U.S. patent number 3,740,910 [Application Number 05/194,276] was granted by the patent office on 1973-06-26 for simulated brick panels.
This patent grant is currently assigned to Merry Companies Incorporated. Invention is credited to Charles E. Nichols, Jr., L. James Taylor.
United States Patent |
3,740,910 |
Taylor , et al. |
June 26, 1973 |
SIMULATED BRICK PANELS
Abstract
A simulated brick panel that can be applied to any type building
structure to give the appearance of full-size masonry construction.
The panel includes a dense backing sheet coated with a uniform
layer of water-impermeable epoxy resin adhesive and faced with
several courses of thin facing slabs. The panel has longitudinal
upper and lower edges and transverse side edges, one of the
longitudinal edges and one of the side edges being plain and the
other longitudinal edge and side edge each having a central
caulking groove cut therein with the side wall of the groove
adjacent the inner side of the panel of less height than the height
of the groove side wall adjacent the outer side of the panel. The
bottom course of slabs projects below the lower edge of the panel
so that the slabs will partially overlie the upper part of a panel
therebeneath. Caulking compound in excess of that required to fill
the grooves is applied so that it can flow laterally toward the
inner and outer faces of the panel as the upper panel is pressed
downwardly against a lower panel and laterally against the end of
an adjacent panel. All exposed portions of the joints between the
panels are sealed with adhesive, and then sand is applied thereto
before the adhesive sets. The blank spaces at the vertical joints
between adjacent panels, when present, are filled by adhesively
bonding a flat filler slab in place. Blank spaces in the panels at
the corner of a building are filled by similarly applying L-shaped
filler slabs.
Inventors: |
Taylor; L. James (Augusta,
GA), Nichols, Jr.; Charles E. (Augusta, GA) |
Assignee: |
Merry Companies Incorporated
(August, GA)
|
Family
ID: |
22716964 |
Appl.
No.: |
05/194,276 |
Filed: |
November 1, 1971 |
Current U.S.
Class: |
52/315; 52/393;
52/420; 428/15 |
Current CPC
Class: |
B44F
11/06 (20130101); B44F 9/04 (20130101) |
Current International
Class: |
B44F
11/00 (20060101); B44F 11/06 (20060101); B44F
9/00 (20060101); B44F 9/04 (20060101); B44f
007/00 () |
Field of
Search: |
;52/314,315,311,420,419,417,416,606,396,403,394,393 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
516,203 |
|
Dec 1939 |
|
GB |
|
24,902 |
|
Dec 1896 |
|
GB |
|
Primary Examiner: Abbott; Frank L.
Assistant Examiner: Raduazo; Henry E.
Claims
We claim:
1. In a building structure, a first rectangular panel having
longitudinal edges, and side edges; a second rectangular panel
having longitudinal edges, and side edges, said panels being
positioned with the longitudinal edge of one panel above and
confronting the longitudinal edge of the other panel, one of said
confronting edges being plain and the other having a centrally
located groove extending throughout the length thereof, and lands
on opposite sides of said groove, said groove having a bottom wall
and opposed side walls, one of said side walls being of a greater
height than the other; a coating of water impermeable adhesive on
one side of each of said panels; a plurality of courses of slab
material embedded in said adhesive, said slabs being spaced apart
to simulate a mortar joint therebetween, the groove side wall of
greater height being nearest to said one side of said panels having
said slab material thereon; and caulking material filling said
groove and extending between said lands and the plain confronting
edge of said other panel and spacing the panels apart a distance
equal to said simulated mortar joint.
2. A building structure as defined in claim 1, in which the
confronting longitudinal edge of the one panel contains the groove,
and the confronting longitudinal edge of the other panel is
plain.
3. A building structure as defined in claim 1, in which the
confronting longitudinal edge of the one panel is plain and the
confronting edge of the other panel has the groove.
