BACKGROUND
Field
The present invention relates to devices, systems, and methods for handling building materials during installation of the building materials. In particular, the present invention relates to devices, systems, and methods for supporting masonry units during installation of the masonry units on a substrate.
Description of Background Art
Masonry is the trade related to constructing a structure and/or the ornamental components of the structure using masonry materials. Masonry materials traditionally include stone, brick, concrete blocks, and various other materials. Brick and stone are used generally in masonry applications. One reason why brick and stone are used typically in masonry applications is due to the fact that brick and stone generate an aesthetically pleasing presentation when outwardly visible as part of a structure and/or the ornamental components of the structure. In particular, bricks are used in masonry applications because of the various colors and shades that are available, as a result of the various material compositions of bricks, and the various orientations that are possible for installation, as a result of the modular nature of bricks.
Brick sizing can be considered to fall within, but is not limited to, the following categories: Modular, Engineer Modular, Queen Size, and King Size. Generally, Modular bricks in the United States can have standard dimensions as follow: 3½ inches depth/width, 2¼ inches height, and 7⅝ inches length. Engineer Modular bricks in the United States can have standard dimensions as follow: 3½ inches depth/width, 2¾ inches height, and 7⅝ inches length. Queen Size bricks in the United States can have standard dimensions as follow: 3 inches depth/width, 2¾ inches height, and 7⅝ inches length. King Size bricks in the United States can have standard dimensions as follow: 2⅝ inches depth/width, 2¾ inches height, and 9⅝ inches length. However, modular and non-modular bricks in the United States are available in various other dimensions depending on anticipated usage or installation location and the mortar joint sizing that will be used in conjunction with the brick. Brick installation using various standard sizes is typically done by a mason or bricklayer in which mortar is used between the bricks to bind the bricks together to form a structure or ornamental components of the structure. Brick installation is time intensive and requires skilled labor as it is done unit by unit or, literally, in a “brick by brick” manner.
Various developments have been pursued to reduce the material costs, time demand, and cost of skilled labor that are all necessary for brick installation. One such development has been the production of brick veneers or thin bricks. Brick veneers or thin bricks are designed to mimic the outward appearance of brick, after installation, by having similar ornamental face sizes as standard brick, while having a reduced thickness, depth, or width than that of standard brick. Brick veneers or thin bricks can have ornamental face sizes that are similar to the standard dimensions of modular or non-modular brick, while having a depth/width that is below the standard dimensions of modular or non-modular brick. For example, brick veneers or thin bricks can have, but are not limited to having, the following dimensions: ½ inch depth/width, 2¼ inches height, and 7⅝ inches length; ½ inch depth/width, 2¾ inches height, and 7⅝ inches length; and ½ inch depth/width, 2¾ inches height, and 9⅝ inches length.
Brick veneers or thin bricks can be installed by adhering a face of the thin brick to a layer of mortar applied to a flat surface. Similar to traditional brick installation, brick veneer or thin brick installation is also done in a unit by unit manner. However, brick veneer or thin brick installation that is done in a unit by unit manner, similar to traditional brick installation, is time consuming and costly. Therefore, while brick veneers or thin bricks may have lower material costs than traditional brick, unit by unit installation of brick veneers or thin bricks poses extensive time demands and requires skilled labor to generate a suitable or pleasing visible appearance of a surface finished with brick veneer or thin brick.
Therefore, there remains a need for devices, systems, or methods that can facilitate installation speed and reduce installation cost for brick veneers or thin brick.
SUMMARY
In some non-limiting embodiments or aspects of the present disclosure, a frame for supporting at least one of masonry units during installation on a substrate includes a support panel having a front and back surface, first and second spacer members extending transversely from the front surface of the support panel, and engagement members extending from at least one of the following: the front surface of the support panel, the first spacer members, the second spacer members, or any combination thereof. The front surface of the support panel is configured to abut a first face of each of the masonry units. The engagement members are releasably engageable with a second face of each of the masonry units or the second face and a third face of each of the masonry units.
One or more of the following features can be included in the non-limiting embodiments or aspects of the frame for supporting at least one of the masonry units during installation on the substrate.
The engagement members can be manually disengageable with the second face of each of the masonry units or the second face and the third face of each of the masonry units after a fourth face of each of the masonry units is set in a bonding material applied on the substrate. The fourth face of each of the masonry units can be opposite from the first face of each of the masonry units.
The engagement members can be configured to engage the second face of each of the masonry units or the second face and the third face of each of the masonry units. The engagement members can be configured to disengage the second face of each of the masonry units or the second face and the third face of each of the masonry units after a fourth face of each of the masonry units is set in a bonding material applied on the substrate. The fourth face of each of the masonry units can be opposite from the first face of each of the masonry units.
The engagement members can be manually disengageable with the second face of each of the masonry units or the second face and the third face of each of the masonry units by applying a force to the frame in a direction away from the bonding material and the substrate.
The engagement members being releasably engageable with the second face of each of the masonry units or the second face and the third face of each of the masonry units can allow removal of the frame from each of the masonry units that are set in a bonding material applied on the substrate.
The support panel can define apertures extending through the support panel from the front surface of the support panel to the back surface of the support panel. The apertures of the support panel can be configured to allow air to pass therethrough upon removal of the frame from each of the masonry units that is set in the bonding material applied on the substrate.
The frame for supporting masonry units can also include a surface treatment configured to resist bonding to a bonding material applied on the substrate.
At least one of the second spacer members can meet at least one of the first spacer members at substantially a middle point of a length of the at least one of the first spacer members.
The first face of each of the masonry units can be an ornamental face.
