U.S. patent application number 17/664850 was filed with the patent office on 2022-09-08 for fiber enforced thin brick sheet and process.
The applicant listed for this patent is Old Mill Brick LLC. Invention is credited to Garrick Hunsaker, Jason Hunsaker, Jeffrey Walker.
Application Number | 20220282492 17/664850 |
Document ID | / |
Family ID | 1000006348816 |
Filed Date | 2022-09-08 |
United States Patent
Application |
20220282492 |
Kind Code |
A1 |
Hunsaker; Jason ; et
al. |
September 8, 2022 |
FIBER ENFORCED THIN BRICK SHEET AND PROCESS
Abstract
A fiber enforced sheet for use as a wall or floor covering which
comprises of adhered thin bricks bonded to a fiber-reinforced,
backing layer. Thin brick is adhered to the fiber enforced sheet.
The fiber enforced backing increases strength and rigidity to the
thin brick during handling, and installation permits the thin
bricks to be adhered to proper specification and spacing to be cut
using ordinary tile or thin brick tools.
Inventors: |
Hunsaker; Jason; (Woodland
Hills, UT) ; Walker; Jeffrey; (South Weber, UT)
; Hunsaker; Garrick; (Bluffdale, UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Old Mill Brick LLC |
Bluffdale |
UT |
US |
|
|
Family ID: |
1000006348816 |
Appl. No.: |
17/664850 |
Filed: |
May 24, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16601378 |
Oct 14, 2019 |
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17664850 |
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|
16059994 |
Aug 9, 2018 |
10443247 |
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16601378 |
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15380733 |
Dec 15, 2016 |
10072426 |
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16059994 |
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13278815 |
Oct 21, 2011 |
9556619 |
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15380733 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 156/1092 20150115;
E04F 13/142 20130101; E04F 13/147 20130101; E04F 15/08 20130101;
E04F 13/09 20130101; E04F 13/0862 20130101; E04F 13/0733 20130101;
E04F 15/166 20130101; E04F 13/0885 20130101 |
International
Class: |
E04F 13/09 20060101
E04F013/09; E04F 15/16 20060101 E04F015/16; E04F 15/08 20060101
E04F015/08; E04F 13/08 20060101 E04F013/08; E04F 13/14 20060101
E04F013/14; E04F 13/073 20060101 E04F013/073 |
Claims
1-41. (canceled)
42. A method of installing thin brick sheets, comprising: applying
a first adhesive to a wall or floor surface; and applying a thin
brick sheet to the wall or floor surface, wherein the thin brick
sheet comprises a backing layer and a plurality of thin bricks that
are bonded to the backing layer via a second adhesive, wherein the
backing layer defines a grid that comprises a plurality of holes,
and wherein the plurality of thin bricks are bonded to the backing
layer such that the first adhesive penetrates through the plurality
of holes to hold the brick sheet to the wall or floor surface.
43. The method of claim 42, wherein the backing layer is
non-stretchable.
44. The method of claim 42, wherein the backing layer comprises at
least one of fiberglass, polyester, graphite, aramid, or
carbon.
45. The method of claim 44, wherein the backing layer comprises
fiberglass.
46. The method of claim 42, wherein the plurality of bricks are
adhered to the backing layer in a running bond pattern or a stack
bond pattern.
47. The method of claim 46, wherein the plurality of bricks are
adhered to the backing layer in a stack bond pattern.
48. The method of claim 42, wherein the adhesive penetrates through
a plurality of holes disposed behind the plurality of thin bricks
to bond the thin bricks to the wall or floor surface.
49. The method of claim 42, wherein the plurality of thin bricks
comprise one or more of clay bricks, cast bricks, or wire cut
bricks.
50. The method of claim 42, wherein the thin brick sheet consists
of four rows of thin bricks.
51. The method of claim 50, wherein the thin brick sheet consists
of three thin bricks per row.
52. A method of installing thin brick sheets, comprising: applying
a first adhesive to a wall or floor surface; and applying a thin
brick sheet to the wall or floor surface, wherein the thin brick
sheet comprises a backing layer and a plurality of thin bricks that
are bonded to the backing layer via a second adhesive, wherein the
backing layer defines a grid that comprises a plurality of holes,
and wherein the plurality of thin bricks are bonded to the backing
layer such that the first adhesive penetrates through the plurality
of holes to hold a rear surface of the brick sheet to the wall or
floor surface.
53. The method of claim 52, wherein the backing layer is
non-stretchable.
54. The method of claim 52, wherein the backing layer comprises at
least one of fiberglass, polyester, graphite, aramid, or
carbon.
55. The method of claim 54, wherein the backing layer comprises
fiberglass.
56. The method of claim 52, wherein the adhesive penetrates through
a plurality of holes disposed behind the plurality of thin bricks
to bond the thin bricks to the wall or floor surface.
57. The method of claim 52, wherein the plurality of thin bricks
comprise one or more of clay bricks, cast bricks, or wire cut
bricks.
58. The method of claim 52, wherein the thin brick sheet consists
of four rows of thin bricks.
