Patent Application
20250043956
The present invention relates generally to the field of firebrick liner panel devices. More specifically, the present invention relates to an improved liner device for expediting brick liner installation in fireplaces. Accordingly, the present disclosure makes specific reference thereto. Nonetheless, it is to be appreciated that aspects of the present invention are also equally applicable to other like applications, devices and methods of manufacture.
By way of background, this invention relates to improvements in firebrick liner panel devices. Generally, brick liner installation in fireplaces can take considerable time and must be done by a professional mason. Lining fireplaces in the conventional manner can delay construction for other tradespeople. Further, multiple trips to and from a brick storage location can be required if installing bricks piece by piece. Additionally, installers typically need to be on their hands and knees to install fireplace brick liners, causing strain on the back and knees.
Furthermore, installing individual bricks one at a time, by hand, expends a lot of energy and takes a large amount of time. Additionally, a highly skilled tradesman is needed and may not be available for the length of the job. Thus, lining fireplaces in the conventional manner can be time-consuming and difficult.
Accordingly, there is a demand for an improved firebrick liner panel device that expedites brick liner installation in fireplaces. More particularly, there is a demand for a firebrick liner panel device that allows users to prefabricate the liner panels and install them quickly, saving extensive time and effort on a worksite.
Therefore, there exists a long felt need in the art for a firebrick liner panel device that provides users with an improved liner device for expediting brick liner installation in fireplaces. There is also a long felt need in the art for a firebrick liner panel device that features a masonry panel constructed using bricks. Further, there is a long felt need in the art for a firebrick liner panel device that allows users to install a perfectly even set of bricks into the fireplace rather than installing bricks one by one. Moreover, there is a long felt need in the art for a device that includes different sizes to accommodate various fireplace walls being lined with bricks. Further, there is a long felt need in the art for a firebrick liner panel device that allows users to prefabricate the liner panels and install them quickly, saving extensive time and effort on a worksite. Finally, there is a long felt need in the art for a firebrick liner panel device that eliminates the need for workers to be on their hands and knees installing individual bricks within a fireplace.
The subject matter disclosed and claimed herein, in one embodiment thereof, comprises a firebrick liner panel device. The device is used to expedite the brick liner installation in fireplaces in a more conventional fashion. The firebrick liner panel device comprises a panel component made of a fire brick liner with a maximum thickness of one and a half inches but no less than 1.25 inches thick as required by code. The panel component may be made in different sizes to fit a variety of fireplace walls to be lined. The panel component is constructed using a cement board or other planer surface. The brick is then placed in a pattern with spacers in between to create even separation of the bricks. Users then fill the joint spaces with mud, then a sheet of diamond mesh lath is positioned over the bricks. The user with a trowel, adds a 0.25″ mud bed over the mesh and lets it dry. Once completed, the panel component is installed within the fireplace by a user with minimal mason experience.
In this manner, the firebrick liner panel device of the present invention accomplishes all of the forgoing objectives and provides users with a device that allows users to prefabricate liner panels for quick installation. The device can be constructed in various sizes. The device eliminates the need for users to be on their hands and knees installing individual bricks.
The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some general concepts in a simplified form as a prelude to the more detailed description that is presented later.
The subject matter disclosed and claimed herein, in one embodiment thereof, comprises a firebrick liner panel device. The device is used to expedite the brick liner installation in fireplaces in a more conventional fashion. The firebrick liner panel device comprises a panel component made in different sizes to fit a variety of fireplace walls to be lined. The panel component is constructed using a cement board on which firebricks are placed in a pattern with spacers in between to create even separation of the bricks. Users then fill the joint spaces with mud, then a sheet of diamond mesh lath is positioned over the bricks and a mud bed applied over top. Once completed, the panel component is installed within the fireplace by a user.
In one embodiment, the firebrick liner panel device provides users with an improved liner device for expediting brick liner installation in fireplaces. Specifically, the firebrick liner panel device provides a masonry panel constructed using bricks, allowing users to install a perfectly even set of bricks into the fireplace rather than installing bricks one by one. The device allows users to prefabricate the liner panels and install them quickly, saving extensive time and effort on a worksite.
