Panel system and method
First Claim
1. A panel for use in building construction in conjunction with bricks of orthogonal configuration having a front face, a rear face, a first and second opposed sides and a first and second opposed ends with thickness of said sides and ends being less than the width or length dimension of said front and rear faces, comprising:
- (a) an inner portion, including insulating material,(b) an outer portion for supporting bricks,(c) said outer portion being bonded to said inner portion,(d) said panel having a length and width dimension;
(e) a number of equally spaced channel bars forming channels with substantially flat bottom surface corresponding to the widths of bricks to be supported on said panel, each of said channel bars having a substantially constant cross section along its entire length and extending substantially the entire width dimension of said panel and being sufficiently resilient to hold said bricks between adjacent channel bars by friction; and
(f) said channel bars being configured to deform and engage the sides of a brick to be supported upon pressing said brick into said channel.
2 Assignments
0 Petitions
Accused Products
Abstract
A structure and method is disclosed for facilitating the construction of a brick facade. A panel is provided made of bonded vacuum formed polystyrene and extruded polystyrene foam. The outer portion is specially configured to secure bricks in place by a friction fit until mortar is laid. The rear surface of the bricks are secured by adhesive to the surface of the outer portion of the panel. Channel bars separate the bricks in a vertical direction while other spacing means are used to locate the bricks in the horizontal direction the proper distance from one another. The mortar is then laid in place by hand to create the effect of bricks laid by a mason. Because of the materials used and the configuration, the panel can be cut at the work site to accommodate variations in the structure being erected. The cutting operation can be accomplished by a commercial cutting knife, the panel nailed in place, and bricks laid within the panel by an unskilled construction worker.
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Citations
29 Claims
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1. A panel for use in building construction in conjunction with bricks of orthogonal configuration having a front face, a rear face, a first and second opposed sides and a first and second opposed ends with thickness of said sides and ends being less than the width or length dimension of said front and rear faces, comprising:
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(a) an inner portion, including insulating material, (b) an outer portion for supporting bricks, (c) said outer portion being bonded to said inner portion, (d) said panel having a length and width dimension; (e) a number of equally spaced channel bars forming channels with substantially flat bottom surface corresponding to the widths of bricks to be supported on said panel, each of said channel bars having a substantially constant cross section along its entire length and extending substantially the entire width dimension of said panel and being sufficiently resilient to hold said bricks between adjacent channel bars by friction; and (f) said channel bars being configured to deform and engage the sides of a brick to be supported upon pressing said brick into said channel. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
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16. A panel for use in building construction comprising:
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(a) an inner portion, including insulating material; (b) an outer portion for supporting bricks; (c) said outer portion being bonded to said inner portion; (d) a number of equally spaced channel bars forming channels corresponding to the widths of bricks to be supported on said panel, said channel bars being sufficiently resilient to hold said bricks between adjacent channel bars by friction; (e) each of said channel bars being substantially of uniform height along its entire length, the height of each channel bar being less than the thickness of the brick to form a horizontal space of sufficient depth between adjacent bricks to receive the mortar for holding the bricks in place; (f) each of said channel bars further including a top wall and a bottom wall spaced from one another sufficiently to permit the reception of mortar to hold the bricks in place, said walls being deformable to deflect toward each other upon the insertion of the brick between the channel bars and away from each other upon removal of the brick or in a normal disposition; (g) said top wall and said bottom wall of each channel extending outwardly from the base portion of said outer portion at an acute angle of about eighty-three degrees; (h) said outer portion having an outer surface for supporting the bricks and being roughened to provide an adhesive surface for adhesive bonding of brick to the panel; and (i) the outer surface of each of said channel bars including grooves and dimples for holding the mortar in place, said grooves being formed in a diamond configuration with said dimples arranged in three rows along the length of the channel and spaced symmetrically between the grooves to form the diamond.
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29. A panel used in building construction comprising for use in conjunction with bricks having a width and length
(a) an inner portion of foamed polystyrene; -
(b) an outer portion of vacuum formed polystyrene substantially coextensive with said inner portion said outer portion having a thickness substantially less than said inner portion and being bonded to said inner portion by adhesive; (c) said outer portion defining a number of equally spaced channel bars forming channels therebetween each channel having a width corresponding to the width of the brick; (d) each channel bar extending substantially the entire width of the panel and having a substantially uniform cross-sectional configuration therethrough, the height of each channel bar being less than the thickness of the brick to form a horizontal space for receiving of sufficient depth to receive mortar; (e) each channel includes a top wall and a bottom wall each wall extending outwardly at about an eighty-three degree angle in diverging relationship to form a dove-type configuration, said walls being sufficiently resilient to hold bricks in channel by friction; and (f) a number of channels including a series of recess to provide relief for fastening means.
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Specification