural finish element10is in the form of a panel and comprises a body12formed of a rock-based composite material comprising a low density solid particle additive14and a plurality of unitary real stone veneer elements, such as shown at16,18and20for example, bonded to the body.

In this embodiment, the rock-based composite material forming the body12is comprised of Portland cement mixed with water and an aggregate comprised of pumice in a ratio of 1.5:1:2. In this embodiment, the veneer elements, such as shown at16,18and20for example, may be bonded to the body12by casting the body adjacent the veneer elements.

The solid particle additive14may be recycled waste, non-toxic waste, post manufacturing waste, or post consumer waste, for example, such as is available under the trade name Re-Ad from CLP Technologies, LLC of Seattle, Wash., USA.

Alternatively, or in addition, the solid particle additive14may comprise lightweight synthetic particles such as polymer particles available from Syntheon Inc. of Moon Township, Pa., USA under the trade name Elemix.

The body12is formed such that it comprises about 25% to about 50% of the low density solid particle additive14by volume and such that the rock-based composite material and the low density solid particle additive are provided in amounts suitable to cause the body to have a density of no more than about 4 pounds per square foot. The real stone veneer elements16,18,20are cut thinly such that they add no more than about 6 to 11 pounds per square foot so that the completed architectural finish element will have a density of between about 10 pounds per square foot to about 15 pounds per square foot. This provides a panel of a weight suitable for manipulation by most persons and one that complies with most building codes.

At the time of manufacture, the unitary real stone veneer elements16,18,20are bonded to the body12in courses22,24,26,28, for example, extending in a first direction30and in a random non-repetitive pattern. The real stone veneer elements16,18,20are bonded to the body12such that a spacing32between adjacent courses is generally between 0 inches to about ¼ inches and such that respective face surfaces of the unitary real stone veneer elements generally lie in a common plane to form an overall face surface34of the architectural finish element, causing it to have a dry-stacked appearance. A dry-stacked appearance is one in which the individual stone veneer elements16,18,20are arranged so closely together that there are no “mortar” lines or “mortar joints”, i.e. gaps between adjacent such elements.

Still referring toFIG. 1, the body12has a main portion40and top, bottom, and left and right edges42,44,46and48. Referring toFIG. 2, the left and right edges46,48have complementary shapes for engaging with corresponding right and left edges50and52of left and right adjacent similar architectural finish elements54,56respectively. In the embodiment shown, the left and right edges46,48of the body12have a complementary stepped-shape, wherein the left edge has an upper projection60and the right edge has a lower projection62, both projecting from opposite ends of the main portion40by the same distance, so as to form a lower receptacle64on the left side of the main portion and an upper receptacle66on the right side of the main portion. This permits a lower projection68of the adjacent left element54to be received in the lower receptacle64, while the upper projection60of the left edge46is received in an upper receptacle70of the adjacent left element54. Similarly, an upper projection72of the adjacent right element56is received in the upper receptacle66, while the lower projection62of the right edge is received in the lower receptacle74of the adjacent right element56.

Referring toFIG. 3, which is an end view of the left edge46, the top and bottom edges42and44have top and bottom edge profiles80and82respectively. Referring back toFIG. 1, the top edge profile80extends along the main portion of the body12and along a top portion84of the upper projection60on the left edge46of the body12and along a top portion86of the lower projection62on the right edge48of the body. The bottom edge profile82extends along the main portion40of the body12and along a bottom portion88of the upper projection60on the left edge46of the body and along a bottom portion90of the lower projection62on the right edge48of the body. In the embodiment shown, the top and bottom edge profiles80and82are flat planar surfaces that permit the top and bottom edges of adjacent architectural finish elements to be butted up against each with no readily visible joint line.

Referring back toFIG. 3, the body12further has a rear portion99disposed opposite the face surface. The rear portion faces the architectural structure on which the architectural finish element is to be mounted. The rear portion has a rear surface opposite the face surface of the body. The rear surface is generally flat planar.

The architectural finish element may be directly secured to a flat surface of the architectural structure by placing wet mortar on the flat surface and then setting the architectural finish element into the mortar, like a wall title.

