Patent Abstract:
A tile inset device for securely and removably attaching two or more masonry products, such as concrete blocks, bricks and the like, to one another without the use or mortar, adhesives or the like. In a preferred embodiment, both the top and bottom portions of the device comprise two or more spaced apart inserts for insertion into an opening in a masonry product. The tile insert devices permit the associated masonry products to be repeatedly reused without causing damage thereto, and permit a builder to modify a partially constructed structure without incurring significant time or financial hardship. The tile insert devices are particularly useful in constructing temporary, non-dwelling, structures, but can also be used in the construction of permanent structures.

Full Description:
CROSS-REFERENCE 
       [0001]    This application claims priority from Provisional Patent Application Ser. No. 61/600,068 filed on Feb. 17, 2012. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to a masonry tile insert that enables a user to construct a temporary masonry structure, such as a brick wall, fire-pit, barbeque, etc., without permanently mortaring the bricks or blocks together. Because the bricks or blocks are not permanently affixed to one another, the structure can later be deconstructed and the bricks or blocks can be re-used for other purposes. The tile insert device is relatively easy to install and use, inexpensive to manufacture and can be used in conjunction with a variety of masonry products. 
       BACKGROUND 
       [0003]    Many non-dwelling structures, such as walls, mailboxes, fire pits, barbeques, etc., are constructed of masonry products, such as concrete blocks, bricks and the like, due to the durability and aesthetically pleasing appearance of said products. Traditionally when building with masonry products, the blocks and/or bricks are affixed to one another with mortar, which creates a permanent bond between the various blocks and/or bricks. However, if the resulting structure is no longer needed or desired, it is typically not possible to deconstruct the structure in a manner that would permit the blocks or bricks to be reused in the same fashion. This is true because it is typically not possible to remove or separate the various mortared bricks or blocks without damaging the same or incurring significant expense. Consequently, structures that are no longer needed or desired are typically demolished and the ruble, consisting or broken bricks, block and mortar, is either discarded or used as excavating fill. 
         [0004]    Further, masonry products such as concrete blocks and bricks can be relatively expensive to purchase, and typically require the services of a skilled mason to install, which further increases the cost of using said materials in the building process. Therefore, individuals desiring to construct a temporary structure may forgo masonry products because of their expense, permanency and the forgoing problems associated with dismantling the same, even though the user may prefer the appearance of masonry. 
         [0005]    Another problem associated with the use of permanently affixed masonry products occurs if an individual makes a mistake during the construction process or desires to change the design of the partially completed structure. More specifically, once the masonry products are permanently affixed to one another with mortar, it is typically not possible to undo or change what has already been constructed without incurring significant time and expense. Currently, there is no device or method for securely and removably attaching masonry products to one another without permanently mortaring the same. Additionally, there is also no current device or method for recycling used masonry products in the same manner as their initial use, e.g., in a wall, mailbox, fire pit, barbeque or other aesthetically pleasing structure. 
         [0006]    Consequently, there exists in the art a long-felt need for a tile inert device that can be used to securely and removably attach masonry products to one another without permanently affixing the same. There also exists in the art a long felt need for a tile insert device that permits the associated masonry products to be repeatedly reused and/or recycled without causing damage thereto. Moreover, there is a long felt need for a tile insert device that permits a builder to modify and or change the design of a masonry structure, or correct a construction mistake, during the construction process and without incurring significant time or financial hardship. Finally, there is a long-felt need for a tile insert device that accomplishes all of the forgoing objectives and that is relatively inexpensive to manufacture, aesthetically pleasing, and safe and easy to use. 
       SUMMARY 
       [0007]    The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later. 
         [0008]    The subject matter disclosed and claimed herein, in one aspect thereof, is a masonry tile insert device useful for securely and removably attaching masonry products to one another without permanently mortaring the same together. Each of said tile insert devices is preferably comprised of a base with a top surface and a bottom surface; a first insert positioned along said top surface for insertion into an opening in a first masonry product and a second insert positioned along said top surface for insertion into an opening in a second masonry product; and a third insert positioned along said bottom surface for insertion into an opening in a third masonry product and a fourth insert positioned along said bottom surface for insertion into an opening in a fourth masonry product. In a preferred embodiment of the present invention, the tile insert devices could be ornamentally designed to give the appearance of a typical mortar joint. 
         [0009]    The masonry tile inserts of the present invention allow a builder to securely and removably attach various masonry products to one another without permanently mortaring the same together, thereby enabling the builder to change or modify the design of the structure being constructed during the construction process at minimal time and expense. Additionally, when the structure is no longer needed and/or desired, the tile insert devices of the present invention enable the builder to dismantle the structure without damaging the masonry products previously used to build the structure. By preserving the integrity and aesthetics of the original masonry products and the devices, the builder will be able to utilize the same in subsequent projects and therefore realize significant cost savings. Finally, the tile insert devices of the present invention accomplish all of the forgoing objectives and are relatively inexpensive to manufacture, aesthetically pleasing, and safe and easy to use. 
