Abstract:
A brick veneer assembly having improved installation capabilities, improved accommodation of brick tolerances, improved moisture control, simple assembly, and lower cost relative to the prior art. A plurality of bricks having a mortised groove providing both a locating advantage and a locking mechanism are provided. An easy to handle support panel provides horizontal rows of shaped receptors, each of which are alternately aligned vertically, and each of which have resilient retainers integrated within the walls of said receptors to engage the brick.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    Not applicable. 
       FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       REFERENCE TO A MICROFICHE APPENDIX 
       [0003]    Not applicable. 
         [0004]    Not applicable. 
       BACKGROUND OF THE INVENTION 
       [0005]    1. Field of the Invention 
         [0006]    The present invention generally relates to an external wall for a building. More specifically, this invention is directed to an improved support panel to secure external wall forming members such as brick, tiles or stones to complete the exterior wall. 
         [0007]    2. Description of the Related Art 
         [0008]    Brick walls have been used for centuries as a premium building material due to their strength, beauty, and durability. Unfortunately, brick walls are typically laid brick-by-brick, which tends to be time consuming, labor intensive, and therefore expensive. Thin brick veneer was developed as a means for achieving the beauty and durability of brick walls without the associated expense. 
         [0009]    Thin brick veneer is produced using a variety of manufacturing methods including thin bed set, thick bed set and prefabrication in cast molds. Thin brick panels can be premanufactured or can be assembled to a wall of a building on-site. Thin brick panels generally include a substratum, such as steel, aluminum, plywood, asphalt-impregnated fiber board, cementitious board, polyurethane, and polystyrene foam board. With the on-site assembly method, the substratum is fastened to the exterior wall of a building and an array of thin bricks are applied to the substratum, typically with an adhesive. 
         [0010]    Then mortar, or grout, is applied between the thin bricks to obtain a permanent brick veneer wall assembly. 
         [0011]    The prior art has suggested a variety of thin brick panel constructions. For example, U.S. Pat. No. 2,924,963 to Taylor et al. teaches a method for attaching a clay veneer brick to preexisting buildings. Taylor et al. disclose a brick unit, a wall clip, and mortar. The brick unit includes a back side, a face section, and longitudinal ribs along the top and bottom. The longitudinal ribs are beveled at a front side at a 45 degree angle. The clip is made from sheet metal and is made to resiliently receive the brick unit. The clip includes a flat upstanding lug and a bent tail lug, both of which have fastener holes punched therethrough. 
         [0012]    Extending perpendicularly from the clip are a plurality of resilient clamping members, each having a downturned lip to resiliently receive a respective longitudinal rib of a respective brick unit. The downturned lip also has an upturned flange, which, when the clip is fitted to the veneer brick, rides against the longitudinal rib of the brick unit, causing the downturned lip to deflect and resiliently retain the brick unit. 
         [0013]    Unfortunately the clip of Taylor et al. is unnecessarily complex with many detailed bends. Moreover, an overabundance of individual clips must be handled and secured to a building just to construct a single wall, which is inefficient, labor intensive, and costly. Finally, great amounts of care and time must be given to the precise positioning of each clip to ensure that each brick is squarely aligned with respect to the other bricks. 
         [0014]    U.S. Pat. No. 2,087,931 to Wallace et al. teaches a means for attaching bricks to a wall such that each brick is individually supported so that its position in the wall is not dependent upon the other bricks. Specifically, Wallace et al. disclose wall sheeting having a plurality of spaced apart strap members secured thereto by nails. A plurality of support clips are riveted to the strap members at regularly spaced intervals. The support clips have extending portions that are bent outwardly to form arms with inwardly bent terminals for engagement with surfaces of the bricks. The natural resiliency of the clip so constructed forces the terminals into engagement with the brick surfaces. The terminals are angularly disposed relative to the adjacent surfaces of the brick such that a sharp edge of the terminals engage the brick thereby materially increasing the tenacity of the holding action. 