The first spacer members, the second spacer members, and the engagement members can each extend a distance from the front surface of the support panel. Each distance can be only a portion of a thickness of each of the second face, the third face, a fifth face, and a sixth face of each of the masonry units. The first spacer members, the second spacer members, and the engagement members, each extending the distance from the front surface of the support panel that is only a portion of the thickness of each of the second, third, fifth, and sixth face of each of the masonry units, can expose a second portion of the thickness of each of the second face, the third face, the fifth face, and the sixth face of each of the of the masonry units and can expose the entire surface area of the fourth face of each of the masonry units.
The engagement members can be configured to engage only a portion of a thickness of the second face of each of the masonry units or of each of the second face and the third face of each of the masonry units. The engagement members, engaging only the portion of the thickness of the second face of each of the masonry units or of each of the second face and the third face of each of the masonry units, can expose a second portion of the thickness of each of the second face, the third face, a fifth face, and a sixth face of each of the masonry units and can expose the entire surface area of the fourth face of each of the masonry units.
The engagement members can be configured to engage the second face and the third face of each of the masonry units. The third face of each of the masonry units can be opposite from the second face of each of the masonry units.
Two of the first spacer members can meet two of the second spacer members to form a recess. The recess can be configured to receive one of the masonry units.
Each of the masonry units can be a thin brick and the substrate can be a wall, floor, ceiling, and/or an archway.
The first spacer members can be longitudinal spacer members, and the longitudinal spacer members can be substantially parallel or substantially linear with one another. The second spacer members can be vertical spacer members, and the vertical spacer members can be substantially parallel or substantially linear with one another and substantially perpendicular with the longitudinal spacer members.
The frame for supporting masonry units can also include at least one connector configured to unite the frame to a second frame.
In some non-limiting embodiments or aspects of the present disclosure, a frame for supporting at least one of thin bricks during installation on a wall includes a support panel having a front and back surface, first and second spacer members extending transversely from the front surface of the support panel, and engagement members extending from at least one of the following: the front surface of the support panel, the first spacer members, the second spacer members, or any combination thereof. The front surface of the support panel is configured to abut a first face of each of the thin bricks. The engagement members are releasably engageable with a second face of each of the thin bricks or the second face and a third face of each of the thin bricks.
In some non-limiting embodiments or aspects of the present disclosure, a method for installing masonry units on a substrate using at least one frame for supporting at least one of the masonry units includes: applying a bonding material on the substrate; positioning each of the masonry units at least partially within the at least one frame by abutting a first face of each of the masonry units with a surface of a support panel of the at least one frame and by engaging a second face of each of the masonry units or the second face and a third face of each of the masonry units with engagement members of the at least one frame; setting a fourth face of each of the masonry units in the bonding material by applying a force to the at least one frame in a first direction toward the bonding material and the substrate, the fourth face of each of the masonry units being opposite from the first face of each of the masonry units; disengaging the engagement members from the second face of each of the masonry units or the second face and the third face of each of the masonry units by applying a force to the at least one frame in a second direction away from the bonding material and the substrate; and removing the at least one frame from each of the masonry units that is set in the bonding material.
One or more of the following features can be included in the non-limiting embodiments or aspects of the method for installing masonry units on a substrate using at least one frame for supporting at least one of the masonry units.
The at least one frame can include a first frame and a second frame. The method can include uniting the first frame and the second frame.
Each of the masonry units can be a thin brick and the substrate can be at least one of the following: a wall, a floor, a ceiling, an archway, or any combination thereof.
The method for installing masonry units can include orienting the at least one frame diagonally relative to the substrate when setting the fourth face of each of the masonry units in the bonding material thereby generating a diagonal bond pattern of each of the masonry units on the substrate.
In some non-limiting embodiments or aspects of the present disclosure, a frame system for supporting masonry units during installation of the masonry units on a substrate includes a first frame, a second frame, and at least one connector uniting the first frame and the second frame. Each of the first frame and the second frame includes a support panel having a front and back surface, first and second spacer members extending transversely from the front surface of the support panel, and engagement members extending from at least one of the following: the front surface of the support panel, the first spacer members, the second spacer members, or any combination thereof. The front surface of the support panel is configured to abut a first face of each of the masonry units. The engagement members are releasably engageable with a second face of each of the masonry units or the second face and a third face of each of the masonry units.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of at least one frame for supporting masonry units, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 2 is a front view of the at least one frame for supporting masonry units of FIG. 1, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 3 is a perspective view of a frame for supporting a masonry unit, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 4 is a front view of at least one frame for supporting masonry units, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 5 is a rear view of the at least one frame for supporting masonry units of FIG. 4, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 6 is a perspective view of multiple frames for supporting masonry units after the masonry units are positioned at least partially within the frames, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 7 is a perspective view of a masonry unit or thin brick displaying at least the first face of the masonry unit or thin brick, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 8 is a perspective view of the masonry unit or thin brick of FIG. 7 displaying at least the fourth face of the masonry unit or thin brick, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 9 is a perspective view of the at least one frame for supporting masonry units of FIGS. 1 and 2 including an enlarged view of a portion of the at least one frame, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 10 is a perspective view of at least one frame for supporting masonry units after a face of each of the masonry units is set in a bonding material applied on a substrate, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 11 is a perspective, rear view of a frame system for supporting masonry units after a face of each of the masonry units is set in a bonding material applied on a substrate but before the frame system is removed from the masonry units set in the bonding material, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 12 is a perspective view of a substrate after a face of each of the masonry units is set in a bonding material applied on the substrate and after the frame system is removed from the masonry units set in the bonding material, according to some non-limiting embodiments or aspects of the present disclosure.
