U.S. patent application number 12/636476 was filed with the patent office on 2010-04-15 for adjustable masonry form.
Invention is credited to MICHAEL EUGENE BAILEY.
Application Number | 20100088983 12/636476 |
Document ID | / |
Family ID | 37522815 |
Filed Date | 2010-04-15 |
United States Patent
Application |
20100088983 |
Kind Code |
A1 |
BAILEY; MICHAEL EUGENE |
April 15, 2010 |
Adjustable Masonry Form
Abstract
An adjustable masonry form is disclosed for use in masonry
constructions. The adjustable masonry form comprises a planar base
section to support the masonry elements which will comprise the
masonry construction, and a plurality of attachment elements
secured to the planar base and at least one horizontal breakaway
element for use in modifying the width of the planar base. The
adjustable masonry form is constructed from material rigid enough
to support the masonry elements, but flexible enough to be bent to
conform to any given masonry construction without unwanted buckling
of the form. The form is left in position permanently, obviating
the need to build a temporary arch support saving time and expense
and obviating waste of materials.
Inventors: |
BAILEY; MICHAEL EUGENE;
(ASHVILLE, AL) |
Correspondence
Address: |
BRADLEY ARANT BOULT CUMMINGS LLP;INTELLECTUAL PROPERTY DEPARTMENT
1819 FIFTH AVENUE NORTH
BIRMINGHAM
AL
35203-2104
US
|
Family ID: |
37522815 |
Appl. No.: |
12/636476 |
Filed: |
December 11, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11148904 |
Jun 9, 2005 |
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12636476 |
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Current U.S.
Class: |
52/204.2 ;
52/745.16 |
Current CPC
Class: |
E04F 2013/061 20130101;
E04G 21/1841 20130101; E04G 21/1866 20130101; E04F 13/06
20130101 |
Class at
Publication: |
52/204.2 ;
52/745.16 |
International
Class: |
E04G 15/02 20060101
E04G015/02; E04G 21/18 20060101 E04G021/18 |
Claims
1. An adjustable masonry form for supporting a masonry
construction, the masonry construction comprising a plurality of
masonry elements each having a width, the form comprising: (a) a
planar base receiving and supporting the plurality of masonry
elements, the planar base capable of adjustment between a first
width about equal to or greater than the width of the plurality of
masonry elements and a second width substantially less than the
width of the plurality of masonry elements, the planar base
comprising: two ends, a front edge, a rear edge, a bottom surface,
and a top surface; and (b) a plurality of attachment elements
secured to the planar base; the adjustable masonry form remaining a
permanent part of the masonry construction.
2. The adjustable masonry form of claim 1 wherein the form is
manufactured from a material sturdy enough to support the masonry
elements, but flexible enough to conform to the contours of the
masonry construction without deforming the planar base and the
attachment elements.
3. The adjustable masonry form of claim 1 where the masonry
construction is an arched construction or a horizontal
construction.
4. The adjustable masonry form of claim 1 comprising at least one
horizontal breakaway element, said horizontal breakaway elements
spaced apart on said planar base by a distance, said distance being
independently selected from the range of 0.25 inches to 2.0
inches.
5. The adjustable masonry form of claim 1 further comprising a
horizontal breakaway element that is horizontal to a longitudinal
axis of the planar base.
6. The adjustable masonry form of claim 1 where the first width of
the planar base is greater than the width of the masonry
elements.
7. The adjustable masonry form of claim 1 further comprising at
least one horizontal breakaway element used to modify the width of
the planar base.
8. The adjustable masonry form of claim 7 where the planar base has
a thickness and the at least one horizontal breakaway element is a
groove, said groove having a depth that is less than the thickness
of the planar base.
9. The adjustable masonry form of claim 7 where the planar base has
a thickness and the at least one horizontal breakaway element is a
score line, said score line comprising a plurality of cuts
separated by a plurality of interspaced areas.
10. The adjustable masonry form of claim of claim 9 where the cuts
extend through the thickness of the planar base.
11. The adjustable masonry form of claim 10 where the interspaced
areas have a depth and the depth is equal to the thickness of the
planar base or less than the thickness of the planar base.
12. The adjustable masonry form of claim 9 where the cuts and the
interspaced areas each have a distance, the distance being
independently selected from the range of 0.25 inches to 2.0
inches.
13. The adjustable masonry form of claim 9 where the plurality of
cuts comprise a first cut, said first cut having a having a length
greater than the remaining cuts of the score line and positioned
contiguous to the first or second end of the planar base.