         [0015]    The Wallace et al. disclosure relies on a plurality of strap members and a plurality of support clips for applying bricks to a wall. Manufacturing all the components required for the Wallace et al. disclosure and the process of assembling the components to a wall unnecessarily incur additional labor and material cost. Furthermore, Wallace et al. do not teach a means for accommodating oversized and undersized bricks, nor do they teach a means to control retention of water behind the brick. 
         [0016]    U.S. Pat. No. 6,098,363 to Yaguchi teaches a support panel for supporting external wall forming members, or bricks. The bricks are of rectangular parallelepiped shape, meaning they have oppositely parallel surfaces all over. The bricks each have a main surface, a rear surface, side surfaces, and end surfaces. The side surfaces include elongated upper and lower lateral extensions that define flat ledges or minor surfaces that are parallel with the main surface. The support panel includes a flat back plate and is stamped from stainless metal sheet to form parallel rows of C-shaped upper and lower engaging members terminating in respective upper and lower securing fingers. The distance between the upper and lower engaging members is substantially identical to the width of a respective brick. A brick is inserted between the upper and lower engaging members. 
         [0017]    This insertion pushes the upper lateral extension of the brick into a space defined by the upper engaging member and upper securing finger thereby causing the upper engaging member to elastically deform while the lower lateral extension of the brick is urged flat against the back plate of the support panel within the lower engaging member. As a result, the brick is clamped between the upper and lower engaging members and by the bent securing fingers. 
         [0018]    In an alternative embodiment, each brick only has an upper lateral extension and an oppositely disposed flat side surface. Respectively, the support panel includes only rows of upper engaging members and securing fingers. Each upper engaging member has an outer, top surface and an inner bottom surface. As before, the upper lateral extension of each brick is pushed into the space defined by the respective upper engaging members such that the upper lateral extension of the brick engages the inner bottom surface of the respective upper engaging member. Simultaneously, the brick is pushed toward the back plate of the support panel until the flat side surface locates against the top surface of the respective engaging member below. Thus, the brick becomes pinched between the upper engaging member and the top of an upper engaging member from the row of upper engaging members below the brick. 
         [0019]    In both of the Yaguchi embodiments, however, the support panel clamps on oppositely disposed parallel surfaces of the brick. This is detrimental because the size of the bricks varies significantly compared to the stamping tolerances attainable with the support panel. In other words, either one of two undesirable conditions must occur. The bricks must be held to an extremely close width tolerance to accommodate reliable and repeatable snap fit insertion to the support panel. This is extremely costly, if at all possible, on a mass production basis. 
         [0020]    Or, each brick must be oversize with respect to the distance between the rows of engaging members to ensure firm clamping of each brick. Oversize bricks will fit fine in the first row of engaging members, but will start to interfere when they are assembled to adjacent rows of engaging members because the engaging members will be filled with bricks and have no room to deflect. Alternatively, if the bricks are undersize, they will fit loosely within the engaging members thereby leading to problems. When the mortar gets applied, loose bricks will shift due to the slack and hairline cracks in the mortar may result. 
         [0021]    In a similar patent, U.S. Pat. No. 6,990,778 B2 to Passeno teaches a method of attaching brick to a wall whereby a brick with a top tapered edge is engaged in position on a sheet metal support panel by means of resilient L-shaped retainers positioned in horizontal rows. Each retainer is L-shaped in such a way that the main body of the retainer is positioned perpendicular to the panel, and a portion of the retainer is bent downward in an acute angle. The brick is engaged by forcing the tapered edge of the top portion of the brick under the downward directed part of the L-shaped retainer thereby deforming the retainer and causing tension on the brick. Compressing the bottom edge of the brick to the back of the panel forces the brick to rest on the top surface of the lower adjoining retainer and is held into place by the tension created by the upper L-shaped retainer. 
         [0022]    In both the Yaguchi and the Passeno embodiments however, the preferred material for the support panel is a sheet metal. As is easily understood, metal is becoming more and more expensive, relatively heavy, and does not lend itself to easy handling from a construction perspective, with lacerations prevalent among craftsmen who work in metal. Furthermore, an historical concern with thin brick panel assemblies has been the treatment of moisture that gets trapped between the panel assembly and the wall that supports the brick panel assembly. In none of the above mentioned art is this problem addressed. 