FIG. 13 is an enlarged side view of a connector configured to unite a first frame for supporting masonry units to a second frame for supporting masonry units, according to non-limiting embodiments or aspects of the present disclosure.
FIG. 14 is an enlarged perspective view of at least one first frame for supporting masonry units being united to at least one second frame for supporting masonry units by at least one connector, according to non-limiting embodiments or aspects of the present disclosure.
Corresponding reference characters indicate corresponding features throughout the several views of the drawings. The representations set out herein illustrate exemplary aspects of the disclosure, and such representations are not to be construed as limiting the scope of the disclosure in any manner.
DETAILED DESCRIPTION
While this disclosure is made as having exemplary designs, the present disclosure can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims.
Referring to FIG. 1, there is shown a perspective view of at least one frame 10 for supporting masonry units 12, according to some non-limiting embodiments or aspects of the present disclosure. Referring to FIG. 2, there is shown a front view of the at least one frame 10 for supporting masonry units 12 of FIG. 1, according to some non-limiting embodiments or aspects of the present disclosure. Referring to FIG. 3, there is shown a perspective view of a frame 10 for supporting at least one of masonry units 12, according to some non-limiting embodiments or aspects of the present disclosure. Referring to FIG. 4, there is shown a front view of at least one frame 10 for supporting masonry units 12, according to some non-limiting embodiments or aspects of the present disclosure. Referring to FIG. 5, there is shown a rear view of the at least one frame 10 for supporting masonry units 12 of FIG. 4, according to some non-limiting embodiments or aspects of the present disclosure. The frame 10 includes a support panel 16 having a front surface 18 and back surface 20. The support panel 16 can be a substantially planar sheet or layer of material.
The frame 10 also includes first spacer members 24 and second spacer members 26 extending transversely from the front surface 18 of the support panel 16. The first spacer members 24 can be substantially parallel or linear with one another, and the second spacer members 26 can be substantially parallel or linear with one another and substantially perpendicular with the first spacer members 24. The first spacer members 24 and second spacer members 26 can be structured as ridges extending from and running along the front surface 18 of the support panel 16. For example, each of the first spacer members 24 and second spacer members 26 can extend transversely from the front surface 18 of the support panel 16 at a right angle such that each of the first spacer members 24 and second spacer members 26 extend substantially perpendicularly from the front surface 18 of the support panel 16. Nonetheless, in other embodiments, each of the first spacer members 24 and second spacer members 26 can extend transversely from the front surface 18 of the support panel 16 at other angles. In addition, with reference to FIG. 9, each of the first spacer members 24 and second spacer members 26 can be structured as having a first linear portion 50 and a second curved portion 52. The first linear portion 50 can be positioned closest to the front surface 18 of the support panel 16, while the second curved portion 52 can be positioned farthest from the front surface 18 of the support panel 16.
The frame 10 also includes engagement members 28 extending from at least one of the following: the front surface 18 of the support panel 16, the first spacer members 24, the second spacer members 26, or any combination thereof. With reference to FIGS. 1-5 and FIG. 9, the engagement members 28 are shown as extending from front surface 18 of the support panel 16.
For example, the engagement members 28 can also extend transversely from the front surface 18 of the support panel 16. The engagement members 28 can be structured as tabs extending from the front surface 18 of the support panel 16. If the engagement members 28 are tabs, the tabs can be flexible and capable of bending without breaking. For example, at least a portion of the engagement members 28 as tabs may be capable of pivoting. In one embodiment, each of the engagement members 28 can extend transversely from the front surface 18 of the support panel 16 at a right angle such that each of the engagement members 28 extend substantially perpendicularly from the front surface 18 of the support panel 16. In addition, with reference to FIG. 9, each of the engagement members 28 can be structured as having a first linear portion 54 and a second tooth portion 56. The tooth portion 56 can extend transversely from the linear portion 54 of each of the engagement members 28. The first linear portion 54 can be positioned closest to the front surface 18 of the support panel 16, while the second tooth portion 56 can be positioned farther from the front surface 18 of the support panel 16. Nonetheless, each of the engagement members 28 can extend transversely from the front surface 18 of the support panel 16 at any angle.
With reference to FIG. 1-5 and FIG. 9, the engagement members 28 are shown as being positioned or located proximately to the first spacer members 24 and as extending from the front surface 18 of the support panel 16 independent from the first spacer members 24. That is, the engagement members 28 can be positioned or located parallel to the first spacer members 24, and there can be a gap between each of the engagement members 28 and the first spacer members 24. While not shown in the Figures, the engagement members 28 can have various other positions on the frame 10. For example, the engagement members 28 can be positioned or located proximately to the second spacer members 26 and as extending from the front surface 18 of the support panel 16 independent from the second spacer members 26. That is, the engagement members 28 can be positioned or located parallel to the second spacer members 26, and there can be a gap between each of the engagement members 28 and the second spacer members 26. In one embodiment, the engagement members 28 can be positioned or located proximately to the first spacer members 24 and proximately to the second spacer members 26.
While not shown in the Figures, each of the engagement members 28 can also extend from the first spacer members 24 or the second spacer members 26 or from both the first spacer members 24 and the second spacer members 26, instead of extending from the front surface 18 of the support panel 16. For example, each of the engagement members 28 can also extend transversely from the first spacer members 24, the second spacer members 26, or from both the first spacer members 24 and the second spacer members 26. For example, each of the engagement members 28 can extend transversely from the first spacer members 24, the second spacer members 26, or from both the first spacer members 24 and the second spacer members 26 at a right angle such that each of the engagement members 28 extend substantially perpendicularly from the first spacer members 24, the second spacer members 26, or from both the first spacer members 24 and the second spacer members 26. Nonetheless, each of the engagement members 28 can extend transversely from the first spacer members 24, the second spacer members 26, or from both the first spacer members 24 and the second spacer members 26 at any angle.