4. A building structure as defined in claim 1, wherein one of the
side edges of the first and second panels each has a centrally
located groove extending throughout its length and wherein each
groove has a bottom wall and opposed side walls, one of said side
walls being of greater height than the other, the groove side wall
of greater height being nearest to the one side of the panels
having the slab material thereon.
5. A building structure as defined in claim 1, in which the
lowermost course of slabs on the first panel projects beyond the
lower edges of said first panel and onto the upper portion of the
second panel.
6. A building structure as defined in claim 5, wherein the exposed
adhesive material simulating the mortar joints is coated with fine
sand, and wherein adhesive material is added to the longitudinal
joint between the first and second panels at the spaces between
adjacent slabs to conceal the joint, and wherein the added adhesive
is coated with fine sand.
7. A building panel, comprising: a generally rectangular backing
sheet of high density, asphalt-impregnated material or other
suitable backing having longitudinal upper and lower edges, and
side edges; a coating of water impermeable adhesive on one side of
said sheet; and several courses of slab material embedded in said
adhesive, said slabs being of substantially uniform length and
width and being substantially equally spaced apart to simulate
mortar joints therebetween, one of said longitudinal edges and one
of said side edges of said sheet each having a centrally located
caulking groove extending throughout the length thereof, said
grooves having a bottom wall and opposed side walls, one of said
side walls of each groove being of greater height than the other,
said sidewall of greater height being nearest said one side of said
sheet having said slab material thereon.
8. A building panel as defined in claim 7, in which the adhesive at
the simulated mortar joints is coated with sand to present the
appearance of cement mortar.
9. A building panel as defined in claim 7, in which the grooves are
formed in the upper edge and one side edge of the panel and the
lower edge and the other side edge of the panel are plain.
10. A building panel as defined in claim 7, in which the grooves
are formed in the lower edge and one side edge of the panel and the
upper edge and the other side edge of the panel are plain.
11. A building panel as defined in claim 7, in which the courses
contain the same number of slabs, and wherein the end slab in
alternate courses is closer to one side edge of the backing sheet
than the corresponding end slab in the intermediate courses.
12. A building panel as defined in claim 11, wherein the distance
between the end slab of said alternate courses from the one side
edge of the backing sheet is slightly less than half the length of
a slab.
13. A building panel as defined in claim 7, in which each course of
slabs is spaced from the side edges of the backing sheet and
wherein the end slabs of adjacent courses are spaced different
distances from the respective side edges of the backing sheet.
14. A building panel as defined in claim 7, wherein the spacing
distance of the end slabs in the courses from one side edge of the
backing sheet is equal to about one-third the length of the slab
and the spacing distance at the opposite end of the backing sheet
is equal to about two-thirds the length of a slab.
15. A building panel as defined in claim 7, in which the end slabs
of alternate courses project beyond one side edge of the backing
sheet, and in which the slabs in the intermediate courses are
spaced inwardly from both side edges of the backing sheet.
16. A building panel as defined in claim 7, in which the slabs in
the lowermost course adjacent to the lower edge of the sheet
project beyond said lower edge, and wherein the upper course of
slabs is spaced from the upper edge of the sheet a distance equal
to the projecting portion of the lowermost course of slabs, plus
the width of the mortar joint between the courses of slabs, whereby
when the panel is mounted in place above a similar panel, the
projecting slabs will overlap the upper portion of said similar
panel.
17. A building panel as defined in claim 7, in which the end slabs
in all of the courses project beyond one side edge of the backing
sheet.
18. A building panel as defined in claim 17, in which the end slabs
in alternate courses project beyond one side edge of the backing
sheet a distance slightly less than one-half the length of a
slab.
19. A building panel as defined in claim 12, in combination with a
similar panel, and arranged in end-to-end relation therewith, and
wherein filler slabs are mounted in the spaces in the alternate
courses, straddling the joint between the ends of the panels and
forming continuous courses of slabs.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to simulated brick panels to be
secured to wood or metal studs of a building, to brick or concrete
walls, etc., to provide a simulated masonry wall.
