Note: Descriptions are shown in the official language in which they were submitted.
CA 02621937 2013-12-19
METHOD AND ELEMENTS FOR FORMING A BUILDING FACADE
FIELD OF THE INVENTION
The present invention relates to a façade element and a method of
forming a building façade using a plurality of façade elements.
BACKGROUND
Stone foundations on buildings are known to have a desirable
appearance. Due to the costly nature of forming a foundation of stone and the
difficulties involved in retro-fitting stone onto an existing building it is
popular to
make use of a façade to imitate that look of a stone foundation. Known façades
generally involve use of flat stones or imitation stones made of plaster which
are
mounted on an upright supporting surface of the building using mortar and
grout to
hold the stones in place. In each instance, costly and skilled labour is
typically
required to achieve a desirable finished appearance.
Various imitation stones formed of plastic material are known in the
prior art as shown in the following United States Patents: 4,940,558 to Jarboe
et
al.; 5,395,577 to Garski; 5,826,373 to Mrdjenovich; 6,248,411 to Krause;
4,197,684
to Johnson and D502,281 to Krause. None of the known prior art designs of
imitation stones are suited for replacing stones in a stone building
foundation
though due to their size and configuration.
SUMMARY OF THE INVENTION
According to one aspect of the invention there is provided a method
of forming a façade on an upright supporting surface, the method comprising:
forming a plurality of façade elements of plastic material having a flat
rear side and a decorative front side protruding from the rear side such that
the flat
and rear sides define a hollow interior therebetween, the decorative front
side
being free of any apertures;
abutting the flat rear side of each element against the upright
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supporting surface such that the elements are in spaced relation with one
another;
securing the elements to the upright supporting surface by piercing
the decorative front side with nails such that the nails are driven across the
hollow
interior and embedded through the rear side and into the supporting surface.
The use of façade elements which are formed of plastic are low in
cost and can be easily mounted on an upright supporting surface using nails or
adhesive by securing the elements directly to the supporting surface without
any
skilled labour being required.
The method may include securing the elements to the upright
supporting surface with nails by driving the nails fully through the front
side of the
elements so as to be embedded through the rear side and into the supporting
surface.
Alternatively, the elements may be secured to the upright supporting
surface using adhesive.
The front side may be formed to be generally dome shaped with a
stone-like texture, or alternatively to be rectangular in shape with the front
side
having a masonry-like texture.
The flat rear side preferably encloses a hollow interior of the element.
The method may include: 1) forming the elements to include a
peripheral flange lying in a common plane with the flat rear side to project
outwardly in opposing directions; and 2) securing the elements to the upright
supporting surface by securing the peripheral flange to the upright supporting
surface.
Alternatively, the method may include forming the elements with nails
integrally molded therein which project rearwardly beyond the flat rear side
of the
elements.
Subsequent to mounting the elements on the upright supporting
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surface, the method preferably includes grouting between the elements using
conventional mortar or caulking.
According to a second aspect of the present invention there is
provided a façade element comprising:
a plastic body having a flat rear side and a decorative front side
protruding from the rear side;
mounting means at the rear side of the plastic body for securing the
rear side in abutment with an upright supporting surface.
The mounting means may comprise a flat panel at the rear side
which is formed integrally with the front side of the plastic body and nails
for being
received through the flat panel.
The mounting means may alternatively comprise a peripheral flange
in a common plane with the flat rear side which projects outwardly in opposing
directions from the body with which the flanges are integrally molded.
In yet a further embodiment, the mounting means may comprise nails
which are integrally molded within the plastic body to project rearwardly
beyond
the flat rear side of the body.
The rear side may comprise a pair of flat panels supported
perpendicularly to one another to define an interior angle therebetween.
The plastic body of the element may be formed of polyethylene or
another suitable material which is sufficiently rigid to be self supporting,
yet resists
cracking with penetrated with a nail.
The rear side may include a plurality of protrusions formed integrally
thereon which project rearwardly from the rear side opposite the decorative
front
side, for abutment directly against the supporting surface so that the rear
side is
accordingly maintained at a slight spacing from the supporting surface for
breathability of the supporting surface. The protrusions may comprise spaced
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rows of integrally formed dome structures or elongate ridges, preferably
projecting
a uniform distance of near 1/16 of an inch from the rear side.
Various embodiments of the invention will now be described in
conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a perspective view of a building upon which the façade
elements have been installed.
Figure 2 is a side elevational view of a first embodiment of the façade
element.
Figure 3 is sectional view of the element according to Figure 2 as
shown installed on an upright supporting surface.
Figure 4 is a perspective view of a corner façade element.
Figure 5 is a partly sectional top plan view of the element according
to Figure 4.
Figure 6 is a sectional elevational view of a further embodiment of
the façade element.
Figure 7 is sectional side elevational view of yet a further
embodiment of the façade element.
Figure 8 is perspective view of another embodiment of the façade
element.
Figure 9 is a partly sectional perspective view of yet another
embodiment of the façade element.
In the drawings like characters of reference indicate corresponding
parts in the different figures.
DETAILED DESCRIPTION
Referring to the accompanying figures there is illustrated a façade
element generally indicated by reference numeral 10. The element 10 is used in
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cooperation with a plurality of other elements of similar configuration to
form a
building façade 11 which imitate the appearance of a natural stone or brick
foundation. Though various embodiments of the elements are described and
illustrated in the following, the common feature of each will first be
described
5 herein.
