Patent Publication Number: US-6708418-B1

Title: Brick laying form

Description:
FIELD OF THE INVENTION 
     The present invention relates to a method and apparatus for a masonry guide brick laying form for use in laying of a column of bricks or other structural material. More specifically, the masonry guide allowing the column of bricks to be placed in a straight, or spiral, format while keeping each layer within the column both plumb and level. 
     BACKGROUND OF THE INVENTION 
     Masonry guides have long been used in alignment of bricks for control of successive layers. A very specific aspect of masonry is the construction of columns of bricks. Such columns are used in the support of specific structural members, decorative columns for fences or entrances, decorative mailbox support structures, and the like. In the building of any brick structure, the time and effort in keeping alignment, leveling, and placing of bricks is very time consuming. In the case where a decorative design is required, the time aspect of the job of layering the bricks is even more consuming. The use of plumb strings, external posts are labor consuming while complicated brick-laying apparatus is expensive. 
     What is needed is a low cost tool that would give the construction personnel ease of use, quickness in brick layering, exactness in incrementally layering for decorative spiraled construction, and uniform mortar thickness throughout the construction. 
     The apparatus of the present invention provides the above needs as will be described in the following embodiment. 
     SUMMARY OF THE INVENTION 
     The main aspect of the present invention is to provide for an apparatus to control the layering of bricks in a straight or spiraled brick column. 
     Another aspect of the present invention is to provide for ease of adjustment and control when placing a layer of brick with respect to a previous layer. 
     Another aspect of the present invention is to provide for a variable amount of layers of brick (tiers) per 360° of spiral rotation within a spiral shaped column. 
     Another aspect of the present invention is to provide for control of overall dimensions per layer with respect to the bricks and the mortar used. 
     Another aspect of the present invention is to provide for an apparatus that is adjustable for various sizes manufactured bricks. 
     Another aspect of the present invention is to provide an apparatus that is low in cost and easy to manufacture. 
     Another aspect of the present invention is to provide and apparatus that provides for timesaving in construction of a spiraled column. 
     Another aspect of the present invention is to provide for a hexagonal, octagonal, etc. column design. 
     Other aspects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views. 
     The main embodiment of the present invention consists of a square shaped layer adjustable jig (LAJ) that allows for control of the layering of bricks or other structural material in straight or spiral column designs. Each layer of brick can be offset or plumb with respect to the previous layer of brick. 
     Alternate embodiments of the present invention allow for rectangular shaped, round shaped, hexagonal, octagonal or curved shaped layer adjustable jigs for various brick layering designs. Each shape can be built in a straight-up column or can be built with a spiral shape as the column progresses upward. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The apparatus of the present invention consists of a layer adjustable jig (LAJ) that allows for control of the layering of bricks or other structural material in a straight or spiral column designs. Each layer can be offset or plumb with the previous layer. Thus a column could be constructed with various designs, including but not limited to: 
     1. Square or rectangular; 
     2. Spiraled with each level being square or rectangular; 
     3. Hexagonal or octagonal with each level plumb to the previous level; 
     4. Hexagonal or octagonal with each layer offset by 9° or multiple of 9° from layer to layer. 
     Construction of the column would consist of the following basic steps: 
     A. Construction of a base footer and placing a center post in a fixed position in the base footer of the column to be constructed, the center post could be either round or rectangular in shape and extend the height of the column; 
     B. Plumbing the center post vertically and horizontally in its fixed position; 
     C. Attaching the LAJ to the center post above the layer to be placed; 
     D. Laying a level of mortar in the base position of the column such that the front base edges are parallel to a street or reference wall; 
     E. Placing the “first” layer of brick lightly on the mortar with ends mortared and then using the LAJ as a position guide for rough (eyeball) brick placement; 
     F. Lowering the LAJ onto the mortared bricks for establishing a final alignment; 
     G. Moving the LAJ upward, locking it in place, and then rotating the LAJ to the desired angle using the index wheel of the LAJ for the “next” layer of brick with respect to the “last” layer of brick; 
     H. Placing a layer of mortar over the top of the “last” layer of brick; 
     I. Laying the “next” layer of mortar then brick using the preset LAJ as a brick-positioning guide; 
     J. Proceeding as per step “G” through “I” above for subsequent layers of brick up to the last 2-4 layers; 
     K. Removing the LAJ prior to the last 2-4 layers, which would be completed manually. 
     The construction would begin with a center post placed within the column area to be constructed. The center post (round or square) would be placed in a permanent position and leveled in both vertical and horizontal dimensions. The LAJ would attach/detach to the center post by means of a post guide. A locking center post cam would hold the LAJ in place vertically and a center post guide would hold the LAJ in place horizontally. The center post guide would be constructed to have an opening, which would allow it to mount around the center post. In the cases where there would be no obstacles above the column to be built an alternate means of construction would entail using a removable shaft over a smaller center post. For example, a two inch (square or round) diameter base center post of length 6″-36″ or so, would be mounted in the base. Then a slide-over post with an inside dimensions slightly larger than the base center post would slide over the base center post. The LAJ would then mount on the slide-over post to be used during construction and would then remove from the column top after completion of the column. 