14. The adjustable masonry arch form of claim 1 further comprising
at least one vertical breakaway element.
15. The adjustable masonry form of claim 14 comprising a plurality
of vertical breakaway elements, said vertical breakaway elements
spaced apart on said planar base by a distance, said distance being
independently selected from the range of 1 inch to 36 inches.
16. The adjustable masonry form of claim 14 where said at least one
vertical breakaway element is perpendicular to a longitudinal axis
of the planar base.
17. The adjustable masonry form of claim 14 where the vertical
breakaway elements are used to modify the length of the form.
18. The adjustable masonry form of claim 14 where the planar base
has a thickness and the at least one vertical breakaway element is
a groove, said groove having a depth that is less than the
thickness of the planar base.
19. The adjustable masonry form of claim 1 where the attachment
elements are spaced apart along the rear edge of the planar base
and form a generally perpendicular angle with the planar base.
20. A method of constructing an arch, comprising: securing the arch
form of claim 1 to an exterior of a structure; placing a plurality
of masonry elements on the arch form to create a masonry arch;
adjusting the planar base from the first width to the second width;
and allowing at least a portion of the arch form to permanently
remain secured to the exterior of the structure.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 11/148,904, filed Jun. 9, 2005 (currently pending), which is
incorporated by reference herein in its entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates generally to a device for use
in masonry applications. In particular, the present disclosure
relates to an adjustable masonry form to support masonry elements
in masonry construction.
BACKGROUND
[0003] In building projects, such as residential homes and
commercial buildings, ornamental masonry elements are often placed
over/around various structural features for aesthetic purposes.
Structural features commonly include windows and doors. However,
other types of structural features may also be included such as but
not limited to walls. As used in this specification, a "masonry
element" shall mean any element, such as, but not limited to, stone
and brick, used for construction purposes, generally using mortar
as a bond. A masonry element can be manufactured from any material
and can be of regular or irregular shape. The presence of masonry
accents in a residential home can greatly increase its resale
value, and provides the homeowner with the desired aesthetic look
and feel he/she is seeking.
[0004] The process of installing masonry elements over and/or
around a desired structural feature varies depending on the shape
of the desired structural feature. In some cases, the top of the
structural feature will be horizontal (horizontal construction). In
other cases, the top of desired structural feature will have an
arched component (arched construction). By "horizontal
construction" it is meant that the structural feature does not have
a change in elevation at any point intermediate between the ends of
the structural feature. By "arched construction" it is meant the
structural feature that has a change in elevation at any point
intermediate between the ends of the structural feature. The tern
"masonry construction" is used to refer to both horizontal and
arched constructions. In the case of horizontal constructions, the
standard practice is to lay the masonry elements across a
supporting horizontal beam or support (commonly referred to as a
lintel) set in place over the structural feature, for example a
window. The lintel can be made from steel, wood, or reinforced
concrete, depending on the size of opening and weight to be
supported. The lintel commonly rests on the masonry that is
installed up the sides of the window. The masonry elements are then
installed on the horizontal face of the lintel in the configuration
desired. The lintel remains a part of horizontal construction above
the window or door.
[0005] In arched constructions, this practice cannot be employed.
As stated above, the lintels are generally constructed from steel,
wood, or reinforced concrete and cannot be easily adapted to fit
the contours of an arched construction. Therefore, other methods
must be used to support the masonry elements that form a masonry
arch in an arched construction. Several methods are typically used
to support the masonry elements that form a masonry arch. The first
method is to build an arch faun, which is commonly constructed from
plywood and dimensional lumber. The arch form must be constructed
to exactly fit the contours of the masonry arch to be constructed,
and is supported in place with wooden legs or other supports. The
arch provides the surface to support the masonry elements forming
the arched construction while the mortar hardens. Once the mortar
hardens, the arch four is removed and discarded. In addition, the
mortar must generally be scratched or chiseled to conform to the
appearance of the mortar forming the remainder of the
structure.
[0006] The second method is to drive nails or similar items into
the outer edge of the exterior of a structure to support the
masonry elements that forms the masonry arch. In order to provide
sufficient support for the masonry elements, the nails must be
placed close together, which necessitates the use of a large number
of nails. Once the mortar hardens, the nails are removed. The
removal of the nails leaves multiple holes in the exterior molding
that must be repaired by filling the holes and painting the
surface
[0007] The third method is to support a section of lumber
horizontal to the bottom edge of the masonry arch to be
constructed. Once the section of lumber is in place, bricks or
other material are stacked on the horizontal section of lumber to
support the masonry elements that form the masonry arch. As is
obvious, the bricks are placed in a jigsaw fashion until the proper
height is reached to support each section of the masonry elements.
