Note: Descriptions are shown in the official language in which they were submitted.
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AN ARTIFICIAL MASONRY UNIT, A MASONRY WALL, A KIT AND A METHOD
FOR FORMING A MASONRY WALL
FIELD OF THE INVENTION
The present invention relates to the field of masonry works and installations.
More
particularly, it concerns an artificial masonry unit suitable for use with a
panel having
depressions adapted to receive masonry units so as to form a masonry wall with
a
predetermined pattern of stonework or brickwork.
PRIOR ART
Already known in the prior art , there is the panel system disclosed in the
prior PCT
application PCT/CA02/00748 in the name of the Applicant, which system makes it
possible to easily and rapidly make an artificial masonry wall that looks like
a
conventional and natural masonry wall. For that, the system makes use of
panels
similar to the ones shown in figure 1. These panels (1 ), which are typically
made of
foam, comprise, in a front face thereof, masonry unit receiving depressions
(2) and
protruding ribs (4) defining and bordering the depressions (2), which are
sized to
receive respective artificial masonry units (5) in a close-fitting
relationship. Usually,
when a masonry wall is made using such panels (1 ), a mixture of adhesive
cement
is applied into each depression (2) prior to the insertion of masonry units
(5) therein.
When a masonry unit has been inserted in each of the depressions (2), the
masonry
units (5) are mortared together, using any type of mortar known in the art.
The
mixture of adhesive helps retaining the masonry units into the depressions
until the
whole structure is mortared.
As can be easily understood, the use of such mixture of cement to temporarily
retain
the masonry units is time consuming, unhandy and messy.
The following prior art documents provide other examples of waif construction
using
panels and/or masonry units: US patents 2,339,489; 3,238,589; 3,350,827;
3,435,577; 3,496,694; 3,521,418; 3,712,825; 3,884,737; 3,908,326; 4,433,518;
4,510,729; 4,589,241; 4,656,722; 4,858,410; 5,009,387; 5,228,937; 5,232,608;
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5,232,646; 5,232,646 (re-examined); 5,386,963; 5,459,938; 5,501,049;
5,570,551;
5,632,922; 5,836,572; 5,839,251; 5,855,075; 5,894,676; 6,041,567; 6,164,037;
and
RE 35,380.
SUMMARY OF THE tNVENT10N
In order to overcome that drawback, the present invention provides an
artificial
masonry unit suitable for use with a panel, preferably made of a compressible
material. The panel has masonry unit receiving depressions in a front face
thereof
and protruding ribs defining and bordering the depressions which are sized to
receive respective artificial masonry units in a close-fitting relationship.
Each of the
artificial masonry units comprises a body bounded by a front face, a back
face, and
a lateral face providing a thickness to the unit. The unit further comprises a
back
peripheral edge joining the back face and the lateral face, and a tooth
projection
projecting from the lateral face next to and parallel to the back peripheral
edge for
thrusting into the protruding rib when the masonry unit is inserted in a
respective
depression.
Thanks to the tooth projection that is thrusting into the rib of a respective
depression
and that helps retaining the masonry unit within the depression prior to
mortaring the
wall, there is no more need for using a mixture of cement to temporarily
retain the
masonry units within the depression. A masonry unit according to the invention
thus
helps a professional, and also unskilled persons, to even more easily and
rapidly
construct a masonry work having the look of a traditional masonry work made by
highly skilled artisans.
According to another aspect, the present invention also provides a masonry
wall
covering a building surface and comprising a plurality of panels mounted side
by
side on the building surface. Each one of the panels comprises a back face
covering
the building surface, and a front face with a plurality of depressions defined
and
bordered by protruding ribs. The depressions are shaped and sized to receive
respective artificial masonry units. The masonry wall further comprises a
plurality of
artificial masonry units as defined above inserted into the depressions, and a
mortar
material binding the masonry units together.
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Preferably, the masonry wall comprises a plurality ofi wail-ties for securing
the
masonry wall to the building surface. Each of the wall-ties consists of a
generally L-
shaped bracket mounted in a corner of a respective one ofi the depressions of
the
panel between the masonry unit inserted therein and the respective depression,
the
corner being defined by a bottom fiace and the rib of the depression. The L-
shaped
bracket comprises a first flange screwed to both the bottom face of the
depressian
and the building surface; and a second flange extending at right angle to the
first
flange along the rib. The second flange has an end projecting out of the
depression.
