Patent Application
20230257999
The present invention related generally to masonry support structures.
Cellular glass insulation is a thermal insulation that has recycled glass and sand as base materials, supplemented by mineral substances and other natural materials. It is inorganic insulation material that is composed of millions of sealed glass cells. The closed cell structure captures gas produced in the cells, giving the material an insulative property and ensuring a stable thermal conductivity. No water molecules can diffuse in the glass cells and internal condensation is impossible. The result is a vapor-tight, incombustible material with very high compressive strength. (What is cellular glass insulation? [online] [retrieved on 2022-02-16]. Retrieved from the Internet <URL: https://www.foamglas.com/en/advice-center/general-advice/what-is-cellular-glass-production-process>) A common cellular glass insulation, and the preferred cellular glass insulation most commonly referenced herein, is that sold under the trademark FOAMGLAS® sold by Pittsburgh Corning. FOAMGLAS® cellular glass insulation is waterproof, dimensionally stable, and acid-resistant because it consists of pure glass; pest-proof because it is inorganic and cannot rot; compression-proof without deformation even with longterm loads due to its cell geometry; incombustible because it consists of pure glass; and vapor-tight because it consists of hermetically sealed glass cells.
Cellular glass insulation is used in many applications as an excellent insulator. Cellular glass insulation is easily cut into any desired measurement with a simple tool, such as a saw blade or hand saw. In this way, sections of cellular glass insulation may be customized and fabricated for elements such as pipe insulation, curved sidewall segments, specialty tank heads, and detailed pipe insulation, such as elbow and T sections. Applications include insulation for cryogenic systems, heated and chilled water systems, underground piping, and any application that requires fire-resistant insulation. Cellular glass insulation is sometimes referred to as foam glass gravel or foamed glass aggregate. Cellular glass insulation is sometimes used as an inert, non-leaching fill in civil and infrastructure applications. (What is Cellular Glass? [online blog] [retrieved on 2022-02-16]. Retrieved from the Internet <URL: https://www.glavel.com/what-is-cellular-glass-insulation/>) Cellular glass insulation may, for example, act as a thermal bridge behind masonry veneer walls. (TOMASULO, Katy, Owens Corning Foamglas Perinsul SIB. Jan. 20, 2022 [online] [retrieved on 2022-02-16]. Retrieved from the Internet <URL: https://www.woc360.com/masonry/owens-corning-foamglas-perinsul-sib>)
As used herein, the term “cellular glass insulation” refers to a material as described above and may specifically refer to FOAMGLAS® cellular glass insulation.
A scratch coat is a textured coating applied to a surface to which a masonry hanging will be applied and is commonly used in the field of masonry. A scratch coat is typically made of plaster or mortar of the type used in masonry. Once applied and dried, the scratch coat provides a rough surface with many small tiny indentions. When it is time for a masonry hanging, such as a masonry veneer, to be applied to the surface, a second layer of masonry plaster or mortar is applied and adheres to the scratch coat by filling those tiny indentations. The scratch coat therefore primes the surface to be a structural support for a masonry hanging.
The present invention is a structural support and structural support kit.
In its most basic form, the structural support of the present invention is a block of cellular glass insulation having an exterior surface with a scratch coat disposed on at least a portion of the exterior surface of the block.
While cellular glass insulation has been used in many applications for insulation, it has not been used as a support structure for masonry veneers before the present invention. The inclusion of the scratch coat on the exterior surface of the block of cellular glass insulation is a physical component that indicates and is required by this intended use. As discussed above, although sheets of cellular glass insulation have been used as a thermal bridge behind masonry veneer walls, the cellular glass insulation in that application were not used as a support structure on which masonry veneers were applied, but only as a thermal bridge. Heretofore, the innate qualities of cellular glass insulation, including being lightweight, easy to cut and shape, compression-proof, waterproof, and vermin-resistant, have only been harnessed in using the material in its insulative capacity. The present invention uses these qualities in a new way.
It is preferred that the scratch coat consist of veneer mortar. As veneer mortar will be mentioned in regards to several aspects of the present invention, the veneer mortar that may form the scratch coat is referred to herein as “exterior veneer mortar,” as it is disposed on the exterior surface of the block. The scratch coat may be disposed on the entire exterior surface of the block or only a portion of the exterior surface. In some applications of the structural support of the present invention, it may make sense for the base of the block to remain uncoated with scratch coat, for example.
The block may be any shape but has at least two preferred configurations, the first of which is when the block takes the form of a rectangular prism. As rectangular prisms will be mentioned in regards to several aspects of the present invention, the rectangular prism that is that shape of the preferred block is referred to herein as “block rectangular prism.” Preferred dimensions of the block rectangular prism include 12″×12″×12″ and 12″×12″×18″. While the block rectangular prism may be formed of a single block of cellular glass insulation, in some embodiments, the block is formed by at least two strata of cellular glass insulation. Each of these strata will have at least one interior surface that will be in physical contact with an interior surface of an adjacent stratum. As used herein, “interior surface” refers to the one or more surfaces of the strata (or other structural components of the block, as discussed below) that will be within the block and that form no part of the exterior surface of the block. A stratum is considered “adjacent” to another stratum when it is directly below or above the other stratum in the stack of strata that is forming the block. When the block is formed by strata, a layer of veneer mortar is disposed between the interior surfaces of the strata so that the strata are adhered to one another. When veneer mortar is used between interior surfaces, it is referred to herein as “interior veneer mortar.” Given standard sizing of cellular glass insulation, it is preferred that the block include three strata. In this configuration, the middle stratum has two interior surfaces and is sandwiched between the outer strata, each of which has one interior surface in physical contact with the interior surfaces of the middle stratum.