The frame 10, including the support panel 16, the first spacer members 24, the second spacer members 26, and the engagement members 28, can have various material compositions.
The frame 10 and all constituent elements can be made of any rigid material or any combination of materials strong enough to support the masonry units 12 during installation of the masonry units 12 on a substrate 14, as shown in FIG. 11 and FIG. 12. For example, the frame 10 and all constituent elements can be made of a polymer. A typical polymer used for the material composition of the frame 10 can include polyethylene, such as high-density polyethylene (HDPE).
With reference to FIGS. 4-8 and FIGS. 10-12, each of the masonry units 12 can be a thin brick 12. The substrate 14 can be a wall, floor, ceiling, archway, etc. Thin brick 12, like traditional brick, have a height h, a length l, and a depth d. The thin bricks 12 can be considered to have a substantially hexahedron shape. A hexahedron is a solid figure with six planar faces. Specifically, each of the masonry units or thin bricks 12 of the present disclosure can be a rectangular cuboid having six rectangles as faces or six substantially rectangular faces. For example, each of the masonry units or thin bricks 12 of the present disclosure can be a rectangular cuboid if the dimensions of the depth d or width, height A, and length e are each different. Therefore, each of the masonry units or thin bricks 12 of the present disclosure can have six planar faces, six substantially planar faces, or six faces some of which are planar faces and some of which are substantially planar faces. In one embodiment, each of the faces of the masonry units or thin bricks 12 can be substantially flat. In another embodiment, each of the faces of the masonry units or thin bricks 12 can have rounded edges, vertices, and/or corners. In yet another embodiment, some of the faces of the masonry units or thin bricks 12 are flat or substantially flat and some of the faces of the masonry units or thin bricks 12 have rounded edges, vertices, and/or corners.
With reference to FIG. 7 and FIG. 8, each of the masonry units or thin bricks 12 have a height h, a length l, and a depth d. For example, the masonry units or thin bricks 12 can be considered to have: two faces opposite from one another in which the edges are height A and length l, two faces opposite from one another in which the edges are height A and depth d, and two faces opposite from one another in which the edges are length l and depth d. In one embodiment, the two faces in which the edges are height A and length l have the greatest surface area of all faces. In one embodiment, the two faces in which the edges are height A and depth d have the lowest surface area of all the faces. In one embodiment, the two faces in which the edges are length e and depth d have the midmost surface area of all the faces.
With reference to FIGS. 5, 7, 10, and 12, each of the masonry units or thin bricks 12 has a first face 22. The front surface 18 of the support panel 16 is configured to abut a first face 22 of each of the masonry units or thin bricks 12. As shown at least in FIG. 5, through the apertures 36 defined by the support panel 16 and extending therethrough, the first face 22 of each of the masonry units or thin bricks 12 abuts the front surface 18 of the support panel 16. As will be discussed in additional detail below, the first face 22 of each of the masonry units or thin bricks 12 can be an ornamental face.
With reference to FIGS. 4, 6, 7, and 8, each of the masonry units or thin bricks 12 has: a second face 30; a third face 30; a fifth face 30; and a sixth face 30. With continued reference to FIGS. 4, 6, and 8, each of the masonry units or thin bricks 12 has a fourth face 32. The engagement members 28 are releasably engageable with a second face 30 of each of the masonry units or thin bricks 12, or the engagement members 28 are releasably engageable with a second face 30 and a third face 30 of each of the masonry units or thin bricks 12. For example, as shown in FIGS. 4, 6, 7, and 8, any of faces 30 can be considered to be the second face, any of the remainder of faces 30 can be considered to be the third face, any of the remainder of faces 30 can be considered to be the fifth face, and any of the remainder of faces 30 can be considered to be the sixth face.
With reference to FIGS. 7 and 8, in one embodiment, the first face 22 of each of the masonry units or thin bricks 12 and the fourth face 32 of each of the masonry units or thin bricks 12 can be opposite from one another and can be considered to have edges that are height A and length e. In one embodiment, the second face 30 of each of the masonry units or thin bricks 12 and the third face 30 of each of the masonry units or thin bricks 12 can be opposite from one another and can be considered to have edges that are length l and depth d. In another embodiment, the second face 30 of each of the masonry units or thin bricks 12 and the third face 30 of each of the masonry units or thin bricks 12 can be opposite from one another and can be considered to have edges that are height A and depth d. In one embodiment, the fifth face 30 of each of the masonry units or thin bricks 12 and the sixth face 30 of each of the masonry units or thin bricks 12 can be opposite from one another and can be considered to have edges that are length l and depth d. In another embodiment, the fifth face 30 of each of the masonry units or thin bricks 12 and the sixth face 30 of each of the masonry units or thin bricks 12 can be opposite from one another and can be considered to have edges that are height A and depth d.
The engagement members 28 can be manually disengageable with the second face 30 of each of the masonry units or thin bricks 12 after a fourth face 32 of each of the masonry units or thin bricks 12 is set in a bonding material 34 applied on the substrate 14. In one embodiment, the engagement members 28 can be manually disengageable with the second face 30 and the third face 30 of each of the masonry units or thin bricks 12 after a fourth face 32 of each of the masonry units or thin bricks 12 is set in a bonding material 34 applied on the substrate 14. The fourth face 32 of each of the masonry units or thin bricks 12 can be opposite from the first face 22 of each of the masonry units or thin bricks 12.