         [0023]    From the above, it can be appreciated that thin brick panel assemblies of the prior art are either cumbersome and complicated, don&#39;t cost effectively accommodate typical brick tolerances, require the use of a material not user friendly in the construction, and do not address the issue of moisture control, all of which increase costs to the consumer. Therefore, what is needed is a combination of a thin brick veneer assembly that incorporates novel and simple retaining features in a substratum or support panel and related features in a brick to advance the art of veneer brick assembly. 
       BRIEF SUMMARY OF THE INVENTION 
       [0024]    According to the preferred embodiment of the present invention, there is provided a brick veneer assembly adapted for mounting to a wall of a building structure. The method and apparatus for making a brick veneer wall facing includes thin bricks, a support panel and mortar. 
         [0025]    The thin bricks are generally rectangular and each brick, as viewed when assembled on a wall, has a front surface, a back surface, a top surface, a bottom surface, and opposed side surfaces. It is an important feature of the present invention that the top and bottom of the brick, when viewed from the front surface, mortised with groove, which include the top and bottom sides. The preferred embodiment of the present invention will be described hereinafter as having a mortised groove, said groove mortised into the top and bottom edge of the brick when viewed from the front surface. 
         [0026]    The width of each thin brick is defined between the opposed side surfaces, the height is defiled between top and bottom surfaces, and the thickness or depth is defined between the back and front surfaces. Most manufacturing processes known in the art for producing the thin bricks introduce variation such that some bricks are oversized and some are undersized. Manufacturing variation thereby defines a maximum width, height and depth, and a minimum width, height and depth. 
         [0027]    The support panel is preferably composed of a plastic composite such as polypropylene or polyethylene, and has a front surface and a rear surface. The front surface is comprised of horizontally rows of rectangular hailed receptors, alternate rows of receptors aligned vertically, each receptor having a depth of such size as to allow for the thickness of the thin brick. Flexible tabs are integrated into the horizontal walls of the receptors, extending into the void of the receptor slightly further than the dimensions of the thin brick that will fill the void in such a way as to compress the tab toward the back of the assembly panel. Once the groove of the brick reaches a prescribed depth, the flexible to resume their original position, now inserted in said groove, and lock the thin brick into the receptor. The rear surface of the assembly panel is molded to form diagonal lengths of ribs projecting downward at an approximate forty-five degree angle and of such thickness as to provide for a means of diverting moisture downward to prescribed weep holes in the brick wall. 
         [0028]    The vertical distance between the horizontal walls of the receptor, and the horizontal distance between the vertical walls of the receptor, are greater than the outside dimensions of the inserted brick, thus providing a clearance between adjacent bricks. Furthermore, flexible tabs are integrated into the horizontal walls of the receptor projecting perpendicular from said receptor walls and extending into the void formed by the walls by a margin greater than the perimeter of the brick, but marginally less than the perimeter of the interior of the groove of the brick. In this manner, the support panel is able to accommodate variation of the thin bricks height and length in a manner that does not interfere with the other bricks. 
         [0029]    The back surface of the support panel is attached to a wall of a building structure with fasteners such as ring shank nails or screws. Then each thin brick is mounted to the support panel by approaching the panel holding the brick at an angle such that either the groove at the top or the bottom of the brick is introduced over the flexible tab integrated in the wall of the receptor. Each thin brick is then pushed flat against the support panel to engage the tabs on the opposite wall thereby compressing the tabs toward the back of the assembly panel until said tabs are able to spring back to a normal state after penetrating the void of the groove in the brick, thus engaging the brick to the panel. 
         [0030]    In this manner the thin bricks are applied to the support panel, and mortar is disposed between the thin bricks. The mortar flows into the space between the bricks, into the open area of the groove of the brick, and into the space that is created between the back of the brick and the front of the back of the panel, encapsulating the receptor walls, creating an improved mortar lock between the bricks and the support panel. 
         [0031]    It is an object of the present invention to provide an improved brick veneer assembly and related method. 
         [0032]    It is another object to provide a brick veneer assembly capable of accommodating dimensional variation of bricks in a manner that does not interfere with other bricks. 
