Patent Publication Number: US-2009223158-A1

Title: Sculpture brick

Description:
FIELD OF THE INVENTION 
     The present Invention relates to simulated brick walls. More specifically, the present invention relates to a method for making a wall panel or surround which appears to be made of brick but is comprised of mortar and cart be made in situ. 
     BACKGROUND OF THE INVENTION 
     It is known to make simulated masonry walls by first coating a base pane structure with a base coat to simulate mortar and then coating the base coat with a finish coat layer. For example, U.S. Pat. No. 3,819,396 Jun. 25, 1974 to Yocum discloses a simulated masonry wall and a process for its making wherein simulated mortar joints are provided by simultaneously cutting each of several sets of grooves extending to, into or through the base layer with a plurality of knife members having their knife edges guided above the surface of the base panel structure. The Yocum patent also suggests that previously known processes for making simulated masonry panels were provided by cutting each groove individually by hand, grooves in each set being cut sequentially. 
     There remains a need, however, for an improved method for making a simulated brick, wall using a technique which allows for a variety of designs and which can be carried out by unskilled as well as skilled workers. There also remains a need for a straightforward process which can be carried out to make a simulated brick wall in less time than a brick veneer wall and at less cost. There also remains a need for an improved process for making a simulated brick wall which allows the artisan to control the size, shape, color, and design of every brick in the wall. And there remains a need for an improved method for making a simulated brick wall which method does not require structural modifications to existing walls or footings. 
     Accordingly, the present invention provides an improved method, for making a simulated brick wall which method is straightforward, easily carried out, requires no structural modifications of existing walls and allows a great deal of flexibility or control of size, shape, color and design. Further understanding of these and other advantages of the present invention will be had from the following disclosure taken in conjunction with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an elevational view of a preferred embodiment of a sculpture brick panel of the present invention illustrated as a window surround; 
         FIG. 2  is a sectional view, broken away, taken along line  2 - 2  in  FIG. 1 ; 
         FIG. 3  is a perspective view, broken away, illustrating a step of the method of the present invention; 
         FIG. 4  is a perspective view, broken away, illustrating another step of the method of the present invention; 
         FIG. 5  is a perspective view, broken away, illustrating a further step of the method of the present invention: 
         FIG. 6  is a side elevation showing a preferred embodiment of a tool of the present invention for use in carrying out the method of the invention; 
         FIG. 7  is a plan view of the tool of  FIG. 6 ; 
         FIG. 8  is an elevational view, broken away, of an alternative preferred embodiment of a sculpture brick panel of the present invention illustrating simulation of antique brick; and 
         FIG. 9  is an plan view of an alternative embodiment of a tool of the present invention. 
     
    
    
     SUMMARY OF THE INVENTION 
     A method for making a panel which simulates the appearance of brick, comprises the steps of:
         (A) providing a base panel;   (B) applying a first layer of mortar having a first color on a surface of the base panel, said first color being selected to simulate mortar;   (C) applying a second layer of mortar having a second color over said first layer of mortar, said second color being selected to simulate brick; and   (D) selectively cutting grooves in said second layer to a depth sufficient to expose said first layer.       