The second preferred configuration of the block of the present invention has a “C” or “U” shape. The shape is formed by a bridge connecting first and second legs. The first and second legs are parallel to one another and perpendicular to the bridge. The bridge is a rectangular prism, referred to specifically herein as “bridge rectangular prism,” having six bridge sides, which are the six surfaces of the bridge rectangular prism. Each of the first and second legs is also a rectangular prism, referred to specifically herein as “leg rectangular prisms,” having the same size and shape so that the first and second legs are identical. Each leg rectangular prism has six leg sides, which are the six surfaces of the respective leg rectangular prism. The first and second legs extend from the same bridge side such that five of the six legs of each of the first and second legs form part of the exterior surface of the block. The first and second legs extend from and edge of that same bridge side so that a first flush surface is formed between a second bridge side and one of the leg sides of the first leg and a second flush surface is formed between a third bridge side and one of the leg sides of the second leg. Two opposite surfaces of the block therefore form a “U” or “C” shape. A top down view of one of these surfaces is referred to herein as a “side view” of the block in this configuration. The two-dimensional side view has a single line of symmetry and is therefore symmetrical.
The preferred “C”/“U” configuration of the block has dimensions that are fulfilled when each of the following conditions are met: two of the three dimensions of the bridge rectangular prism are 15″×12″; the first flush surface is 12″×7.5″; the second flush surface is 12″×7.5″; a leg side of the first leg that is as far from the bridge as possible is 4″×12″; and a leg side of the second leg that is as from the bridge as possible is also 4″×12″. In some embodiments of the “C”/“U” configuration of the block, the block is formed from a single piece of cellular glass insulation that has been cut into the “C”/“U” shape as described above. In some embodiments, the first and second legs are adhered to the bridge with a layer of interior veneer mortar between the first or second leg and the first bridge side from which it extends.
It is understood that while two preferred embodiments of the structural support of the present invention, as a block rectangular prism and in a “C”/“U” configuration, have been described in detail above, the structural support of the present invention may be of any shape or size. Cellular glass insulation is easily shaped into any shape or size and the structural support of the present invention only requires a block of cellular glass insulation (of any shape or size) with a scratch coat disposed on at least a portion of the exterior surface of that block.
In one embodiment of its most basic form, the structural support kit of the present invention includes at least one structural support of the present invention, as described above, and at least one masonry veneer. The masonry veneer may be any commonly used in the art, such as brick or stone, or other decorative sheet or surface. A masonry veneer is a non-structural external layer that will be applied to the structural support of the present invention.
The kit may also include a supply of veneer mortar. This supply of veneer mortar is a separate aspect of the invention from either the exterior veneer mortar that may be used for the scratch coat of the structural support or the interior veneer mortar that may be used to adhere parts of the block of the structural support together. It is understood that as used herein, the term “supply of veneer mortar” is referring to a separate component of the kit from the block and the interior and/or exterior veneer mortar that may be used therein or thereon. In practice, the supply of veneer mortar will be used to apply a second coating of veneer mortar on top of the scratch coat of the structural support and the masonry veneer will be adhered to and applied on top of this second coating.
Any veneer mortar used within the present invention, whether it is interior veneer mortar, exterior veneer mortar, or a supply of veneer mortar may be any masonry veneer mortar commonly used in the art, such as any of those designated as Type N, O, S, or M mortars and that are typically a blend of sand, Portland cement, and lime. The preferred veneer mortar, however, is that sold under the trademark The Original Thin-Stone Veneer Mortar™ by Umaco. This masonry mortar is a blend of aggregates, Portland cement, dry polymers, and additives.
The kit may also include at least one masonry wall tie. The masonry wall tie may be any commonly used in the art of masonry. A masonry wall tie is typically a wire or sheet metal device used to connect two or more masonry wythes or to connect masonry veneers to a structural backing system. Examples of common masonry wall ties include stainless steel cable ties; crimped lengths of galvanized steel; and/or lengths of stamped or other patterned metal. In practice, the masonry wall tie may be used to affix the block of the structural support to an existing structure or to secure two blocks of the structural support together.
The kit may also include at least one post bracket. The post bracket may be any commonly used in the art of masonry. A post bracket is typically a wood or metal bracket having at least one 90° angle. In this way, one surface of the post bracket may be affixed to one object and the perpendicular surface of the post bracket may be affixed to another object such that the two objects are held in position relative to one another. In practice, the post bracket may be used to affix the block of the structural support to an existing structure and position the block securely in relation to the existing structure.
In another embodiment of its most basic form, the structural support kit of the present invention includes at least one structural support of the present invention, as described above, and at least one masonry wall tie. This kit may also include at least one masonry veneer. This kit may also include a supply of veneer mortar. This kit may also include at least one post bracket.
These aspects of the present invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, claims, and accompanying drawings.
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Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the description should not be limited to the description of the preferred versions contained herein.