This requires that the bricks be cut into smaller pieces to support
various sections of the arch. In addition to being very time
consuming, such a method leads to many bricks being wasted. In
addition, the bricks can fall easily requiring the temporary form
be reconstructed. Once the mortar hardens, the bricks and the
horizontal section of lumber are removed.
[0008] A fourth method to support the masonry elements that form a
masonry arch is to use prefabricated arch supports. These arch
supports are shipped with the arch structure preformed. However,
these items must be specially ordered since the configuration of
masonry arches varies from application to application, making a
"standard" prefabricated arch form impractical. As a result, these
prefabricated supports are expensive. In addition, the
prefabricated supports create other problems. Since the supports
are prefabricated in the form of an arch, they are bulky to ship
and store, further increasing their cost. In addition, these
preformed supports are susceptible to damage during shipping and
storage. As a result, if the units are damaged, construction may be
delayed while replacement supports are obtained.
[0009] Each of the methods discussed above suffer from several
shortcomings. In general, the methods are tedious and time
consuming to implement. As a result, the cost of the final
construction can be increased dramatically. In addition, the arched
constructions lack the strength of the horizontal constructions
because of the lack of a solid lintel. In most cases, much of the
weight of the masonry arch in supported directly by the structure
over which the arch is installed, such as a door or window. This
additional weight can cause damage.
[0010] In addition, the Applicant has previously described an
adjustable masonry form for use in supporting masonry elements in
horizontal and arched constructions (see U.S. Pat. No. 6,848,224).
While the device described by Applicant is effective in meeting the
needs of the art, it has been found that certain portions of the
adjustable arch form are visible when the arched or horizontal
construction is viewed from the underside.
[0011] Therefore, it would be desirable therefore to have an
adjustable masonry form was at least partially concealed in the
finished horizontal or arched construction. In addition, it is
desirable that such adjustable arch form be simple to use, be
installed conveniently and economically without the need for the
removal of temporary supports. Finally, it would be desirable if
the adjustable arch form eliminated the need to make costly repairs
to the exterior of the structure caused by the installation
process. Such a device is currently lacking in the art. The present
disclosure provides and novel and inventive solution in providing
an adjustable arch from to meet the needs of the art.
BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1A is a perspective top view of one embodiment of the
adjustable masonry form of the present disclosure.
[0013] FIG. 1B is a perspective bottom view of one embodiment of
the adjustable masonry form of the present disclosure illustrating
one embodiment of the horizontal horizontal breakaway elements.
[0014] FIG. 1C is a perspective view of the one embodiment of the
adjustable masonry form of the present disclosure illustrating an
alternate embodiment of the horizontal horizontal breakaway
elements.
[0015] FIG. 2 is a perspective view of the adjustable masonry form
of FIGS. 1A and B being installed over an arched construction, in
this figure a door.
[0016] FIG. 3 is a side, cutaway view of the adjustable masonry
form of FIGS. 1A and B as installed in an arched construction.
[0017] FIG. 4A is a side view of the adjustable masonry form of
FIGS. 1A and B illustrating one embodiment of the grooves.
[0018] FIG. 4B is a side view of the adjustable masonry form of
FIGS. 1A and B illustrating an alternate embodiment of the
grooves.
[0019] FIG. 5 is a partial cutaway view of the adjustable masonry
form of FIGS. 1A and B installed over an arched construction, in
this figure a window.
SUMMARY
[0020] The adjustable masonry form of the present disclosure is an
improvement over current devices available for use in masonry
construction. The adjustable masonry form comprises a planar base
section to support at least one masonry element which will comprise
the masonry arch, a plurality of attachment elements secured to the
planar base and at least one horizontal breakaway element located
on the planar base to allow adjustment of the width of the planar
base. In addition, the adjustable masonry form may further comprise
at least one vertical breakaway element located on the planar base
to allow adjustment of the length of the adjustable masonry form.
