Abstract:
A veneer product and system includes a body having an aesthetic front surface and a back surface for installation adjacent the building. The body has a top side and a bottom side and a bracket attached to body and projecting away from the back surface of the body, the bracket further comprising a first end adjacent the top side for attachment to the building and a first protrusion for positioning the back surface a predetermined distance from the building and a second end having a second protrusion for positioning the bottom of the back surface a predetermined distance from the building and a bottom projection adjacent the bottom side for engagement with a second body to retain the bottom end of the veneer product.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority to U.S. application Ser. No. 13/420,142, filed Mar. 14, 2012. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX 
       [0003]    Not Applicable 
       TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION 
       [0004]    The present invention is in the technical field of masonry veneer products, and includes a system using such products. More particularly, the present invention is in the technical field of masonry veneer products installed without a scratch coat and lath system. 
       BACKGROUND OF THE INVENTION 
       [0005]    As described in copending U.S. patent application Ser. No. 13/420,142, which is incorporated herein by reference in its entirety, Masonry veneer systems are commonly used for exterior cladding, as architectural or aesthetic features on residential and commercial buildings. 
         [0006]    As described in detail by the Masonry Veneer Manufacturers Association (MVMA), proper installation of stone on a framed building requires the installation of a weather resistant barrier (WRB), then application of a lath secured to the framing with corrosion resistant fasteners and a nominal ½ inch scratch coat. The lath must be properly applied to the wall in order to avoid intrusion of water, and to provide an acceptable structure to which the cladding will be adhered. The lath must be corrosion resistant, applied in an overlapping fashion, and with a corrosion resistant nail that penetrates the studding according to the MVMA recommendations. Additionally, the scratch coat must be applied using a correct mortar at the proper moisture content and thickness, embedded properly in the lath, allowed to cure to “thumb dry”, the scratched to provide grooves, and allowed to cure. These additional products and steps add cost, additional labor and provide opportunities for human error, which can result in a poor installation and future problems. The installation of the WRB, lath and scratch coat must be performed up to 48 hours or more before the installation of the veneer product, allowing the scratch coat to properly cure. Further details are set forth by the MVMA. 
         [0007]    Once the scratch coat is properly applied and cured, adhered concrete masonry veneer (ACMV) products are then adhered to the scratch coat using a mortar applied to the ACMV. The MVMA guidelines recommend that the scratch coat should be moist cured to prevent cracking, and that both the scratch coat and the ACMV should be “dampened” when applying the ACMV, adding additional requirements on the installer. The installer typically will take individual ACMV products, “butter” the back of each individual product with mortar, and apply the “buttered” product to the scratch coat, forcing the mortar into the scratch coat to adhere the ACMV to the wall. The consistency of the scratch coat, mortar and skill of the installer each play a role in the reliability of the installation. Additionally, the installation should not be performed during rain or cold weather, thus limiting the time available (and time delay) for completion of the building. These all add to cost and customer dissatisfaction during the construction process. 
         [0008]    ACMV products are typically installed as discrete individual stones or brick adhered to a scratch coat on the exterior of a building as described above. Stones are typically installed from the top of the building, and the wall is covered in a downward direction. If the wall is struck (e.g. if drywall is installed on the interior of the building) before the mortar is cured, the stone may be dislodged from the wall. This creates re-work for the installer, or partially dislodged stones may become loose at a later date. 
         [0009]    An optional installation technique described in the MVMA guidelines includes a rainscreen drainage plane system, which provides a space to permit incidental water to escape. The recommended ways to provide this space include a drainage mat, formed polymer sheeting (such as Delta®-Dry Stucco and Stone, available from Cosella-Dorken, ref. http://www.cosella-dorken.com), strapping or furring to provide the recommended MVMA air gap of 3/16 to ¾ inch. These systems allow moisture to escape from behind the veneer, but add additional material and labor cost, time and complexity during installation of the ACMV product, and are not used in many installations. 
         [0010]    A panelized veneer product, Versetta Stone, is sold by Boral Stone, LLC. (http://masonry.owenscorning.com/versettastone). These panelized veneer products are secured to the exterior of a building using mechanical fasteners driven through a flange embedded in the top of the veneer product. These systems reduce some of the issues with the adhered ACMV products, because the lath, scratch coat and adhesive mortar can be eliminated in many installations of these panelized veneer products. However, these panelized veneer products are relatively large (typically about 8-10 inches high and approximately 32-36 inches wide) and have a limited drainage plane gap. While this enables fast installation on structures where penetrations are not present (such as windows or outlets) or corners, the presence of these penetrations on most buildings results in a large number of panels being trimmed and a fairly large amount of waste (Boral&#39;s installation instructions instructs an installer to initially estimate 10% scrap). The large number of cuts takes time and produces excess waste. Additionally, these products are more expensive to manufacture, and the designs present challenges in manufacturing. 