     Center posts can be of variable sizes but the most economic manufacture of the LAJ would be to use center posts within a specific range such that the LAJ would have a standard manufacturing size with regard to the area that attaches to the center post. 
     The LAJ would provide for control of several aspects when moving from one layer of the column to the next. The LAJ would control: 
     A. The rotational angle within a 360° spiral. 
     B. Dimension control of each layer with respect to the center post. 
     C. Dimensional control within of each layer with respect to the layer dimensions (bricks and mortar) itself. 
     D. Ability to adjust (or not adjust) each subsequent layer by a multiple of about 9° or an angle that would divide equally into 180°. 
     The LAJ is constructed to have an index wheel circumferentially attached to its post guide. The index wheel would have index holes. For example, index holes positioned about every 9° would provide for 40 layers of brick (tiers) per 360° spiral within a column. If layers were incremented every 6°, there would be 30 layers per 180° rotation. Thus, the number of layers per complete rotation can be controlled as well as the angle of rotation from one layer of brick to the next. 
     The LAJ is designed to provide for control of overall dimensions per layer with respect to the bricks and the mortar used. Both the inner and outer frame members of the LAJ have adjustable mating points to accommodate various size bricks. The adjustment, once made, will keep a constant distance between the bricks and the center post, between the outside dimensions of the layer, mortar spacing, etc. 
     The LAJ employs a design that is easy to manufacture and low in cost. The LAJ is simple to use, readily attachable/detachable to the preset center post, easily moved upward or downward on the center place, and locks in place to the center post via a simple locking cam. The design of the LAJ provides for timesaving in construction of a spiraled column without the need of a highly skilled mason. 
     The LAJ can provide for ease of construction of various type columns. Each layer can be square, rectangular, hexagonal, octagonal, etc. Each subsequent layer within the column can be spiraled at a controlled angle with respect to the previous column. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a top view of the LAJ, the preferred embodiment of the present invention, attached to a center post and in a 9° rotational position with respect to a layer of brick. 
     FIG. 2 is a side view of the LAJ. 
     FIG. 3 is a front perspective view of the center post. 
     FIG. 4 is an exploded front perspective view of the LAJ, center post, and a layer of brick. 
     FIG. 5 is a front perspective view of the LAJ positioned over a layer of bricks. 
     FIG. 6 is a front perspective view of the LAJ placed in a rotational position respect to a subsequent layer of brick. It is ready to be used as a visual guide to roughly position the next row of bricks. 
     FIG. 7 is a perspective view of a portion of a completed spiral column. 
     FIG. 8 is a top view of an adjustable LAJ, an alternate embodiment of the present invention, positioned over a layer of bricks. 
     FIG. 9 is a front perspective view of the LAJ attached to a round center post. 
     FIG. 10 is a top view of a round shaped layer position jig, yet another alternate embodiment of the present invention. 
     FIG. 11 is a top view of a curve shaped layer position jig, yet another alternate embodiment of the present invention. 
     FIG. 12 is a side view of the curve shaped layer position jig of FIG. 11, an alternate embodiment of the present invention. 
     FIG. 13 is a flow chart of the basic process to be followed in use of the LAJ or alternate embodiments of the present invention. 
    
    
     Before explaining the disclosed embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown, since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation. 
     DETAILED DESCRIPTION OF DRAWINGS 
     FIG. 1 is a top view of the LAJ  100 , the preferred embodiment of the present invention, attached to center post  10  and with a 9° rotational position A depicted with respect to a layer of bricks  18 . LAJ  100  can rotate about the layer of bricks  18  in axis R. LAJ  100  is attached to center post  10  by post guide  11  which is held in place by cam  20  when locking cam handle  12  is rotated in an horizontal position. Cam  20  is shown in the locked (horizontal) attached to post guide  11  by cam-to-post guide locking pin  15 . When cam  20  is in the unlocked (locking cam handle  20  vertical) position, LAJ  100  can be moved upward or downward along center post  10 . Index wheel  13  is rigidly attached to guide post  11  and contains index holes  14 , which are typically offset by 9° angle A. LAJ frame  17  is rigidly attached to frame plate  21 . Index wheel  13  allows frame plate  21 , and thus LAJ frame  17 , to rotate within the three frame-to-index wheel guide and supports  22  which also function to support LAJ frame  17 , allowing support LAJ frame  17  to hang from index wheel  13 . Index wheel to frame plate locking pin  16  is inserted into one of index holes  14  and through one hole in frame plate  21  (not visible) to lock frame plate  21  to index wheel  13 . Frame plate  21  (and thus LAJ frame  17 ) can thus rotate about index wheel  13  (and thus center post  10 ) in 9° A increments by lifting frame plate locking pin  16 , rotating LAJ frame  17  to the desired rotational position and resetting frame plate locking pin  16 . FIG. 1 shows (dotted lines) LAJ frame  17  rotated to a new rotational position  19 . It should be noted that although index wheel  13  is depicted with 9° increments, it is relatively simple to adjust the design parameters to other incremental angles by changing the position of the wheel index holes. 
