Patent Publication Number: US-2010107531-A1

Title: Thin brick matrix panel and related methods and systems

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to an apparatus and method for forming a brick wall. More specifically, the present disclosure relates to a “thin brick” system and methods which utilize a matrix and mortar to form at least a portion of a wall. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present embodiments will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that the accompanying drawings depict only typical embodiments, and are, therefore, not to be considered to be limiting of the invention&#39;s scope, the embodiments will be described and explained with specificity and detail in reference to the accompanying drawings as listed below. 
         FIG. 1  is a perspective view of a portion of a wall formed by using a system for forming a thin brick wall. 
         FIG. 2  is a cross section view of a portion of the wall formed by using the system of  FIG. 1 . 
         FIG. 3  is a cross section view of an apparatus for forming channels in a deformable matrix. 
         FIG. 4  is a cross section view of another apparatus for forming channels in a deformable matrix. 
     
    
    
     INDEX OF ELEMENTS IDENTIFIED IN THE DRAWINGS 
     
         
           10  substrate 
           15  moisture barrier 
           100  thin brick system 
           110  matrix-type receiving panel 
           111  cross member of matrix 
           112  aperture of matrix 
           120  channel 
           121  protrusion 
           122  first side of protrusion 
           123  second side of protrusion 
           124  apex of protrusion 
           125  first bend 
           126  second bend 
           128  void of channel 
           130  thin brick units 
           140  mortar 
           150  fastener 
           200  press apparatus 
           210  matrix panel 
           261  first portion of press 
           262  recesses 
           263  second portion of press 
           264  protrusions 
           300  roller apparatus 
           310  matrix panel 
           320  channel 
           321  protrusion 
           370  rollers 
           371  first roller 
           372  recesses 
           373  second roller 
           374  protrusions 
       
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     It will be readily understood that the components of the embodiments as generally described and illustrated in the figures herein could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of various embodiments, as represented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of various embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated. 
     The phrases “connected to,” “coupled to” and “in communication with” refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interaction. Two components may be coupled to each other even though they are not in direct contact with each other. The term “abutting” refers to items that are in direct physical contact with each other, although the items may not necessarily be attached together. 
     Architectural thin face brick, commonly referred to as “thin brick”, is typically kiln dried brick units that have height and width dimension similar to those dimensions of conventional brick, but have a relatively small thickness. Some other thin brick units are formed from concrete. Such thin brick is typically used as a decorative element to an existing architectural structure. A thin brick receiving panel, such as a panel of foam or metal is typically adhered to a structure with an adhesive. The adhesive holding the panel to the structure is usually allowed to dry over night, and then the thin brick units are coupled to the panel also using an adhesive, which typically requires over night curing. Finally, the thin brick are typically grouted with mortar to give the resulting panel the appearance of a panel formed from full-sized brick units. 
       FIG. 1  depicts a thin brick system  100  from a perspective view. Thin brick system  100  may comprise a matrix-type brick receiving panel  110 , a plurality of thin brick units  130 , mortar  140 , and a plurality of fasteners  150 . Thin brick system  100  is configured to allow mortar  140  to be used to adhere bricks  130  to matrix-type brick receiving panel  110 , wherein the mortar becomes enmeshed in the matrix of the panel. Mortar  140  also binds bricks  130  to each other and is grouted into spaces between adjacent thin brick units to form mortar joints. Thin brick system  100  as described herein may be employed to form a wall or decorative element on an exterior or interior portion of a structure. Additionally, the thin brick stem described herein may be used in various methods for forming a thin brick wall. 
     Matrix-type brick receiving panel  110  may comprise a plurality of cross members  111 , which form a plurality of apertures  112  such that the matrix may be called a mesh, web, or lath. Matrix  110  also comprises channels  120  that are defined by laterally extending protrusions  121 , wherein the protrusions are configured such that when the matrix is coupled to a substrate, the protrusions form a substantially horizontal channel. 