2. Description of the Prior Art
Simulated brick panels have been heretofore proposed, consisting of
a backing material to which strips of fibrous material simulating
brick have been applied by adhesive and wherein the backing
materials have been provided along the longitudinal edges with
grooves forming a lap joint (U.S. Pat. No. 2,241,898). This type of
structure has the objection that the fibrous strips crack and
otherwise deteriorate in a short period of time and present an
unsightly appearance. Further, the backing sheets supporting the
fibrous strips are designed so that the side edges thereof meet at
a point coinciding with the simulated mortar joint between the
adjacent side edges of the panels without caulking or other
material to provide a seal against penetration of rain, etc.
Other simulated brick panels have been proposed wherein the
material intended to simulate bricks is poured into a mold and a
base layer consisting of a cement mix is added to the mold to
adhere to the brick layer (U.S. Pat. No. 3,304,673). Panels of this
type are to applied to concrete structures and require the
insertion of a specially formed section with projecting simulated
brick portions mounted between them. This type of construction
results in panels that are very heavy and, hence, difficult to
handle when made of any substantial size, and are also subject to
cracking or breaking in handling, while being transported, while
being mounted, etc.
Still other proposals have included large, plain panels provided
with tongue and groove joints at their longitudinal edges to be
filled with caulking material, which is completely exposed at the
outer face of the panels (U.S. Pat. No. 2,387,431). The panels are
also grooved at their side edges to receive the flange of an
I-beam, the space between adjacent ends of the panel being filled
with caulking material and also being exposed to the elements. This
type of construction has the disadvantage of leaving the caulking
material surrounding the panels exposed to the sun and other
elements so that it dries out in a short time and cracks or
shrinks, thereby rendering the joints non-waterproof.
SUMMARY OF THE INVENTION
The present invention overcomes the defects and objections to
structures such as those described above, in that the brick slab
facings are permanently bonded to the outer face of the panels by a
suitable coating of waterproof epoxy resin adhesive material, the
exposed portions of which simulate a mortar joint. Further, all
edges of the panels are caulked and all exposed portions of the
joints between the panels are covered with the same adhesive or
matrix so that the entire wall formed by the panels is rendered
water-tight.
The panel itself is made of a hard, pressed, asphalt-impregnated
fiberboard backing sheet, so that it is waterproof and thus
impervious to rain and moisture penetration. The panels are
preformed with a central caulking groove in either the lower or
upper longitudinal edge, and in one vertical side edge thereof. The
side walls of the grooves are greater in height adjacent the outer
side of the sheet than adjacent the inner side. Thus, the lands at
the inner side of the panel will be spaced farther from the plain
edge of an adjoining panel to provide a greater thickness of
caulking at the inner side of the panel.
In accordance with the principles of the present invention, the
panels can be made in any size desired, although for non-special
purposes, the length of the panel coincides with multiples of the
conventional center-to-center stud spacing of 16 to 24 inches. In
one practical embodiment of the invention, the backing sheet of the
panels is 96 inches in length and 211/2 inches in height; and with
eight courses of facing slabs applied thereto, weighs only about 67
lbs. The panels are designed to be fastened to the studs at their
ends and at one or more intermediate points, not in excess of 32
inches apart. The grooves in the panel edges are filled with a
volume of caulking material greater than that required to fill the
grooves themselves, so that when the panels are mounted in place,
the caulking material is displaced laterally in both directions
from the grooves, with the greater volume flowing to the inner side
of the panel, as indicated above.
The facing slabs are mounted upon the backing sheet or panel in
courses, with the lowermost course extending below the lower edge
of the panel, and with the joints in alternate courses staggered
relative to each other. In one form of the invention, the courses
of slabs are also arranged so that the edges of the slabs do not
project beyond the side edges of the panel, but are spaced closer
to one vertical edge of the sheet than they are to the other
vertical edge, with the edge spacing being reversed in adjacent
courses. A panel of this type serves well as a corner panel. A
cooperating panel has slabs in alternate courses that project
beyond the right edge of the panel to cover the shorter space left
blank in the corresponding course of an adjacent panel. Thus, a
slab bridges the joint between the panels and the edges of two
adjacent panels do not coincide with the simulated mortar joints
between the facing slabs. In such panel design empty spaces between
adjacent slabs at the joint are formed in the remaining courses.