     FIG. 2 is a side view of LAJ  100  in position placed above layer of bricks  18 . Shown is the frame-to-index wheel guide and support  22  that holds index wheel  13  in place allowing rotation of LAJ frame  17 . Also shown is cam-to-post guide locking pin  15  that attaches cam  20  to post guide  11 . It should be noted that although the frame-to-index guide and support  22  is depicted as a C-shaped slot design in three locations, it is relatively simple to change the design to various length slots or other design while maintaining its relative function to contain index wheel  13  when LAJ frame  17  is in one of various rotational positions with respect to post guide  11 . 
     FIG. 3 is a front perspective view of the center post  10  rigidly attached to base post footer  23 . As previously discussed, center post  10  would be set into base post footer  23  in a plumbed position, that is, leveled in a vertical and horizontal position and would have the length required for the column construction. 
     FIG. 4 is an exploded front perspective view of LAJ  100 , center post  10 , and a layer of bricks  18 . Frame plate  21  is rigidly mounted to LAJ frame  17 . LAJ frame  17  contains three frame-to-index wheel guide and supports  22  and three frame plate locating holes  27 . Frame-to-index wheel guide and supports  22  serve to enclose index wheel  13 , which is rigidly attached to post guide  11 , allowing frame plate  21  (and thus LAJ frame  17 ) to rotate about post guide  11  (and thus rotate about center post  10 ). Index wheel to frame plate locking pin  16  holds the assembly from rotation when in place. Cam to post guide locking pin  15 , when removed, allows cam  20  to be removed, thereby providing an opening allowing LAJ  100  to be removed from center post  10 . It should be noted that although only one index wheel to frame plate locking pin  16  is shown, two others could be used for securing index wheel  13  to frame plate  21  within frame plate locating holes  27 . 
     FIG. 5 is a front perspective view of LAJ  100  positioned over layer of bricks  18 . Locking cam handle  12  is shown in the vertical position (unlocked) and, as such, LAJ  100  can be moved in a direction upward on center post  10  (see FIG.  6 ). 
     FIG. 6 is a front perspective view of LAJ  100  placed in a rotational position with respect to a subsequent layer of bricks  18 . Layer of bricks  18  is shown with inter-brick mortar  25  and top mortar layer  24 . LAJ  100  is shown in a raised position over layer of bricks  18  with LAJ frame  17  rotated in a counterclockwise position along rotational axis R. Rotation is achieved by lifting index wheel to frame plate locking pin  16 , rotation LAJ frame  17  the desired number of increments, then replacing frame plate locking pin  16 . Once LAJ  100  is at the desired height locking cam handle  12  is positioned in the locking (horizontal) position to hold LSJ  100  into place along center post  10 . 
     FIG. 7 is a perspective view of a portion of completed spiral column  200 . Respective rotated brick layers  26  are located at a rotational angle relative to each individual layer of bricks  18 . The angle of rotation is determined as previously described. It should be noted that LAJ  100  could be easily used to build a non-spiraled column by election to only raise LAJ  100  along center post  10  without rotating LAJ frame  17  with respect to center post  10 . 
     FIG. 8 is a top view of layer adjustable and variable jig LAVJ  300 , an alternate embodiment of the present invention, positioned over layer of bricks  18 . In this alternate embodiment, LAJ frame  17  is replaced with an adjustable frame consisting of inner frame members  28  and outer frame members  29 . Inner frame members  28  have adjustment slots  32 . Outer frame members  29  have adjustment slots  31 . Inner frame members  28  are held in place to outer frame members  29  by slot locking pins  30 . This alternate embodiment of the present invention allows for an adjustable frame to accommodate various size brick dimensions that effect the length and with of the outer body with respect to location from center post  10 . Construction is otherwise similar to LAJ  100  previously described. 
     FIG. 9 is a front perspective view of an alternate embodiment LAJ  1000  attached around center post  33 . Locking cam handle  12  is shown in a horizontal (locking) position to secure cam  20  to round center post  33 . An equivalent lock would be a simple bolt and turning handle. This simplified embodiment has a U-shaped center post guide  1001  which may have angle markings  1002  to locate the offset of each layer of brick when spiraling. The entire frame  1013  rotates with the guide  1001  for use the same as the preferred embodiment of FIG.  1 . This is a less expensive device to build. A square post could be accommodated by adjusting a cross-bolt  1005  to lock the U-shaped guide  1001  around the corners of a square post. 
     FIG. 10 is a top view of a round shaped layer position jig  400 , an alternate embodiment of the present invention. Round frame  40  is the only basic difference between round shaped layer position jig  400  and LAJ  100 . Frame plate  21  is rigidly attached to round frame  40 . Frame plate  21 , cam  20 , locking cam handle  12 , post guide  11 , etc. are all the same as previously described. Thus the detachable parts, round frame  40  and frame plate  21  are interchangeable with and can be readily removed and replaced with a square or rectangular frame assembly as previously described. Shown are pre-cut bricks  41  which could be assembled in an octagonal layer. Brick edge location guides  42  are positioned to align each brick around the periphery of round frame  40 . Each octagonal layer could be offset from each subsequent octagonal layer by rotation of round frame  40  with respect to angle markings (not shown) in the same manner as previously described in FIG. 9 above. Thus round shaped layer position jig  400  can be used to build a straight up octagonal layered column or can be used to build a spiraled octagonal layered column. It should be noted that although a octagonal layer is depicted in the drawing of FIG. 10, other shaped, such as hexagonal, can readily be constructed depending on the size and pre-cut dimensions of the bricks to be used. Also, as previously described FIG. 9 above, a square post could be accommodated by adjusting a cross-bolt to lock the U-shaped guide  1001  around the corners of a square post. 
     FIG. 11 is a top view of curve shaped layer position jig  500 , yet another alternate embodiment of the present invention. Curve shaped layer position jig  500  is a design for construction of a curve shaped structure using the same basic concept in moving the form up center post  10  as previously described. The curvilinear shape of curve guide jig  50  determines the basic curve of curve brick wall  55  to be constructed. Depending on the size of flanged curve guide jig  50 , there would be at least two points of connection to post guides  53 . Flanged curve guide jig  50  is rigidly attached to curve guide post attach arm  51 , which in turn, is rigidly attached to modified post guide  53 . Cam  20  and locking cam handle  12  are used to move flanged curve guide jig  50  up center post  10  (as previously described) as curved brick wall  55  is constructed. Center post base plates  54  are attached to a footer via assembly  52  (nuts and bolts). It should be noted that the post guide  53  could be constructed such that locking cam handle  12  would be accessible on any side other than that shown. 
     FIG. 12 is a side view of curve shaped layer position jig  500  (see FIG.  11 ), an alternate embodiment of the present invention. In this view, modified post guide  53  is shown attached to center post  10  in a position with curved brick wall  55  having three tiers. Center post  10  is seated within center post base plate  54 . As stated previously, it should be noted that post guide  53  could be constructed such that locking cam handle  12  would be accessible on any side other than that shown. 
     FIG. 13 is a flow chart of the basic process to be followed in use of the LAJ or alternate embodiments of the present invention. 
     In FIG. 13, the following steps of the process are described as: 
     Step  1300 —Construct the base footer and placing a center post in a fixed position in the base footer of the column to be constructed. 
      Note: The center post could be either round or rectangular in shape and extend the height of the column; 
     Step  1301 —Plumb center post vertically and horizontally within base footer; 
      Note: Post should be hardened into place before proceeding, for example, the concrete should be hard. 
     Step  1302 —Attach LAJ to the center post above layer to be placed; 
      Note: Allow room to lightly place bricks below the LAJ position. 
     Step  1303 —Layer a level of mortar in the base position of the column; 
      Note: The front base edges should be parallel to a street or reference wall. 
     Step  1304 —Place a layer of brick lightly on the mortar and add mortar between the bricks using the LAJ as a rough guide; 
      Note: Final brick placement will be per LAJ setup. 
     Step  1305 —Lower the LAJ back down for final brick alignment. 
     Step  1306 —Raise, lock, and rotate the LAJ to the desired angle using the index wheel of the LAJ for the “next” layer of brick laid; 
      Note: The LAJ should be in the proper position with respect to the “last” layer of brick. 
     Step  1307 —Mortar over the top of the “last” layer of brick; 
     Step  1308 —Lay the “next” layer of brick using the preset LAJ as a brick-positioning guide; 
     Step  1309 —If not within the last 2-4 layers to be placed, proceed to step  1305 , else continue to step  1310 . 
      Note: Depending on the overhead clearance, the LAJ should be left on for as many brick tiers as possible. 
     Step  1310 —Remove LAJ prior to the last 2-4 layers which would be completed manually. 
      Note: Again, the LAJ should be left on for as many brick tiers as possible. 
     Once the column is completed, the LAJ can be used over and over for subsequent columns. 
     Although the present invention has been described with reference to preferred embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred.