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Fiber enforced thin brick sheet and process

  • US 9,556,619 B2
  • Filed: 10/21/2011
  • Issued: 01/31/2017
  • Est. Priority Date: 10/21/2011
  • Status: Active Grant
First Claim
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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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