The adjustable masonry form is constructed from material rigid
enough to support the masonry elements, but flexible enough to be
bent to conform to any given masonry construction. The adjustable
masonry form is secured to the exterior of a structure by means
known in the art, such as screws, nails or staples; suitable
adhesives may also be used if desired. The masonry elements which
will comprise the masonry construction are placed directly on the
planar base of the adjustable masonry form in the desired
configuration and secured in the masonry construction, such as by
using mortar or similar methods. The adjustable masonry form is
left in position permanently, obviating the need to build a
temporary support saving time and expense and obviating waste of
materials, while providing additional strength to the masonry
construction. The adjustable masonry arch may be modified by
removing at least a portion of the planar base using the horizontal
breakaway elements. In addition, there is no repair required to the
exterior surface of the structure.
[0021] Therefore, it is an object of the disclosure to provide an
adjustable masonry form that is capable of being installed in any
masonry construction at a construction site without the need to
create individually configured temporary supports for the masonry
construction. It is another object of the disclosure to provide an
adjustable masonry form that is permanently installed in a masonry
construction, thereby obviating the time consuming and wasteful
practice of creating temporary forms, and which provides additional
strength to the masonry arch. An additional object of the
disclosure is to provide an adjustable masonry form such that the
planar base and/or attachment elements will not be deformed as the
adjustable masonry form is bent to conform to the contours of a
masonry construction. Yet another object of the disclosure to
provide an adjustable masonry form that is economical to produce
and simple to install, decreasing the overall cost of the finished
masonry construction. It is a further object of the disclosure to
provide an adjustable masonry form that can be easily shipped,
transported and stored, thereby minimizing the risk of damaging the
form and avoiding costly construction delays caused by ordering
replacement arch forms. It is also an object of the disclosure to
provide an adjustable masonry form that will prevent damage to the
structure to which masonry construction is installed. Furthermore,
it is an object of the disclosure to provide an adjustable masonry
form that can be modified to conform to the individual dimensions
of the masonry construction so as to decrease or eliminate the
visibility of the adjustable masonry form. Additional objects and
advantages will become apparent through the drawings and
descriptions that follow.
DETAILED DESCRIPTION
[0022] The adjustable masonry form 10 is illustrated in FIGS. 1-5,
where like numbers in the figures refer to like elements. While the
adjustable masonry form 10 can be used in any masonry construction,
the description below describes the use of the adjustable masonry
form 10 in an arched construction. However, it should be understood
that the adjustable masonry arch from 10 can also be used in a
horizontal construction.
[0023] As illustrated in FIG. 1, the form 10 is comprises a planar
base 12, a plurality of attachment elements 22 and at least 1
horizontal breakaway element 19 located on the planar base 12. The
planar base 12 comprises a longitudinal axis 14, a front edge 16
and a rear edge 18 parallel to the axis 14, an upper surface 15, a
lower surface 17 and two ends 20A and 20B. The width of the planar
base 12 is sufficient to support the masonry elements to be
incorporated into the masonry construction. The width of the planar
base 12 may be greater than or less than the width of the masonry
elements and can be varied as determined by individual applications
as can be determined by one of ordinary skill in the art. In one
embodiment the planar base 12 is 3 inches wide. For aesthetic
purposes, it is desired that the width of the planar base 12 be
slightly less than the width of the masonry elements to be
incorporated into the masonry arch (as illustrated in FIG. 3). The
width of the planar base may be manufactured to be less than the
width of the masonry elements or be modified to be less than the
width of the masonry elements either before of after installation
using the horizontal breakaway elements 19 as described herein. The
adjustable masonry form 10 can be manufactured in any length
desired and can be cut to fit a given installation at the job
site.
[0024] A plurality of attachment elements 22 are secured to the
rear edge 18. In the embodiment illustrated, the attachment
elements 22 are shown as flanges (although any configuration of
attachment elements may be used). The flanges may be of any desired
configuration, but in the embodiment shown the flanges are shown
with rounded edges for ease of installation and to remove sharp
edges which may cause injury to the installer. In one embodiment
the attachment elements 22 each have an opening 24 for receiving an
element to secure the form 10 to a structure. In one embodiment,
the opening 24 is centered on the attachment elements 22 for ease
of use, but opening 24 may be placed anywhere on flange 22.