These spaces are then covered by filler slabs adhesively held in
place.
The present panel designs also provide for a unique corner
structure in that they provide empty or blank areas in the corner
panels that are covered by L-shaped filler pieces initially having
one leg shorter than the other, or having both legs of equal length
to be clipped to a length to suit field or factory conditions.
The permanent bonding of the facing slabs to the panels eliminates
the problem of the facings falling off; and the provision of the
grooves along two of the edges of the panel to receive caulking
material provides a water tight joint that is further protected by
the slabs extending beyond the lower edge of the panel and
projecting beyond the side edge of the panel, respectively, so that
only small areas constituted by the joints between slabs are
exposed to the elements. The longitudinal offsetting of the courses
of slabs on the panel assures that the vertical joints between
adjacent panels is likewise protected by overlying slabs, thereby
covering the entire vertical joint except for the exposed areas at
the simulated mortar joints, between the courses of slabs. This
same feature is incorporated in the corner joint in conjunction
with the L-shaped filler pieces. All such portions of the joints,
both horizontal and vertical, are covered by applying the
waterproof matrix thereto to seal the same.
A further embodiment of panel design provides slabs extending
across the vertical joint between adjacent panels without requiring
the use of filler slabs.
Accordingly, the principal object of the invention is to provide a
unique simulated brick panel designed so that the panel can be
applied in a minimum of time to the studs of a building, or to a
wall surface, to present the appearance of a masonry type wall.
Another object is to provide a simulated brick panel designed so
that a minimum amount of the joints between the edges of adjacent
panels is exposed to the atmosphere.
A further object is to provide a panel designed so that the
vertical edges between adjacent panels do not coincide with the
joint between adjacent slabs of facing material mounted on the
panels.
A still further object is to provide a panel designed so that the
joint formed by the panels at a corner of the building has a
minimum area exposed to the atmosphere.
Still another object is to provide a panel construction having
grooves formed in only one longitudinal and one vertical edge
thereof and designed so that a substantial body of caulking
material can be received in the grooves and flow toward both the
inner and outer faces of the panel, with the greater amount of
caulking material flowing toward the inner face of the panel so
that a good seal is provided, while at the same time the
longitudinal and vertical joints between the panels of the outer
side thereof are hardly noticeable, and which in any event are
exposed only at points between slabs and can be readily covered and
sealed by a matrix.
Still another object is to provide simulated brick panels that can
be quickly and uniformly fabricated and which are superior to and
more versatile than panels of prior construction.
A still further object is to provide a simulated brick panel
design, wherein the slabs of facing material are arranged so that
they substantially cover the outer region of the joints between
adjacent and superposed panels, to thus minimize the possibility of
moisture penetrating the joints between the panels.
Other objects and advantages of the invention will be apparent from
the following description taken in conjunction with the
accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of a corner of a building
structure including conventional wood studs and illustrating the
manner in which simulated brick panels constituting embodiments of
the present invention can be applied to the studs at the corner of
the building.
FIG. 2 is a perspective view of a pair of panels, one of which is
designed to serve as a corner panel and the other to be positioned
in longitudinal relation to the first panel, with both panels
having a groove in the lower edge and in the vertical edge at the
right end of the panels.
FIG. 3 is a fragmentary elevational view showing the caulking at
the joints of the juncture of four panels.
FIG. 4 is a greatly enlarged cross-sectional view, taken on the
line 4--4 of FIG. 3, particularly showing the matrix seal that is
applied later over the caulking material to conceal the joint
between adjacent slabs.
FIG. 5 is an enlarged fragmentary sectional view showing the
longitudinal edges of adjacent panels with one of the panels having
caulking material in a groove in the lower edge thereof ready to be
pressed against the plain edge of a panel therebeneath.