The engagement members 28 can be configured to engage the second face 30 of each of the masonry units or thin bricks 12 or the second face 30 and the third face 30 of each of the masonry units or thin bricks 12, and the engagement members 28 can be configured to disengage the second face 30 of each of the masonry units or the second face 30 and the third face 30 of each of the masonry units after a fourth face 32 of each of the masonry units or thin bricks 12 is set in a bonding material 34 applied on the substrate 14. The fourth face 32 of each of the masonry units or thin bricks 12 can be opposite from the first face 22 of each of the masonry units or thin bricks 12. The engagement members 28 can be configured to disengage the second face 30 of each of the masonry units or thin bricks 12 or the second face 30 and the third face 30 of each of the masonry units or thin bricks 12 by applying a force to the frame 10 in a direction away from the bonding material 34 and the substrate 14.
As will be discussed in detail below, a fourth face 32 of each of the masonry units or thin bricks 12 can be set in the bonding material 34 by applying a force to the frame 10 in a first direction toward the bonding material 34 and the substrate 14. The engagement members 28 can then be disengaged from the second face 30 of each of the masonry units or thin bricks 12 or the second face 30 and the third face 30 of each of the masonry units or thin bricks 12 by applying a force to the at least one frame 10 in a second direction away from the bonding material 34 and the substrate 14. The engagement members 28 being releasably engageable with a second face 30 of each of the masonry units or thin bricks 12 or the second face 30 and a third face 30 of each of the masonry units or thin bricks 12 allows removal of the frame 10 from the masonry units or thin bricks 12 that are set in a bonding material 34 applied on the substrate 14.
Referring to at least FIGS. 1-5, the support panel 16 can define apertures 36 extending through the support panel 16 from the front surface 18 of the support panel 16 to the back surface 20 of the support panel 16. The apertures 36 of the support panel 16 can be configured to allow air to pass therethrough upon removal of the frame 10 from each of the masonry units or thin bricks 12 that are set in the bonding material 34 applied on the substrate 14. That is, the support panel 16 having apertures 36 can have less air resistance or drag upon removal of the frame 10 from each of the masonry units or thin bricks 12 that are set in the bonding material 34 applied on the substrate 14 than a support panel 16 that does not have apertures 36. As shown in FIGS. 1-5, the apertures 36 can have a rectangular shape. While not shown in the Figures, the apertures 36 can have various different shapes and can be defined by the support panel 16 at various different positions of the support panel 16.
Referring to FIGS. 9 and 14, the support panel 16 can define pilot holes 44 or guiding holes 44 extending through the support panel 16 to the back surface 20 of the support panel 16. The pilot holes or guiding holes 44 can be screw pilot holes or screw guiding holes. In another embodiment, other fasteners can be utilized in the pilot holes or guiding holes 44. The pilot holes or guiding holes 44 can be configured to allow screws to be driven into the substrate 14 and/or the bonding material 34 applied on the substrate 14 so that the frame 10 can be fastened to the wall. The pilot holes or guiding holes 44 can have a tubular shape. In one embodiment the pilot holes or guiding holes 44 extend through the support panel 16 from the back surface 20 of the support panel 16 through the first spacer members 24. In other embodiments the pilot holes or guiding holes 44 extend through the support panel 16 from the back surface 20 of the support panel 16 through the second spacer members 26 or through both the first spacer members 24 and the second spacer members 26.
With reference to FIG. 9, the frame 10 for supporting masonry units or thin bricks 12 can include a surface treatment 38 that is configured to resist bonding to a bonding material 34 applied on the substrate 14. For example, as shown in FIG. 9, the surface treatment 38 can include a surface pattern or design, such as indentations, ridges or ribs, dimples, etc., that has properties that resist bonding to the bonding material 34 applied on the substrate 14. In another embodiment, the surface treatment 38 can include a coating composition that has properties that resist bonding to the bonding material 34 applied on the substrate 14.
Referring to FIG. 4, two of the first spacer members 24 can meet two of the second spacer members 26 to form a recess 40. The recess 40 can be a rectangular recess. The recess 40 can be configured to receive one of the masonry units or thin bricks 12. As shown in FIG. 4, multiple recesses 40 are formed in the frame 10 by, in each instance, two substantially parallel first spacer members 24 meeting two second spacer members 26, these two second spacer members 26 being substantially parallel with one another and substantially perpendicular with the first spacer members 24 that they meet. Therefore, by having multiple recesses 40, the frame 10 is capable of supporting multiple masonry units or thin bricks 12. As shown in FIG. 4, the frame 10 can have twenty recesses 40 and can, therefore, support twenty masonry units or thin bricks 12.
Referring to FIG. 3, in one embodiment, the frame 10 can be configured to support a single masonry unit or thin brick 12. The embodiment of the frame 10 shown in FIG. 3 has just one recess 40 to receive a single masonry unit or thin brick 12. The embodiment of the frame 10 shown in FIG. 3 can also include at least one connector 42. As will be discussed below in the present disclosure, the frame 10 shown in FIG. 3 can be united to a second frame 10 by the at least one connector 42. In this way, each of the frames 10 can be considered to have a modular nature.
Referring to FIG. 4, each of the recesses 40 is shown as having four engagement members 28 and the engagement members 28 are shown as being positioned proximately to the first spacer members 24. As discussed above, however, the engagement members 28 can have various other positions on the frame 10. For example, the engagement members 28 can be positioned proximately to the second spacer members 26 instead of being positioned proximately to the first spacer members 24. Furthermore, less than or more than four engagement members 28 can be positioned in each recess 40. For example, only one engagement member can be positioned in each recess 40. Referring again to FIG. 4, the engagement members 28 are shown as being positioned proximately to each of the first spacer members 24 that are opposite and parallel from one another which form each of the recesses 40. However, in another embodiment, each of the engagement members 28 can be positioned proximately to just one of the first spacer members 24 or proximately to just one of the second spacer members 26 which form each of the recesses 40.
