Simulated brick building panel

A cementitious fiberboard sprayed with an acrylic sand composition and enamel spray paint which is then tooled to a brick-looking face. Variations in the brick-like color and texture are provided by varying the acrylic paint color and sand particle size and density.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to fabricated panels and, more specifically, to a cementitious fiberboard sprayed with an acrylic sand composition and enamel spray paint which is then tooled to a brick-looking face. Variations in the brick-like color and texture are provided by varying the acrylic paint color and sand particle size and density.

2. Description of the Prior Art

There are other fabricated panels' designed as building materials. Typical of these is U.S. Pat. No. 2,178,535 issued to Willson on Oct. 31, 1939.

Another patent was issued to Bilodeau on Apr. 6, 1965 as U.S. Pat. No. 3,177,279. Yet another U.S. Pat. No. 3,882,218 was issued to Bixel, Jr. on May 6, 1975 and still yet another was issued on Aug. 14, 1979 to Wilhelm as U.S. Pat. No. 4,164,598.

Another patent was issued to Schiffer on Sep. 14, 1982 as U.S. Pat. No. 4,349,588. Yet another U.S. Pat. No. 4,510,729 was issued to Syring on 4,510,729. Another was issued to McKinnon on Dec. 4, 1990 as U.S. Pat. No. 4,975,303 and still yet another was issued on Apr. 2, 1996 to Zember et al. as U.S. Pat. No. 5,502,941.

Another patent was issued to Sherry on Aug. 4, 1998 as U.S. Pat. No. 5,787,666. Yet another Japan Patent No. JP2000120248 was issued to Nakama on Apr. 25, 2000. Another was issued to Moore et al. on Jul. 21, 1971 as U.K. Patent No. GB 1240041.

A form for molding a concrete wall provided with strips of resilient material arranged in parallel relation on its inner face for removably holding individual tiles thereon, said strips being positioned and dimensioned to yield to admit the tiles between them so as to exert pressure from opposite directions against the tiles by engagement with the edge surfaces thereof which extend transversely of their exposed faces in the finished wall, whereby said resilient strips act frictionally to retain the tiles on the form, and removable spacer strips dimensioned to fit between adjacent strips of the parallel series for spacing the tiles from each other.

A method of forming a decorative building panel that will have an exterior surface simulating in relief true reproductions of a plurality of shapes bonded by mortar joints consisting essentially of the following steps:

(a) providing a resilient mold which contains a portion having impressions of shapes, complementary ridges and undercuts

(b) applying to the surface of said mold a layer consisting of a polymerizable resin, a polymerization catalyst, a colorant and rock particles, which first layer when polymerized becomes solidified;

(c) spraying on the surface of said first layer a second layer consisting essentially of a polymerizable resin, a polymerization catalyst, and a plurality of randomly oriented fiber glass strands, which second layer when polymerized becomes bonded to the first layer;
(d) polymerizing said two layers to solidify them into an integral panel;
(e) stripping said mold from said panel;
(f) and, dusting the exterior surface of the panel with rock dust to give a dull finish thereto.

Base Building panels, which have been cut from large blocks of expanded, high-density, foamed plastic, include an array of grooves which, together with the non-grooved areas of the panels simulate the desired brick-and-mortar appearance, the grooves having been formed by an appropriate array of heating elements. The panels may be utilized as skirting or underpinning for mobile homes so as to present a permanent foundation appearance for the home. To install the panels, small blocks of expanded, high-density, foamed plastic are bonded to the back surfaces of the panels so as to provide a panel interlock mechanism. A perimetrical trench is excavated beneath the exterior wall surfaces of the mobile home, whereupon the bottom edge portions of the panels are inserted within the trench, while the upper edge portions are secured to the mobile home undersurface by means of additional small blocks of foamed plastic which have been coated with plastic adhesive. Access panels and ventilation means may be inserted within the skirt enclosure, and the enclosure may be painted a particular color or a multitude of colors according to a particular design.

A veneer wall covering to simulate a brick wall through the provision of adhering a plurality of thin blocks formed from dry wall sheet stock to an interior wall in any known brick layup patterns, applying a coating over the blocks to produce a textured surface which duplicates the texture of bricks, followed by applying a desired color selected from the prevailing color or real brick, or variations thereof.

A method for making simulated brick or tile wall or floor using cement, water-based adhesive and water-insoluble powdered pigment. The mixture is applied and then partially set. Scoring indentations are made to remove cement. After being completely set, mortar is placed in the indentations as a grout and allowed to set. The final step is a clear water-resistant coating on the entire surface.