The above-described architectural finish element provides a body12with an overall face surface34provided by a unitary collection of real stone veneer elements16,18,20having a dry-stacked appearance. In the embodiment shown, the overall length of the architectural finish element is about 30 inches and the height is about 8 inches. Each projection60and62extends about 4 inches from the main body and has a height of about 4 inches. The use of an architectural finish element according to the specific embodiment described provides about 1.33 square feet of coverage to the architectural structure and can be applied as a unit, avoiding individual placement of real stone veneer directly on the architectural structure. This enables rapid application of a finishing surface or outer cladding to an architectural structure 1.33 square feet at a time, rather than direct application of real stone veneer elements that cover only a few square inches at a time, while still achieving a dry-stacked appearance.

The courses of the unitary real stone veneer elements16,18,20are bonded to the body12such that upper and lower edges100and102of left side veneer elements, one of which is shown at16adjacent the left edge46of the body12, are generally the same distances from the bottom edge44of the body as corresponding upper and lower edges104and106of veneer elements adjacent the right edge48of the body such that when the left edge52of a first similarly configured adjacent architectural finish element56is engaged with the right edge50of the architectural finish element10, corresponding courses of real stone veneer elements16,18,20are aligned to create the appearance of continuous courses of the real stone veneer elements across the architectural finish element10and the similarly configured adjacent architectural finish element56. Similarly, when a right edge50of a second similarly configured adjacent architectural finish element54is engaged with the left edge46of the architectural finish element10, corresponding courses of real stone veneer elements are aligned to create the appearance of continuous courses of the real stone veneer elements across the architectural finish element and the second architectural finish element54. In addition, referring toFIG. 4, due to the engagement of the stepped left and right edges46and48with left and right adjacent architectural finish elements110and112and due to the abutment of the top and bottom edges42and44with adjacent upper and lower architectural finish elements114and116, and due to the consistent placement of the real stone veneer elements in courses aligned at each edge, when a plurality of such architectural finish elements are engaged as shown to form an overall surface on the architectural structure, the resulting overall surface has a consistent, uniform dry-stacked appearance with the randomness of stones in respective courses, but with the regularity of courses along the entire length of the finished surface.

In the embodiment shown inFIGS. 1 to 4, the rear surface is flat planar. Referring toFIG. 5, in an alternative embodiment, there is provided an architectural finish element as shown at120, which is the same as the architectural finish element shown inFIGS. 1 to 4but has a body123having a rear surface that is formed to have a plurality of generally coplanar portions124and a plurality of parallel spaced apart spacers126extending between top and bottom edges128and130of the body. In the embodiment shown, the spacers126comprise dovetailed tenons each having an outer surface132operable to contact a surface the architectural structure to which the associated architectural finish element120is to be secured.

The architectural finish element120may be directly secured to a flat surface of the architectural structure by placing wet mortar on the flat surface and then setting the architectural finish element into the mortar such that the mortar becomes disposed between adjacent tenons and in contact therewith. When the mortar sets, it takes the shape of a complementary dovetail engaged with the dovetailed tenons of the architectural finish element and thus the dovetailed tenons of the architectural finish element are held securely by the mortar, which causes the architectural finish element to be secured to the surface of the architectural structure.

Referring toFIG. 6an architectural finish element according to a third embodiment is shown generally at140. Referring toFIGS. 6 and 7the architectural finish element140according to this embodiment is the same as that of the second embodiment with the exception that it has, a top edge142having a profile that includes first, second and third flat top surfaces144,146,148arranged in a step pattern and has a bottom edge150having a profile that includes generally rectangular outer and inner projections152and154spaced apart by a generally rectangular groove156. These profiles of the top and bottom edges142and150enable the use of a dual architectural finish element support apparatus, such as shown at160inFIGS. 9 and 10according to another aspect of the invention, to be used to secure the architectural finish element140to the surface of the architectural structure. Also, to facilitate the use of the dual architectural finish element support apparatus160, the dovetailed tenons158have recesses159as shown inFIG. 8.

Referring toFIGS. 9 and 10, the dual architectural finish element support apparatus160comprises a second body162having a mounting portion164facilitating mounting the second body to the surface of the architectural structure, a first holder166operably configured to hold a portion of a bottom edge167of the first architectural finish element shown at140inFIG. 6and a second holder168operably configured to hold a portion of the top edge169of a second architectural finish element170of the type shown inFIG. 6, adjacent to the bottom edge167of the first architectural finish element140and in alignment with the bottom edge of the first architectural finish element such that finish surfaces172and174of the first and second architectural finish elements140and170are generally coplanar. The first and second holders166and168hold the bottom edge167of the first architectural finish element140and the top edge169of the second architectural finish element170within about ¼ inches of each other. Referring toFIG. 9, in the embodiment shown, the body of the architectural finish element support apparatus is formed of a unitary piece of sheet metal bent into a form defining the mounting portion164, the first holder166and the second holder168.