The recesses 40 can have dimensions that are greater than the dimensions of the masonry units or thin bricks 12. For example, the length of each of the first spacer members 24, which meet two of the second spacer members 26 to form the recess 40, can be greater than a length of each of the first face 22 and the fourth face 32 of the masonry units or thin bricks 12. Furthermore, the height of each of the second spacer members 26, which meet two of the first spacer members 24 to form the recess 40, can be greater than a height of each of the first face 22 and the fourth face 32 of the masonry units or thin bricks 12. The recesses 40 having dimensions (for example, length and height dimensions) that are greater than the dimensions (for example, length and height dimensions) of the masonry units or thin bricks 12 can accommodate the engagement members 28 and can allow the masonry units or thin bricks 12 to be easily positioned at least partially within the frame 10 and the recesses 40.
As discussed above and with reference to FIG. 9, each of the first spacer members 24 and second spacer members 26 can be structured as having a first linear portion 50 and a second curved portion 52. The first linear portion 50 can be positioned closest to the front surface 18 of the support panel 16, while the second curved portion 52 can be positioned farthest from the front surface 18 of the support panel 16. The second curved portion can curve in a direction away from a central portion of each of the recesses 40. The second curved portion curving in a direction away from a central portion of each of the recesses 40 can allow the masonry units or thin bricks 12 to be easily positioned at least partially within the frame 10 and the recesses 40. That is, the second curved portion curving in a direction away from a central portion of each of the recesses 40 may aid in positioning the masonry units or thin bricks 12 at least partially within the frame 10 and the recesses 40.
Referring to at least FIGS. 1, 2, and 4, at least one of the second spacer members 26 can meet at least one of the first spacer members 24 at substantially a middle point of a length of the at least one of the first spacer members 24. As shown in FIGS. 1, 2, and 4, each of the various second spacer members 26 can, in each instance, meet at least one of the first spacer members 24 at substantially a middle point of a length of the at least one of the first spacer members 24, which results in an offset or overlapping pattern for the masonry units or thin bricks 12. The offset pattern shown in FIGS. 1, 2, and 4, in which the bricks in a course are offset by 50% of the length of the bricks in each of the courses above and below, generates what is referred to in masonry as a stretcher bond or running bond. While not shown in the Figures, spacer members 24, 26 can have various other orientations which result in various other coursing and bond patterns. For example spacer members 24, 26 can generate all coursing and bond patterns including, but not limited to, running bond, herringbone, stack bond, soldier course, basket weave, etc. Specifically, the spacer members 24, 26 can be longitudinal spacer members 24 and vertical spacer members 26, and the longitudinal spacer members 24 and the vertical spacer members 26 can have similar or different orientations and can have any of the same features or elements as the first spacer members 24 and the second spacer members 26 as described above and throughout this disclosure. Furthermore, the spacer members 24, 26 can be first diagonal spacer members 24 and second diagonal spacer members 26, and the first diagonal spacer members 24 and the second diagonal spacer members 26 can have similar or different orientations and can have any of the same features or elements as the first spacer members 24 and the second spacer members 26 as described above and throughout this disclosure.
Referring to FIG. 10, there is shown a perspective view of at least one frame 10 after the fourth face 32 of each of the masonry units or thin bricks 12 is set in the bonding material 34 applied on the substrate 14. The first spacer members 24, the second spacer members 26, and the engagement members 28 can each extend a distance from the front surface 18 of the support panel 16. Each distance can be only a portion of a thickness of each of the second face 30, the third face 30, a fifth face 30, and a sixth face 30 of each of the masonry units or thin bricks 12. Each distance that the first spacer members 24, the second spacer members 26, and the engagement members 28 extend from the front surface 18 of the support panel 16 can be the same or different. For example, in one embodiment, the distance that the first spacer members 24 and the second spacer members 26 extend from the front surface 18 of the support panel 16 can be the same, while the distance that the engagement members 28 extend from the front surface 18 of the support panel 16 can be different.
Referring to FIG. 10, the first spacer members 24 and the second spacer members 26 can be configured to extend a distance D from the front surface 18 of the support panel 16. The engagement members 28 can also be configured to extend a distance from the front surface 18 of the support panel 16, and this distance can be the same as or different from distance D. As shown in FIG. 10, the distance D can be only a portion of a thickness of each of the second face 30, the third face 30, the fifth face 30, and the sixth face 30 of each of the masonry units or thin bricks 12. As shown in FIG. 10, because the first spacer members 24, the second spacer members 26, and the engagement members 28 can each extend a distance from the front surface 18 of the support panel 16 that is only a portion of a thickness of each of the second, third, fifth, and sixth face 30 of each of the masonry units or thin bricks 12, a second portion of the thickness of each of the second, third, fifth, and sixth face 30 of each of the of the masonry units or thin bricks 12 can be exposed. As shown in FIG. 10, this can allow at least some of the bonding material 34 applied on the substrate 14 to adhere to the second portion of the thickness of each of the second, third, fifth, and sixth face 30 of each of the of the masonry units or thin bricks 12. Furthermore, because the first spacer members 24, the second spacer members 26, and the engagement members 28 can each extend a distance from the front surface 18 of the support panel 16 that is only a portion of a thickness of each of the second, third, fifth, and sixth face 30 of each of the masonry units or thin bricks 12, the entire surface area of the fourth face 32 of each of the masonry units or thin bricks 12 can be exposed. As shown in FIG. 10, this can allow the entire surface area of the fourth face 32 of each of the masonry units or thin bricks 12 to adhere to the bonding material 34 applied on the substrate 14.
