Patent Publication Number: US-2017350146-A1

Title: Grid form panel masonry veneer from liner

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     Reference is made to the Applicants patent, McCary, U.S. 2010/0051779, now U.S. Pat. No. 8,153,046, and incorporates by reference the disclosure of the earlier application and then patent to the extent necessary for a full enabling disclosure of the present invention. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to the masonry veneer form liner used with a concrete/cementitious material flow-through grid forming panel during a concrete/cementitious pour. 
     BACKGROUND OF THE INVENTION 
     Conventional, concrete forms consist of plywood or wooded and metal panels temporarily maintained in spaced apart and parallel relationship by means of ties. The concrete in poured between these forms which are then stripped away after the concrete has set up. These panels can be expensive and awkward to manufacture, store, and ship. 
     Alternatively and more recently forms such as insulated concrete forms with foamed plastic panel that becomes part of the poured wall or structure have gained acceptance in the construction industry. Some difficulties have developed in some applications due to the outside of the panel being made of foam plastic which include; penetrability of the foamed plastic, insect entrance questions, waterproofing difficulties, the stigma of previous stucco (EIFS) application failures and the question of fire ratings. 
     In McCary, U. S. 2010/0051779, now U.S. Pat. No. 8,153,046, discloses a method of assembling a plurality of modular forming units to create a freestanding structure, wherein each unit consists of a least one lattice or grid framework panel having a plurality of openings there through and another spaced apart forming panel to create a forming cavity. 
     Concrete/cementitious flowable material is introduced into the cavity, wherein the concrete/cementitious flowable material fills the cavity and flows non-restrictively through the lattice framework panel(s) such that the cementitious material extends beyond the external surface of the lattice framework or grid panel(s) creating an external surface layer; and then allowing the material to set and become a monolithic structure. McCary had described the attachment of stencils and form liners to the exterior face of the concrete/cementitious grid flow-through forming panel but had not addresses the attaching of masonry veneers, such as thin brick, to the exterior face of the grid form panel before the concrete/cementitious pouring into the cavity of the concrete/cementitious form. 
     Various patents were issued to masonry veneer style holding forms, including Goldman, U.S. Pat. No. 4,858,410 Aug. 22, 1989, where masonry veneer could be placed in horizontally placed holding forms with the face or to be exposed side of the masonry veneer facing down. Then concrete/cementitious material would be poured upon the masonry veneer and holding form. When the concrete/cementitious material had dried sufficiently then the masonry veneer holding form would be pulled off exposing the face of the masonry veneer and the concrete/cementitious poured material now representing the mortar joint between the masonry veneers. 
     Vertical applications were introduced of holding masonry veneers in a vertical holding form or bracket, as in Scott, U.S. Pat. No. 5,667,190 Sep. 16, 1997, later in Scott, U.S. Design Pat. No. D625,846 Oct. 19, 2010, in Marshall, U.S. Pat. No. 6,360,505 and in Williams, U.S. Pat. No. 6,360,505, Mar. 26, 2002. In Scott, Marshal and Williams, masonry veneers holding forms are attached on the interior face of a vertical concrete/cementitious forming panels and masonry veneers placed in the masonry veneer holding forms before the concrete/cementitious pour into the forming cavity. After the concrete/cementitious material is poured and allowed to harden to the desired stiffness the forming panels are removed along with the masonry veneer holding forms, exposing the face of the masonry veneer and the concrete/cementitious poured material now representing the mortar joint between the masonry veneers. 
     THE INVENTION 
     The present invention is a masonry veneer holding form liner that attaches to the exterior face of a concrete/cementitious grid flow-through forming panel. The grid form masonry veneer holding form liner is primarily in pattern shapes of the mortar joints surrounding an assembly of masonry veneers such as bricks, thin bricks, stone, thin stone, block or thin block. There are periodically spaced holding or catch points on the circumference of the mortar joint pattern. The masonry veneer holding form liner is attached to the concrete/cementitious flow-through grid form usually by screws and bolts that protrude through periodic holes in the grid form mortar shaped masonry veneer holding form liner. The attaching screws or bolts either then have grapple style catches then attached to the attaching ends of the screws or bolts or the screws or bolts without grapple catch first attached are pushed through the concrete/cementitious grid form grid openings and then a grapple style catch, wing nut style catch or other catch that holds the mortar joint patterned masonry veneer holding form liner on the exterior face of the concrete/cementitious flow-through grid forming panel. Masonry veneers, usually thin bricks, thin blocks, tiles or pavers can then be placed into the masonry veneer holding form liner spaces between the mortar joint pattern masonry veneers holding form liner. Either periodically placed catches on the circumference of the holding form liner masonry veneer holding spaces or friction of the mortar joint pattern holding form hold the placed masonry veneers in place during a concrete/cementitious pour. When concrete/cementitious material is poured into the vertical or horizontal (as in pavers, tiles) oriented forming cavity with the masonry holding form liner attached to the concrete/cementitious flow-through grid forming panel(s) the concrete/cementitious material flows through the grid openings of the grid forming panel&#39;s grid openings up to the interior or non-exposed face of the masonry veneer and up to the interior side of the masonry veneer holding form liner. After the concrete/cementitious material is allowed to harden to the desired stiffness the masonry veneer holding forms are unscrewed or unbolted from the concrete/cementitious embedded grapple, wing nut or other style holding catch and masonry veneer mortar joint pattern holding form liner is released from the exterior of the grid form, exposing the face of the masonry veneer and the concrete/cementitious poured material now representing the mortar joint between the masonry veneers. Alternatively, the concrete/cementitious poured material now representing the mortar joint between the masonry veneer can be so narrow that all or a portion of the masonry veneers have the appearance of dry stacked, having no mortar joint, or very narrow mortar joint. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1 . in a frontal view shows a mortar joint patterned masonry veneer holding form liner with a masonry veneer placed in one of the masonry veneer placement and holding openings. 