The mounting portion164comprises a generally planar sheet portion180of the sheet metal body having a flat surface182, which in some embodiments may rest against the surface of the architectural structure, although in other embodiments the flat surface182may be spaced apart from the surface of the architectural structure. The mounting portion164cooperates with a load absorber shown generally at183that is operably configured to absorb mechanical forces between the mounting portion164and the architectural structure11. The load absorber183includes a load absorbing member184, a fastening bar186and a fastener188to secure the body162to the architectural structure.

Force Absorbing Member Holder

The mounting portion164includes a force absorbing member holder190formed into the mounting portion of the sheet metal body.

The force absorbing member holder190has a wall192defining an opening194in the mounting portion164, such that portions of the sheet portion about the opening define margins196and198around the opening. In the embodiment shown the opening194has a rectangular shape with first and second long side portions197and199and first and second short side portions200and202. The force absorbing member holder190also has first and second guides204and206extending in parallel spaced apart relation from the wall192and disposed adjacent the first and second long side portions197and199of the opening194for holding a portion of the force absorbing member184in the opening and for holding another portion thereof between the guides. The guides204and206may be formed by cutting an “h” form having a center cut into the planar mounting portion164of the body162and then bending solid portions on opposite sides of the “h” form to extend parallel to each other, perpendicularly to the plane of the mounting portion.

Force Absorbing Member

In this embodiment, the force absorbing member184comprises a resilient body210comprised of Neoprene. The resilient body is formed to include a first aligner212operably configured to align the force absorbing member184in the opening194and a second aligner214operably configured to align the force absorbing member184against the guides204and206. The first aligner212includes a projection216on the force absorbing member184, the projection216having a flat outer surface218for bearing against the surface of the architectural structure and having a shape complementary to the shape of the opening194which, in the embodiment shown, is rectangular. The second aligner214comprises a rectangular holding portion220on the force absorbing member adjacent the projection216and having first and second opposite end portions222and224extending outwardly on opposite sides of the projection216such that the first and second opposite end portions overlap with corresponding margins196and198of the sheet portion on opposite short side portions200and202of the opening194when the projection216is received in the opening194.

The load absorber fastening bar186has a bearing surface230having a shape corresponding to the shape of the holding portion220of the force absorbing member (i.e. rectangular). The fastening bar186also has an opening232for receiving the fastener188. The fastener188is operable to extend through the fastening bar186and through the force absorbing member184and into the surface of the architectural structure as shown inFIG. 10such that the fastener engages with the architectural structure and, when tightened, bears against the fastening bar186to cause the bearing surface230of the fastening bar186to bear against the holding portion220of the force absorbing member184to press the opposite end portions222and224of the holding portion220against the margins196and198on opposite sides of the opening194, while holding the flat surface218of the projection216in contact with the surface of the architectural structure.

First Holder

The first holder166includes a first projection250operably configured to project upwardly when in use and operable to be received in the groove156in the bottom edge150of the architectural finish element.

The first holder166also includes a first receptacle252spaced apart from the mounting portion164and terminated in the first projection250. The first receptacle252holds a portion of the bottom edge150of the architectural finish element140in a position spaced apart from the surface of the architectural structure. More particularly, the first receptacle252holds the inner projection154on the bottom edge150of the architectural finish element, while the first projection250is received in the groove156between the inner and outer projections154and152on the bottom edge150.

To facilitate use of the dual architectural finish element support apparatus160in areas of the architectural finish element140which have dovetailed tenons, at least some of the dovetailed tenons158are configured with a recess159to receive the guides204and206extending from the mounting portion164. In this case, the tenons158are configured to extend from the top edge142of the architectural finish element140to near the bottom edge150but not completely to the bottom edge. Rather, lower end portions270of the tenons158are spaced apart from the bottom edge150by the distance between the first receptacle252and a top272of the mounting portion164, leaving only a planar surface portion274of the rear surface of the architectural finish element exposed in this area. The enables the entire mounting portion164to be received in the space defined by the lower end portion270of the tenon158, and the planar surface portion274between the lower end portion of the tenon and the bottom edge150of the architectural finish element. In addition, the guides204and206on the dual architectural finish element support apparatus160are configured such that their distal surfaces260and262extend a distance264from the generally planar sheet portion180to touch the flat planar surface274between the lower end portion270of the tenon158and the bottom edge167of the architectural finish element140. In addition, distal flat surfaces280of the tenons158touch the flat surface282of the architectural structure. This provides for additional support.