     One embodiment of the present invention comprises a sculpture brick panel having the above-mentioned first and second layers of mortar and wherein the second layer has linear grooves therein simulating brick mortar lines and further has irregular grooves cut partially therein to simulate cracks in bricks. The present invention further comprises a tool for creating the cracks and/or grooves in the second layer of mortar. 
     DETAILED DESCRIPTION OF THE INVENTION  
     The present invention involves a method of making a panel which simulates a panel, made of brick or a panel having a brick veneer thereon. The present invention involves use of a first mortar having a color simulating mortar and a second mortar having a color simulating brick. Generally speaking, the method of this invention comprises the steps of first providing a base panel or other surface structure to which a layer of mortar can be applied, applying a first coating of the first mortar on the panel, applying a second coating of the second mortar over the first mortar, and then cutting grooves through the second coating of mortar to expose the first coating of mortar to thereby simulate mortar lines. 
     The base panel can be a masonry board such as Dura-Rock or Hardi-board nailed or otherwise secured to studs or other wall support, structure. Of course, any panel or structure having a surface suitable to support, a layer of mortar may be used in the present invention. For example, the base panel can be a cement block wall or a poured cement wall or the like. 
     The first mortar can be any conventional mortar material, for example, type S mortar, and can be gray or any color desired by the artisan to simulate mortar. Suitable mortar materials are well known in the art. 
     The second mortar also can be any conventional mortar material and can be red or any color desired by the artisan to simulate brick. The mortar material can be the same as that used as the first mortar material except is of a color to simulate brick. 
     Now referring to  FIG. 1 , a preferred embodiment of a sculpture brick panel of the present invention is shown and indicated generally by the numeral  10 . Sculpture brick panel  10  has a plurality of simulated bricks  12  which are separated by simulated mortar lines  14 . As illustrated in  FIG. 1 , sculptured brick panel  10  is shown as a window surround for window  16 . Sculpture brick panel  10  is illustrated with two vertically extending side sections  18  and  20  and an arched section  22 . Arched section  22  comprises a plurality of simulated bricks  24  which appear to have been cut in a manner to form a key stone structure. 
     As best shown in  FIG. 2 , sculpture brick panel  10  is provided on conventional 2×4 studs  28  and comprises a base panel  26  of masonry board attached to studs  28 , first mortar layer  30  and second mortar layer  32 , Grooves  34  are cut through second mortar layer  32  and preferably into first layer  30  as illustrated in  FIG. 2  so that one viewing sculpture brick panel  10  from the left in  FIG. 2  will see first mortar layer  30  through grooves  34 . The appearance of sculpture brick panel  10  is thus that of a panel of bricks with mortar between the bricks. 
     Now referring to  FIGS. 3 to 5 , the method of the present invention will be described. The initial step of the present invention involves provision of a panel suitable as a base panel for the first layer of mortar. Thus, as is illustrated in the embodiment shown in  FIG. 3 , an initial step of the present invention is to apply base panel  26  of masonry board to studs  28  (only one stud  28  being shown in the Figure). The masonry board may be any suitable base panel such as ¼″ Dura-Rock masonry board. The next step of the present invention is to apply first mortar layer  30  over panel  26  as is illustrated in  FIG. 4 . Layer  30  is preferably chosen to have a color suitable for mortar such as gray and can be any suitable thickness such as ¼″ thickness. Mortar layer  30  can be allowed to set or dry before second mortar layer  32  is applied over it in the next step. Thus, as illustrated in  FIG. 5 , second mortar layer  32  is applied over first mortar layer  30 . Second mortar layer  32  may be applied over first mortar layer  30  before or after first mortar layer  30  has hardened. Second mortar layer  32  should be selected to have the color of brick it is desired to simulate and can be of any desired thickness for example ¼′ thickness has been found to be suitable. Finally, and preferably before second mortar layer  32  has set up or hardened, grooves are cut through second mortar layer  32  to selectively expose first mortar layer  30  to simulate mortar lines. Generally speaking, it will be preferable to measure and cut the horizontal grooves first and then cut the vertical lines between the horizontal lines to thereby simulate the ends of bricks. 
     It will be appreciated that the present invention can be practiced with hand tools. A plastering trowel for applying mortar and cutting tool for cutting grooves may be all of the tools required for some installations. Of course, a screwdriver or hammer for securing the base panel to a supporting structure, a tape measure for measuring location of the grooves and a circular saw for cutting the base panel may also be used. Also a soft brush for texturing the second mortar layer may be desired to enhance the simulated brick appearance of the second layer. 
     A preferred hand tool of the invention for cutting grooves through mortar layer  32  is illustrated in  FIGS. 6 and 7  and indicated generally by the numeral  40 . Tool  40  has an elongated handle  42  which is sized to fit comfortably in the hand of the user. Handle  42  can be made of polymeric material, wood, metal or any other suitable material and has a slot  44  in a forward end thereof which is adapted to receive a wide blade  46  which can also be made of any suitable material such as metal, for example steel, or a polymeric material. Blade  46  is held in place in handle  42  by fasteners  48  which can be bolts and nuts as shown in  FIG. 7 . The forward face  50  of Blade  46  is of a width to correspond to the desired width of a mortar line in the final sculpture brick panel. Blade  46  has a hollow interior  52  to facilitate removal of mortar material during its use. 
     Now referring to  FIG. 8 , an alternative sculpture brick panel of the present invention is shown and indicated generally by the numeral  100 . Sculpture brick panel  100  has grooves  134  which are analogous to grooves  34  of panel  10  and is generally made in a manner analogous to panel  10  with a first mortar layer  130  and a second mortar layer  132 . Sculpture brick panel  100  also has grooves  101  and  103  in mortar layer  132  to simulate cracks in bricks. Thus grooves  101  are cut to a shallow depth not entirely through layer  132  which grooves  103  are cut to a depth to extend through layer  132  to expose layer  130  to view. One advantage of the method of the present invention is that grooves can be cut into the second mortar layer on a straight line to simulate mortar between bricks or can be cut in an irregular line and to different depths to simulate cracks in the brick such as might be found in antique brick walls. 
     Now referring to  FIG. 9 , an alternative embodiment of a tool for use herein is disclosed and indicated generally by the numeral  200 . Tool  200  is generally analogous to tool  40  but has a blade  202  with a forward width  204  which blade  202  is molded into handle  206  or alternatively blade  202  is made or molded as a one-piece construction of polymeric plastic or metal with handle  206 . 
     While a preferred embodiment of the present invention has been disclosed and illustrated as a window surround, it will be appreciated that the present invention is suitable for use wherever a simulated brick panel is desired and offers a great deal of design flexibility. For example, the present invention can be used to provide a simulated brick panel having brick in a herringbone pattern or any other pattern. It is an advantage of the present invention that such alternative patterns can be made much more easily with the present invention than with conventional brick. Also, the present invention may be used indoors for example to simulate brick on a feature wall or a wainscote in a dining room, or a brick back-splash in a kitchen or a fireplace. The invention may be used outdoors for example to reface a home in brick or cover the foundation block in brick. These and other uses of the present invention are contemplated to be within the scope of this invention which is intended to be limited only by the following claims.