         [0033]    It is yet another object to provide a support panel that offers improved handling capabilities. 
         [0034]    It is still another object to provide a support panel that offers improved brick retention compared to the prior art. 
         [0035]    It is yet another object to provide a brick veneer assembly and related method that does not rely on adhesive for brick retention before the mortar is applied. 
         [0036]    It is a further object to provide a brick veneer assembly and related method that offers improved mortar interlock compared to the prior art. 
         [0037]    It is still a further object to provide a more positive brick location means to prevent movement of the bricks while the mortar sets. 
         [0038]    It is yet a further object to provide a less expensive and less labor intensive brick veneer assembly and related method. 
         [0039]    These objects and other features, aspects, and advantages of this invention will be more apparent after a reading of the following detailed description, appended claims, and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0040]      FIG. 1  is a partial exploded perspective view of a brick panel assembly according to the present invention; 
           [0041]      FIG. 2  is a perspective view of the brick shown in  FIG. 1 ; 
           [0042]      FIG. 3  is a front view of the brick shown in  FIG. 2 ; 
           [0043]      FIG. 4  is a top or bottom view of the brick shown in  FIG. 2 ; 
           [0044]      FIG. 5  is a end view of the brick shown in  FIG. 2 ; 
           [0045]      FIG. 6  is a perspective front view of the support panel shown in  FIG. 1 ; 
           [0046]      FIG. 7  is a partially exploded perspective of the support panel shown in  FIG. 6 ; 
           [0047]      FIG. 8  is a rear view of the support panel shown in  FIG. 6 ; 
           [0048]      FIG. 9  is a partially exploded rear view showing the alignment tab indicated on the support shown in  FIG. 8 ; 
           [0049]      FIG. 10  is a partially exploded rear view showing an alignment receptacle indicated on the support panel shown in  FIG. 8 ; 
           [0050]      FIG. 11  is a partially exploded side view of the panel assembly showing the brick positioned to snap into place; 
           [0051]      FIG. 12  is a partially exploded side view of the panel assembly showing the brick fully engaged with the support assembly. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0052]    Generally shown in the Figures, a brick veneer assembly is provided in accordance with the present invention. While the figures depict an embodiment of the present invention in which thin bricks are applied to an exterior wall of a building, it should be appreciated that the present invention also teaches the application of other materials (i.e. tile, stone, etc.) to a variety of surfaces (i.e. interior walls, floor, ceiling, etc.). Referring to the Figures, there is shown in  FIG. 1  a portion of a brick veneer assembly  10  that is constructed in accordance with a method of the present invention. The brick veneer assembly  10  includes thin bricks  20 , a support panel  50 , and mortar (not shown). The brick veneer assembly of  FIG. 1  depicts the thin bricks arranged in rows, however, it should be understood that other thin brick arrangements could be adopted by one of ordinary skill in the art. 
         [0053]    Referring now to  FIGS. 2 ,  3 ,  4 , and  5 , the thin bricks  20  are generally rectangular, and each, as viewed when assembled on a wall, has a front surface  22 , a back surface  24 , a top surface and bottom surface  26 , opposed side surfaces  28 , and a mortised groove  30 , extending the length of the brick including top and bottom  26 . The width of each thin brick  20  is defined as the distance between the opposing side surfaces  28 , the height is defined as the distance between the top surface  26  and the bottom surface  26 , and the thickness or depth is defined as the distance between the front surface  22  and the back surface  24 . Most manufacturing processes known in the art for producing the thin bricks  20  introduce variation such that some bricks are oversized and some are undersized. The manufacturing variation thereby defines a maximum width, height and depth, and a minimum width, height and depth. 
         [0054]    As best seen in  FIGS. 2 ,  3 ,  4  and  5 , the back surface  24  and the front surface of each thin brick  20  are the same size and parallel. In the preferred embodiment, the top surface  26  and the bottom surface  26 , are the same size and parallel, and the side surfaces  28  are the same size and parallel. Also, the groove  30  is mortised an equal distance from the back surface  24 , is equal in size and depth, and extends the length of the thin brick  20  to include the top and bottom  26 . 
