Brick panel apparatus

• US 5,311,714 A
• Filed: 02/19/1993
• Issued: 05/17/1994
• Est. Priority Date: 04/03/1991
• Status: Expired due to Fees

• Current Assignee: Real Brick Products Incorporated
• Original Assignee: National Brick Panel Systems, Inc.
• Inventors: Passeno, James K.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): CANFIELD, ROBERT
• Application Number:
  US08/020,312
• Time in Patent Office: 452 Days
• Field of Search: 52/385-387, 52/314, 52/309.12, 52/389-391, 52/384
• US Class Current: 52/314
• CPC Class Codes: E04F 13/0801 Separate fastening elements E04F13/088, E04F13/0885 take precedence
• 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 13/14 stone or stone-like materials, e.g. ceramics concrete,; of glass or with an outer layer of stone or stone-like materials or glass E04F13/0864 takes precedence; producing shaped elements from concrete, ceramic compositions or other stone-like materials B28B; prefabricated panels in general E04C2/00
• CPC Class Codes: Y10T 156/1089 of discrete laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/1092 All laminae planar and face to face

Abstract

A brick panel construction apparatus including a stiff backing member such as a polystyrene insulated board is laminated to a water impermeable sheet which is primarily planar in shape. A plurality of integrally formed projections are disposed in a plurality of horizontal rows on the impermeable sheet whereby these projections and the sheet constitute a one-piece structure. A plurality of spaced apart thin bricks are adhesively attached to the sheet and the bricks are disposed between the rows of projections. Grout is then applied to the spaces between the bricks and covers the rest of the sheet, including the projections. Brackets are utilized to attach the thin sheet and backing member to a vertical sub-straight and these brackets have a planar portion for allowing the fastener to pass through it, through the thin sheet and through the backing member to a vertical structural member. These brackets also have a top portion which supports the bottom of any brick it is under and also provides a mortar lock for ensuring that the mortar does not separate from the thin sheet.

Claims

1. A brick panel construction apparatus comprising:

a stiff backing member;

a water impermeable sheet, which is primarily planer in shape, one side of said sheet being attached to one side of said backing member;

a plurality of integrally formed spaced apart projections disposed in a plurality of horizontal rows on said impermeable sheet whereby said projections and said sheet constitute a one piece structure, said projections extending to the other side of said sheet, at least some of the projections which are adjacent to each other in each of the horizontal rows being spaced from each other by portions of said primarily planer in shape water impermeable sheet;

a plurality of spaced apart bricks attached to said other side of said sheet, said bricks being disposed between said rows of projections; and

grout disposed between adjacent bricks and covering said sheet and said projections.

2. The apparatus of claim 1 wherein said sheet is constructed of vacuum formed polystyrene material.

3. The apparatus of claim 1 wherein said sheet and projections are comprised of one sheet of vacuum formed polystyrene material.

4. The apparatus of claim 1 wherein said stiff backing member is comprised of extruded polystyrene foam material.

5. The apparatus of claim 1 wherein an adhesive means is provided between each of the bricks and said sheet, thereby bonding the bricks to said sheet.

6. The apparatus of claim 1 including a vertical structural member and means for attaching said panel construction apparatus to said vertical structural member.

7. The apparatus of claim 6 wherein said attaching means comprises a bracket in abutment with said other side of said sheet and having a fastener means extending therethrough, said fastener means extending into said vertical structural member.

8. The apparatus of claim 1 wherein each of said projections includes a top shelf and a lower portion, the bottom of one of said bricks being disposed on said top shelf.

9. The apparatus of claim 8 including a bracket having a planar lower portion in abutment with said sheet and an upper portion disposed underneath and in contact with the lower portion of one of said projections.

10. The apparatus of claim 9 wherein said upper portion of said bracket includes at least one flange means for permitting grout to be disposed between said flange and one of said projections whereby said grout and bricks will be further secured from separation with said sheet.

11. The apparatus of claim 10 including means for attaching said panel construction apparatus to said vertical structural member and means for fastening said bracket and said sheet to said vertical structural member.

12. The apparatus of claim 11 wherein said fastening means extends through said bracket, through said sheet and into said vertical structural member.

13. The apparatus of claim 12 wherein the extreme upper portion of said bracket is in contact with the lower bottom of a brick disposed on said shelf for further supporting said brick.

14. The apparatus of claim 13 wherein said brick has at least one groove disposed on the back side thereof, and said fastener means extends at least partially into said groove whereby the brick can be in more complete abutment with said sheet to insure a strong attachment to said sheet.

15. The apparatus of claim 1 wherein said sheet is comprised of vacuum formed polystyrene material.

16. The apparatus of claim 15 wherein said polystyrene material includes means for blocking the ultraviolet rays of the sun to prevent damage to said polystyrene material during the construction process of said brick panel construction apparatus.

17. The apparatus of claim 1 wherein said stiff backing member is constructed of extruded polystyrene foam.

18. The apparatus of claim 1 wherein said stiff backing member is constructed of sheetrock or gypsum board.

21. The apparatus of claim 10 including means for attaching said panel construction apparatus to said vertical structural member and means for fastening said bracket and said sheet to said vertical structural member.

23. The apparatus of claim 21 wherein the extreme upper portion of said bracket is in contact with the lower bottom of a brick disposed on said shelf for further supporting said brick.

19. A brick panel construction apparatus comprising:

a stiff backing member;

a water impermeable sheet, which is primarily planer in shape, one side of said sheet being attached to one side of said backing member;

a plurality of integrally formed spaced apart projections disposed in a plurality of horizontal rows on said impermeable sheet whereby said projections and said sheet constitute a one piece structure, said projections extending to the other side of said sheet;

a plurality of spaced apart bricks attached to said other side of said sheet, said bricks being disposed between said rows of projections;

wherein each of said projections includes a top shelf and a lower portion, the bottom of one of said bricks being disposed on said top shelf,

grout disposed between adjacent bricks and covering said sheet and said projections;

a vertical structure member;

means for attaching said panel construction apparatus to a vertical structural member; and

wherein said attaching means comprises a bracket in abutment with said other side of said sheet and having a fastener means extending therethrough, said fastener means extending into said vertical structural member, said bracket having a planar lower portion in abutment with said sheet and an upper portion disposed underneath and in contact with the lower portion of one of said projections.

20. The apparatus of claim 19 wherein said upper portion of said bracket includes at least one flange means for permitting grout to be disposed between said flange and one of said projections whereby said grout and bricks will be further secured from separation with said sheet.

22. The apparatus of claim 20 wherein said fastening means extends through said bracket, through said sheet and into said vertical structural member.

24. The apparatus of claim 22 wherein said brick has at least one groove disposed on the back side thereof, and said fastener means extends at least partially into said groove whereby the brick can be in more complete abutment with said sheet to insure a strong attachment to said sheet.

25. The apparatus of claim 19 wherein said sheet is comprised of vacuum formed polystyrene material.

26. The apparatus of claim 24 wherein said polystyrene material includes means for blocking the ultraviolet rays of the sun to prevent damage to said polystyrene material during the construction process of said brick panel construction apparatus.

27. The apparatus of claim 19 wherein said stiff backing member is constructed of extruded polystyrene foam.

28. The apparatus of claim 19 wherein said stiff backing member is constructed of sheetrock or gypsum board.

29. A brick panel construction apparatus comprising:

a water impermeable sheet, which is primarily planer in shape, one side of said sheet being adapted to be attached to a stiff backing member;

a plurality of projections disposed in said sheet on the other side of said sheet;

a drainage structure disposed between adjacent projections for allowing water to drain down past said adjacent projections on said other side of said sheet when said sheet is in a vertical orientation,

a plurality of spaced apart bricks attached to said other side of said sheet, said bricks being disposed between said projections; and

grout disposed between adjacent bricks and substantially covering said sheet and said projections.