Fiber enforced thin brick sheet and process

• US 10,443,247 B2
• Filed: 08/09/2018
• Issued: 10/15/2019
• 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:
  US16/059,994
• Publication Number:
  US 20190119927A1
• Time in Patent Office: 432 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 brick sheets, comprising:

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

a first backing layer; and

a first plurality of bricks that are bonded to the first backing layer, wherein the first backing layer defines a grid that comprises holes, and wherein each brick of the first plurality is bonded to the first backing layer such that a portion of the rear surface of the brick is free from an adhesive,

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

a second backing layer; and

a second plurality of bricks that are bonded to the second backing layer such that a portion of some of the 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 bricks of the second plurality to the first brick sheet.

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

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

4. The method of claim 1, wherein the first backing layer comprises fiberglass, polyester, graphite, aramid, or carbon.

5. The method of claim 4, wherein the first backing layer comprises fiberglass.

6. The method of claim 1, wherein the first plurality of bricks are bonded to the first backing layer in a running bond pattern or a stack bond pattern.

7. The method of claim 6, wherein the first plurality of bricks are bonded to the first backing layer in a stack bond pattern.

8. The method of claim 1, wherein the portion of some of the bricks of the second plurality overhang the second backing layer at a first lateral edge of the second backing layer.

9. The method of claim 1, wherein the adhesive comprises an epoxy adhesive or a silicone adhesive.

10. The method of claim 1, wherein the first backing layer comprises holes between 1/16 inch and 2 inches.

11. A method of installing brick sheets, comprising:

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

a first backing layer; and

a first plurality of bricks that are bonded to the first backing layer, wherein the first backing layer defines a grid that comprises holes, and wherein each brick of the first plurality is bonded to the first backing layer such that a portion of the rear surface of the brick is free from an adhesive,

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

a second backing layer; and

a second plurality of bricks that are bonded to the second backing layer such that a portion of at least one of the bricks of the second plurality overhangs the second backing layer at a first edge of the second backing layer; and

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

12. The method of claim 11, wherein the first plurality of bricks are thin bricks.

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

14. The method of claim 11, wherein the first backing layer comprises fiberglass, polyester, graphite, aramid, or carbon.

15. The method of claim 14, wherein the first backing layer comprises fiberglass.

16. The method of claim 11, wherein the first plurality of bricks are bonded to the first backing layer in a running bond pattern or a stack bond pattern.

17. The method of claim 16, wherein the first plurality of bricks are bonded to the first backing layer in a stack bond pattern.

18. The method of claim 11, wherein the portion the brick of the second plurality overhangs the second backing layer at a first lateral edge of the second backing layer.

19. The method of claim 11, wherein the adhesive comprises an epoxy adhesive or a silicone adhesive.

20. The method of claim 11, wherein the first backing layer comprises holes between 1/16 inch and 2 inches.