WO2016004464A1

WO2016004464A1 - A veneer quoin and a method of constructing the same

Info

Publication number: WO2016004464A1
Application number: PCT/AU2015/000400
Authority: WO
Inventors: Rito CALABRESE
Original assignee: Tasmanian Sandstone Quarries Pty Ltd
Priority date: 2014-07-09
Filing date: 2015-07-09
Publication date: 2016-01-14

Abstract

The present invention relates to veneer quoin (10) including a first veneer panel (12), a second veneer panel (14), a corner member (16) and a support member (18). Adhesive (50) is used to adhere the support member (18) to at least a part of a rear face (12a) of the first veneer panel (12) and a part of a rear face (14a) of the second veneer panel (14). The adhesive (50) also adheres the first veneer panel (12) to the corner member (16) and the second veneer panel (14) to the corner member (16). The corner member (16) is located between the first and second veneer panels (12, 14).

Description

A Veneer Quoin and a Method of Constructing the Same

Related Application

[0001] This application claims convention priority from Australian provisional patent application 2014902659 filed on 9 July 2014, the full contents of which are incorporated herein by this reference.

Technical Field

[0002] The present invention relates to a veneer quoin and a method of constructing the same. The present invention also relates to a column incorporating veneer quoins and a method of establishing a column with an appearance of a solid block construction using such veneer quoins.

Background of Invention

[0003] Traditionally, quoins are larger bevelled stones used to give emphasis to a corner of a structure. Quoins provide a form of decoration to a structure by visually outlining the geometry of that structure and also provide some additional strength to the corners of the structure. Stone quoins are typically used on stone or brick buildings and each quoin is a solid block of material (for example solid stone) which is individually cut to the required size and shape. Hence, such quoins are heavy to transport and to work with and are quite expensive to manufacture.

[0004] Brick quoins may appear on brick buildings and they are typically positioned to extend from the facing brickwork so as to give the appearance of bricks or blocks that are larger than the bricks forming the remainder of the structure.

[0005] Where quoins are used for decoration and are not load-bearing, they may be made from a wide variety of materials including stone, timber and cement render. They are typically applied over the actual material forming the corner of the structure and are commonly referred to as stucco quoins or veneer quoins. For example, veneer quoins may be applied at the corner of a structure made from bricks or over the walling sheets forming the structure. These types of quoins have a thickness equal to the distance they are required to protrude out from the wall and are thus relatively thin. Such quoins do not provide any structural strength.

[0006] Although veneer quoins are popular because they are relatively

inexpensive compared to solid block quoins, they do not have the same visual appeal and are thus unacceptable to some consumers. One problem with veneer quoins is in the manner in which the adjacent panels forming the veneer quoin join at a corner. One approach is to abut the end face of one veneer panel forming the veneer quoin to the rear face of the adjacent veneer panel of the same quoin (Figure 8(a)). Another approach is to bevel the end face of each quoin panel and to then abut them along their bevelled faces (Figure 8(b)). A variation to this bevel approach is to cut the bevel with a setback so that an inset vertical chamfer is formed at the corner when the panels of the veneer quoin are abutted (Figure 8(c)). Figure 8(d) illustrates a variant of the arrangement shown in Figure 8(a). All of these approaches result in a visible join at or adjacent the corner and do not establish the more traditional join free corner with an external or exposed chamfer achieved with solid quoin blocks.

[0007] It is possible to generally achieve the appearance of quoins with a join free chamfered corner by rendering the corners of the structure and then fixing veneer flat panels at the same course level but slightly away from the corner. The rendered corner is thus visible and provides the chamfered corner appearance desired.

However, the rendered corner is easily damaged and the appearance of the render must be maintained by painting to ensure a high quality appearance. Such

maintenance is often undesirable to the consumer.

[0008] In the past, attempts have been made to form a veneer quoin of unitary construction so as to avoid corner joins and to provide an appearance of greater resemblance to solid quoin blocks. When cut from a solid stone block such veneer quoins have been unsuccessful because they are easily broken at the corner causing them to break into two. Accordingly, it is not possible to transport such veneer quoins after manufacture without excessive breakage rates. [0009] US patent application publication 2009/0056257 teaches a simulated stone, brick or masonry panel product. The product is arranged to form a panel and one or more of such panels are used together to form the wall of a building or other structure. The panels are arranged to interconnect, somewhat like jig-saw pieces to form a continuous wall panel. The product described in US patent application publication 2009/0056257 is not a veneer quoin.

