Thin brick panel system
First Claim
1. An expanded polystyrene foam panel for use in a thin brick panel system with thin bricks,wherein the expanded polystyrene foam panel has a front side, a back side, a left side, a right side, a top side and a bottom side, wherein said back side has at least one depression adapted to provide increased surface area for an adhesive used to adhere the back side to a substrate, wherein said front side has a plurality of laterally extending channels that each are sized and adapted to receive a plurality of thin brick units initially held by an adhesive to the channels, wherein said channels are each defined by a pair of laterally extending spacing members that are integrally formed with said panel, wherein said plurality of laterally extending spacing members are positioned to provide proper spacing between the thin brick units to enable the thin brick units to form rows, and wherein each laterally extending spacing member has a height that is less than the thickness of the thin brick units and each laterally extending spacing member has a width that is sufficient to enable a mortar joint to be formed on each laterally extending spacing member between rows of thin brick units.
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Accused Products
Abstract
A thin brick panel system and method of forming a thin brick wall includes an expanded polystyrene foam panel having a plurality of laterally extending channels formed therein for receiving a plurality of thin brick units. The thin brick units are bonded with an adhesive directly to the foam panel and the seams between adjacent brick are filled with a mortar that bonds to the foam panel. The foam panel may be attached to a substrate with an adhesive as well as fasteners. Strips of a mesh fabric may span several panels to bind the panels together to form a structurally sound thin brick wall.
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Citations
20 Claims
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1. An expanded polystyrene foam panel for use in a thin brick panel system with thin bricks,
wherein the expanded polystyrene foam panel has a front side, a back side, a left side, a right side, a top side and a bottom side, wherein said back side has at least one depression adapted to provide increased surface area for an adhesive used to adhere the back side to a substrate, wherein said front side has a plurality of laterally extending channels that each are sized and adapted to receive a plurality of thin brick units initially held by an adhesive to the channels, wherein said channels are each defined by a pair of laterally extending spacing members that are integrally formed with said panel, wherein said plurality of laterally extending spacing members are positioned to provide proper spacing between the thin brick units to enable the thin brick units to form rows, and wherein each laterally extending spacing member has a height that is less than the thickness of the thin brick units and each laterally extending spacing member has a width that is sufficient to enable a mortar joint to be formed on each laterally extending spacing member between rows of thin brick units.
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8. A thin brick panel system, comprising:
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an expanded polystyrene foam panel for use with thin bricks; and
mechanical fastening means for securing the panel to a substrate;
wherein the expanded polystyrene foam panel has a front side, a back side, a left side, a right side, a top side and a bottom side, wherein said back side has a plurality of depressions adapted to provide increased surface area for an adhesive used to adhere the back side to a substrate, wherein said front side has a plurality of laterally extending channels that each are sized and adapted to receive a plurality of thin brick units initially held by an adhesive to the channels, wherein said channels are each defined by a pair of laterally extending spacing members that are integrally formed with said panel, wherein said plurality of laterally extending spacing members are positioned to provide proper spacing between the thin brick units to enable the thin brick units to form rows, and wherein each laterally extending spacing member has a height that is less than the thickness of the thin brick units and each laterally extending spacing member has a width that is sufficient to enable a mortar joint to be formed on each laterally extending spacing member between rows of thin brick units. - View Dependent Claims (9, 10, 11)
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12. A method of forming a wall of thin bricks, comprising:
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providing an expanded polystyrene foam panel having a front side and a back side, said front side defining a plurality of laterally extending channels, said channels each defined by a pair of laterally extending spacing members integrally formed with said panel;
wherein said plurality of laterally extending spacing members are positioned to provide proper spacing between the thin brick units to enable the thin brick units to form rows, and fastening said panel to a substrate by applying an adhesive to the back side of the panel and into at least one depression in the back side;
applying an adhesive to the panel within said plurality of channels; and
pressing a plurality of thin brick units into said adhesive and within said plurality of channels;
wherein each laterally extending spacing member has a height that is less than the thickness of the thin brick units and each laterally extending spacing member has a width that is sufficient to enable a mortar joint to be formed on each laterally extending spacing member between rows of thin brick units. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20)
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Specification