[0025] The attachment elements 22 are placed at intervals along
rear edge 18 of the planar base 12. In one embodiment, the
attachment elements 22 are placed 1 inch apart along the length of
the rear edge 18. By spacing the attachment elements 22 apart from
one another, the adjustable masonry form 10 can be bent to conform
to the contours of a desired masonry construction without deforming
planar base 12 and/or the attachment elements 22. In prior devices,
when the form is made to conform to the contours of an arched
construction, the device would be deformed at undesirable locations
in response to the bending force applied. This deformation is often
referred to as splaying or buckling. As a result of the splaying or
buckling of prior devices, the masonry elements could not be
installed in a uniform and aesthetically pleasing manner. The
spacing apart of the attachment elements 22 along the rear side 18
also allows the form 10 to be bent without requiring excessive
bending force to be applied, allowing the form 10 to be installed
at a jobsite with no special equipment required. The width of each
individual attachment elements 22 is such that the attachment
elements 22 can be secured, but narrow enough so that the
attachment elements 22 will not interfere with the flexibility of
the form 10. In one embodiment the width of the individual
attachment elements is 1 inch. The above spacing distances and
widths are given as examples only, and other spacing distances and
flange widths may be used as determined by one of ordinary skill in
the art and should be considered within the scope of this
disclosure.
[0026] The adjustable masonry form 10 further comprises at least
one horizontal breakaway element 19 on the planar base 12. The
horizontal breakaway element 19 may be positioned on the lower
surface 17, the upper surface 18, or both as desired. The
horizontal breakaway element 19 allows a user to configure the
adjustable masonry form 10 to a particular installation by altering
the width "W" of the planar base 12. In this manner, the width of
the planar base 12 of the adjustable masonry form 10 can be custom
tailored to each masonry construction if desired. In one
embodiment, the horizontal breakaway element 19 is a groove,
designated 19a (FIGS. 1A and 1B and 4A and 4B). In an alternate
embodiment, the horizontal breakaway element is a scored line
designated 19b (FIG. 1C). Other horizontal breakaway elements may
be used as is known in the art. The horizontal breakaway element 19
runs at least partially down the length of the planar base 12. In
one embodiment, the horizontal breakaway element runs the entire
length or substantially the entire length of the planar base 12.
The horizontal breakaway element 19 may be parallel to the
longitudinal axis 14 of the planar base 12. A plurality of
horizontal breakaway elements 19 may be positioned on the planar
base 12 at varying distances from the rear edge 18 of the planar
base 12. In one embodiment, a horizontal breakaway element 19 is
placed every 0.25 inches, or every 0.5 inches or every 1 inch or
every 2 inches from the rear edge 18 and/or the front edge 16. The
placement of the horizontal breakaway elements as described allows
a user to select a particular horizontal breakaway element 19 for
use in tailoring the width of the planar base 12 as described
below. For the purpose of the present disclosure and the figures
presented herein, the horizontal breakaway element 19 is shown as
groove 19a and score line 19b.
[0027] The groove 19a has a depth (indicated by the distance "X" in
FIGS. 4A and B) and an outer configuration 21. In one embodiment,
the groove 19a runs horizontal to the longitudinal axis 14 of the
planar base 12. The groove 19a extends into planar base 12 a
distance (or depth) X that is less than the thickness of the planar
base 12 (designated "T" in FIGS. 4A and 4B) such that the groove
19a does not extend completely through the planar base 12. The
depth X of the groove 19a is selected so that the planar base 12
may be cut by a blade or other cutting device when required with
minimal effort. In one embodiment, the depth X extends up to 75% of
the thickness T; in an alternate embodiment, the depth X extends up
to 90% of the thickness T; in yet another alternate embodiment, the
depth X extends up to 95% of the thickness T, in still another
alternate embodiment, the depth X extends up to 98% of the
thickness T; in a further embodiment, the depth X extends up to 99%
of the thickness T. The groove 19a also has an outer configuration
21. The outer configuration may take on a number of shapes and is
not critical to the present disclosure. In one embodiment, the
outer configuration is a curved or arcuate. In an alternate
embodiment, the outer configuration takes a geometric shape, such
as a triangle, a square, a rectangle or a polygon. FIGS. 4A and 4B
provide two examples of the outer configuration of groove 19a. The
outer configuration of the groove 19a may be adapted to receive a
blade or other cutting device to allow the planar base 10 to be
configured to a particular masonry construction.
[0028] In the embodiment illustrated in FIG. 1C where the
horizontal breakaway element 19 is a scored line 19b, the scored
line 19b comprises a series of cuts 19d that extend completely
through the thickness T of the planar base 12, with the cuts 19d
being separated by interspaced areas 19e. The interspaced areas 19e
may have a thickness equal to the thickness T of the planar base 12
or less than the thickness T of the planar base 12. The cuts 19d
and interspaced areas 19e may be of any length desirable. In one
particular embodiment, the cuts 19d are from 0.25 to 2 inches in
length and the interspaced areas 19e are from 0.25 to 1 inch in
length. The length of the cuts 19d and the interspaced areas 19e
determined the overall spacing of the cuts 19d along the planar
base 12. In one embodiment, a cut 19d is placed adjacent to one or
both of the ends 20A or 20B and is referred to as the "first cut".