Similarly, as shown in FIG. 10, the engagement members 28 can be configured to engage only a portion of the thickness of the second face 30 of each of the masonry units or thin bricks 12 or the thickness of each of the second face 30 and the third face 30 of each of the masonry units or thin bricks 12. Because the engagement members 28 can engage only the portion of the thickness of the second face 30 of each of the masonry units or thin bricks 12 or the thickness of each of the second face 30 and the third face 30 of each of the masonry units or thin bricks 12, a second portion of the thickness of each of the second, third, fifth, and sixth face 30 of each of the masonry units or thin bricks 12 can be exposed. This can allow at least some of the bonding material 34 applied on the substrate 14 to adhere to the second portion of the thickness of each of the second, third, fifth, and sixth face 30 of each of the of the masonry units or thin bricks 12. Furthermore, because the engagement members 28 can engage only the portion of the thickness of the second face 30 of each of the masonry units or thin bricks 12 or the thickness of each of the second face 30 and the third face 30 of each of the masonry units or thin bricks 12, the entire surface area of the fourth face 32 of each of the masonry units or thin bricks 12 can be exposed. As shown in FIG. 10, this can allow the entire surface area of the fourth face 32 of each of the masonry units or thin bricks 12 to adhere to the bonding material 34 applied on the substrate 14.
As mentioned previously and as shown in FIG. 7, the first face 22 of each of the masonry units or thin bricks 12 can be an ornamental face. The front surface 18 of the support panel 16 is configured to abut the first face 22 or ornamental face of each of the masonry units or thin bricks 12. For example, the masonry units or thin bricks 12 can be positioned at least partially within the at least one frame 10 by abutting a first face 22 of each of the masonry units or thin bricks 12 with the front surface 18 of the support panel 16 of the frame 10 and, by doing so, the engagement members 28 engage a second face 30 of each of the masonry units or thin bricks 12 or the second face 30 and a third face 30 of each of the masonry units or thin bricks 12. Next, the fourth face 32 of each of the masonry units or thin bricks 12 can be set in the bonding material 34 by applying a force to the at least one frame 10 in a first direction toward the bonding material 34 and the substrate 14. In this way, the fourth face 32 of each of the masonry units or thin bricks 12 is opposite from the first face 22 of each of the masonry units or thin bricks 12. The frame 10 can then be removed from the masonry units or thin bricks 12 after the fourth face 32 of each of the masonry units or thin bricks 12 is set in bonding material 34.
Referring to FIG. 12, there is shown a perspective view of a substrate 14 after the fourth face 32 of each of the masonry units or thin bricks 12 is set in the bonding material 34 applied on the substrate 14 and after at least one frame 10 is removed from the masonry units or thin bricks 12 that are set in the bonding material 34. As shown in FIG. 12, removal of the at least one frame 10 reveals the first face 22 or ornamental face of each of the masonry units or thin bricks 12. The ornamental face of each of the masonry units or thin bricks 12 can be considered to be the face that is ultimately outwardly visible.
Referring to at least FIGS. 1, 2, 4, 6, 9, and 12, the first spacer members 24 and the second spacer members 26 can be configured to establish a space or gap between each of the masonry units or thin bricks 12. The space or gap between each of the masonry units or thin bricks 12 establishes the joint sizing or spacing between the masonry units or thin bricks 12. In some embodiments, the first spacer members 24 and the second spacer members 26 can be configured to establish a space or gap of ⅜ inch between the masonry units or thin bricks 12. In other embodiments, the first spacer members 24 and the second spacer members 26 can be configured to establish a space or gap of from ⅛ inch to ¾ inch between the masonry units or thin bricks 12. For example, the first spacer members 24 and the second spacer members 26 can have a gauge or thickness and the gauge or thickness of the first spacer members 24 and the second spacer members 26 is directly proportional to the size of the space or gap between each of the masonry units or thin bricks 12. That is, if the gauge or thickness of the first spacer members 24 and the second spacer members 26 is increased, the size of the space or gap between each of the masonry units or thin bricks 12 is increased. If the gauge or thickness of the first spacer members 24 and the second spacer members 26 is decreased, the size of the space or gap between each of the masonry units or thin bricks 12 is decreased.
As shown in FIG. 12, after the at least one frame 10 is removed from the masonry units or thin bricks 12 that are set in the bonding material, there is a space or gap surrounding each of the masonry units or thin bricks 12 that is established by the first spacer members 24 and the second spacer members 26. This space or gap surrounding each of the masonry units or thin bricks 12 can then be filled with additional bonding material 34. The bonding material 34 that is applied on the substrate 14 can be cementitious mortar or construction adhesive, preferably cementitious mortar. The bonding material 34 that is filled in the spaces or gaps surrounding each of the masonry units or thin bricks 12 can be cementitious mortar or grout.
Referring to FIG. 6, there is shown a perspective view of multiple frames 10 for supporting masonry units or thin bricks 12 after the masonry units or thin bricks 12 are positioned at least partially within the frames 10. Referring to FIG. 11, there is shown a perspective, rear view of a frame system 100 for supporting masonry units or thin bricks 12. That is, the present disclosure is also directed to a frame system 100 for supporting masonry units or thin bricks 12 that can be made of multiple frames 10. In one embodiment, the frame system 100 can include a first frame 10, a second frame 10, and at least one connector 42 uniting the first frame 10 and the second frame 10.