[0010] US patent application publication 2012/0247045 teaches a system and method of attaching a natural stone to a wall surface. This is achieved by attaching a piece of stone to a base plate so as to leave at least a portion of the base plate uncovered by the stone. The veneer is then attached via the base plate to the wall surface. Multiple such veneers are used to form a continuous wall panel as shown in Figure 1 of US patent application publication 2012/0247045. It will be noted that the base plate of adjacent veneers must be formed or trimmed so that the base plate of each veneer is not visible when a continuous wall panel is established. The veneer 10c shown in Figure 5 of the publication is formed using an "L" shaped piece of stone. The veneer 10c is not suitable for use as a quoin because at least some part of the base plate would need to be exposed and this would be unsightly.

[0011] US patent 2,305,280 teaches a siding corner piece for use with siding panels. The siding corner piece includes flap portions 23 that extend beyond the side edges 18. These flap portions 23 are covered in use by siding panels 17. The siding corner pieces cannot be used as veneer quoins because of the exposed flap portions 23. It is also noted that the siding corner pieces do not establish an appearance in any way similar to a solid block quoin. The siding corner piece of this patent is intended to be used in conjunction with multiple siding panels.

[0012] The present invention seeks to provide a veneer quoin that in situ adopts the appearance of a solid block quoin.

[0013] The discussion of the background to the invention herein is included to explain the context of the invention. This is not to be taken as an admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of this application. Summary of Invention

[0014] According to the present invention there is provided a method of constructing a veneer quoin with a unitary construction, said method including: a) providing a first veneer panel, a second veneer panel, a corner member and a support member; b) abutting a first end face of the first veneer panel to a first end face of the corner member; c) abutting a first end face of the second veneer panel to a second end face of the corner member whereby the corner member is located between the first and second veneer panels; and d) applying adhesive to adhere the support member to at least a part of a rear face of the first veneer panel and a part of a rear face of the second veneer panel, said adhesive also adhering the first veneer panel to the corner member and the second veneer panel to the corner member whereby the unitary construction is established.

[0015] The method further preferably includes the step of: e) adhering the support member to at least a part of a rear face of the corner member.

[0016] The method may further include the step of: f) cleaning off any adhesive exposed to an exterior side of the constructed veneer quoin.

[0017] Preferably, the step of cleaning the exposed adhesive occurs after the adhesive has gone off.

[0018] The first veneer panel and second veneer panel are preferably rectangular shaped panels. The rear face of each panel is preferably substantially planar. Each panel has a front face that may adopt different configurations. For example, the front face may be planar, may adopt a sawn appearance, may adopt a hewn appearance or a honed appearance and may include a chamfered border.

[0019] The corner member is preferably a member of L-shape cross section. The corner member preferably has first and second end faces of height substantially equal to the height of the first end faces of each of the first and second veneer panels.

[0020] The support member is shaped so that it can be positioned against the rear face of each panel and be adhered thereto in such a manner that the support member and adhesive do not interfere with the later installation of the veneer quoin on a construction. The support member and adhesive provide strength to the constructed veneer quoin. The support member is shaped so that it is not visible when the veneer quoin is later adhered to a corner of a construction.

[0021] The support member is preferably a member of L-shape cross section. In one preferred form, the support member is formed from a piece of wire mesh bent to the required configuration. The wire mesh is selected so that it can be bent into the required shape but is of such rigidity that it will retain that shape unless a force equal to or greater than the original bending force is applied. The use of wire mesh is advantageous because it is of light weight as compared to a solid construction and the mesh pattern facilitates capture of the adhesive against the rear face of the panels whilst the adhesive is going off. Other materials may be used to construct the support member.

[0022] The adhesive may be any suitable adhesive and may vary depending on the material of the first and second veneer panels. An example of a suitable adhesive when the panels are made of sandstone is Chemgrip® cement.

[0023] The method may further include the step of colouring the adhesive.

[0024] The invention further provides a veneer quoin including a first veneer panel, a second veneer panel, a corner member and a support member, and wherein adhesive is used to adhere the support member to at least a part of a rear face of the first veneer panel and a part of a rear face of the second veneer panel, said adhesive also adhering the first veneer panel to the corner member and the second veneer panel to the corner member. The first and second veneer panels and the corner member are arranged so that a first end face of the first veneer panel abuts against a first end face of the corner member, and a first end face of the second veneer panel abuts against a second end face of the corner member whereby the corner member is located between the first and second veneer panels.

[0025] In accordance with a preferred embodiment and when the veneer quoin is in use on a structure, the first end face of the first veneer panel and the first end face of the second veneer panel extend in a substantially vertical plane.