59. The method of claim 58, wherein the thin brick sheet consists
of three thin bricks per row.
60. A method of installing thin brick sheets, comprising: applying
a first adhesive to a wall or floor surface; and applying a thin
brick sheet to the wall or floor surface, wherein the thin brick
sheet comprises a backing layer and a plurality of thin bricks that
are bonded to the backing layer via a second adhesive, wherein the
plurality of thin bricks comprise one or more of clay bricks, cast
bricks, or wire cut bricks, wherein the backing layer defines a
grid that comprises a plurality of holes, wherein the plurality of
thin bricks are bonded to the backing layer such that the first
adhesive penetrates through the plurality of holes to hold a rear
surface of the brick sheet to the wall or floor surface, and
wherein the thin brick sheet consists of four rows of thin
bricks.
61. The method of claim 60, wherein the thin brick sheet consists
of three thin bricks per row.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] This invention relates to fabricated thin brick sheets for
use as wall or floor coverings and a process for manufacturing such
sheets. The invention is a veneer, one layer of which comprises of
an array of glued or adhesive applied thin bricks.
2. The Prior Art
[0002] Thin brick has long been a highly desired backing material
for walls and floors, for interior and exterior, and the like. It
is attractive, durable, waterproof, and fireproof. Thin bricks are
available in a wide variety of sizes, shapes, colors, patterns,
textures, and surface finishes. They are uniquely suited to a
variety of applications ranging from decorative accents in the
homes to complete commercial exterior finishes.
[0003] Thin brick per se is relatively inexpensive, being made
essentially from clay minerals fired at high temperature. Not so
its installation. The conventional construction of a thin brick
wall, for example, begins with the installation of metal lath over
a vapor barrier secured sheathing. Next, a scratch coat of mortar
is applied to the lath followed by an accurately leveled mortar bed
for the thin brick. Should the scratch coat be uneven, a separate,
additional leveling layer of mortar may be required. When using
adhesive brick are set one by one then grouted using mortar applied
between thin brick. Individual thin bricks must be cut using
special equipment and tools to fit them to spaces requiring less
than a full thin brick or to fit them around fixtures and the
like.
[0004] Thin brick setting is a skilled occupation, commanding high
wages. The level of skill required, and the time-consuming nature
of conventional thin brick installation render the process very
expensive. Unfortunately, due to the high cost of thin brick
installation, some builders have attempted installation shortcuts
in a misguided effort to save money. Improper installation
techniques frequently result in expensive repairs for the homeowner
or general contractor.
[0005] Given this situation, it is not surprising to find a number
of proposed solutions to the problem in the prior art. The concept
of a prefabricated thin brick sheet which would not require any
thin brick setting at the installation site has long been
considered. However, the thin brick sheets previously described
have all proved unsatisfactory for reasons such as insufficient
strength, excessive weight, complexity of installation, and high
labor cost. And none have met with commercial success to any
significant extent.
[0006] Thus, it will be appreciated that the prefabricated thin
brick sheets known in the art prior to this disclosure all relied
on a core part, commonly of steel, plastic, foam, or a relatively
thick backing layer to impart some measure of structural strength
and rigidity to the sheets. These cores substantially increase the
thickness of the sheets, and this in turn necessitates special
mounting hardware for installation.
SUMMARY OF THE MENTION
[0007] The present invention comprises a thin, lightweight thin
brick sheet which greatly simplifies and reduces the cost of
installing thin brick walls, floors, and the like. The invention
further comprises a method of making such a sheet and or
installation.
[0008] The thin brick sheets of the invention include a plurality
of thin bricks pre-assembled and mounted on a fiber enforced sheet.
The spaces between the thin bricks are filled with grout to seal
these spaces against moisture, etc. The term "grout" should be
understood to include both the conventional thin, cementitious
mortar used for filling joints in masonry as well as chemicals that
solidify, such as polyurethanes, room temperature vulcanizing
silicones, other elastomers, plastics, and the like. The sheets
normally feature a regular pattern of substantially rectangular
thin bricks in a side-by-side, laterally spaced rectangular array;
however, a wide variety of thin brick shapes and trim pieces are
contemplated.
[0009] The thin bricks of the invention are preferably thinner and
lighter than common bricks. Thus, the thin bricks will generally be
greater than 0.125 inch thick, and less then 3 inches. The light
weight of the thin bricks makes it possible for relatively large
sheets of such thin bricks to be assembled and handled with
comparative ease. The fiber enforced sheet may be made of a variety
of materials. The sheets themselves will normally be flexible, but
it is important that they be substantially non-stretchable. This
quality is important because the backing and backing sheets on each
thin brick sheet co-act to render the sheet rigid enough to be
readily handled and worked.
[0010] Working of the thin brick sheets for example, may include
cutting or drilling with tools such as razor knifes, table saws,
and the like. After the thin bricks are adhered the sheets can then
be cut between bricks using just a razor knife. This enables such
working to be carried out with very little breaking, chipping, or
other damage to the thin brick elements.