         [0055]    Referring now to  FIGS. 6 and 7 , the support panel  50  has a plurality of rows rectangular-shaped receptors  52 , formed by horizontal receptor walls  54 , and vertical receptor walls  56 . The horizontal distance between the center of the vertical receptor walls  54  is the width of the thin brick  20  and the width of a mortar joint. The vertical distance from the center of the horizontal receptor walls is the height of the thin brick  20 , and the height of a mortar joint. Each horizontal receptor wall  54  has perpendicularly integrated flexible holding tabs  58 , that extend into the void of the receptor further than the width or the height of the thin brick  20 , but not as far as the back of the mortised groove  30 . Each vertical receptor wall  56 , has spacer tabs  57 , integrated to facilitate the proper horizontal spacing of the brick. The support panel  50 , is preferably composed of a plastic composite such as polypropylene or polyethylene. 
         [0056]    As best seen in  FIG. 8 , molded into the back side of the panel assembly  50  are multiple ribs  64  that are designed to channel moisture down the inside of the panel assembly, and provide additional strength. Said ribs  64  project in a convex manner from back of panel forming a slight protrusion that runs in a diagonally downward direction so as to facilitate the migration of moisture to weep holes placed in the wall. (Not shown.) 
         [0057]      FIGS. 8 and 9  show projecting alignment tabs  60  on one vertical side and one horizontal side of the assembly panel  50 , said alignment tabs designed to mate with alignment receptacles  62 , shown on vertical and horizontal sides of assembly panel  50 , and more clearly in  FIG. 10 . Alignment tabs  60 , and alignment receptacles  62 , are shown on opposite sides of assembly panel  50 . Introducing alignment tabs  60  into alignment receptacles  62  facilitate both vertical and horizontal alignment of assembly panels  50 . 
         [0058]    As seen in  FIGS. 8 and 10 , the assembly panel  50  is formed with fastener holes  65 , in vertical rows for attachment of said assembly panel to any support surface (not shown) by means of ring-shank nails or screws (not shown). 
         [0059]      FIG. 11  shows cross-section of thin brick  20  being introduced into assembly panel  50 , with flexible tabs  58  of assembly panel  50  inserted into mortised groove  30  of one side of thin brick  20 . In  FIG. 12 , thin brick  20  is fully engaged with assembly panel  50 , with flexible tabs  30  on top and bottom sides of receptor  52  inserted into mortised groove  30  of thin brick  20 . 
         [0060]      FIG. 12  also shows the remaining void in receptor  52  between the thin brick  20 , the vertical receptor walls  56 , horizontal receptor walls  54 , and the front of the assembly panel  50 , allowing for the injection of mortar to further bond thin brick  20  to assembly panel  50 . The mortar is preferably applied with a single point applicator nozzle and mortar pump system or in accordance with any other method well known in the art. The mortar flows into the spaces between the edge of the thin bricks  20 , both top, bottom and sides, encapsulating receptor walls  54 ,  56  and forced between the thin bricks  20  and the support panel  70 . 
         [0061]    As is understood from the above discussion, the present invention provides for improved handling handibility. 
         [0062]    As is understood from the above discussion, the present invention provides improved accommodation of the tolerance variation of the bricks by providing a more resilient system for locating and retaining the bricks. Specifically, the present invention does not rely on oppositely disposed parallel surfaces of the brick as in the prior art, but rather provides a retention system based on an interference fit between a stepped locating feature of the brick and resilient L-shaped retainers such that the retention system is capable of accommodating both oversized and undersized bricks regardless of tolerance variation of the brick. Furthermore, the retention system is effective without the use of adhesive relied upon by the prior art so that the present invention is simpler to assemble and less expensive. Finally, the holes in the support panel enable better interlocking of the mortar, the bricks and the support panel. 
         [0063]    While the present invention has been described in terms of a preferred embodiment, it is apparent that other forms could be adopted by one skilled in the art. In other words, the teachings of the present invention encompass any reasonable substitutions or equivalents of claim limitations. For example, the structure, materials, sizes, and shapes of the individual components could be modified, or substituted with other similar structure, materials, sizes, and shapes. Accordingly, the scope of the present invention is to be limited only by the following claims.