         [0011]    Accordingly, it would be desirable to provide an improved product and system for installing veneer products and to eliminate the lath and scratch coat. 
       SUMMARY OF THE INVENTION 
       [0012]    In accordance with the purposes of the present invention as described herein, an improved masonry veneer product (“MVP”) and system (“MVS”) are provided. Such a product and system includes a bracket embedded in the product, the bracket having a first end for securing the upper end of the product to a building. In one embodiment, the bracket also creates an integral air gap behind the product for the escape of moisture. The bracket may include a second end for retaining the bottom end of the product to the building through an interference fit to an adjacent MVP. The system further includes a projection between adjacent MVP to impede moisture from passing between MVP&#39;s, and a WRB installed adjacent the structure and air gap to keep moisture from entering the structure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  provides a front view of a pair of masonry veneer products according to the present invention; 
           [0014]      FIG. 2  provides a front view of a corner masonry veneer product according to the present invention; 
           [0015]      FIGS. 2A and 2B  provide isometric views of a drip ledge corner product according to the present invention; 
           [0016]      FIG. 3  provides an isometric view of a masonry veneer product according to the present invention; 
           [0017]      FIG. 4  provides an isometric view of a first wire retainer according to the present invention; 
           [0018]      FIG. 5  provides an isometric view of a second wire retainer according to the present invention; 
           [0019]      FIG. 6  provides an isometric view of a masonry veneer product according to the present invention having a long width dimension; 
           [0020]      FIG. 7  provides an isometric view of a masonry veneer product according to the present invention useful as an accessory; 
           [0021]      FIG. 8  provides an isometric view of a masonry veneer product installed into a starter strip over a WRB according to the present invention; 
           [0022]      FIG. 9  provides an end view of a starter strip profile according to the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]    Referring now to  FIG. 1  there are shown a pair of masonry veneer products  10 ,  10 ′ illustrated schematically and described herein typically as a dry stack stone product body  12 , similar to a typical box material in appearance. However, the new MVP and MVS have additional inventive features as described herein. The present invention could be applied to nearly any texture of manufactured stone or brick, but is primarily illustrated with a dry stack installation for the sake of simplicity (and as a representative installation). Although not illustrated, one skilled in the art appreciates that an embodiment of the present invention may be used with a grouted texture, and would preferably include a flange on one of the top and bottom of the stone and a second flange on either the left or right end, the flanges each serving as a ledge for a grouted joint. One skilled in the art could modify the current design to utilize the present invention with other textures and configurations. 
         [0024]    The embodiment shown in  FIG. 1  includes a pair of brackets  14 ,  14 ′ embedded in the product body  12 . Each bracket includes a top end  16  and bottom end  18 . The top end  16  is illustrated as having a looped construction forming an eye for receiving a fastener  40  as illustrated in  FIG. 8 . The ends  16 ,  18  are designed to extend and nest under an adjacent stone as illustrated in  FIG. 1  at  21 . Each end preferably includes a curved shape  17 ,  19  as illustrated in  FIGS. 4 and 5  for holding the body  12  away from the wall to create an air gap for drainage and to allow for deflection of the ends  16 ,  18  when attached to the wall. In a preferred embodiment as illustrated in  FIG. 4 , the wire  14  includes two attachment eyes  25 ,  26  at the bottom end  18  and two attachment eyes  27 ,  28  at the top end  16 , formed in a unitary bracket  14 . A lateral connector  13  is provided to enable the formation of the bracket into a single piece, preferably as a unitary construction, to enable efficient manufacture of the product  10 . Although shown connecting the top ends  16 , another embodiment includes a connector for connecting the bottom ends or intermediate portions  20 . 