It is the object of the invention to give also the non-professional the possibility to apply, by means of this method and a template, mineral plaster in the form of clinker plastering to a wall surface. To this end a template with a network corresponding to joints and made of impregnated cardboard is applied to a continuous carrier film by means of a non-hardening adhesive, and is folded in zig-zag form. The network is removed from the carrier film and stuck to the same extent to a wall surface. Afterwards the mineral plaster is applied to the wall surface. After removing the network a clinker or brick-work like structure is attained. In the spray rendering method embodiment the network is made of paper-thin, tension-resistant material. The network and carrier film are then rolled up in a roll.

A process for covering a substrate with a textured simulated marble surface and the resulting product. Cement and sand are mixed to form a first mixture to which is added an aqueous solution of an adhesive resin such as an acrylic resin to create a mortar. The mortar is spread on the substrate and one or more color pigments are added to the surface at randomly-spaced locations prior to the complete curing of the mortar. Air is blown onto the surface of the mortar and serves to blend the color pigments into the mortar and into each other. As the air stream moves across the surface of the mortar, color patterns are formed.

An ornamental coating and process for applying the coating to a substrate includes mixing a first batch of liquid mortar composed of sand, cement and an aqueous solution of acrylic resin, and trowelling or spraying a first layer of the liquid mortar onto the substrate and allowing the liquid mortar to cure. A second batch of liquid mortar is mixed which is the same as the first except that it contains a color pigment contrasting with the color of the first batch. A template defining a pattern of grout lines is placed over the cured first batch and the second batch of liquid mortar is trowelled or sprayed over the first batch and the template as a second layer and allowed to cure only to the extent that the second layer is firm, but not hard. The template is then removed, removing that part of the second layer immediately above the template thus exposing lines of the cured first batch which then appear as grout lines between areas of colored mortar which appear as bricks, flagstone or tiles etc. When the second batch has completely cured, two layers of concrete sealer are applied.

A system of light weight, high strength, thin masonry panels having one or more mateable seam hiding edges. The seam hiding edge may be serpentine or some other shape consistent with the masonry element chosen for the panel surface. The aforementioned thin masonry panels are used to construct patio or walkway surfaces as well as provide a decorative facing for walls, fireplaces, and the like. The thickness of the panels is limited to the range of 1 to 2 inches in order to assure a light weight for ease of construction. Each panel is a reinforced series of masonry elements such as stone or brick pavers bound together by a cement or mortar-like material. The claimed invention also includes an attachment plate for affixing the panels to other surfaces and structures.

Japan Patent Number JP2000120248

PROBLEM TO BE SOLVED: To provide a wall panel having a pattern arranged with a plurality of brick, stone, tile or the like particularly with simple work for jointing together a plurality of wall panels having good appearance with the joints simulating brick joints. SOLUTION: A wall panel 1 for architectural decoration has a pattern of a plurality of sequentially stacked or adhered brick, stone, tile or the like provided with symmetrical stepwise projected portions at the left edge 4 and right edge 5 in such a manner that both the edges can be mutually interlocked, and projected ribs 6 or recessed stripes 7 are provided at predetermined position of this stepwise projected portions in configuration.

Inventor: Michael Frank Moore et al.

A brick tile is produced by cutting a thick layer from the surface of a fired clay brick so that it has one natural face and one plain flat face for adhesively securing to a wall surface. Opposite faces of a brick may be cut off to give two tiles. A number of the elements may be assembled together as a panel before application to a wall.

SUMMARY OF THE PRESENT INVENTION

A primary object of the present invention is to provide a simulated brick-like building panel.

Another object of the present invention is to provide a simulated brick-like building panel using fiber cement board as the base material providing a building panel that is durable, resistive to weathering, insects and vermin.

Yet another object of the present invention is to provide a simulated brick-like building panel using fiber cement board that is treated on one side with an acrylic paint and sand mixture to simulate a brick-like finish.

Still yet another object of the present invention is to provide a brick-like building panel wherein the treated side is highlighted with an enamel paint to enhance the brick-like appearance.

Another object of the present invention is to provide a brick-like building panel wherein the brick-like panel is tooled to simulate the mortar-like spacing between laid bricks.

Yet another object of the present invention is to provide a brick-like building panel where the fiber cement board once treated is scored through the enamel, acrylic paint and sand composition to a depth to give the appearance of brick interdisposed motar.

Still yet another object of the present invention is to provide a brick-like building panel having opposing edges scored on opposing sides whereby a plurality of said panels can be assembled with an overlap from panel to panel.

Another object of the present invention is to provide a brick-like building panel that requires no special tools for assembly.

Yet another object of the present invention is to provide a brick-like building panel that can be used as a skirt for modular homes.

Still yet another object of the present invention is to provide a brick-like building panel that can be used in place of laid bricks thereby obviating the need for a foundation footing.

The present invention overcomes the shortcomings of the prior art by providing a cementitious fiberboard sprayed with an acrylic sand composition and enamel spray paint which is then tooled to a brick-looking face. Variations in the brick-like color and texture are provided by varying the acrylic paint color and sand particle size and density.

DESCRIPTION OF THE REFERENCED NUMERALS

Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the figures illustrate the Simulated Brick Building Panel of the present invention. With regard to the reference numerals used, the following numbering is used throughout the various drawing figures.10Simulated Brick Building Panel of the present invention12fiber cement board14acrylic paint and sand mixture16enamel paint18faux mortar line20prior art22brick and mortar cement siding24brick layer26concrete footing28trench30footing support32mobile building structure34axle of3236hydraulic support38vertically overlapped joint40overlap of3842underlap of3844installer46nailer48gang saw cut50quick brick foundation facing52first coarse54second coarse56classic red finish58rustic brown finish

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1is an illustrative view of prior art20. Conventional brick and fiber cement siding22have been around for a long time. They are costly and a time consuming job that must be installed by an experienced bricklayer24and also require a concrete footing26in a trench28with footing supports30. Shown is a bricklayer24installing brick and mortar siding22under a prefab house32. The present invention overcomes this problem by providing a simulated brick siding that installs with basic carpentry skills and is cost effective and does not require a concrete footing.

FIG. 2is an illustrative view of prior art20. Shown is a trailer type home32having no skirting around the open base of the trailer. The axle34and hydraulic supports36are visible and the open space allows access to animals, rodents, bugs and other critters.

FIG. 3is an illustrative view of the present invention10in use. The present invention10is a fiber cement board12coated with a brick finish and cut with a modular brick pattern. The process of creating the fiber cement board12of the present invention10is the fiber cement board12sprayed with a mixture of 100% acrylic paint mixed with sand14for texture. Then the board is highlighted with the brick look using enamel spray paint16. The faux mortar lines18defining the brick pattern is sawed, using a gang saw. The vertically overlapped joints38are then hand cut using a grinder. The board is washed down and is now ready for installation.

FIG. 4is an illustrative view of the present invention in use. Shown is the installer44preparing the fiber cement board12for installation using basic carpentry skills. The finished boards12are secured to nailers46with fastening elements such as nails or screws.

FIG. 5is an illustrative view of the present invention10in use. Shown is the present invention in use on a trailer type home32. The cement board12skirting of the present invention10hides the trailers32under side equipment such as axles and hydraulic supports, adding elegance and increasing the value of the home. The skirting also prevents critters from finding habitat under the home.

FIG. 6is a perspective view of one tile of the present invention10. The faux mortar lines18defining the brick pattern of the quick brick foundation facing50are made with gang saw cuts48. The vertically overlapped joints38of the board12are then hand cut using a grinder to form an overlap40on one edge and an underlap42at the opposing edge. The board is washed down and is ready for installation.

FIG. 7is a perspective view of the present invention10in use. Shown is the present invention10having a first course52of boards12installed and a second course54ready for installation by mating the overlap40of the first course52with the underlap42of the second54to form a vertically overlapped joint38.

FIG. 8is a chart of the process of the present invention10. Shown is a chart of the process of creating the simulated brick fiber cement board12of the present invention10by spraying the fiber cement board12with acrylic paint mixed with sand14, then applying enamel spray paint16to the board12, using gang saw cuts48to define a brick-like pattern and using a grinder to make the vertically overlapped joints38.

FIG. 9is a perspective view of the present invention10. Shown is the next step in creating the fiber cement siding of the present invention10. The brick pattern is sawed producing gang saw cuts48. The vertically overlapped joints38are then hand cut using a grinder. The board12is washed down and is now ready for installation.

FIG. 10is a cross sectional view of the present invention10taken fromFIG. 9as indicated. Shown is the cement board12having a brick foundation facing50sprayed with acrylic paint and sand mixture14and enamel paint16and scored with gang saw cuts48. The overlap40and underlap42of the vertically overlapped joints38are hand cut using a grinder.

FIG. 11is a chart of the attributes of the present invention10. Shown is a chart demonstrating the advantages and the benefits of the simulated brick panel of the present invention10.

FIG. 12is an illustrative view of the present invention10. The finished cement board12is available in at least two colors which include a classic red finish56and a rustic brown finish58.