         [0010]    To the accomplishment of the foregoing and related ends, certain illustrative aspects of the disclosed innovation are described herein in connection with the following description and the annexed drawings. These aspects are indicative, however, of but a few of the various ways in which the principles disclosed herein can be employed and is intended to include all such aspects and their equivalents. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  illustrates a perspective view of a preferred embodiment of the tile insert device of the present invention. 
           [0012]      FIG. 2  illustrates a perspective view of the tile insert device depicted in  FIG. 1  about to be installed on a pair of side by side masonry bricks. 
           [0013]      FIG. 3  illustrates a perspective view of a partially constructed structure comprised of a plurality of masonry bricks removably and securely attached to one another via a plurality of tile insert devices. 
           [0014]      FIG. 4  illustrates a perspective view of an alternative embodiment of the tile insert device of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0015]    The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. 
         [0016]    Referring initially to the drawings,  FIG. 1  illustrates a perspective view of a preferred embodiment of a tile insert device  100  of the present invention, which is useful in creating a temporary interlocking or interconnecting masonry structure. Device  100  is preferably comprised of a base  110  and more than one insert  140  extending outwardly from said base  110 . Unless otherwise stated, device  100  and its various components are preferably comprised of plastic, though it is contemplated that other suitable materials such as fiberglass, concrete, cement, wood, metal, etc. could also be used provided that the same is generally weather resistant. Base  110  and inserts  140  may be integrally formed, or one or more of inserts  140  may be attached to base  110  by any common means known in the art depending upon the type of materials used. For example, if base  110  and inserts  140  are constructed of plastic or fiberglass, insert  140  may be glued to base  110 . 
         [0017]    As illustrated in  FIG. 1 , base  110  is preferably an elongated, plate-like structure comprised of a top  112 , a bottom  116 , a front surface  120 , a back surface (not shown) and sides  128 . In a preferred embodiment of the present invention, the overall length and width of base  110  should be approximately the same as the length and width of the masonry block or brick with which it is being used. For example, a device  100  for use with a standard concrete masonry block may comprise a base  110  that is approximately 15½ to 16 inches in length, as measured between sides  128 , and may have a width of approximately 7½ to 8 inches, as measured between front surface  120  and back surface. By comparison, a device  100  for use with a standard sized masonry brick may comprise a base  110  that is approximately 9 to 10 inches in length, as measured between sides  128 , and may have a width of approximately 3½ to 4¼ inches, as measured between front surface  120  and back surface. Of course, it is contemplated that other size bases  110  could also be used to suit user preference or a particular application. 
         [0018]    The overall thickness of base  110  is preferably equal to that of a standard mortar joint and may be approximately ¼ to ⅝ inches, as measured from top  112  to bottom  116 . In a preferred embodiment of the present invention, front surface  120  and back surface (not shown) will also have the general appearance of a standard mortar joint so as to give the appearance that the various masonry products (i.e., blocks and/or bricks) were permanently mortared together. 
         [0019]    Each of inserts  140  are preferably block like structures that extend outwardly from top  112  and/or bottom  116 , and are comprised of an outward facing surface  144  and sides  148 . In the preferred embodiment of device  100  depicted in  FIG. 1 , two inserts  140  are located in spaced apart relationship along top  112  and two additional inserts  140  are located in spaced apart relationship along bottom  116 . Notwithstanding the forgoing, it is also contemplated that device  100  could be comprised of a single insert  140  on each of the top  112  and bottom  116 , or a single insert  140  along the top  112  and two inserts  140  along the bottom  116 , or vice versa. As described more fully below, this alternative embodiment of device  100  is particularly useful for producing the appearance of staggered masonry products and mortar joints. 
         [0020]    It is also contemplated that more than two inserts  140  could be positioned in spaced apart relationship along top  112  and/or bottom  116 , or that insert(s)  140  could be positioned along the bottom  116  but not the top  112  (or vice versa). This type of device  100  is particularly useful along the top row of a structure to not only removably connect the two blocks  220  immediately below device  100  but to also provide a relatively flat cap to the structure being constructed. 
         [0021]    In order to reduce the overall weight and cost of device  100 , and to make the same easier to handle during the installation and/or de-installation process, one or more of inserts  140  may further comprise an opening  150  in outwardly facing surfaces  144 , such as a continuous opening, therein. Openings  150  are also useful for receiving mortar or concrete if, at some point in the future, a user (not shown) decides to make the structure permanent, and desires to core the same with concrete or mortar to add strength to the overall structure. 
         [0022]    Because inserts  140  are inserted into openings  208  formed in a masonry product  200  such as a brick or concrete block, the overall size, shape and spacing of inserts  140  along top  112  and/or bottom  116  should correspond to the particular type of masonry product  200  that device  100  is being used with, as well as the size, shape and spacing of the openings  208  therein.  FIG. 2  illustrates a device  100  about to be installed onto a pair of masonry blocks/bricks  200  positioned immediately adjacent to one another. Masonry blocks and bricks are well known in the art, and each of the masonry blocks  200  depicted in  FIG. 2  is comprised of a top surface  204 , a front surface  210 , a back surface (not shown), and sides  214 . During the construction process, one of the inserts  140  positioned along the bottom  116  of base  110  is inserted into opening  208  of the first block  200  and the remaining insert  140  positioned along the bottom  116  of base  110  is inserted into opening  208  of the second block  200 , such that device  100  straddles the intersection of the two blocks  200  and interlocks the same. In a similar fashion, additional blocks  200  can now be placed on top of the inserts  140  located along top  112  so that inserts  140  fit within openings  208  to create an interlocking structure. 