[0026] The invention also provides a method of establishing a column with an appearance of a solid block construction, said method including fixing veneer quoins according to an embodiment of the invention to a column structure. Preferably, the method includes the steps of fixing at least one veneer quoin to an external face of the column structure so that the veneer quoin establishes a corner of the column.

Brief Description of Drawings

[0027] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0028] Figure 1 is a front isometric view of a veneer quoin according to an embodiment of the invention;

[0029] Figure 2 is a rear isometric view of the veneer quoin shown in Figure 1 ;

[0030] Figure 3 is a top isometric view of the corner portion of the veneer quoin shown in Figures 1 and 2;

[0031] Figure 4 depicts two different corner members as used in the construction of veneer quoins according to embodiments of the invention;

[0032] Figure 5 is a view of a support member as used in the construction of the veneer quoin shown in Figure 1 ;

[0033] Figure 6 is an isometric view illustrating part of the assembly process of a quoin according to an embodiment of the invention; [0034] Figure 7 illustrates a cross sectional view of a column constructed with veneer quoins according to an embodiment of the invention; and

[0035] Figures 8(a) to 8(d) illustrate prior art veneer quoin configurations made from individual veneer panels.

Detailed Description

[0036] Figures 1 to 3 illustrate a veneer quoin 10 according to an embodiment of the invention. The quoin 10 includes a first veneer panel 12, a second veneer panel 14 and a corner member 16. In accordance with the illustrated embodiment, each of the first panel 12, second panel 14 and corner panel 16 are made from sandstone. However, this need not be the case and it is envisaged that the invention could be used to manufacture veneer quoins from a range of different stones (natural and manufactured) as well as other appropriate material. It is also anticipated that the first panel 12, second panel 14 and corner panel 16 need not necessarily be made from the same material. However, it is envisaged that making each of the first panel 12, second panel 14 and corner panel 16 from the same material and where possible from the same source, will result in a veneer quoin that when in use most closely resembles a traditional solid quoin block.

[0037] As illustrated, the first and second panels 12, 14 have a rear face 12a, 14a that is generally planar (for example as sawn) and an external face 12b, 14b which is hewn. Other finishes for the rear face 12a, 14a and external face 12b, 14b of each of the panels 12, 14 are envisaged.

[0038] Also as illustrated, the first and second panels 12, 14 are rectangular. The first panel 12 is of greater length than the second panel 14, whilst they are of identical or substantially identical height. The first panel 12 has a length of 350mm and the second panel 14 has a length of 230mm. The height of each panel 12, 14 is 368mm. This configuration of first and second panels 12, 14 of different lengths is adopted to establish a veneer quoin with an appearance similar to a traditional rectangular shaped solid quoin block. It will of course be appreciated that the present invention is not limited to first and second panels 12, 14 of such relative size, shape or stated dimensions. [0039] Figure 4 illustrates two corner members 16. The illustrated corner members 16 have the same configuration but are made of stone of different colour. As shown, each corner member 16 has an L-shape cross section and the external sides of the leg of each part of the "L" are approximately 30mm in length. The external sides of the corner member 16 are generally planar and are finished so that when attached to the first and second panels 12, 14 adopt the configuration and

appearance of an external vertical chamfer typically included at the corner of a traditional stone solid quoin block.

[0040] Figure 5 illustrates a support member 18 as used to construct the veneer quoin 10. The support member 18 has a mesh configuration and is formed from a rectangular sheet of wire mesh. The wire mesh is bent into an L-shape configuration and is sized so as to be fitted into the corner created by the first panel 12, second panel 14 and intervening corner member 16. The support member 18 is arranged to be adhered to the rear face 12a, 14a of the first and second panels 12, 14 as best depicted in Figures 2 and 3. The support member 18 is covered by an adhesive 50 in these Figures however the mesh configuration of the support member 18 is still clearly visible.

[0041] The veneer quoin 10 is constructed by abutting a first end face 12c of the first veneer panel 12 to a first end face 16a of the corner member 16. A first end face14c of the second veneer panel 14 is abutted to a second end face 16b of the corner member 16. A small amount of adhesive is preferably placed along each first end face 12c, 14c to help adhere each of the panels 12, 14 to the corner member 16. Preferably, the adhesive placed along each of the first end faces 12c, 14c is of a colour to match the material of the first and second panels 12, 14 and the corner member 16. Correctly colour matching the adhesive to the material of the panels 12, 14 and corner member 16 will help to ensure that the constructed veneer quoin 10 appears as a solid quoin block.