In each instance the element 10 includes a body formed of plastic
material, for example polyethylene, which is formed to include a substantially
flat
rear side 12 and a decorative front side 14 which is textured and which
protrudes
outwardly from a rear plane of the flat rear side 12. The plastic is formed so
as to
have sufficient strength to be rigid and self-supporting, yet will have
sufficient
resilience to prevent cracking when pierced with nails and the like during
mounting
of the elements on an upright supporting surface 16. The flat rear side 12 is
to be
configured to mount to the upright supporting surface 16 directly in abutment
therewith.
Turning now to Figures 2 and 3, a first embodiment is illustrated in
which the element is fully enclosed about a hollow interior. The flat rear
side 12
comprises an enclosed flat panel formed integrally with the front side 14
which
comprises a domed surface having a stone like texture at the outer side
thereof.
A plurality of protrusions 15 are integrally formed on the rear side 12.
The protrusions 15 comprise small domes or ridges which protrude, rearwardly
and outwardly opposite the front side 14, a uniform distance in the range of
less
than % of an inch and preferably near 1/16 of an inch. Accordingly, the rear
side
12 is maintained at a very slight spacing from the supporting surface for
ventilation
and breathability of the supporting surface if required. Certain supporting
surfaces
may not require the use of protrusions 15 and accordingly the rear side may be
directly abutted against the supporting surface in this instance.
When mounting on the building, the flat rear panel is substantially
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abutted against the upright supporting surface by placing the protrusions
directly
against and in contact with the supporting surface. Nails are used to secure
the
element in place. Using an air driven nailer, nails 17 are inserted at the
front side
so as to be driven fully through the front side 14 then remain imbedded
through the
flat rear panel at the rear 12 and the supporting surface 16 for gripping the
flat rear
panel to the supporting surface. As shown in Figure 3, each of the elements is
secured to the upright supporting surface with a plurality of the nails such
that the
nails are in non-parallel relation to one another and at an inclination to the
supporting surface. Additional elements 10 are mounted in a similar manner in
spaced apart relation with one another on the upright supporting surface. A
grouting material 18 is then used to fill the gaps between adjacent elements.
The
grouting material may comprise conventional mortar or a caulking material.
Turning now to Figures 4 and 5 a corner façade element is illustrated
which is similarly formed as an enclosed element having a hollow interior. The
rear
side 12 comprises two flat panels 20 oriented perpendicularly to one another
to
define an interior corner which overlaps an exterior corner of the upright
supporting
surface 16 on the building. The front side 14 is similarly formed integrally
with the
rear side to form a domed surface with a stone texture. Nails are similarly
driven
through the front side 14 for gripping the rear side 12 and being embedded
into the
supporting surface 16.
Turning now to Figure 6 a further embodiment of the element is
shown in which the rear side 12 is open and is defined by a peripheral flange
22
lying in a common rear plane of the element to project generally radially
outwardly
from opposing peripheral edges of the elements. The front side in this
instance is
similarly domed to protrude outwardly from the rear plane and includes a stone
texture thereon. Nails 17 can then be driven directly into the peripheral
flange 22 at
the rear side to secure the flange to the upright supporting surface with the
rear
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side in direct abutment with the supporting surface.
Turning now to Figure 7 a further embodiment is illustrated in which
the rear side 12 is similarly open and includes a peripheral rim 24 lying in
the rear
plane at the rear side. The front side 14 is domed and projects outwardly from
the
rear side with a stone texture thereon. A series of posts 26 are mounted
within the
hollow interior of the element to project from the front side to terminate in
the rear
plane commonly with the peripheral rim 24 at the rear side. Nails 28 are
molded
integrally within the post 26 to project rearwardly beyond the rear plane
defined by
the peripheral rim 24. In order to mount the element of Figure 7 to the
upright
supporting surface, the entire element is urged towards the upright supporting
surface so that the rear side is in direct abutment therewith by using a
rubber
mallet or the like to effectively hammer the integral nails 28 into the
upright
supporting surface 16.
Turning now to Figure 8 a further embodiment of the element is
illustrated in which the plastic formed body is fully enclosed with a hollow
interior
similarly to the first embodiment. The rear side is flat with the front side
14 being
generally rectangular and protruding outwardly from the rear side to form a
rectangular brick like shape. The front side 14 includes a masonry-like
texture for
resembling a conventional masonry brick. In order to mount the element to the
wall, nails are similarly used to be driven fully through the front side 14 to
be
embedded in the rear side 12 and the upright supporting surface 16.
In further embodiments, the elements 10 may be secured by
adhesive or other suitable fastening means which permit the rear side 12 to be
abutted against the upright supporting surface upon which the building façade
12
is to be formed.
Turning now to Figure 9, a further embodiment is illustrated in which
the element 10 is substantially the same as the embodiment of Figures 2 and 3,
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however the substantially flat rear side 12 includes protrusions 15 in the
form of
elongate ridges instead of domed structures as noted in the previous
embodiments. The flat rear side is thus corrugated in cross-section. In
practice
however, the corrugations are very small, commonly protruding near 1/16 of an
inch from the plane of the rear side so that the rear side remains
substantially flat.
When mounted on the supporting surface, the element 10 accordingly to figure 9
is
positioned so that the ridges directly abut against the supporting surface
while the
space between the ridges ensures that the supporting surface remains
breathable.
In all embodiments, a plurality of façade elements are formed of
plastic material and are mounted with their rear sides in abutment with the
upright
supporting surface in spaced apart relationship with one another. Nails are
typically provided for adequately securing the elements to the supporting
surface.
Once mounted on the supporting surface, a suitable caulking or grouting
material
18 is used to fill the gaps between adjacent elements 10.
The façade elements can be formed by various manufacturing
techniques including injection moulding, rotational moulding, blow moulding or
thermoforming depending upon the desired characteristics of the finished
elements.