         [0025]    As further illustrated in  FIG. 3 , the bracket  14  is embedded into the stone body  12 , with an intermediate portion  20  as shown in  FIGS. 4 and 5 . The intermediate portion  20  is embedded in the product body  12  a depth sufficient to ensure adequate engagement to support the stone body  12  when attached to a building (not shown), preferably for the life of the building. The depth and shape may affect the pullout strength, and should be coordinated with the size, shape and weight of the product. In a preferred embodiment, the embedded depth is approximately ¾-1 inch, but may be more or less depending on the surface area of the bracket, the characteristics of the body composition, and the size and shape of the body. In one embodiment the depth is ½ inch. In a heavier product, the depth may be 1.5 inch or more, depending on requirements. The brackets  14  penetrate the stone body  12  to a depth that provides sufficient engagement between the bracket and cured concrete stone, but also which retains a thickness of concrete that will ensure the face of the stone body  12  does not expose the wire or fracture during the life of the building. The brackets  14  are preferably formed from a wire that is corrosion resistant, such as a stainless steel or galvanized steel, and having sufficient strength and sufficient stiffness to not deform and to provide the installation with an interference fit at the bottom as described below. The bracket  14  should be rigid enough to withstand handling, packaging, transport and installation without excessive deformation. In another embodiment, the brackets  14  are formed from a fiberglass material, or any material known to one skilled in the art that is not corroded and will support the masonry product  10 . In yet another embodiment (not shown), the brackets  14  are stamped from sheet metal or formed or molded from another non-corrosive material in a more flattened cross section. One skilled in the art appreciates the bracket preferably has adequate strength and shape retention or memory. 
         [0026]    As shown in the embodiment illustrated in  FIGS. 1 and 3 , the product may include water shedding feature, which is described herein to include a flashing lip  22  along the top surface  29  of the stone body  12 . This lip  22  is intended to inhibit the passage of moisture, such as wind driven rain, between the stone body  12  and an adjacent stone  10 ′ as illustrated in Fig. In such an embodiment, each stone body  12  may also include a corresponding recess  24  on the bottom surface  30  of the stone body  12  to correspond with the opposing lip  22  of the adjacent stone. This lip  22  and recess  24  also serve to obscure a view of the WRB installed beneath the stone to create a visually appealing dry stack installation. It also enables easier leveling during installation. 
         [0027]    Although not illustrated here, the lip  22  may contact the body within the recess, thereby setting the gap between the products. In a similar manner, each stone preferably includes a lip along one end of the stone body, and a corresponding recess along the opposite end of the stone body, which will inhibit moisture intrusion, obscure visibility behind the product, and set the side to side gap. 
         [0028]    While the lip and recess  22 ,  24  are illustrated in  FIGS. 1 and 3  as an angled or chamfered protrusion and recess, one skilled in the art appreciates that while not illustrated as such, the lips  22 ,  24  could be simple ridge, a rabbet, shiplap, or other type of configuration that provides a moisture block and an improved line of sight. 
         [0029]    As illustrated in the embodiment of  FIG. 3 , the bracket  14  includes a first protrusion  34  formed in the bracket  14 . The protrusion extends below the back surface  32  of the stone body  12  to bear against the structure  39  illustrated in  FIG. 9  and create an air gap G 1  under the product  10  when installed on a structure, preferably installed over a WRB  38 . In the illustrated embodiment, the bracket  14  includes a bend  36  which holds the top end  16  away from the structure  39  and WRB  38  to create a second gap G 2 . When the bracket  14  is secured through the WRB  38  to the structure  39  as illustrated in  FIG. 8 , the top end is urged by the fastener  40  toward the structure  39 . This force on the top end  16  acts as a lever, which urges the opposite second end  18  of the bracket  14  away from the structure  39  and toward the back surface  32 ′ of a second body, such as an adjacent product  10 ′, or into a channel on e.g. a starter strip  42 . Because the second end  18  is wedged below the lower product  10 ′, this causes a second protrusion  35  at the bottom end  18  to be held securely against the structure  39  and therefore the product is secured both at the top by the nail and at the bottom by a wedging action against the second product  10 ′. In a preferred embodiment, the top end is positioned approximately ⅛ inch further away from the structure to ensure the wedging action occurs. This dimension can be modified depending on the stiffness of the wire and the surface against which it bears to provide a gap greater than the height off the wall to enable a cam locking action. 
         [0030]    As illustrated in  FIG. 3 , in a preferred embodiment, the gap under the top GT is approximately ½ inch and the gap under the bottom GB is approximately ⅜ inch. One skilled in the art appreciates this dimension may be modified based on the air gap desired, concrete penetration and the deformation of the bracket  14 . As illustrated in  FIG. 1  the top end  16  preferably extends a distance B 2  above the body  12  and bottom end  18  extends a distance B 1  below the body  12 . In a preferred embodiment B 1  extends approximately ½ inch further than B 2 . In one embodiment B 1  is approximately 1⅝ inch and B 2  is approximately 1⅛ inch. In another embodiment, B 1  is approximately 1¼ inch and B 2  is approximately ¾ inch. One skilled in the art appreciates this dimension may be changed to increase or decrease overlap depending on the nature of the wire, the size of the stone, and other manufacturing and installation factors, and in some embodiments, the dimensions may be the same or opposite to reflect the overall design requirements. One skilled in the art appreciates that the overlap can be lengthened to the height of the stone or more if designed with no interference, and greater overlap may provide a more stable wall. 
         [0031]    In another embodiment (not illustrated), the top end of the bracket  14  does not have a bend  36 , and the bottom end  18  of the bracket is bent to lie in a plane above the back surface  32  of the stone body  12 , so the bottom end  18  is installed under an adjacent product (not shown) simply using an interference fit. This interference may be at least 1 mm and could be 2, 3, 4, or 5 mm or more, depending on the stiffness of the bracket. Accordingly, the configuration of the bottom bracket illustrated in  FIG. 2  may be used with or without the bent configuration of the top end  16  as illustrated in  FIG. 2 . Additionally, the second end  18  may be wedged against another body, such as a starter strip or an accessory, such as a ledge. In certain applications, it may be sufficient to fasten the second end using adhesives, nails, stapes, screws or the like as a substitute for the second body. While the protrusions are illustrated herein as bent wires, one skilled in the art appreciates that a different configuration could include a molded protrusion, a weldment, or other configurations to provide the desired gap. 
         [0000]    Page 10 Top—The overlap of the wire can be greater or less so I would broaden the claim dimensions. The overlap can be the entire length of the stone or more in reality if designed with no interference. We suggest that it should be a minimum of a half inch and the longer the better to provide a stable wall.
 
Page 10 bottom—Concerning the word “wedged” as it relates to the bottom clip to the starter strip, we should say that “bending and wedging” the bottom legs into a groove of the starter strip provide the stability for the stone when the top clip eyelets of the stone are screwed in to the wall
 
         [0032]    A system including the product  10  described above preferably includes a building structure  39  such as a frame and sheathing or concrete structure, a weather resistant barrier  38  installed over the structure (similar in nature and installation to that specified by the MVMA), a plurality of products  10  attached to the structure over the WRB  38  and attached to the structure  39  using fasteners  40  projecting through the brackets  14 . The fasteners  40  are preferably non-corrosive, such as galvanized roofing nails, screws or staples; provided however that the fasteners must provide sufficient strength to secure the product  10  to the structure  39  for the life of the structure. 
         [0033]    In one embodiment, installation begins from the bottom of the building. In such an instance, a starter strip  42  is installed to the building in a level manner. A preferred starter strip is illustrated in  FIG. 9 . The starter strip  42  preferably includes a recess  44  to receive the bottom  18  of the brackets  14 . The starter strip preferably includes weep holes  46  at the bottom of the recess  44  to enable water to drain. The recess  44  preferably includes a lead angle  48  to enable easy installation of the bracket  14  and preferably narrows to a line to line or interference fit to wedge the bracket  14  and hold it in place. In one embodiment, the lead angle is approximately twenty degrees, and the recess has a bottom radius R 1  of 0.06 inch for a 0.12 diameter wire, and a depth L 1  of approximately ½ inch. Products having characteristics similar to the starter strip are also preferably used as flashing around windows and other openings. The starter strip  42  is preferably made from galvanized steel, aluminum, PVC or any common noncorrosive building material used in similar applications. Furthermore, the bottom of the bracket may experience bending and wedging as the bottom legs are fit into the recess of the starter strip and the brackets are secured to the wall. e 
         [0034]    The starter strip  42  also includes a back portion  50  which extends under the WRB  38  to ensure water does not enter under the WRB, to comply with ASTM requirements. In a preferred embodiment the back portion  50  has a height L 2  of 3.5 inches to satisfy ASTM. In another embodiment, 2 inches may be sufficient. The overlap may be less in some situations or may be more, but practicality limits one is normally acceptable. In another embodiment, a simple j-channel or other starter is used with the products  10  of the present invention. Similarly, one skilled in the art appreciates that either a starter strip or weep screed should provide ventilation at the bottom, and therefore accommodations should be made to provide for air passage. Once the first row is secured to the wall using the starter strip  42  and the top end  16  of the brackets is secured as described above, the second row is installed by inserting the bottom ends  18  of the second row of products behind the rear surface  32  of the first row of products previously installed. Then the top end of successive rows of the product being installed is pushed against the structure  39  and secured at the top end  16  as described above. 