         [0023]      FIG. 3  illustrates a perspective view of a partially constructed structure comprised of a plurality of masonry bricks  200  removably and securely attached to one another via a plurality of tile insert devices  100 . More specifically, each of the devices  100  depicted in  FIG. 3  are comprised of a base  110  with a top surface  112  and a bottom surface  116 . Two inserts  140  are positioned along the top surface  112  of said base  110  in spaced apart relationship for insertion into corresponding openings  208  in two adjacent bricks  200  positioned above said base  110 , and two inserts  140  are positioned along the bottom surface  116  in spaced apart relationship for insertion into corresponding openings  208  in two adjacent bricks  200  positioned below said base  110 . In this manner, the various bricks  200  and tile insert devices  100  can be removably interlocked together to create a structure without the need for mortar or other more permanent adhesive materials. Further, as previously stated, the front surfaces  120  and back surfaces (not shown) of base  110  may further comprise ornamentation to give the general appearance of a standard mortar joint, which is both aesthetically pleasing and implies that the structure has been permanently constructed. 
         [0024]      FIG. 4  illustrates a perspective view of an alternative embodiment of the tile insert device  100  of the present invention, which is further comprised of at least one panel  124  that extends outwardly from top  112  and/or bottom  116  of base  100  and serves as a vertical spacer between the various masonry blocks  200  being used to build the structure (in place of the otherwise present mortar joint in a permanent structure). Panel  124  may further comprise a front surface  126  and back surface (not shown), each of which may also have the general appearance of a standard mortar joint so as to give the appearance that the various masonry products (i.e., blocks and/or bricks) were permanently mortared together. It is worth noting that the device  100  depicted in  FIG. 4  is but one example of how panels  124  can be positioned along base  110 , and that numerous other configurations are contemplated and possible to suit user need and/or preference. 
         [0025]    Having now described the overall structure of tile insert device  100 , its use and usefulness will now be summarized. A user (not shown) desiring to construct a temporary masonry structure, such as a brick or block wall, fire-pit, barbeque, etc., without permanently mortaring the bricks or blocks together could place two blocks  200  adjacent to one another as shown in  FIG. 2 , and removably connect said blocks  200  with device  100 . More specifically, the user (not shown) would place device  100  over blocks  200  such that one of the inserts  140  positioned along the bottom  116  of base  110  is inserted into opening  208  of the first block  200 , and the remaining insert  140  positioned along the bottom  116  of base  110  is inserted into opening  208  of the second block  200  so that device  100  straddles the intersection of the two blocks and removably interconnects the same. 
         [0026]    In a similar fashion, additional blocks  200  can now be placed adjacent to the two interconnected blocks and interlocked therewith with additional devices  100  to increase the overall length of the structure. Additionally, to increase the overall height of the structure, additional blocks  200  can be placed on top of the inserts  140  located along top  112  so that inserts  140  fit within openings  208  to create an interlocking structure, as is shown in  FIG. 3 . Additional devices  100  can then be placed on top of the second row of blocks  200 , and so on and so forth until the desired structure is complete. Moreover, as previously mentioned, the front surface  120  of base  110  and/or the front surface of panels  124  may further comprise ornamentation or texture that gives the general appearance of a standard mortar joint. 
         [0027]    As an important aspect of the present invention, because the various blocks/bricks  200  and devices  100  are not permanently affixed to one another, a user (not shown) can easily disassemble the structure by removing each layer of blocks and devices when the structure is no longer needed or desired, and the various blocks/bricks  200  and devices  100  can be reused. 
         [0028]    Consequently, the tile insert devices  100  of the present invention allow a builder to securely and removably attach various masonry products, such as concrete blocks, bricks and the like, to one another without having to permanently mortar the same. Because a builder can also relatively easily dismantle a masonry structure constructed with the tile insert devices  100  of the present invention, the builder can change or modify the design of the structure during the construction process at minimal time and expense. Additionally, when the structure is no longer needed and/or desired, the tile insert devices  100  of the present invention further enable the builder to dismantle the structure without damaging the masonry products previously used to build the structure and reuse the same in subsequent projects, therefore resulting in significant time and cost savings. The tile insert devices  100  may also be reused. Finally, the tile insert devices  100  of the present invention accomplish all of the forgoing objectives and are relatively inexpensive to manufacture, aesthetically pleasing, and safe and easy to use. 
         [0029]    Other variations are within the spirit of the present invention. Thus, while the invention is susceptible to various modifications and alternative constructions, a certain illustrated embodiment thereof is shown in the drawings and has been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims. 
         [0030]    The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
         [0031]    Preferred embodiments of this invention are described herein. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventor intends for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

Technology Classification (CPC): 4