       Shown in  FIG. 2 ., in a side cross-sectional view, a mortar joint patterned masonry veneer holding form liner attached to a concrete/cementitious flow-through grid forming panel. 
         FIG. 3 ., in a side cross-sectional view shows a mortar joint patterned masonry veneer holding form liner attached to a concrete/cementitious flow-through grid forming panel with masonry veneers placed in the mortar joint patterned masonry veneer holding form liner. 
       Shown in  FIG. 4 ., in a side cross-sectional view, is concrete/cementitious material poured into a vertical or horizontal oriented concrete/cementitious form with one of the forming panels being a concrete/cementitious flow-through grid forming panel with an attached mortar joint patterned masonry veneer holding form liner with masonry veneer placed in the mortar joint patterned masonry veneer holding form liner. 
         FIG. 5 . shows in a side cross-sectional view the hardened concrete/cementitious material that was poured into a concrete/cementitious form with one of the forming panels being a concrete/cementitious flow-through grid forming panel with a previously attached mortar joint patterned masonry veneer holding form liner removed now showing the exposed face of the masonry veneer and the concrete/cementitious mortar joints. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
       FIG. 1 . in a frontal view shows the mortar joint patterned masonry veneer holding form liner  10  with the mortar joint patterned form liner  11 , the masonry veneer placement and holding openings  12 , with a masonry veneer  13  placed in one of the masonry veneer placement and holding openings  12 . Shown are circumference catch points  14  that help to hold the placed masonry veneer  13  on the circumference of the mortar joint patterned form liner  11 . Also shown are attaching holes  15  periodically placed in the joint patterned form liner. 
     Shown in  FIG. 2 ., in a side cross-sectional view, a mortar joint patterned masonry veneer holding form liner  10  attached to a concrete/cementitious flow-through grid forming panel  16 . Shown are attaching screws, bolts or other threaded rod style fasteners  17  placed through holes  15  in the joint patterned form liner  10 , pushed through the grid openings  18  of the concrete/cementitious material flow-through grid form  16 , with a grapple catch, wing nut or other threaded holding catches  19  attached to the attaching ends  20  of the screws, bolts or other threaded rod style fastener  17 . The side of circumference catch points  14  and offset screed points  21  on the side of the concrete/cementitious flow-through grid forming panel  16  are also shown. 
       FIG. 3 ., in a side cross-sectional view shows a mortar joint patterned masonry veneer holding form liner  10  attached to a concrete/cementitious flow-through grid forming panel  16  with masonry veneers  13  placed in the veneer placement and holding openings  12  of the mortar joint patterned masonry veneer holding form liner  10 , with the placed masonry veneers  13  resting close to or against the offset screed points  21 . Shown are the circumference catch points  14  helping to hold the masonry veneers  13 . Again shown are attaching screws, bolts or other threaded rod style fasteners  17  placed through holes  15  in the mortar joint patterned from liner  10 , pushed through the grid openings  18  of the concrete/cementitious material flow-through grid form  16 , with a grapple catch, wing nut or other threaded hold catches  19  attached to the attaching ends  20  of the screws, bolts or other threaded rod style fastener  17 . 
     Shown in  FIG. 4 ., in a side cross-sectional view, is concrete/cementitious material  22  poured into a vertical or horizontal oriented concrete/cementitious form  23  with one of the forming panels being a concrete/cementitious flow-through grid forming panel  16  with an attached mortar joint patterned masonry veneer holding form liner  10 , with masonry veneer  13  placed in the mortar joint patterned masonry veneer holding form liner  10 . Shown are the circumference catch points  14  and the offset screed points  21 . The other forming panel of the concrete/cementitious form  23  is a solid vertical or horizontal oriented forming panel  24 . Shown are attaching screws, bolts or other threaded rod style fasteners  17  placed through holes  15  in the mortar joint patterned from liner  10 , pushed through the grid openings  18  of the concrete/cementitious material flow-through grid form  16 , with a grapple catch, wing nut or other threaded holding catch  19  attached to the attaching ends  20  of the screws, bolts or other threaded rod style fastener  17 . The concrete/cementitious material  22  is shown flowing through  25  the grid openings  18  of the concrete/cementitious material flow-through grid form panel  16  up to and adhering to the interior or non-exposed face  26  of the masonry veneer  13 , and the concrete/cementitious material  22  is shown flowing up to the interior side  27  of the mortar joint patterned masonry veneer holding form liner  10 . 
       FIG. 5 . shows in a side cross-sectional view the hardened concrete/cementitious material  22  that was poured into a concrete/cementitious form  23  with one of the forming panels being a solid panel  24  and the other forming panel is a concrete/cementitious flow-through grid forming panel  16  with attached offset screed points  21 . A previously attached mortar joint patterned masonry veneer holding form liner  10  is shown removed, now showing the exposed face  28  of the masonry veneer  13  and the hardened concrete/cementitious material  22  as mortar joints  29  between the masonry veneers  13 .