         [0035]    The top row of the product may be capped or may extend to the soffit. It is desirable to include an air gap where possible to provide for air flow. Where water drainage does not permit this, MVMA details may be followed. Where the product extends to the soffit, an installation similar to typical brick installation may be performed, i.e. the soffit may be installed after the product is installed. Alternatively the soffit j-channel may include a spacer against the wall to provide for air flow at the top of the wall. 
         [0036]    Although not illustrated, in one embodiment, after the product is secured to the structure, a bead of caulk or other material is optionally installed on the product along one of the top and bottom, plus one of the ends, so that the joint between adjacent products is filled with the material to provide a substantially effective water seal. In yet another embodiment, a bead of caulk or foam dam is provided on the top or bottom and one end of each stone at the factory to provide a substantially watertight joint between adjacent products without a field-applied caulk. 
         [0037]    One skilled in the art appreciates that while not illustrated here, a grout product may optionally be installed between adjacent products for certain textures. Such a grout is preferably flexible, so that it can perform for an extended period without cracking. Such a grout is also preferably water resistant to minimize the amount of water that enters between adjacent products. Additionally, a grout may be used with the flanged design described above. 
         [0038]    As illustrated in  FIG. 3 , the product  10  preferably includes a single bracket  14 , but one skilled in the art appreciates that more than one bracket may be utilized to provide additional support and attachment, or to facilitate manufacture. The nature of the product (size, weight) and the nature of the brackets, fasteners and structure and environment can affect these requirements. 
         [0039]    As illustrated in  FIGS. 2, 2A   6  and  7 , the invention is also applied to corners and accessories, such as drip ledge corners, trim stones, keystones, ledges, light fixtures, outlets, column wraps and other products. In the case of corners, in one embodiment shown in  FIG. 2 , only one side of the stone corners are attached to the structure, and a spacer is provided on the backside of the return to provide a consistent air gap and exterior thickness. As shown in  FIG. 2 , the corner  60  includes a long leg  62  and a return leg  64 . The bracket  14  is used to attach the long leg  62  to the building and the short leg  64  is supported as part of the body. While the corner  60  is illustrated with the top  66  installed so the return is on the left side, the corner  60  could be inverted so the bottom  68  is installed upwardly so the return  66  is on the right side of the corner  60 . Thus, the corners  60  are reversible. Preferably the reversible corners have a reversible clip that is embedded in the concrete to allow for ease of ordering materials, using as left and right corners and staggered joints during installation to give a more authentic stone look. 
         [0040]    As illustrated in  FIG. 2B , a corner may include two wires  214 ,  214 ′ to ensure both legs are sufficiently supported. In this example, the corner may be a ledge corner. In a similar manner,  FIG. 6  illustrates an elongate product  10 ″having two brackets  614 ,  614 ′ to support the elongate product. While not limiting, in this illustration, the elongate product  10 ″ may comprise a ledge piece.  FIG. 7  illustrates another accessory piece  70  including brackets  714  according to the principles of this invention. Referring to  FIGS. 7 and 2B , one skilled in the art appreciates that one can use single or double clips or a combination of single and double clips and can be installed in vertical or horizontal configurations. This principal can be applied to other accessories including trim stones, surrounds, drip ledge corners, light boxes and other accessories. 
         [0041]    In another embodiment, the installation instructions teach the installer to set a gap manually, or to use separate spacers, such as foam or molded parts. In another embodiment, the instant invention is applied to a panelized product. In such a case, it may be necessary to utilize a greater number of brackets to adequately support and secure the panelized product due to its size and weight. 
         [0042]    One embodiment of the present invention is applied to individual stones or bricks. This makes installation simple, as fewer products will be cut and less scrap created. Furthermore, it avoids the potential that an installer will align the panels to create unsightly lines or an unattractive panelized wall. Additionally, the individual products also make it simpler to create accessory products that are compatible with this system. As noted above, however, applicant envisions that a panelized system could utilize the present invention, either alone or in combination with the individual products as described above. 
         [0043]    While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention.