WO1999022091A1

WO1999022091A1 - Brick facing panel

Info

Publication number: WO1999022091A1
Application number: PCT/US1998/018483
Authority: WO
Inventors: Robert W. Bauer
Original assignee: Global Systems, Limited
Priority date: 1997-10-27
Filing date: 1998-09-15
Publication date: 1999-05-06
Also published as: JP2001521086A; EP1027508A1; EP1027508A4; KR20010031438A; AU9378298A

Abstract

The invention relates to the facing of buildings with an exterior brick facing, and more particularly to a preformed thermoplastic skin (1), shaped and sized to be received on the exterior surface of a building structure and configured on its exterior surface in a manner to receive facing masonry such as bricks (3) to produce a non-load bearing brick or masonry facade. In a further embodiment, such panels are configured so as to receive stone or other irregularly shaped masonry products to produce the facade.

Description

BRICK FACING PANEL

Background of the Invention

The invention relates to the facing of buildings with an exterior brick facing, and more particularly to a preformed thermoplastic skin-shaped and sized to be received on the exterior surface of a building structure and configured on its exterior surface in a manner to receive facing masonry such as bricks to produce a non-load bearing brick or masonry facade. In a further embodiment, such panels are configured so as to receive stone or other irregular shaped masonry products to produce the facade.

The use of specially configured panels for receiving bricks is known and representative of the state-of-the-art is U.S. Patent No. 4,809,470 issued March 7, 1989 to Robert W. Bauer et al., which is incorporated by reference herein in its entirety.

The panel construction shown in the above-identified patent includes a skin of vacuum-formed thermoplastic, preferably polystyrene having an insulating backing and a configuration on the exterior facing side or brick side of raised channels extending substantially the entire width dimension of the panel. The raised channels are U-shaped with a flat top corresponding to the bottom of the U-shape. While this structure has found some acceptance, it has been discovered that the insulating backing is not necessary or desirable in all installations and may be too rigid or stiff for some construction applications, and that the mortar between the facing bricks does not adhere as required for the extended service requirements including moisture and temperature changes encountered in use.

It is, therefore, an object of the present invention to provide a facing panel that is easier to install and better able to conform to a wide variety of structures and better able to withstand the ravages of the environment than the prior art panels. SUMMARY OF THE INVENTION

A building panel for applying to the exterior of a wall construction comprising a thermoplastic sheet having formed thereon spaced apart channels having a generally M-shaped cross section extending outward from the panel and in horizontally disposed discontinuous rows. The M-shaped channels being spaced vertically apart by roughly the width dimension of a facing brick and extending the application of the facing bricks. Preferably the M-shaped channels or ribs are discontinuous uniformly horizontally but the spaces formed are not in vertical alignment with the spaces in the next adjacent rows of ribs or channels.

BRIEF DESCRIPTION OF TFIE DRAWINGS

Figure 1 is a partial perspective of the panel of the present inventions showing the relative position of the ribs and the facing bricks.

Figure 2 is a partial top view of the panel of Figure 1 showing the spacing of one row of the channels or ribs.

Figure 3 is a partial cross-sectional view of two channels where they are vertically contiguous showing the M-shaped channel for mortar retention.

Figure 4 is a perspective of a panel for holding other masonry or stone facing materials containing cup-shaped retaining channels for mortar and stone or masonry retention the application of the facing bricks. Preferably, the M-shaped channels or ribs are discontinuous uniformly horizontally but the spaces formed are not in vertical alignment with the spaces in the next adjacent rows of ribs or channels. DETAILED DESCRIPTION OF THE INVENTION

In Figure 1, the facing bricks 3 are shown positioned between the ribs 2 provided on the panel 1. The panel in use is positioned on an interior or exterior wall (not shown) fastened there to by any conventional means, and the facing bricks 3 are inserted between the ribs 2 or channels and mortar placed between all of the sides of the bricks. The M-shaped channel 4 (Figure 3) is shaped to help retain the mortar in the V-shaped recess at the top or outermost exterior surface of the rib 2. The novel shape will also accommodate slightly larger than standard sized bricks adding to the utility of the invention .

The ribs 2 are sized in length to be less than the length of a facing brick 3 such as shown in Figures 1 and 2. In this manner, the opening or space between horizontally adjacent bricks is located on at least the top or bottom adjacent a space between the ribs as shown in Figure 1. In this manner, the appreciation of mortar will fill the open space as well as space remaining to be filled between the top of the channel and the face of the brick. This particular innovation permits the finishing to be performed by less skilled personnel without excessive cleaning and without sacrificing the ability to achieve a monolithic facing as more surface of each brick is available for bonding to the mortar thereby contributing to the overall strength of the facing after the mortar has set. The prior constructions provided less bonding surface and was subject to undesirable weakness when the installation was not performed in a manner which bonded the bricks and mortar adequately. The panel of the present invention reduces the risk of that from occurring and improves mortar retention between the bricks where the ribs are located thereby improving the bonding at that location as well.

The embodiment of Figure 4 is illustrated to show how other masonry or stone facades may be constructed using the similar concept of maximizing the bonding that will occur between the mortar and the masonry or stone. Ledges are supplied on the panel to retain the masonry or stone vertically while the mortar is^* appπeαf The-shapβ¹ and location of the ledges may be random or ordered depending on the facing material that will be used and the esthetic effect sought. Likewise, the ledge size and depth can be varied for the same reasons. The only limitation on the dimensions will be the need to have the ledges completely covered with mortar or cement in the finished panel once they have been sized adequately to support the facing material chosen.

The invention has been described in terms of the most preferred embodiments but it will be appreciated by those skilled in the art that the thickness of the panel can be varied, the material selected from a wide variety of thermoplastic materials or even thermosetting materials that are capable of being formed into a sheet that can be attached to a vertical building surface. Likewise, the panel can even be deployed horizontally when there is provision made to prevent the facing material from being dislodged while the mortar is setting. The inventive concepts described herein are to be limited only by the applicable prior art.

Claims

WE CLAIM:

1. A panel for use in building constructions in conjunction with bricks of orthogonal configuration having a front face, a rear face, a first and second opposed sides and a first and second opposed ends with thickness of said sides and ends being less than the width or length dimension of said front and rear faces, comprising: an inner surface; an outer surface; said panel having a length and width dimension; a number of equally spaced channels on the outer surface defining a substantially flat bottom surface corresponding to the widths of bricks to be supported on said panel there between, each of said channels having a M-shaped cross-section along its length and extending in the direction of the width dimension of said panel; said channels being discontinuous with spaces there between said spaces being located vertically adjacent at least one of the spaces provided for mortar between two horizontally adjacent bricks.

2. The panel according to claim 1, wherein each of said channels are substantially of uniform height along its entire length, the height of each channel bar being less than the thickness of the brick to form a horizontal space of sufficient depth between adjacent bricks to receive mortar for holding the bricks in place.