The first cut may form an opening or gap in one or both of the ends
20A or 20B and may have a length greater than the remaining cuts
19d to aid in tearing the planar base 12 along the scored line
19b.
[0029] The adjustable masonry form 10 may further comprise at least
one vertical breakaway element 30 on the planar base 12. The
horizontal breakaway element 19 may be positioned on the lower
surface 17, the upper surface 18, or both as desired. The vertical
breakaway element 30 allows a user to configure the length of the
adjustable masonry form 10 to a particular installation easily and
efficiently. In one embodiment, the vertical breakaway element 30
is a groove, designated 30a (FIG. 1B). In an alternate embodiment,
the vertical breakaway element 30 is a scored line designated 30b
(FIG. 1C). Other vertical breakaway elements 30 may be used as is
known in the art. The vertical breakaway element 30 runs at least
partially across the width W of the planar base 12. In one
embodiment, the vertical breakaway element 30 runs substantially
the entire width W of the planar base 12. The vertical breakaway
element 30 may be perpendicular to the longitudinal axis 14 of the
planar base 12. A plurality of vertical breakaway elements 30 may
be positioned on the planar base 12 at varying distances from the
ends 20A and/or 20B of the planar base 12. In one embodiment, a
vertical breakaway element 30 is placed every 1 inch, or every 5
inches or every 12 inch or every 24 inches or every 36 inches from
the ends 20A or 20B. The placement of the vertical breakaway
elements 30 as described allows a user to select a particular
vertical breakaway element 30 for use in tailoring the length of
the adjustable masonry arch as described. For the purpose of the
present disclosure and the figures presented herein, the vertical
breakaway element 30 is shown as groove 30a and score line 30b. The
groove 30a is understood to be identical in structure to groove 19a
and to share the features as described of groove 19a. Score line
30b is understood to be identical in structure to score line 30b
and to share the features as described of score line 30a
[0030] The adjustable masonry foil 10 is made of a material that is
rigid enough to support the masonry elements comprising the masonry
arch, yet flexible enough to be bent to conform to the contours of
a masonry construction, such as an arched construction as typically
encountered over a window or door. A preferred material for
construction of form 10 is a plastic such as a high strength
plastic. However, other materials may be used provided that such
materials are susceptible to being modified along the horizontal
breakaway elements 19 as discussed herein so as to customize the
adjustable masonry form 10 for a desired masonry construction. For
example, the adjustable masonry foils 10 may be manufactured from
metals, such as aluminum, tin and other light gauge metals, or
composite materials. Since the adjustable masonry form 10 is
flexible, it can be bent from its horizontal configuration to
conform to the contours of an arched construction and secured in
place at the site of use (illustrated in FIGS. 2 and 5).
[0031] In one embodiment, the adjustable masonry form 10 is
manufactured from a plastic. Any plastic material may be used as is
known in the art including but not limited to thermoplastics,
thermosets and elastomers. Exemplary plastics include, but are not
limited to, polyvinyl chloride, polystyrene, nylon, high density
polyethylene, polyethylene, low density polyethylene,
polypropylene, polyimide, polyester, acrylic and vinyl. When
plastic is used, the plastic may be colored by the inclusion of a
pigment in the manufacturing process so as to have a characteristic
color. The characteristic color may be matched with the color of
the masonry elements used in the masonry construction if desired to
provide a more pleasing aesthetic impact. In addition, the plastic
may be clear/transparent so as to be less visible in the finished
masonry construction (for example when an acrylic is used).