In one embodiment, the firebrick liner panel device comprises a transportable brick panel component consisting of a plurality of firebricks arranged in a predetermined pattern on a planar surface and filled with mud between the recesses or gaps of the firebricks.
In one embodiment, the manufacture of the transportable brick panel component is constructed using a cement board or other planer surface. The planar surface can be any suitable shape and size as is known in the art, as long as it's sized to retain a predetermined amount of firebricks in a particular design. Further, the planar surface can be manufactured of any suitable material as is known in the art, although a cement board is typically used. The cement board in its natural state must be flat and not molded to any brick pattern shape as the cement board accommodates many different panel component configurations. Additionally, in the figures, the cement board is shown tilted to a near vertical position for the placing of the firebricks of the panel component on the fireplace, as described below. Initially, however, the cement board is positioned horizontally and the plurality of firebricks applied.
In one embodiment, once the cement board is in a horizontal position on the ground, work table, or other planar surface, the plurality of firebrick are then arranged in a pattern over the cement board, any suitable amount of firebricks can be utilized as is known in the art, depending on the wants and/or needs of a user. The firebricks utilized are conventional firebricks. Generally, a firebrick is a special type of brick made using fire clay and has a good resistance against high temperatures. These bricks are typically used in kilns, lining furnaces, fireplaces and fireboxes, etc. These bricks are manufactured in a way similar to that of normal bricks, except during the burning process, fire bricks are exposed to very high temperatures.
In one embodiment, spacers are positioned in between the firebricks to create an even separation of the bricks. Any suitable brick spacers can be utilized as is known in the art, depending on the needs and/or wants of a user. Conventional brick spacers are typically utilized in between the firebricks. The brick spacers are utilized to create recesses or joint spaces between the firebricks. Users then fill the recesses/joint spaces with mud or mortar. Mortar is the essential ingredient that holds the firebricks together and serves as a sealant and buffer between them. Mortar is frequently made up of a sand, gravel, and/or cement mixture. Further, mortar provides excellent adhesion without compromising its ability to remain flexible enough for thermal expansion and contraction of the firebricks.
In one embodiment, a sheet of diamond mesh lath is positioned over the bricks. Any suitable diamond mesh lath can be utilized as is known in the art. The sheet of diamond mesh lath is a multipurpose expanded steel substrate or other suitable mesh lath as is known in the art. The function of the diamond mesh lath is to prevent the fluid mortar from contaminating the face surface of the bricks, as well as to stabilize the firebricks in their preferred position. The compressible resilient nature of the diamond mesh lath allows the bricks to “sink in”, thus being able to resist lateral forces generated during the preparation or the introduction of the fluid mortar.
In one embodiment, the user with a trowel adds an approximately 0.25″ mud or mortar bed over the diamond mesh lath and lets it dry. Any suitable amount of mud or mortar can be used as is known in the art. Once completed, the panel component has a maximum thickness of one and half inches but no less than 1.25 inches thick as required by code. When this is complete, the panel component is cured sufficiently before tilting vertically and separating from the cement board.
In one embodiment, the user then installs the panel component within the fireplace. Typically, the cement board is removed from the panel component and then the panel component is secured to the fireplace via suitable securing means as is known in the art, such as mud, mortar, etc. The panel component makes it easy for users to install a perfectly even set of bricks into the fireplace. Thus, installation of the panel components can be performed by a user with minimal mason experience.
In one embodiment, the cement board is treated with a protective layer of paper with a cement retardant, or release agent thus enabling the paper, which will adhere to the bricks, to be peeled away and the brickwork then brushed and any blemishes rectified. Thus, the cement board is removed and then the protective layer of paper removed before applying the panel component to the fireplace.
In one embodiment, the recesses between the bricks are filled in with play sand about a ¼″ deep to prevent the bricks from being mortar to the cement board, thereafter the remaining 1″ deep recesses are filled in with mortar to bond the bricks together to create the panel. Once the cement is fully dry, we can turn the panel face over then vacuum the sand off the recesses to be reused.