[0011] Applying thin brick sheets over exterior require
cementitious adhesive sealing all seams and applying a roll on
water barrier following all building codes. When applying thin
brick sheets over interior, a thinset, mastic or equivalent will be
required.
[0012] It will be apparent that the sheets be strong, substantially
non-stretchable, substantially water-resistant, chemically stable,
and capable of being bonded to the thin bricks as well as to
plaster, wood, cement, block, drywall sheets [gypsum board;
sheetrock], etc. with conventional construction adhesives. As
mentioned above, woven fiberglass fabric is an especially preferred
component of the backing sheets; however, other fabrics or
reinforcing agents considered suitable include polyester, graphite,
aramid, or carbon fibers, or any combination thereof. Especially
preferred is a fiberglass combination.
[0013] Synthetic adhesives suitable for impregnating the backing
sheets include unsaturated fiberglass, phenolic, epoxy, and
silicone adhesives.
[0014] In general, the adhesives should possess the same general
characteristics as the backing sheets. The cured adhesive should be
strong, substantially non-stretchable, substantially impervious to
moisture, function as an adhesive to bond the back surfaces of the
thin bricks to the sheet, and be capable of being bonded to common
wall surfaces and the like with conventional construction adhesives
such as thin set or mastic and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 Is a cross-sectional view of fiber enforced thin
brick sheets of the said invention.
[0016] FIG. 2 Cut thru order of fiber enforced thin brick
process.
[0017] FIG. 3 Is a cross-sectional view of corner brick using fiber
enforced thin brick sheets in the process of the said
invention.
[0018] FIG. 4 View of an example layout of the corner thin brick
sheets of said invention showing application arrangement and edges
of such a sheet.
DETAILED DESCRIPTION OF THE DRAWINGS
[0019] The invention will best be understood by referring to the
drawings.
[0020] FIG. 1 shows a portion of a thin brick sheet in cross
section. Individual thin brick elements (5) are supported by
adhesive (6) on a fiber-reinforced backing layer (7). Anti-adhesive
paper on back of thin brick sheets for separation and adhesive
release (8).
[0021] FIG. 2 schematically it a cut thru fabricated thin brick
sheets. Thin layer of anti-adhesive paper to prevent bonding of the
backing layer adhesive (9). Reinforcing fabric (10) for the backing
layer. Adhesive at a high temperature is then impregnated or
applied to either brick or fiber-reinforced backing layer (11).
Individual thin brick elements (12).
[0022] FIG. 3 schematically illustrates corner thin brick sheets.
Thin layer of anti-adhesive paper to prevent bonding of the backing
layer adhesive that is curved in the same position of a typical
thin brick corner (13). Reinforced fabric sheet that is curved in
the same position of a typical thin brick corner (14). Adhesive at
a high temperature is then impregnated or applied to either corner
brick or fiber-reinforced backing layer (15). Thin corner brick
positioner (16) helps in the proper spacing and alignment
process.
[0023] FIG. 4 shows in detail the layout of an optional embodiment
of the thin brick sheets and corner sheets of the present
invention. Corner sheets are typically applied first (17) were
brick are placed opposite of each other. The thin bricks are
staggered in typical brick patterns (18) and fiber-reinforced
backing layer extends beyond the thin brick elements on one edge of
the sheet (19), while on the opposite edge the thin brick elements
overhang the fiber-reinforced backing layer by an equal distance
(20). This permits abutting thin brick sheets to be joined together
in such a way that the joint between bricks are the proper space to
adjacent thin brick sheets.
SUMMARY
[0024] Alternatively, the sheets of the present invention may be
manufactured individually in multiple sizes. Thin bricks are placed
face down or face up within the confines of a frame designed to
hold the loose thin bricks in a rectangular array. Gaps are left
between the edges of adjacent thin bricks to permit the subsequent
insertion of grout as is well known in the art.
[0025] Reinforcing fabric for the hacking layer is then placed over
the exposed rear surfaces of the thin brick elements in the array.
A adhesive is then applied to the fabric first or brick first,
saturating it and extending through it to contact the thin bricks
or sheets. As the adhesive cures it bonds the backing layer to the
thin bricks. This process may be accelerated by the application of
heat to raise the temperature of the adhesive/catalyst mixture
thereby increasing its cure rate.
[0026] When the adhesive of the backing layer has substantially
cured, the hacking layer with the thin brick elements bonded to it
is inverted, exposing the front face of the thin brick elements.
Grout or mortar other suitable or alike material is applied to the
spaces between the thin bricks.
[0027] In use, the thin brick sheets are mounted to conventional
floor or wall surfaces using construction adhesives of the type
previously mentioned.
[0028] While one specific embodiment of the invention has been
disclosed herein, it should be understood that this disclosure is
made by way of illustration rather than limitation. Numerous
changes may be made by those skilled in the art, particularly with
reference to the dimensions, materials and configuration disclosed
herein. Changes of this nature would not depart from the spirit of
the invention or the scope of the appended claims.
* * * * *