[0032] The form 10 can be made by a variety of methods, the
following being provided as example only. The form 10 may be formed
from a single piece of material. For example, when metals are used,
the adjustable masonry form 10 may be stamp cut, die cut or laser
cut to form the planar base 12 and the individual attachment
elements 22 at the desired intervals along the newly formed rear
edge 18. Such methods are well known in the art. Once the
attachment elements 22 are formed, the attachment elements 22 can
be bent upward such that they are generally perpendicular to axis
14 of the planar base 12. The attachment elements 22 are
illustrated as flanges with rounded edges for ease of installation
and to minimize sharp edges, however, any configuration of
attachment elements 22 may be produced. Alternatively, individual
attachment elements 22 may be produced individually and secured to
the rear edge 18 of planar base 12 by any convenient means, such as
by welding. In the case where the adjustable masonry form 10 is
produced from a plastic or similar material, the adjustable masonry
form 10 may be manufactured using any technique known in the art,
such as but not limited to, injection molding, extrusion molding or
blow molding. Such methods are well known in the art. The
attachment elements 22 may be produced in the molding process or
from a precursor sheet as described above using a die-cutting
method, a stamp cutting method or laser cutting method.
[0033] The adjustable masonry form 10 is produced in a horizontal
configuration. The benefits of making the adjustable masonry form
10 in the horizontal configuration include ease of transporting,
shipping and storing the adjustable masonry form 10 as compared to
prefabricated forms. Since the adjustable masonry form 10 is not
prefabricated to a final configuration (such as but not limited to
an arch), much less space is required to ship, transport and store
the adjustable masonry form 10. In addition, because the adjustable
masonry form 10 is made in the horizontal configuration out of a
sturdy material, the adjustable masonry form 10 is less likely to
be damaged during shipping, transport and storage, thereby
eliminating possible delay in construction caused by obtaining
replacement forms. Furthermore, since the adjustable masonry form
10 can be bent to conform to any arched construction, there is no
need to maintain a supply of prefabricated adjustable masonry forms
for use on different types of arched constructions, greatly
decreasing the cost of storage and maintaining the proper
inventory.
[0034] The use of the adjustable masonry form 10 is illustrated in
FIGS. 2, 3 and 5. The adjustable masonry foul 10 is placed at a
desired location to form a masonry construction. In this example an
arched construction is described, but the techniques of use are
applicable to a horizontal construction as well. The adjustable
masonry foil n 10 is secured to a structure at the desired location
for the arched construction, illustrated best in FIGS. 2, 3 and 5.
The adjustable masonry form may be placed against a molding
(designated 50) that defines the arched construction as is known in
the art. The adjustable masonry form 10 is then bent into shape
over the molding 50 to conform to the shape of the molding 50 and
provide a flat surface on which to place the masonry elements which
will comprise the arched construction. FIG. 2 shows the adjustable
masonry form 10 in its horizontal configuration (10A) prior to
bending and after it is bent (10B) to conform to the contours of
the arched construction. The adjustable masonry form 10 can be
manipulated to fit any arched construction by simply cutting the
form 10 to the desired length and bending the form 10 to conform to
the contours of the desired arched construction. In one embodiment,
the form 10 is cut to the desired length before being bent to
conform to the desired arched construction. The vertical breakaway
elements 30 may be used to modify the length of the adjustable
masonry arch to the desired length if desired. Once the adjustable
masonry form 10 is in place, the form 10 is secured to the exterior
of the structure, illustrated as sheathing 52 in FIGS. 3 and 5.
FIG. 3 shows the adjustable masonry form 10 being secured by a nail
54, however, other securing elements, such as screws, staples, or
bolts may be employed. Once the adjustable masonry form 10 is
secured, the flanges 22 may be covered with the appropriate
waterproof construction paper to prevent seepage of water behind
the form 10.
[0035] Once adjustable masonry form 10 is secured in place, masonry
elements 58 are placed on the planar base 12 and arranged according
to the specifications for the given arched construction. While any
masonry elements may be used, FIG. 3 illustrates a typical brick 56
being installed on planar base 12 with a keystone 58a at a desired
location. The individual masonry elements are then secured in the
desired arrangement, such as by mortar or similar material. Once
the mortar hardens, the masonry elements 58 are secured in place.
The adjustable masonry form 10 remains as a part of the arched
installation and it is not required to remove the form 10. An
additional advantage of the adjustable masonry form 10 remaining a
permanent part of the masonry arch is the faun 10 provides strength
to the masonry arch. As a result, the mortar holding the masonry
arch together is less prone to crack as a result of normal settling
of the structure and other factors. As a result, repair and
maintenance cost may be significantly less in masonry
constructions, such as arched constructions, having the additional
strength afforded by form 10, than in arched constructions without
such additional strength.
[0036] As discussed above, it is desirable that the width of the
planar base 12 be less than the width of the masonry elements to be
installed on planar base 12 such that planar base 12 is partially
concealed in the finished masonry construction. However, when
viewed from below, a significant portion of the planar base 12 can
be seen in the finished masonry construction. The present
disclosure allows the adjustable masonry form 10 to be configured
based on the individual masonry construction such that the planar
base 12 is essentially invisible (even when viewed from below) in
the finished masonry construction.