In one embodiment, after installation of the panel components, the spaces between adjacent firebricks of the adjacent panel components are filled with mortar, to complete the installation, and to render the finished fireplace wall indistinguishable from a conventionally bricked fireplace wall.
In one embodiment, the panel components may be made in different sizes and shapes to fit a variety of fireplace walls to be lined.
In yet another embodiment, the firebrick liner panel device comprises a plurality of indicia.
In yet another embodiment, a method of expediting firebrick liner installation in fireplaces is disclosed. The method includes the steps of providing a firebrick liner panel device comprising a panel component constructed in a variety of sizes. The method also comprises positioning a plurality of bricks in a pattern on a cement board. Further, the method comprises placing spacers between the bricks to create even separation. The method also comprises filling the joint spaces with mud. The method also comprises laying a sheet of diamond mesh lath over the bricks. The method comprises adding a mud bed over the mesh and letting it dry. Finally, the method comprises installing the panel component within a fireplace.
Numerous benefits and advantages of this invention will become apparent to those skilled in the art to which it pertains, upon reading and understanding the following detailed specification.
To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and are intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.
The description refers to provided drawings in which similar reference characters refer to similar parts throughout the different views, and in which:
The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof. Various embodiments are discussed hereinafter. It should be noted that the figures are described only to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention and do not limit the scope of the invention. Additionally, an illustrated embodiment need not have all the aspects or advantages shown. Thus, in other embodiments, any of the features described herein from different embodiments may be combined.
As noted above, there is a long felt need in the art for a firebrick liner panel device that provides users with an improved liner device for expediting brick liner installation in fireplaces. There is also a long felt need in the art for a firebrick liner panel device that features a masonry panel constructed using bricks. Further, there is a long felt need in the art for a firebrick liner panel device that allows users to install a perfectly even set of bricks into the fireplace rather than installing bricks one by one. Moreover, there is a long felt need in the art for a device that includes different sizes to accommodate various fireplace walls being lined with bricks. Further, there is a long felt need in the art for a firebrick liner panel device that allows users to prefabricate the liner panels and install them quickly, saving extensive time and effort on a worksite. Finally, there is a long felt need in the art for a firebrick liner panel device that eliminates the need for workers to be on their hands and knees installing individual bricks within a fireplace.
The present invention, in one exemplary embodiment, is a novel firebrick liner panel device. The firebrick liner panel device comprises a panel component constructed in a variety of sizes to fit a variety of fireplace walls to be lined. The panel component is constructed using a cement board or other planer surface. The brick is then placed in a pattern with spacers in between to create even separation of the bricks. Users then fill the joint spaces with mud, then a sheet of diamond mesh lath is positioned over the bricks. The user with a trowel, adds a 0.25″ mud bed over the mesh and lets it dry. Once completed, the panel component is installed within the fireplace by a user. The present invention also includes a novel method of expediting firebrick liner installation in fireplaces. The method includes the steps of providing a firebrick liner panel device comprising a panel component constructed in a variety of sizes. The method also comprises positioning a plurality of bricks in a pattern on a cement board. Further, the method comprises placing spacers between the bricks to create even separation. The method also comprises filling the joint spaces with mud. The method also comprises laying a sheet of diamond mesh lath over the bricks. The method comprises adding a mud bed over the mesh and letting it dry. Finally, the method comprises installing the panel component within a fireplace.
Referring initially to the drawings,
Generally, the firebrick liner panel device 100 provides users with an improved liner device for expediting brick liner installation in fireplaces 116. Specifically, the firebrick liner panel device 100 provides a masonry panel constructed using bricks 106, allowing users to install a perfectly even set of bricks 106 into the fireplace 116 rather than installing bricks 106 one by one. The device 100 allows users to prefabricate the liner panels and install them quickly, saving extensive time and effort on a worksite.
Further, the firebrick liner panel device 100 comprises a transportable brick panel component 102 consisting of a plurality of firebricks 106 arranged in a predetermined pattern on a planar surface 104 and filled with mud 110 between the recesses or gaps 118 of the firebricks 106.
As shown in
Further, once the cement board 104 is in a horizontal position on the ground, worktable, or other planar surface, the plurality of firebrick 106 are then arranged in a pattern over the cement board 104, any suitable amount of firebricks 106 can be utilized as is known in the art, depending on the wants and/or needs of a user. The firebricks 106 utilized are conventional firebricks 106. Generally, a firebrick 106 is a special type of brick made using fire clay and has a good resistance against high temperatures. These bricks 106 are typically used in kilns, lining furnaces, fireplaces and fireboxes, etc. These bricks 106 are manufactured in a way similar to that of normal bricks, except during the burning process, fire bricks 106 are exposed to very high temperatures.
Additionally, spacers 108 are positioned in between the firebricks 106 to create an even separation of the bricks 106. Any suitable brick spacers 108 can be utilized as is known in the art, depending on the needs and/or wants of a user. Conventional brick spacers 108 are typically utilized in between the firebricks 106. The brick spacers 108 are utilized to create recesses or joint spaces 118 between the firebricks 106. Users then fill the recesses/joint spaces 118 with mud or mortar 110. Mortar 110 is the essential ingredient that holds the firebricks 106 together and serves as a sealant and buffer between them. Mortar 110 is frequently made up of a sand, gravel, and/or cement mixture. Further, mortar 110 provides excellent adhesion without compromising its ability to remain flexible enough for thermal expansion and contraction of the firebricks 106.
Furthermore, a sheet of diamond mesh lath 112 is positioned over the bricks 106. Any suitable diamond mesh lath 112 can be utilized as is known in the art. The sheet of diamond mesh lath 112 is a multipurpose expanded steel substrate or other suitable mesh lath as is known in the art. The function of the diamond mesh lath 112 is to prevent the fluid mortar 110 from contaminating the face surface of the bricks 106, as well as to stabilize the firebricks 106 in their preferred position. The compressible resilient nature of the diamond mesh lath 112 allows the bricks 106 to “sink in”, thus being able to resist lateral forces generated during the preparation or the introduction of the fluid mortar 110.
In one embodiment, the cement board 104 is treated with a protective layer of paper 120 with a cement retardant, or release agent 122 thus enabling the paper 120, which will adhere to the bricks 106, to be peeled away and the brickwork then brushed and any blemishes rectified. Thus, the cement board 104 is removed and then the protective layer of paper 120 removed before applying the panel component 102 to the fireplace 116.
As shown in
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Further, after installation of the panel components 102, the spaces 118 between adjacent firebricks 106 of the adjacent panel components 102 are filled with mortar 110, to complete the installation, and to render the finished fireplace wall indistinguishable from a conventionally bricked fireplace wall.
In one embodiment, the panel components 102 may be made in different sizes and shapes to fit a variety of fireplace walls to be lined.
In yet another embodiment, the firebrick liner panel device 100 comprises a plurality of indicia 500. The panel component 102 of the device 100 may include advertising, a trademark, or other letters, designs, or characters, printed, painted, stamped, or integrated into the panel component 102, or any other indicia 500 as is known in the art. Specifically, any suitable indicia 500 as is known in the art can be included, such as but not limited to, patterns, logos, emblems, images, symbols, designs, letters, words, characters, animals, advertisements, brands, etc., that may or may not be firebrick, fireplace, or brand related.
Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different users may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not structure or function. As used herein “firebrick liner panel device”, “firebrick device”, “liner panel device”, and “device” are interchangeable and refer to the firebrick liner panel device 100 of the present invention.
Notwithstanding the forgoing, the firebrick liner panel device 100 of the present invention can be of any suitable size and configuration as is known in the art without affecting the overall concept of the invention, provided that it accomplishes the above stated objectives. One of ordinary skill in the art will appreciate that the firebrick liner panel device 100 as shown in
Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. While the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.
What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
The present application claims priority to, and the benefit of, U.S. Provisional Application No. 63/516,936, which was filed on Aug. 1, 2023, and is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63516936 | Aug 2023 | US |