     Channels  120  may extend across the width of matrix panel  110  and are configured to provide proper spacing between adjacent rows of brick such that spaces can be formed between rows and/or columns of brick. As such, protrusions  121  may be called spacing members. Channels  120  are configured to receive and provide support for mortar  140  and bricks  130 . In the depicted embodiment, the height of channel  120  is greater than the height of a brick such that mortar  140  can be located between a brick and a protrusion  121 . Matrix  110  is configured such that mortar  140  becomes enmeshed with the cross members and apertures  111  and  112  of the matrix. The matrix may be coupled to a structure substrate  10  using a plurality of fasteners  150 . 
     In the depicted embodiment, matrix  110  comprises a piece of galvanized steel diamond lath of the type well known in construction. In one embodiment, the diamond lath comprises a panel of diamond lath matrix that is about 2 feet high and has a width (lateral length) of about 8 feet. Multiple panels of matrix  110  can be employed to build a thin brick wall or element of any size. A contiguous wall of thin bricks can be constructed from the system disclosed herein using multiple panels of matrix  110  by overlapping the edges of adjacent matrix panels. When panels of matrix  110  are overlapped vertically, the tops and/or bottoms of the panels may be spaced such that channels  120  of the two adjacent panels of matrix are evenly spaced vertically. When multiple panels of matrix  110  are overlapped horizontally, the adjacent sides of the panel may be positioned such that a horizontal continuity of channel  120  is maintained and such that a course of brick built on the channel maintains a level or other predetermined orientation. 
     Another feature of the thin brick system disclosed herein is that the system allows for rapid and simple construction of corners. One or more cross members  111  that are located at protrusions  121  of a matrix panel  110  can be cut, which allows the panel to be bent around a corner. The bent matrix panel  110  can be attached to the substrate on each side of the corner by mechanical fasteners  150 . 
     As will be appreciated by those skilled in the art, a variety of types and configurations of matrix-type thin brick receiving panels can be utilized without departing from the scope and spirit of the present invention. For example, in one embodiment matrix  110  comprises 2.5 gage galvanized steel diamond lath while in another it may be 3.5 gage. Matrix  110  may comprise any suitable deformable material, such as a deformable metal matrix. Matrix  110  may comprise any suitable dimension or shape; for example round. Further, matrix  110  can configured such that a user cut the matrix to a custom shape. 
     Thin bricks  130  may comprise any type known in the art, and may be coupled to matrix  110  such that their long axes are horizontally oriented, or alternatively, the bricks may be placed such that they are vertically oriented. In the depicted embodiment, bricks  130  comprise rectangular shapes, however, in alternative embodiments, the bricks may comprise other shapes such as square, round, or rock-like elements. Further, bricks  130  may be arranged to form decorative elements such as circles or geometric patterns, wherein different colors or shapes of bricks may be employed. 
     Mortar  140  may be of any type known in the art and is configured to couple bricks  130  to matrix  110  as well as couple the bricks to each other. In the depicted embodiment, mortar  140  is grouted into spaces between adjacent bricks  130  such that the mortar forms horizontally and vertically oriented portions. Mortar  140  can be finished in a variety of manners that are known in the art. Mortar  140  may be initially placed on a back, top, left, and/or right side of brick  130 , and then the brick is pressed onto matrix  140 , the mortar may be initially placed on the matrix, and then a brick is pressed into the mortar, or a combination of placing mortar on the matrix and the brick may be used. 
     A plurality of fasteners  150  may be employed to anchor matrix  110  to a substrate  10 , such as a skin of plywood, metal or wooden studs, or some other suitable element of the structure. In the depicted embodiment of  FIG.1  and  FIG. 2 , fasteners  150  are configured to project through an aperture  112  of matrix  110  such that a body portion of the fastener projects into a substrate  10 . A head portion of the fastener is configured to abut at least a portion of a cross member  111  of the matrix on a substrate-distal side of the matrix. In this way, the matrix can be anchored to the substrate. In the depicted embodiment, fasteners  150  comprise staples, however in alternative embodiments, the mounting hardware may comprise nails or screws, and may further comprise washer members. A moisture barrier  15 , which comprises a water repellant material such as tar paper may be located between substrate  10  and matrix  110 . The tar paper may be overlapped to prevent water from seeping between adjacent sections of the tar paper. Moisture barrier  15  is an optional component, and some embodiments of system  100  may not include a moisture barrier. Since matrix  110  and the resulting thin brick wall are attached to substrate  10  with fasteners rather than a layer of adhesive, a liquid that finds its way behind the thin brick wall can flow between the back side of the wall and the tar paper without becoming trapped therein and resulting in water damage to the substrate, such as mildew, or rot. 
       FIG. 2  is a cross section view of a portion of a wall formed according to thin brick system  100 . As described above, system  100  comprises a matrix panel  110  for receiving thin brick units  130 . Bricks  130  are attached to matrix panel  110  and to each other by mortar  140 , which becomes enmeshed in the matrix panel. Matrix panel  110  is anchored to substrate  10  by a plurality of mechanical fasteners  150 . 
     A plurality of horizontally oriented laterally oriented channels  120  define a front face of matrix panel  110  and are formed by laterally extending protrusions  121 , which in the depicted embodiment comprise a substantially square transverse cross section. In other embodiments, protrusions  121  may comprise substantially triangular or rectangular cross sections. 
     Protrusions  121  may be formed in matrix panel  110  after the matrix panel has been manufactured, and as such, the protrusions are integral to the matrix panel. In one embodiment, protrusions  121  are formed on-site by a user, and in another embodiment, the protrusions are formed off-site. Protrusions  121  may be formed by pressing or rolling matrix panel  110 . Protrusions  121  may comprise a first side  122 , a second side  123 , and an apex  124 , wherein the first side is located between a first bend  125  and apex  124 , and the second side is located between a third bend  126  and apex. Apex  124  itself may define a second bend. A void  128  may be formed by the bending of panel  110  to create protrusions  121 . 
     In the depicted embodiment, a transverse cross section of protrusion  121  is substantially square, but may also be described as being rectangular and may be somewhat ovalized at apex  124 . The transverse cross sectional shape of protrusion  121  may vary from the depicted embodiment, and may comprise a triangular, rectangular, or oval shape. The distance to which a protrusion  121  protrudes from matrix panel  110  may be varied according to different applications, and in the depicted embodiment, that distance is less than the width of a thin brick unit  130 . Thus, it can be said that protrusions  121  have a height that is less than that of a thin brick unit  130 . In an alternative embodiment, when the thin brick wall formed by system  100  is finished, the distance D 2  to which a protrusion  121  protrudes is less than about ½ of the width of a thin brick unit  130 , when the brick unit is coupled to matrix  10 , as depicted in  FIG. 2 . 
     In one embodiment, the height of a protrusion  FIG. 2 , D 1 , is within a range of about 0.25 inches and 1.5 inches. The depth D 2  that a laterally extending protrusion might protrude from the front side of the matrix as depicted in  FIG. 2  may comprise a range of about 0.2 inches to about 1.0 inches. In another embodiment, D 1  is about 0.75 inches. In another embodiment, D 2  is about 0.5 inches. 
     In one embodiment, the height D 3  of a laterally oriented channel is about 2.5 inches to about 3.0 inches high as measured between the apexes of adjacent protrusions, and the channel is configured to receive thin brick units that are about 2.25 inches high. In the above embodiment if rectangular shaped thin brick units are adhered within the channel, the thin brick units are oriented such that their long axes are horizontally oriented. In one embodiment, D 3  is about 2.75 inches. In another embodiment, the height of the channel D 3  is between about 8.0 inches and 8.5 inches high as measured between protrusion apexes and the channel is configured to receive thin brick units that are about 7.625 inches high. If rectangular thin brick units are used in this embodiment, the thin brick units are oriented with their long axes vertically oriented. In another embodiment, D 3  is about 8.125 inches. 
