Fiber enforced thin brick sheet and process

• US 10,072,426 B2
• Filed: 12/15/2016
• Issued: 09/11/2018
• Est. Priority Date: 10/21/2011
• Status: Active Grant

• Current Assignee: Old Mill Brick Incorporated
• Original Assignee: Old Mill Brick Incorporated
• Inventors: Hunsaker, Jason, Walker, Jeffrey, Hunsaker, Garrick
• Primary Examiner(s): Glessner, Brian E
• Assistant Examiner(s): Barlow, Adam G
• Application Number:
  US15/380,733
• Publication Number:
  US 20170159298A1
• Time in Patent Office: 635 Days
• Field of Search: None
• CPC Class Codes: E04F 13/0733 for corners
• CPC Class Codes: E04F 13/0862 composed of a number of elements which are identical or not, e.g. carried by a common web, support plate or grid
• CPC Class Codes: E04F 13/0885 specially adapted for being adhesively fixed to the wall; Fastening means therefor; Fixing by means of plastics materials hardening after application
• CPC Class Codes: E04F 13/09 of elements attached to a common web, support plate or grid not used, see E04F13/0862
• CPC Class Codes: E04F 13/142 with an outer layer of ceramics or clays
• CPC Class Codes: E04F 13/147 with an outer layer imitating natural stone, brick work or the like
• CPC Class Codes: E04F 15/08 only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass E04F15/02005 takes precedence
• CPC Class Codes: E04F 15/166 Flooring consisting of a number of elements carried by a common flexible web, e.g. rollable parquet
• CPC Class Codes: Y10T 156/1092 All laminae planar and face to face

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.

Claims

1. A method of installing thin brick sheets, comprising:

applying a first thin brick sheet to a wall or floor surface, wherein the first thin brick sheet comprises;

a first backing layer that comprises a first edge and a second edge that are at opposite sides of the first backing layer; and

a first plurality of thin bricks that are bonded to the first backing layer, wherein each thin brick of the first plurality of thin bricks comprises;

a first portion that extends in a first direction; and

a second portion that extends in a second direction;

wherein the first portions of the thin bricks of the first plurality are staggered such that some of the first portions are recessed from the first edge of the first backing layer;

wherein the first backing layer defines a grid that comprises holes, and wherein each thin brick of the first plurality is bonded to the first backing layer such that a portion of the rear surface of the thin brick is free from an adhesive, wherein the portion of the rear surface of the thin brick that is free from the adhesive overlaps one or more holes in the first backing layer such that a construction adhesive can penetrate through the first backing layer to adhere to the portion of the rear surface of each of the thin bricks of the first plurality that is free from the adhesive to bond the thin brick to the wall or floor surface;

applying a second thin brick sheet to the wall or floor surface, wherein the second thin brick sheet comprises;

a second backing layer; and

a second plurality of thin bricks that are bonded to the second backing layer such that a portion of some of the thin bricks of the second plurality overhang the second backing layer at a first edge of the second backing layer; and

joining the overhanging portion of the thin bricks of the second plurality to the first thin brick sheet.

2. The method of claim 1, wherein the first backing layer comprises regions that extend beyond some of the first portions of the thin bricks of the first plurality, and wherein the regions of the first backing layer are configured to be coupled with overhanging portions of thin bricks of the second plurality.

3. The method of claim 1, wherein the first backing layer is flexible and substantially non-stretchable.

4. The method of claim 1, wherein the first backing layer comprises reinforcing fibers that comprise one or more of graphite fibers, aramid fibers, carbon fibers, fiberglass fibers, and poly fibers.

5. The method of claim 1, wherein the second thin brick sheet further comprises:

a third plurality of thin bricks that are bonded to the second backing layer, wherein each thin brick of the third plurality of thin bricks comprises;

a first portion that extends in a first direction; and

a second portion that extends in a second direction;

wherein the first portions of the thin bricks of the third plurality are staggered such that some of the first portions are recessed from an edge of the second backing layer.

6. The method of claim 1, wherein the thin bricks of the first plurality are rectangular.

7. The method of claim 1, wherein the first thin brick sheet is a prefabricated thin brick sheet.

8. The method of claim 1, wherein the thin bricks of the first plurality are between 0.125 inches and 3 inches thick.

9. The method of claim 1, wherein the first plurality of thin bricks are spaced from one another to provide spaces between adjacent bricks that are configured to be filled with mortar or grout.

10. The method of claim 1, wherein the first thin brick sheet defines an elongated corner, wherein the first thin brick sheet comprises a first portion that extends away from the corner in the first direction, wherein the first thin brick sheet comprises a second portion that extends away from the corner in the second direction that is different from the first direction.

11. A method of installing prefabricated thin brick sheets, comprising:

applying a first prefabricated thin brick sheet to a wall or floor surface, wherein the first prefabricated thin brick sheet comprises;

a first backing layer that comprises a first edge and a second edge that are at opposite sides of the first backing layer; and

a first plurality of thin bricks that are bonded to the first backing layer with an adhesive, wherein each thin brick of the first plurality of thin bricks comprises;

a first portion that extends in a first direction; and

a second portion that extends in a second direction;

wherein the first portions of the thin bricks of the first plurality are staggered such that some of the first portions are recessed from the first edge of the first backing layer;

wherein the first backing layer defines a grid that comprises holes, and wherein each thin brick of the first plurality is bonded to the first backing layer such that a portion of the rear surface of the thin brick is free from an adhesive, wherein the portion of the rear surface of the thin brick that is free from the adhesive overlaps one or more holes in the first backing layer such that a construction adhesive can penetrate through the first backing layer to adhere to the portion of the rear surface of each of the thin bricks of the first plurality that is free from the adhesive to bond the thin brick to the wall or floor surface;

applying a second prefabricated thin brick sheet to the wall or floor surface, wherein the second prefabricated thin brick sheet comprises;

a second backing layer; and

a second plurality of thin bricks that are bonded to the second backing layer with an adhesive, wherein a portion of some of the thin bricks of the second plurality overhang the second backing layer at a first edge of the second backing layer;

joining the overhanging portion of the thin bricks of the second plurality to the first prefabricated thin brick sheet;

applying a third prefabricated thin brick sheet to the wall or floor surface, wherein the third prefabricated thin brick sheet comprises;

a third backing layer; and

a third plurality of thin bricks that are bonded to the third backing layer with an adhesive, wherein a portion of some of the thin bricks of the third plurality overhang the third backing layer at a first edge of the third backing layer; and

joining the overhanging portion of the thin bricks of the third plurality to the second prefabricated thin brick sheet.

12. The method of claim 11, wherein the first backing layer comprises regions that extend beyond some of the first portions of the thin bricks of the first plurality, and wherein the regions of the first backing layer are configured to be coupled with overhanging portions of thin bricks of the second plurality.

13. The method of claim 11, wherein the first backing layer is flexible and substantially non-stretchable.

14. The method of claim 11, wherein the first plurality of thin bricks are spaced from one another to provide spaces between adjacent bricks that are configured to be filled with mortar or grout.

15. The method of claim 11, wherein the first prefabricated thin brick sheet defines an elongated corner, wherein the first prefabricated thin brick sheet comprises a first portion that extends away from the corner in the first direction, wherein the first prefabricated thin brick sheet comprises a second portion that extends away from the corner in the second direction that is different from the first direction.