FIG. 6 is an enlarged fragmentary vertical sectional view, taken on
the line 6--6 of FIG. 1, illustrating the joint formed between
adjacent panels, and particularly showing the lateral displacement
of the caulking material between the confronting edges of the
panels, and the heads of the countersunk nails securing the panels
to a stud covered with matrix to conceal and seal the same.
FIG. 7 is a fragmentary vertical sectional view, taken on the line
7--7 of FIG. 1, showing the details of the joint between the
horizontal edges of adjacent panels.
FIG. 8 is an enlarged fragmentary perspective view, partly in
cross-section, taken on the line 8--8 of FIG. 1, and showing the
details of the joint at the corner of the building structure.
FIG. 9 is a fragmentary perspective view, partly in cross-section,
of a modified, but preferred, form of panel construction with the
panels secured to a stud, and wherein the grooves for the caulking
material are formed in a top edge and one vertical edge of the
panel, and wherein the slabs are arranged at one end of the panel
so that they all overlap the joint between the vertical edges of
adjacent panels to form uninterrupted courses of slabs.
FIG. 10 is a fragmentary vertical sectional view, taken on the line
10--10 of FIG. 9, showing the caulking compound in the groove in
the upper edge of one of the panels.
FIG. 11 is an elevational view of a panel with the slabs arranged
as shown in FIGS. 9 and 10.
FIG. 12 is an elevational view of a modified form of panel having
slabs arranged so that the slabs in alternate courses will only
slightly overlap the vertical edge of an adjacent panel and cover
the joint between the panels.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the drawings, a portion of a building
structure is shown comprising a double corner stud 2 and side studs
4, with insulating material 6 mounted between the studs. The studs
4 may be spaced 16 inches or 24 inches apart, as is conventional.
Several panels, such as panels 8 and 10 illustrated in FIG. 2, are
shown secured to the studs 2 and 4 by countersunk nails 12. (FIG.
6). Adhesive material 14, FIGS. 1 and 6 to 8, is preferably applied
to the studs 2 and 4 before the panels 8 and 10 are positioned
thereagainst and before the nails 12 are driven into the studs.
Referring particularly to FIG. 2, the panel 8 comprises a
rectangular backing sheet 9 of hard, dense, waterproof,
asphalt-impregnated fiberboard, or any other suitable backing,
having a central groove 16 formed in its lower edge 18 and a
similar groove 20 formed in its vertical edge 22 at the right end
of the sheet. The panel is 1/2 inch thick and the grooves 16 and 20
are one quarter inch wide. However, it will be understood that the
thickness of the backing sheet 9 and the dimensions of the grooves
16 and 20 can be varied to suit different requirements.
The backing sheets for the panels 8 are cut to accurate size from a
larger sheet. The grooves 16 and 20 are cut in the edges 18 and 20,
respectively, before any slabs are applied. In constructing the
panel, the facing slabs are pre-arranged and retained in a jig (not
shown) in a pattern conforming to the slab arrangement to be
applied to the backing sheet. One side of the backing sheet 9 is
preferably coated with a suitable epoxy resin matrix or adhesive M
(or any other suitable adhesive), and is positioned beneath the jig
in proper registration therewith. The jig is then lowered to embed
the slabs in the adhesive material M. Thereafter, the slabs are
released and the jig is withdrawn. Fine sand S is sprinkled over
the entire area of the panel before the adhesive M sets. After
setting, the excess sand S is removed. The sand S adhering to the
adhesive in the spaces between the slabs presents the appearance of
a cement mortar joint. The adhesive material M may be made in
various colors, as may also the facing slabs. Sand or other
granular material of matching color may be applied to the adhesive
before it sets to simulate a cement mortar joint. The panel 10 is
similarly constructed. The sand S does not adhere to the slabs.
The groove 16 in the lower edge 18 of the panel 8 is best shown in
FIGS. 5 and 6, and comprises a bottom wall 24 and side walls 26 and
28, terminating at outer and inner lands 30 and 32, respectively.
The outer side wall 26 is of greater vertical height than the inner
side wall 28, so that when caulking material C in excess of that
required to fill the groove 16 is placed in the groove, and the
confronting edges of the sheets are pressed toward each other, the
caulking material will more readily flow inwardly and a greater
thickness of the caulking material C will be formed at the inner
edge of the panels to assure a leakproof seal. The groove 20 is
best shown in FIG. 7 and has a bottom wall 34 and side walls 36 and
38 terminating at outer and inner lands 40 and 42. The outer side
wall 36 is of greater vertical height than the inner side wall 38.
The panel 8 has a plain upper edge 44 and a plain left end edge
46.
By way of example, and not limitation, the outer groove side walls
26 and 36 may be one quarter inch in height and the inner side
walls 28 and 38 may be 3/16 inches in height, so that when caulking
material C is pressed against the plain upper edge 44 of the
adjacent panel, the excess of caulking material that flows toward
the inner side of the panel will be at least 1/16 of an inch
thicker than the caulking material that is displaced toward the
outer side of the panel. The panel 10 is grooved in the same manner
as the panel 8, that is, a groove 16' formed in its lower or
longitudinal edge, and a groove 20' is formed in its right side
edge, with the two remaining top and left end edges 44' and 46'
being plain.
As is best shown in FIG. 2, the panel 8 has eight rows or courses,
of ceramically fired clay or even brick or other facing slabs.
Alternate courses are numbered 48 and 50 and comprise slabs of
brick clay or other facing material 52 and 54, respectively. These
slabs may be made of any desired thickness, but are preferably
about 3/8 of an inch thick. The length and height of the slabs
preferably correspond to that of conventional size brick, although
the dimensions of the slabs can be varied, as desired. The slabs
are spaced apart 1/2 inch or other desired distance, to simulate
conventional mortar joints.
The slabs 54 in the lowermost course 50 may extend about 1/4 of an
inch or more below the lower edge 18; whereas, the slabs in the
uppermost course 48 are spaced from the upper edge 44 of the panel
a distance equal to the width of the simulated mortar joint between
the courses plus the distance that the slabs 54 in the courses 50
project beyond the edge 18. With the slabs arranged as described,
it will be apparent that the joint H between the lower edge 18 of
one panel and the upper edge 44 of a panel disposed therebelow will
be protected against the elements by the overlapping of the slabs
54 onto the upper portion of the panel therebelow (See FIG. 6).
Accordingly, only those portions of the horizontal joint H lying
between adjacent slabs is exposed. These portions are intended to
be very narrow to provide an inconspicuous joint, which is
facilitated by flow of most of the caulking C toward the inner side
of the panels.
It will be noted that the slabs 52 in the courses 48 are arranged
so that the end slabs 52a are closer to the left edge 46 of the
panel 8 than are the end slabs 52b relative to the right edge 22 of
the panel. The opposite is true of the slabs 54 in the courses 50,
that is, the end slabs 54a are further from the left side edge 46,
than the end slabs 54b are from the right side edge 22. In other
words, the slabs in adjacent courses 48 and 50 are staggered
relatively to each other.
The arrangement of the slabs on the panel 10 is the same as that on
the panel 8, except that an additional slab 52c is added to the
right end of each course 48. These slabs extend beyond the right
side edge 22 a distance approximately equal to about one-third the
length of a slab, or the distance between the left edge 46 of the
panel and the end slabs 52a, minus the width of the simulated
mortar joint between adjacent slabs, that is, about 1/2 inch. On
the other hand, the slabs 54b are set back from the edge 22' a
distance equal to about two-thirds the length of a slab, plus the
width of a mortar joint. As a result, when the panels 8 and 10 are
mounted upon the studs 4, as shown in FIG. 1, the slabs 52c will
partially overlap the panel 8 to present the appearance of an
uninterrupted course of slabs. Thus, the courses 48 on the two
panels 8 and 10 will appear to be continuous upon installation of
the panels. While an overlap of one-third the length of a slab 52c
has been indicated, this distance can be varied within reasonable
limits.
In contrast, a blank space B is left in the course 50 between the
left end slab 54a of the panel 8 and the right end slab 54b of
panel 10. The blank spaces B are formed jointly by the panels 8 and
10 and each space has an overall length equal to the length of a
slab, plus twice the width of the simulated mortar joint. A filler
slab 56 is positioned in each of the blank spaces B to fill the
same and to complete the courses 50. This is done by applying the
adhesive or matrix to one side of the filler slabs 56 and then
pressing the same in place across the joint between the adjacent
ends of the panels 8 and 10. The dot-and-dash lines extending from
the slabs 56 in FIG. 1, indicate the position that the slabs 56
ultimately occupy. The filler slabs 56 are thinner than the slabs
52 and 54 to compensate for the thickness of the matrix used to
adhere the same to the panel. For example, the slabs 56 may be 1/4
inch thick.
FIG. 4 is a greatly enlarged cross-sectional view taken through a
horizontal joint H between the top edge 44 of one panel and the
bottom edge 18 of another panel. This view particularly shows the
manner in which a body of matrix material M' is applied in the
regions between adjacent slabs 54 to seal and conceal the joint and
caulking C. As is here shown, the caulking material C does not
extend all the way to the outer face of the panels. The adhesive
body M' thus extends partly into the space between the panels and
fills the gap between the adhesive material M on the outer face of
the panels, and is smoothed flush therewith and "sanded." Since the
adhesive M' added to seal the joint H is the same as the material M
applied to the backing sheets 9 to bond the slabs thereto, they
blend together so that the joint H is concealed and is not
noticeable.
FIG. 3 illustrates the joints formed by the corners of four
adjacent panels. It will be noted that the slabs 52c overlap the
vertical joint V between the adjacent panels 8 and 10, and that the
slabs 54 in the bottom course 50 overlap the horizontal joint H
between panels 8-8 and 10-10 shown disposed one above the other.
The exposed portions of the vertical joint V are concealed and
sealed by filling the same with the adhesive material so that the
surface is flush with the previously applied adhesive material M.
FIG. 4 illustrates the adhesive material M' as applied to a
horizontal joint H. It will be understood that the vertical joint V
is sealed in the same manner. Hence, the surfaces at the joints
have a homogeneous appearance rendering the initial joints
unnoticeable.
FIG. 6 shows matrix material M" applied to the indentations formed
by countersinking the nails 12. The matrix material covers, seals
and conceals the nail heads. Fine sand S is applied to such matrix
so that the simulated mortar joint is free from interruptions or
blemishes.
Referring to FIGS. 1 and 8, the panels 8 and 10 are arranged at the
corner of the building structure so that the side edge 22 of the
panel 8 is at the inner side of the panel 10 adjacent its side edge
46'. Caulking material C will have been disposed in the groove 20
to form a seal with the inner face of the panel 10. The side edge
46' is preferably coated with matrix at the time of installation to
seal said edge. Thereafter, the spaces in the panels 8 and 10 are
filled by L-shaped filler pieces 58 having one long leg 60 and a
short leg 62. The L-shaped filler pieces 58 are mounted with the
long leg 60 adjacent the end slabs 52b of the courses 48, and the
short leg 62 is positioned to fill the space on the panel 10
between the slab 52a and the left end 46' of the panel.
It will be understood that the L-shaped pieces 58 are coated with
adhesive on the inner side thereof before they are mounted in
place. It will also be understood that the L-shaped pieces 58 are
mounted at the corner of the structure between the slabs 54b and
the slabs 54a to complete the courses 50. The dot-and-dash lines
extending from the L-shaped pieces 58 to the panels 8 and 10 in
FIG. 1 indicate the ultimate position that these pieces will occupy
to complete the facing at the corner of the building.