     Mortar can initially be applied to matrix panel  110 , a thin brick unit  130 , or both the matrix panel and a thin brick unit. A thin brick unit  130  can then be pressed into place, and when a number of bricks have been placed, mortar can be grouted into spaces in between adjacent brick units to form mortar joints. Applying mortar to matrix panel  110 , pressing a thin brick unit  130  into place, and forming mortar joints causes mortar  140  to be pressed into and enmeshed with matrix panel  110 . Thus cross members of matrix panel  110  may become embedded within mortar  140 , apertures of the matrix panel may become at least partially filled with the mortar, and void  128  of a protrusion  121  may become at least partially filled with mortar. In one embodiment, mortar joints formed between adjacent thin brick units have a height or width D 4  within a range of about 0.075 inches and 1.0 inches. Whether D 4  represents a height or a width depends on whether the mortar joint is horizontally or vertically oriented. In another embodiment, D 4  is about 0.31 inches for a mortar joint between bricks in a row and 0.38 inches for a mortar joint between vertically adjacent bricks. 
     A distance D 5  from a matrix proximal side of substrate  10  to a substrate distal surface of brick may be smaller than if a foam based system were used. In one embodiment, D 5  comprises a range from about 0.60 inches to about 2.0 inches, wherein the thin brick units have a depth of about 0.5 inches. In other embodiments, D 5  may be greater than 2.0 inches. In one embodiment, D 5  is about 0.75 inches. Also, the distance to which bricks  130  protrude away from substrate  10  may be increased or decreased compared to that illustrated in  FIG. 2 . Further, the relative distance that some bricks  130  protrude can be varied such that topological differences in substrate  10  can be accommodated and smoothed out. If topological differences in substrate  10  are greater than can be corrected by varying the height of bricks  130 , furring strips or spacers can be under matrix panel  110 . Finally, varying the distance to which bricks  130  protrude can be used to form designs or decorative elements in a thin brick wall formed by employing system  100 . 
       FIG. 3  depicts a press apparatus  200  that can be used to form protrusions in a matrix panel  210 . Apparatus  200  may be considered part of system  100 , and may be employed to form protrusions at a site near which a thin brick wall is to be formed using system  100 . 
     Apparatus  200  may comprise a first portion  261  and a second portion  263 . First portion  261  may comprise a plurality of recesses  262  which are configured with a predetermined depth and transverse cross section. Second portion  263  may comprise a plurality of protrusions  264  which are configured with a predetermined height and transverse cross section, wherein the height and cross section are substantially similar to recesses  262 . The transverse cross section of recesses  262  and protrusions  264  may vary from the depicted embodiment and may comprise a substantially rounded, ovalized, square, or rectangular shape. The length and width of first and second portions  261  and  263  may be approximately equal to the length and width of a matrix panel  210 , or may comprise a multiple or a fraction of the length and width of the matrix panel. 
     Recesses  262  and protrusions  264  are spaced such that when first and second portions  261  and  263  are pressed together, the protrusions may enter the recesses. When a matrix panel  210  is placed between first and second portions  262  and  264  and the portions are pressed together, the matrix panel may become deformed similarly to the shapes of protrusions and recesses  262  and  264 , resulting in a matrix panel similar to panel  110  described herein. The spacing of recesses and protrusions  262  and  264  are of a predetermined distance such that the resulting channels defined by protrusions formed by press apparatus  200  in matrix panel  210  may be used to receive thin brick units as described herein. 
     The components and features of apparatus  200  may be varied to produce matrix panels of different types, than described herein. For example, the depth and height of recess and protrusions  262  and  264  may be greater or lesser than depicted such that the depths of channels formed in panel  210  are altered. Apparatus  200  may be used in one or more methods for forming a thin brick wall. Apparatus  200  may be mobile, wherein it is easily packed and shipped between locations such that a distributor of thin brick systems as described herein, can ship apparatus  200  with components of the thin brick system to a user. Alternatively, apparatus  200  may be mounted on a vehicle, or may be delivered from site to site via a vehicle. 