[0042] The support member 18 is then positioned so it nests within the corner established sequentially by the first panel 12, corner member 16 and second panel 14. Further adhesive is then applied to adhere the support member 18 to at least a part of the rear face 12a of the first veneer panel 12 and a part of the rear face 14a of the second veneer panel 14. It is particularly advantageous to ensure that the support member 16 is also adhered to the rear side of the corner member 16.

[0043] Any adhesive 50 that is exposed to an exterior side of the constructed veneer quoin 10 and that would be visible once the veneer quoin 10 is mounted to the corner of a structure should be removed. In some instances it may be appropriate to wipe off the adhesive before it goes off and in other instances it may be appropriate to remove the adhesive thereafter. For example, where the first panel 12, second panel 14 and corner member 16 are made as illustrated of sandstone, a chisel can be used to break any exposed adhesive off after the adhesive hardens. This results in a finish where the joins between the corner member 16 and the first and second members 12, 14 are almost undetectable.

[0044] As apparent from Figure 1 , the first veneer panel 12, corner member 16, and second veneer panel 14 each have an external face 12b, 16c', 16c", 14b that is exposed to thereby establish a visible face of the veneer quoin 10 when it is attached to a construction.

[0045] A veneer quoin in accordance with an embodiment of the invention adopts a unitary construction (i.e. one piece construction) and has many advantages over prior art veneer quoins. Firstly, a stone veneer quoin according to an embodiment of the invention is lighter in weight than a conventional solid stone block quoin. Hence, it is more cost effective to transport and easier to handle by the user as compared to a conventional sold stone block quoin. The inclusion of a support member in the veneer quoin increases the strength of the constructed veneer quoin and thus it is less prone to breakage than prior art unitary construction veneer quoins (i.e. where the veneer is cut as an L-shaped piece of stone). The support member is not however visible when the veneer quoin is adhered to a structure. The veneer panels are easy to manufacture and can be manufactured with different finishes (for example planar, rough cut, hewn, bird pick, convict pick) on their external face. Thus, a veneer quoin in accordance with an embodiment of the invention can be made to match any appearance required by the consumer. [0046] Veneer quoins according to an embodiment of the invention can also be manufactured from stone that would otherwise not be suitable for use as solid block quoin. This reduces waste.

[0047] Veneer quoins according to an embodiment of the invention require no maintenance and more readily match existing quoins of a structure. Further, when a structure, for example a house, is being extended upwardly, veneer quoins according to an embodiment of the invention can be constructed to match the appearance of any existing quoins and are advantageous because of their lower weight. They are easier to work with but still offer the 'solid' appearance of traditional solid block quoins. Veneer quoins according to an embodiment of the invention can simply be adhered to a corner of a structure to provide the appearance of a solid block quoin. The structure may be made from a range of different materials including brick, concrete blocks, foam blocks, or board.

[0048] One of the most important advantages of a veneer quoin in accordance with an embodiment of the invention is that there are no joins along the length of the actual corner of the constructed veneer quoin because of the inclusion of the corner member. Hence veneer quoins according to an embodiment of the invention more closely resemble solid stone block quoins with an external vertical chamfer at their corner.

[0049] Although embodiments of the invention have been described with the first panel, second panel and corner member being made from sandstone. It is envisaged that in accordance with other embodiments of the invention, such components could be made of other stones such as bluestone, limestone, schist, granite and marble. These components could also be made from clay and fired to form a brick.

[0050] It has also been recognised that veneer quoins according to an

embodiment of the invention could be used on columns so that they adopt the appearance of columns constructed from solid blocks. To this end, a column structure would firstly be formed. The column structure could be formed using various different conventional techniques. For example, walling sheets may be attached to a frame and the frame may be formed around a structural support such as a metal column. Veneer quoins would then be attached to the corners of the column structure. Preferably, veneer quoins would be attached to the column structure in a series of courses. Each veneer quoin according to an embodiment of the invention forming a corner of the column.

[0051] Each course of the veneer quoins is preferably configured so as to establish the appearance that the column was constructed from a number of solid bricks. It will also be appreciated that veneer quoins according to an embodiment of the invention could be attached to a pre-existing column to modify its original appearance. In this way, the pre-existing column could be modified to establish a column with the appearance of a solid brick construction.

[0052] Figure 7 illustrates a cross sectional view of a column 100 constructed using veneer quoins 150 according to an embodiment of the invention. As shown, each course of the veneer column 100 is made from four veneer quoins 150 each secured to the rectangular column structure 200. Each veneer quoin 150 establishes a corner of the column.

[0053] The column structure 200 shown in Figure 7 is schematically depicted simply as four sheets of material. However it will be appreciated that typically such sheets of material would be secured to some form of frame (not illustrated). The column 100 adopts the appearance of a column constructed from courses of solid blocks, each course including four solid blocks.

[0054] It will be appreciated that the dimensions of the first panel, second panel and corner panel of the constructed veneer quoins could be varied depending on the dimension of the column structure. Further, at least one first or second panel could be located between a veneer quoin according to an embodiment of the invention if the columns structure was not square in cross-section or if the column structure was sized so that the four veneer quoins forming the corners of the structure did not establish a complete course of blocks on the column structure.

[0055] The embodiments have been described by way of example only and modifications within the spirit and scope of the invention are envisaged.

Claims

1 . A method of constructing a veneer quoin with a unitary construction, said method including: a) providing a first veneer panel, a second veneer panel, a corner member and a support member; b) abutting a first end face of the first veneer panel to a first end face of the corner member; c) abutting a first end face of the second veneer panel to a second end face of the corner member whereby the corner member is located between the first and second veneer panels; and d) applying adhesive to adhere the support member to at least a part of a rear face of the first veneer panel and a part of a rear face of the second veneer panel, said adhesive also adhering the first veneer panel to the corner member and the second veneer panel to the corner member whereby the unitary construction is established.

2. A method according to claim 1 further including the step of: e) adhering the support member to at least a part of a rear face of the corner member.

3. A method according to claim 1 or claim 2 further including the step of: f) cleaning off any adhesive exposed to an exterior side of the constructed veneer quoin.

4. A method according to claim 3 wherein the step of cleaning the exposed adhesive occurs after the adhesive has gone off.

5. A method according to any one of claims 1 to 4 further including the step of colouring the adhesive.

6. A method according to any one of the preceding claims wherein the step of providing the first veneer panel and second veneer panel includes cutting them from a block of stone.

7. A veneer quoin constructed in accordance with the method of any one of claims 1 to 6.

8. A veneer quoin including a first veneer panel, a second veneer panel, a corner member and a support member, and wherein adhesive is used to adhere the support member to at least a part of a rear face of the first veneer panel and a part of a rear face of the second veneer panel, said adhesive also adhering the first veneer panel to the corner member and the second veneer panel to the corner member whereby the corner member is located between the first and second veneer panels.

9. A veneer quoin according to claim 8 wherein a first end face of the first veneer panel abuts against a first end face of the corner member, and a first end face of the second veneer panel abuts against a second end face of the corner member.

10. A veneer quoin according to claim 8 or claim 9 wherein the first veneer panel and second veneer panel are rectangular shaped panels.

1 1 . A veneer quoin according to any one of claims 8 to 10 wherein the rear face of each panel is substantially planar.

12. A veneer quoin according to any one of claim 8 to 1 1 wherein the corner member is a member of L-shape cross section.

13. A veneer quoin according to any one of claims 8 to 12 wherein the support member is a member of L-shape cross section.

14. A veneer quoin according to any one of claims 8 to 13 wherein the support member has a mesh configuration.

15. A veneer quoin according to any one of claims 8 to 14 wherein the support member is formed from a piece of wire mesh bent to an L-shape cross section.

16. A veneer quoin according to any one of claims 8 to 15 wherein the first veneer panel and second veneer panel are made from stone.

17. A veneer quoin according to claim 156wherein the corner member is made from a stone.

18. A veneer quoin according to claim 16 or claim 17 wherein the stone is selected from sandstone, bluestone, limestone, schist, granite or marble.

19. A veneer quoin according to any one of claims 8 to 15 wherein the first veneer panel and second veneer panel are made from clay.

20. A veneer quoin according to any one of claims 8 to 19 wherein the first veneer panel, corner member, and second veneer panel in use each have an external face that is exposed to thereby establish a visible face of the veneer quoin.

21 . A method of establishing a column with an appearance of a solid block construction, said method including the steps of: a) fixing at least one veneer quoin according to any one of claims 8 to 20 to an external face of a column structure so that the veneer quoin establishes a corner of the column.

22. A method of establishing a column according to claim 21 wherein four veneer quoins are fixed to the external face of the column structure so that each of the veneer quoins establishes a corner of a course of quoins of the column.

23. A method of establishing a column according to claim 22 including fixing further courses of veneer quoins along the length of the column.

24. A column with an appearance of a solid block construction constructed in accordance with the method of any one of claims 21 to 23.