The second holder168includes a second projection290operably configured to project downwardly when in use, in a direction opposite to the first projection250and operably configured to bear against a portion of a top edge169of the second architectural finish element170. In particular, in this embodiment, the second projection290is configured to bear against the second flat top surface146and a vertical surface292between the first and second flat top surfaces144and146of the second architectural finish element170such that the top edge169of the second architectural finish element is aligned with the bottom edge167of the architectural finish element140held by the first receptacle252and first projection250.

When architectural finish elements140and170of the type described are secured to the architectural structure in the above manner, adjacent tenons158and the planar surface portions274between adjacent tenons form air passageways300that extend parallel to the tenons and permit air to move therein, in a direction generally parallel to the orientation of the tenons. This enables moisture that may ingress between adjacent architectural finish elements140and170to reach an air passageway300. Such air passageways300formed by respective vertically adjacent architectural finish elements140and170are in communication with each other and facilitate airflow vertically along the passageways, which facilitates drying of moisture therein, thereby impeding moisture from reaching the architectural structure to which the architectural finish elements are attached. Thus, the tenons158act as integral moisture path interference structures operably configured to interfere with seepage of moisture from between adjacent architectural finish elements toward the architectural structure.

Referring toFIGS. 9 and 10, in the event of any movement of the architectural finish elements140and170relative to the surface of the architectural structure to which they are attached, the force absorbing member184resiliently deforms in response to such movement between the mounting portion164and the surface of the architectural structure and more particularly, absorbs differences in forces between the margins196and198adjacent the opening194in the mounting portion164of the dual architectural finish element support apparatus160and the surface of the architectural structure. This provides for a non-rigid connection between the architectural finish elements140and170and the architectural structure to which they are attached and such connection is operable to absorb at least some seismic forces and/or wind loading forces that can be experienced in some areas. Further, the force absorbing member184may resiliently deform to accommodate for different thermal expansions or contractions of the architectural finish element140and the architectural structure.

A plurality of architectural finish elements as described in connection withFIGS. 6 to 8and at least one dual architectural finish element support apparatus as described in connection withFIGS. 9 and 10can be arranged according to an architectural finishing method according to an embodiment of the invention to cooperate to create an architectural finishing system. Generally, the architectural finishing method comprises mounting the mounting portion164of the body162of at least one dual architectural finish element support160to a surface111of an architectural structure11, causing the first holder166to hold a portion of the bottom edge167of the first architectural finish element140in the first holder166, causing the second holder168on the body162to hold a portion of the top edge169of the second architectural finish element170adjacent to the bottom edge167of the first architectural finish element140and in alignment with the bottom edge of the first architectural finish element such that finish surfaces172and174of the first and second architectural finish elements140and170are generally coplanar and the method further involves absorbing mechanical forces between the first and second architectural finish elements and the architectural structure.

The first and second holders166and168hold the bottom edge167of the first architectural finish element140and the top edge169of the second architectural finish element170within about ¼ inches of each other.

Mounting involves causing the flat surface182of the body162to rest against the surface111of the architectural structure11and absorbing mechanical forces comprises causing the force absorbing member184to be held by the force absorbing member holder190, in a position to absorb the mechanical loads between the body162and the surface111of the architectural structure11.

Causing the force absorbing member184to be held comprises causing a portion of the force absorbing member to be held in the opening194in the mounting portion164and between the guides204and206on opposite sides of the opening194.

Causing the force absorbing member184to be held also comprises aligning the force absorbing member184in the opening194and aligning the force absorbing member between the guides204and206as shown.

Aligning the force absorbing member184comprises causing the flat outer surface218of the first projection216on the force absorbing member184to project through the opening194and bear against the surface111of the architectural structure11and causing the first and second end portions222and224of the holding portion220of the force absorbing member184to overlap with corresponding margins196and198on opposite sides of the opening194when the first projection216is received in the opening194.

Absorbing forces comprises causing the fastening bar186to receive the fastener188through the opening232therein and through the force absorbing member184such that the fastener bears188against the fastening bar186to cause the bearing surface230of the fastening bar186to bear against the holding portion220to press the opposite end portions222and224of the holding portion220against the margins196and198of the mounting portion164, while holding the projection216in contact with the surface111of the architectural structure11, such that differences in forces between the margins196and198and the surface111of the architectural structure11are absorbed by the force absorbing member184.

Absorbing forces also comprises causing the resilient body of the force absorbing member184to resiliently deform in response to forces between the surface111of the architectural structure11and the mounting portion164.

Causing the first holder166on the body162to hold a portion of a bottom edge167of the first architectural finish element140comprises causing the first projection250on the first holder166to be received in the groove156in the bottom edge167of the first architectural finish element140and holding the bottom edge167of the first architectural finish element140in a position spaced apart from the surface111of the architectural structure11.

The method further involves causing coplanar distal surfaces260and262of the guides204and206to touch the planar surface portion274on a back side of the first architectural finish element140to position the first architectural finish element on the surface111.

The method further involves causing the second projection290on the body162to bear against a portion of the top edge169of the second architectural finish element170.

Although the method described above involves a dual architectural finish element support apparatus160, in alternative embodiments, architectural finish element such as those illustrated inFIGS. 6 to 11, for example, may be secured to a surface of an architectural structure by placing wet mortar on the surface of the architectural structure and then setting the architectural finish element into the mortar. In such embodiments, the mortar is admitted into dovetailed recesses (such as the air passageways300shown inFIG. 11). Such admitted mortar hardens and contacts inward-facing surfaces of the dovetailed recesses, and may thus transmit a securing force to the inward-facing surfaces of the dovetailed recesses to secure the architectural finish element mechanically to the architectural structure. Such mechanical securing (in addition to securing from bonding of the mortar against the rear surface) may advantageously strengthen the securing of the architectural finish element to the architectural structure.

Glued Veneer Elements

Referring toFIG. 12an architectural finish element in accordance with another embodiment of the invention, is shown generally at400. In this embodiment individual unitary real stone elements402are lightweight stone elements that are pre-cut and glued together to form a body404having the basic form described above such that the overall architectural finish element has a density of more than about 8 pounds per square foot and no more than about 11 pounds per square foot. The unitary real stone veneer elements are glued, such as by epoxy for example, in courses406extending in a first direction408in a random non-repetitive pattern. The plurality of unitary real stone elements402are glued together such that a spacing between adjacent courses is generally between 0 inches to about ¼ inches and such that respective face surfaces410of the unitary real stone veneer elements generally lie in a common plane to form an overall face surface411of the architectural finish element having a dry-stacked appearance.

Thus, in this embodiment, like the earlier embodiment, the body404has main portion412and top, bottom and left and right edges414,416,418and420. The left and right edges418and420have complementary shapes for engaging with corresponding right and left edges of left and right adjacent similar architectural finish elements respectively as described above. In the embodiment shown, the left and right edges418and420of the body404have a complementary stepped-shape, wherein the left edge has an upper projection422and the right edge has a lower projection424, both projecting from the main portion412by the same distance, to as to form a lower receptacle426on the left side of the main portion412and an upper receptacle428on the right side of the main portion412. As above, this permits a lower projection of an adjacent left element (not shown) to be received in the lower receptacle426, while the upper projection422of the left edge is received in an upper receptacle (not shown) of the adjacent left element. Similarly an upper projection (not shown) of the adjacent right element (not shown) is received in the upper receptacle428, while the lower projection424of the right edge420is received in the lower receptacle (not shown) of the adjacent right element.

Referring toFIG. 3, the top and bottom edges414and416have top and bottom profiles respectively. The top edge profile extends along the main portion412of the body404and along a top portion of the upper projection422on the left side of the body and along a top portion of the lower projection424on the right side of the body. In the embodiment shown, the top and bottom edge profiles are flat planar surfaces such as shown inFIG. 3that permit the top and bottom edges of adjacent architectural finish elements to be butted up against each with no readily visible joint line.

The courses of the unitary real stone elements402are glued together such that upper and lower edges of left side stone elements402adjacent the left edge418of the body404are generally the same distance from the bottom edge416of the body as corresponding upper and lower edges of right side veneer elements adjacent the right edge420of the body such that when a left edge (not shown) of a first similarly configured adjacent architectural finish element (not shown) is engaged with the right edge420of the architectural finish element400, corresponding courses406of real stone veneer elements are aligned to create the appearance of continuous courses of the real stone veneer elements across the architectural finish element400and the similarly configured adjacent architectural finish element and such that when a right edge (not shown) of a second similarly configured adjacent architectural finish element (not shown) is engaged with the left edge418of the architectural finish element400, corresponding courses of real stone veneer elements are aligned to create the appearance of continuous courses of the real stone veneer elements across the architectural finish element and the second architectural finish element. In addition, due to the engagement of the stepped left and right edges418and420and the engagement of the top and bottom edges414and416with adjacent architectural finish elements, and due to the consistent placement of the real stone elements402in courses aligned at each edge, as described above, when a plurality of such architectural finish elements are engaged as described to form an overall surface on the architectural structure, the resulting overall surface has a consistent, uniform dry-stacked appearance with the randomness of stones in respective courses, but with the regularity of courses along the entire finished surface, in a manner similar to that described and shown in connection withFIG. 4.

Referring toFIG. 13, the body404has a rear portion420disposed opposite the face surface411. The rear portion430faces the architectural structure on which the architectural finish element is to be mounted. In the embodiment shown inFIG. 13, the rear portion430has a rear surface432opposite the face surface411of the body404and the rear surface432has no dovetailed tenons, but rather has only a generally flat planar portion operable to be directly glued or secured with mortar to the architectural structure.

Alternatively, referring toFIG. 14a mesh material434such as wire or plastic mesh, for example, may be glued to the planar rear surface432.

As a further alternative, referring toFIG. 15, a plurality of dovetail-shaped recesses436may be cut into the rear surface432from the top edge414to the bottom edge416to admit mortar therein. Once hardened, the mortar admitted into the dovetailed recesses436of the architectural finish element shown inFIG. 15contacts inward-facing surfaces of the dovetailed recesses436, and such admitted mortar may transmit a securing force to the inward-facing surfaces of the dovetailed recesses436to secure the architectural finish element mechanically to the architectural structure. Such mechanical securing (in addition to securing from bonding of the mortar against the rear surface432) may advantageously strengthen the securing of the architectural finish element400to the architectural structure.

In any of the embodiments shown inFIGS. 13, 14, and 15, top and bottom edge profiles having single flat surfaces as shown, facilitating abutting adjacent similar surfaces such as described above, may be cut into the body or the body may be formed in a jig to automatically form these flat top surfaces when gluing the individual stone veneer elements together. An architectural finish element so formed would be used like the architectural finish element described in connection withFIGS. 1 to 4, i.e. directly secured to the architectural structure using mortar, without the use of the dual architectural finish support apparatuses of the type described herein. In the embodiment shown inFIG. 13, mortar or glue alone would secure the architectural finish element to the architectural structure. In the embodiment shown inFIG. 14, the mesh material helps secure the architectural finish element to the mortar and in the embodiment shown inFIG. 15, the dovetailed recesses436in the rear surface432of the architectural finish element admit mortar initially applied to the architectural structure when the architectural finish component is pressed into the mortar.

In alternative embodiments, the top and bottom edges414and416may have cut therein top and bottom edge profiles as shown inFIGS. 6 and 7, whereupon the architectural finish element so formed can be used with dual architectural finish support apparatuses of the type described herein in connection withFIGS. 9 and 10.

Like the architectural finish elements described in connection withFIGS. 1 to 8 and 11, the architectural finish element formed by gluing individual stone veneer elements together, shown inFIGS. 12 to 15provides a body404with a face surface411provided by a collection of real stone elements402arranged to have a dry-stacked appearance. An architectural finish element of this type can be made at least large enough, such as in the dimensions described above, to provide about 1.33 square feet of coverage to the architectural structure and can be applied as a unit, avoiding individual placement of real stone veneer element directly on the architectural structure. Again, this enables rapid application of a finishing surface or outer cladding to an architectural structure 1.33 square feet at a time, rather than direct application of real stone veneer elements that cover only a few square inches at a time, while still achieving a dry-stacked appearance.