       FIG. 4  depicts a roller apparatus  300  that can be used to form protrusions in a deformable matrix  310 . Apparatus  300  may be considered part of system  100 , and may be employed to form protrusions at a site near which a thin brick wall is to be formed using system  100 . In the depicted embodiment, matrix  310  is in a rolled configuration; however, the matrix may comprise panels or sheets. 
     Apparatus  300  may comprise a first roller  371  and a second roller  373 . First portion  371  may comprise a plurality of recesses  372  which are configured with a predetermined depth and transverse cross section. Second roller  373  may comprise a plurality of protrusions  374  which are configured with a predetermined height and transverse cross section, wherein the height and cross section are substantially similar to recesses  372 . The transverse cross section of recesses  372  and protrusions  374  may vary from the depicted embodiment and may comprise a substantially rounded, ovalized, square, or rectangular shape. The width of recesses and protrusions  372  and  374  that are located on first and second rollers  371  and  373  may be approximately equal to the width of a matrix  310 , or may comprise a multiple or a fraction of the length and width of the matrix. 
     Recesses  372  and protrusions  374  are spaced such that when first and second rollers  371  and  373  are rolled in a synchronous manner, the protrusions may enter the recesses. When a matrix  310  is placed between first and second rollers  372  and  374  and the rollers are rolled synchronously, a portion of matrix  310  may be forced into recess  721  by protrusion  374  thereby deforming the matrix similarly to the shapes of protrusions and recesses  372  and  374 . The result may be a matrix similar to panel  110  described herein. The spacing of recesses and protrusions  372  and  374  are of a predetermined distance such that the resulting channels  320  defined by protrusions  321  formed by roller apparatus  300  in matrix  310  may be used to receive thin brick units as described herein. 
     The components and features of apparatus  300  may be varied to produce matrix-type thin brick receiving members of different types compared to those described herein. For example, the depth and height of recess and protrusions  372  and  374  may be greater or lesser than depicted such that the depths of channels formed in panel  310  are altered. Apparatus  300  may be used in one or more methods for forming a thin brick wall. Apparatus  300  may be mobile, wherein it is easily packed and shipped between locations such that a distributor of thin brick systems as described herein, can ship apparatus  300  with components of the thin brick system to a user. Alternatively, apparatus  300  may be mounted on a vehicle, or may be delivered from site to site via a vehicle. 
     The matrix-type thin brick receiving panels  110 ,  210 ,  310 , disclosed herein are examples of means for coupling thin brick units to a substrate. The channels  120 , disclosed herein are examples of means for receiving and spacing thin brick units. The protrusions  121 ,  321  disclosed herein are examples of means for spacing thin brick units. Mortar  140  disclosed herein is an example of means for adhering thin brick units to a thin brick receiving panel; means for adhering thin brick units to each other; and, means for forming mortar joints between adjacent bricks. The mechanical fasteners  150  disclosed herein are examples of means for attaching a matrix-type thin brick receiving member to a substrate. Press apparatus  200  and roller apparatus  300  are examples of means for forming protrusions in a matrix-type thin brick receiving member. 
     Furthermore, any methods disclosed herein comprise one or more steps or actions for performing the described method. The method steps and/or actions may be interchanged with one another. In other words, unless a specific order of steps or actions is required for proper operation of the embodiment, the order and/or use of specific steps and/or actions may be modified. 
     Without further elaboration, it is believed that one skilled in the art can use the preceding description to utilize the present disclosure to its fullest extent. The examples and embodiments disclosed herein are to be construed as merely illustrative and not a limitation to the scope of the present disclosure in any way. It will be apparent to those having skill in the art that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the disclosure described herein. In other words, various modifications and improvements of the embodiments specifically disclosed in the description above are within the scope of the appended claims. Note that elements recited in means-plus-function format are intended to be construed in accordance with 35 U.S.C. §112 ¶6. The scope of the invention is therefore defined by the following claims.