Fiber enforced thin brick sheet and process
First Claim
Patent Images
1. A thin brick system, comprising:
- a first prefabricated fiber enforced thin brick sheet comprising;
a first fiber-reinforced backing layer that defines an elongated corner, wherein the first fiber-reinforced backing layer comprises a first portion that extends away from the corner in a first direction and defines a first edge spaced from the corner, and wherein the first fiber-reinforced backing layer comprises a second portion that extends away from the corner in a second direction that is different from the first direction and defines a second edge that is spaced from the corner, wherein the first fiber-reinforced backing layer comprises fiberglass fibers and one or more holes;
a first plurality of thin bricks that are bonded to the first fiber-reinforced backing layer via an adhesive, wherein each thin brick of the first plurality of thin bricks;
defines a corner that covers a portion of the corner of the first fiber-reinforced backing layer;
comprises a first portion that extends in the first direction and is bonded to the first portion of the first fiber-reinforced backing layer; and
comprises a second portion that extends in the second direction and is bonded to the second portion of the first fiber-reinforced backing layer; and
an anti-adhesive paper that defines a corner that corresponds with the corner of the first fiber-reinforced backing layer,wherein the first portions of the thin bricks of the first plurality are staggered and the second 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 fiber-reinforced backing layer and some of the second portions are recessed from the second edge of the first fiber-reinforced backing layer, andwherein the first plurality of thin bricks are bonded via the adhesive to each of the first fiber-reinforced backing layer and the anti-adhesive paper as a first unitary prefabricated thin brick sheet that is configured to be mounted to a floor or wall surface after release of the anti-adhesive paper from the adhesive, each thin brick of the first plurality being bonded to the first fiber-reinforced backing layer such that a portion of the rear surface of the thin brick is free from the 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 fiber-reinforced backing layer such that a construction adhesive can penetrate through the first fiber-reinforced backing layer to adhere to the portion of the rear surface of the thin brick that is free from the adhesive to bond the thin brick to a wall or floor surface; and
a second prefabricated fiber enforced thin brick sheet comprising;
a second fiber-reinforced backing layer; and
a second plurality of thin bricks that are bonded to the second fiber-reinforced backing layer such that some of the thin bricks of the second plurality overhang the second fiber-reinforced backing at a first edge of the second fiber-reinforced sheet so as to be configured to couple the second prefabricated fiber enforced thin brick sheet to the first prefabricated fiber enforced thin brick sheet.
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Accused Products
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.
39 Citations
17 Claims
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1. A thin brick system, comprising:
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a first prefabricated fiber enforced thin brick sheet comprising; a first fiber-reinforced backing layer that defines an elongated corner, wherein the first fiber-reinforced backing layer comprises a first portion that extends away from the corner in a first direction and defines a first edge spaced from the corner, and wherein the first fiber-reinforced backing layer comprises a second portion that extends away from the corner in a second direction that is different from the first direction and defines a second edge that is spaced from the corner, wherein the first fiber-reinforced backing layer comprises fiberglass fibers and one or more holes; a first plurality of thin bricks that are bonded to the first fiber-reinforced backing layer via an adhesive, wherein each thin brick of the first plurality of thin bricks; defines a corner that covers a portion of the corner of the first fiber-reinforced backing layer; comprises a first portion that extends in the first direction and is bonded to the first portion of the first fiber-reinforced backing layer; and comprises a second portion that extends in the second direction and is bonded to the second portion of the first fiber-reinforced backing layer; and an anti-adhesive paper that defines a corner that corresponds with the corner of the first fiber-reinforced backing layer, wherein the first portions of the thin bricks of the first plurality are staggered and the second 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 fiber-reinforced backing layer and some of the second portions are recessed from the second edge of the first fiber-reinforced backing layer, and wherein the first plurality of thin bricks are bonded via the adhesive to each of the first fiber-reinforced backing layer and the anti-adhesive paper as a first unitary prefabricated thin brick sheet that is configured to be mounted to a floor or wall surface after release of the anti-adhesive paper from the adhesive, each thin brick of the first plurality being bonded to the first fiber-reinforced backing layer such that a portion of the rear surface of the thin brick is free from the 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 fiber-reinforced backing layer such that a construction adhesive can penetrate through the first fiber-reinforced backing layer to adhere to the portion of the rear surface of the thin brick that is free from the adhesive to bond the thin brick to a wall or floor surface; and a second prefabricated fiber enforced thin brick sheet comprising; a second fiber-reinforced backing layer; and a second plurality of thin bricks that are bonded to the second fiber-reinforced backing layer such that some of the thin bricks of the second plurality overhang the second fiber-reinforced backing at a first edge of the second fiber-reinforced sheet so as to be configured to couple the second prefabricated fiber enforced thin brick sheet to the first prefabricated fiber enforced thin brick sheet. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A prefabricated fiber enforced thin brick sheet comprising:
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a fiber-reinforced backing layer that defines an elongated corner, wherein the fiber-reinforced backing layer comprises a first portion that extends away from the corner in a first direction and defines a first edge spaced from the corner, and wherein the fiber-reinforced backing layer comprises a second portion that extends away from the corner in a second direction that is different from the first direction and defines a second edge that is spaced from the corner, wherein the fiber-reinforced backing layer comprises fiberglass fibers and one or more holes; and a plurality of thin bricks that are bonded to the fiber-reinforced backing layer via an adhesive, wherein each thin brick; defines a corner that covers a portion of the corner of the fiber-reinforced backing layer; comprises a first portion that extends in the first direction and is bonded to the first portion of the fiber-reinforced backing layer; and comprises a second portion that extends in the second direction and is bonded to the second portion of the fiber-reinforced backing layer; wherein some of the first portions of the bricks are recessed from the first edge of the fiber-reinforced backing layer and some of the second portions of the bricks are recessed from the second edge of the fiber-reinforced backing layer, wherein regions of the first portion of the fiber-reinforced backing layer extend beyond the first portions of the thin bricks that are recessed from the first edge of the fiber-reinforced backing layer, wherein regions of the second portion of the fiber-reinforced backing layer extend beyond the second portions of the thin bricks that are recessed from the second edge of the fiber-reinforced backing layer, and wherein the regions of the first and second portions of the fiber-reinforced backing layer are configured to be coupled with portions of additional thin bricks, wherein first bricks that have first portions that are recessed from the first edge of the fiber-reinforced backing layer also have second portions that extend to the second edge of the fiber-reinforced backing layer, and wherein second bricks that have second portions that are recessed from the second edge of the fiber-reinforced backing layer have first portions that extend to the first edge of the fiber-reinforced backing layer, and wherein the plurality of thin bricks are bonded via the adhesive to the fiber-reinforced backing layer as a unitary prefabricated thin brick sheet that is configured to be mounted to a floor or wall surface, each thin brick being bonded to the fiber-reinforced backing layer such that a portion of the rear surface of the thin brick is free from the 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 fiber-reinforced backing layer such that a construction adhesive can penetrate through the fiber-reinforced backing layer to adhere to the portion of the rear surface of the thin brick that is free from the adhesive to bond the thin brick to a wall or floor surface. - View Dependent Claims (14, 15, 16, 17)
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Specification