FIGS. 9 to 11 illustrate a further and preferred embodiment of the
invention, wherein a groove 16a, similar to the groove 16 is formed
in the upper edge 44a of a panel 8a, instead of in its lower edge
18a. As is shown in FIG. 10, the lower edge 18a is plain. Either
the right or the left side edge of the panels 8a may be provided
with a groove similar to the groove 20. FIGS. 8 and 11 illustrate a
groove 20a formed in the right edge 22a of the panel 8a, but it
will be understood that the groove 20a could be formed in the left
edge 46a, such edge being presently illustrated as plain.
The arrangement of the facing slabs on panel 8a is also different
from that on the panels 8 and 10, the design of the courses of
slabs on the panel 8a being such that the use of filler slabs to be
put in place after the panels have been applied to a building
structure is eliminated. With specific reference to FIG. 11, the
panel 8a has alternate courses of slabs 64 and 66, a total of eight
courses of slabs being shown. The course 64 comprises slabs 68
arranged so that the slabs 68a at the right side edge 22a project
slightly beyond the edge, say about 1/2 inch. The slab 68b at the
left end of the course is set back from the left edge 46a, a
distance of about 1 inch, so that when a similar panel is
positioned in abutting relation therewith, a space of 1/2 inch
equal to the width of a mortar joint will be present between the
slabs 68a and 68b.
The courses 66 consist of slabs 70 arranged so that an end slab 70a
at the right end of the panel 8a projects slightly less than half
the length of a slab beyond the edge 22a, whereby when a similar
panel is positioned adjacent the left end 46a, it will fill the
space between an end slab 70b at the left end of the course 66,
except for a space equal to the width of a mortar joint. It will be
understood, of course, that adhesive material will be applied to
the end slabs 68a and 70a before the panel 8a is positioned in
abutting relation with the left end of a similar panel, so that the
slabs 68a and 70a will be adhered to the adjacent panel 8a, FIG. 9.
It will likewise be apparent that since all the slabs 68a and 70a
at the right end of the panel 8a extend beyond the edge 22a of the
panel, the vertical joint V between the panels will be
substantially completely covered by the facing slabs, except at the
simulated mortar joint between the course of slabs. Caulking
material C will have been placed in the groove 20a in the same
manner as in the groove 20, so that it will be displaced toward
both the front and rear faces of the panel 8a. The caulking
material at the simulated mortar joint will be covered by adhesive
material to seal the same and sand S applied to the adhesive, as
previously explained, so that all areas between the slabs will have
the same appearance.
FIG. 12 illustrates a further embodiment of the invention in the
form of a panel 10a, which is similar to the panel 10, except that
it has a caulking groove 16b in its top edge 44b and a caulking
groove 20b in its right edge 22a. In the interest of brevity, the
courses and slabs have been identified by the same reference
numerals applied to corresponding parts of the panel 10. One of the
important advantages of the panels 8a and 10a shown in FIGS. 9 to
12, wherein the caulking grooves 16a and 16b, respectively, are
formed in the upper edge of the panels, is that the panels can be
mounted upon a building structure, and the caulking material
applied to the grooves after the panels have been secured in place.
This greatly simplifies and speeds up installation.
The backing sheets 9 for the panels may be made in any size
desired, but in the interest of ease in handling and rapid
installation, the panels are made 8 ft. in length and 211/2 inches
in height, although it is apparent that the panels may be made 48
inches in length or any multiple of the modular distance between
studs. The panels are designed to be nailed to conventional 2 by 4
wooden studs on 16 inch or 24 inch centers. If desired, the bonding
material M may be colored to match or contrast with the shade of
the brick slabs or other facing material. In all instances, the
finished wall has the attractive appearance of high grade,
hand-laid masonry work, but can be done in less time and at
substantially lower cost.
It will be understood that variations may be made in the design and
arrangement of the facing slabs on the backing sheets, and that the
size of the panels and the number of courses of slabs applied
thereto, can be varied to suit requirements without departing from
the principles of the invention or the scope of the annexed
claims.
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