[0037] As best shown in FIG. 5, the adjustable masonry form 10 may
be configured based on the individual masonry construction, in this
example an arched construction. Once the adjustable masonry form 10
is installed and the masonry elements 58 placed thereon and secured
together, the width of the planar base may be decreased using the
horizontal breakaway elements 19. Alternatively, the width of the
planar base 12 may be modified prior to installation. In this
manner, the width of the planar base may be decreased to a point
where only a small portion of the planar base 12 is remaining or no
portion of the planar base 12 is remaining. For example, when the
horizontal breakaway element 19 is a groove 19a, a user places a
cutting element in the groove 19a and moves the cutting element
along the groove 19a such that the planar base is severed along the
groove 19a. Depending on which groove 19a is selected, the amount
of planar base 12 remaining can be selected by the user. As
discussed above, the groove 19a has a depth X that is less than the
thickness T of the planar base 12. The cutting element cuts through
the thickness of the planar base defined by the distance T-X (which
is illustrated in FIGS. 4A and 4B as T1). As discussed above, T1
may be varied by altering the depth X of he groove 19a or by
altering the thickness T of the planar base, or by a combination of
the foregoing. The cutting element may be selected depending on the
material from which the adjustable masonry form 10 is manufactured.
If the adjustable masonry form 10 is manufactured from a plastic or
similar material a knife blade or other blade may be used. If the
adjustable masonry form 10 is manufactured from a metal, a powered
cutting element may be used. Since the width of the planar base 12
can be modified after installation of the adjustable masonry form
12, the initial width of the planar base 12 may be wider than the
width of the masonry elements 58 used in the masonry construction.
The greater width of the planar base 12 may allow the adjustable
masonry form to provide more support to the masonry elements 58
during installation, thereby simplifying the installation process.
As discussed above, the width of the planar base 12 can be modified
using the horizontal breakaway elements 19 so that the planar base
12 of the adjustable masonry faun 10 is not visible or slightly
visible in the finished masonry construction.
[0038] Alternatively, when the horizontal breakaway element 19 is a
scored line 19b, the user simply selects the appropriate scored
line 19b and places sufficient pressure along the scored line 19b
such that the scored line 19b, with the aid of the cuts 19d, tears
along the scored line 19b. The pressure may be applied by hand or
as assisted by a device. Depending on which scored line 19b is
selected, the amount of planar base 12 remaining can be selected by
the user.
[0039] A small portion of planar base 12 may be left in the
finished masonry construction to aid in supporting the masonry
elements 58. However, all or substantially all of the planar base
12 may be removed if desired such that the planar base 12 provide
no or substantially no support to the masonry elements 58. In one
embodiment, a portion of the planar base 12 is left in order to
support the masonry elements 58 in the finished masonry
construction. The portion may be in the range of 0.25 to 2 inches.
The visibility of said portion of the planar base 12 may be
decreased by coloring the adjustable masonry form 10 to match the
color of the masonry elements 58 or the surrounding masonry
construction, or by manufacturing the adjustable masonry form 10 to
be transparent.
[0040] As discussed above, there are several alternate methods of
supporting masonry elements in an arched construction. In most of
these methods, the masonry elements are placed directly on the
molding of the window or door over which they will be installed. In
the case of installation over windows, the weight of the masonry
elements stresses the window such that the panes in the window may
be damaged. For example, it is not uncommon for the seal in a
double-paned window to break under the weight of masonry elements,
which are applied directly on the molding of the window. The use of
the form 10 removes the weight of the masonry elements from the
window or door, thereby preventing damage to these components,
further reducing the costs of construction.
[0041] The above has described several embodiments of the
adjustable masonry form in detail so that the form and its
principles of operation may be understood. The above discussion
should not be interpreted to exclude additional embodiments of the
form. With respect to the above description, it should be
considered that the optimal dimensional relationships for the
various parts of the form, including variations in size, materials,
shape, form, function and manner of operation, assembly and use,
are readily apparent to one of ordinary skill in the art, and all
equivalent relationships to those described above and illustrated
in the figures are intended to be encompassed by the present
disclosure. Therefore, the foregoing is considered illustrative
only, and should not be understood to limit the scope of the
disclosure to the exact construction and operation discussed and
illustrated.
* * * * *