Referring to FIGS. 13 and 14, in one embodiment, the at least one connector 42 can be designed as a two-pronged clip or fastener. If the connector 42 is a two-pronged clip or fastener, the two-pronged clip or fastener can include a first prong 46 and a second prong 48. As shown in FIG. 14, the first frame 10 and the second frame 10 can be united by the first prong 46 engaging a prong-receiving aperture 58 in the first frame 10 and the second prong 48 engaging a prong-receiving aperture 58 in the second frame 10. In one embodiment, multiple connectors 42 can be used to unite the first frame 10 and the second frame 10. However, the at least one connector 42 can have various other designs.
For example, as shown in at least FIGS. 1-4, the at least one connector 42 can include a slide and lock configuration. The at least one connector 42 in the slide and lock configuration allows multiple frames 10 to slide together and prevents the frames 10 from coming apart without the use of a clip or fastener. For example, as shown in at least FIGS. 1-4, the slide and lock connectors 42 can extend outwardly from the spacer members 24, 26. In one embodiment, the slide and lock connectors 42 can extend outwardly from the spacer members 24, 26 in the same plane, substantially the same plane, or partially the same plane as the support panel 16. In one embodiment, the slide and lock connectors 42 of one frame 10 can engage the slide and lock connectors 42 of at least one other frame 10, which secures the frames 10 together and prevents them from coming apart.
Each of the first frame 10 and the second frame 10 can have any of the same features as the frame 10 for supporting masonry units described above and throughout this disclosure. In other embodiments, the frame system 100 can include more than two frames 10 and multiple connectors 42. That is, the frame system 100 can be of various sizes to suit the specific application of the masonry units or thin bricks 12 to the substrate 14 and to suit the manpower that is available during installation. In this way, the frame system 100 can be considered to have a modular nature, and the frames 10 that make up the frame system 100 can be considered to be independent units that can be united to form the frame system 100.
The present disclosure is also directed to a method for installing masonry units or thin bricks 12 on a substrate 14 using the at least one frame 10 for supporting at least one of the masonry units or thin bricks 12. In one step, the method can include applying the bonding material 34 on the substrate 14. In another step, the method can include positioning each of the masonry units or thin bricks 12 at least partially within the at least one frame 10 by abutting the first face 22 of each of the masonry units or thin bricks 12 with the front surface 18 of the support panel 16 of the at least one frame 10 and by engaging the second face 30 of each of the masonry units or thin bricks 12 or the second face 30 and a third face 30 of each of the masonry units or thin bricks with the engagement members 28 of the at least one frame 10. For example, as shown in FIGS. 4-6, multiple masonry units or thin bricks 12 are positioned in each frame 10 shown therein. In another step, the method can include setting the fourth face 32 of each of the masonry units or thin bricks 12 in the bonding material 34 by applying a force to the at least one frame 10 in a first direction toward the bonding material 34 and the substrate 14. For example, as shown in FIGS. 10 and 11, the fourth face 32 of each of the masonry units or thin bricks 12 is set in the bonding material 34 applied on the substrate 14 after a force is applied to the frame 10 or frame system 100 in a first direction toward the bonding material 34 and the substrate 14. In another step, the method can include disengaging the engagement members 28 from the second face 30 of each of the masonry units or thin bricks 12 or the second face 30 and the third face 30 of each of the masonry units or thin bricks 12 by applying a force to the at least one frame 10 in a second direction away from the bonding material 34 and the substrate 14. In another step, the method can include removing the at least one frame 10 from each of the masonry units or thin bricks 12 that are set in the bonding material 34. For example, as shown in FIG. 12, the frame 10 or frame system 100 is removed from the masonry units or thin bricks 12 that are set in the bonding material 34 thereby revealing the first face 22 or ornamental face of each of the masonry units or thin bricks 12. As shown in FIG. 12, the ornamental faces of each of the masonry units or thin bricks 12 are ultimately outwardly visible.
As discussed above, the present disclosure is also directed to a frame system 100 for supporting masonry units or thin bricks 12 that can be made of multiple frames 10. Therefore, in the method for installing masonry units or thin bricks 12 on a substrate 14, the at least one frame 10 can include a first frame 10 and a second frame 10. In another step of the method, the method can include uniting the first frame 10 and the second frame 10. For example, the method can include uniting the first frame 10 and the second frame 10 in the same way as described above and throughout this disclosure. In the method for installing masonry units or thin bricks 12 on a substrate 14, each of the masonry units 12 can be a thin brick and the substrate 14 can be a wall.
In another step of the method for installing masonry units or thin brick 12 on a substrate 14, the method can include orienting the at least one frame 10 diagonally relative to the substrate 14 when setting the fourth face 32 of each of the masonry units or thin bricks 12 in the bonding material 34. Orienting the at least one frame 10 diagonally relative to the substrate 14 when setting the fourth face 32 of each of the masonry units or thin bricks 12 in the bonding material 34 can generate a diagonal bond pattern of each of the masonry units or thin bricks 12 on the substrate 14. As discussed above, the spacer members 24, 26 can have various other orientations which result in various other coursing and bond patterns. Because the at least one frame 10 can be oriented diagonally relative to the substrate 14 and because spacer members 24, 26 can have various orientations, all coursing and bond patterns can be generated by the frame 10, frame system 100, and/or the method of the present disclosure. Such coursing and bond patterns include, but are not limited to, running bond, herringbone, stack bond, soldier course, basket weave, etc.
While exemplary designs have been described above in the detailed description, those of ordinary skill in the art will understand that the exemplary designs of the present disclosure can be further modified within the spirit and scope of this disclosure. Therefore, the above described exemplary designs should not be considered to limit the scope of the appended claims.
Patent Application
20250059785