This end is embedded in the mortar material.
According to further aspects, the present invention provides a kit and a
method for
making a masonry wall as defined above.
The kit comprises:
-a set of panels to be mounted side by side on the building surface, each
one of the panels comprising:
- a back face for covering the building surface; and
- a front face with a plurality ofi depressions defined and bordered by
protruding ribs, the depressions being shaped and sized to receive
respective artificial masonry units;
-a set of artificial masonry units as defiined above to be inserted and
retained
into said depressions; and
-mortar material for binding the masonry units together.
In accordance with a prefierred aspect of the invention, the kit further
comprises a
set of wall-ties as defined above, for securing the masonry wall to the
building
surface.
The method for making a masonry wall according to the present invention
comprises the steps ofi:
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a) mounting side by side, on a building surface, a plurality of panels as
defined above;
b) providing a set of artificial masonry units as defined above;
c) inserting, in each of the depressions, one of the artificial masonry units
and retaining the unit by thrusting the tooth projection into the adjacent
protruding rib of the respective depression; and
d) mortaring the masonry units.
Preferably, the method comprises, before step c), the steps of tying the
masonry
wall to the building surface, which comprises the steps of:
- mounting, in a corner of a plurality of the depressions, a generally L-
shaped bracket as defined above; and
- screwing the brackets to both the panel and the building surface.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon
reading
the detailed description and upon referring to the drawings in which:
Figure 1 is a perspective view showing a section of a wall where a first panel
is
installed, and where a second panel and an artificial masonry unit as in the
prior art
are about to be installed.
Figure 2 is a perspective view of an artificial masonry. unit according to a
first
preferred embodiment of the invention, viewed from the front.
Figure 3 is a perspective view of an artificial masonry unit according to a
second
preferred embodiment of the invention, viewed from the front.
Figure 4 is a cross section view of the masonry unit of figure 3 along line IV-
IV.
Figure 5 is a perspective view of a first variant of a panel having a
plurality of
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depressions adapted to receive masonry units according to the invention.
Figure 6 is perspective view ofi a second variant of a panel having a
plurality of
depressions adapted to receive masonry units according to the invention,
Figure 7 is a perspective view of one of the depressions of the panel shown in
figure
5 5.
Figures 8a and 8b) are cross section views of an artificial masonry unit
according to
the invention being inserted in a depression of either one of the panels of
figures 5
and 6 and showing in figure 8b) the projecting tooth of the unit thrusting
into the rib
of the depression.
Figure 9 is a perspective view of a wall-tie bracket used with a preferred
embodiment of the invention for securing the masonry wall to the building
surface.
Figure 10 is a partial perspective view of the panel shown in figure 5,
showing the
waif-tie bracket of figure 9 mounted in a corner of a depression.
Figure 11 is a cross section view of an artificial masonry unit as shown in
figure 2
inserted in a depression of either one of the panels of figures 5 and 6,
showing how
the masonry wall is secured to the building surface by means of the wall-tie
bracket
of figure 10.
Figure 12 is a perspective view of an accessory holding bracket that can be
used
with a panel system according to the invention.
Figure 13 is a cross section view of a masonry unit of another preferred
embodiment
of the invention.
LIST OF THE NUMERAL REFERENCES
1 panel
2 masonry unit receiving depressions
4 ribs
5 prior art masonry units
6 corner of depression
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7 back face of panel
8 bottom face of depression
9 front face of panel
masonry unit according to the invention
5 11 body of the unit
12 front face
13 backface
14 back peripheral edge
top face
10 17 bottom face
19 side faces
tooth projection
22 reinforcing structure
23 groove
15 30 compressible projections of the pane( .
40 masonry wall
42 building surface
43 mortar material
44 ~ wall-ties (also referred as L-shaped brackets)
20 46 first flange of the bracket
47 screw receiving hole
48 second flange of the bracket
49 screw
50 end of the second flange (also referred to
as the extension)
52 hooks on the bracket
54 accessory bracket
56 front face of bracket
57 back face of bracket
58 hook of the accessory bracket
60 (edge of bracket ,
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DESCRIPTION OF PREFERRED EMBODIMENTS
In the following description, similar features in the drawings have been given
similar
reference numerals and in order to lighten the figures, some elements are not
referred to in some figures if they were already identified in a previous
figure.
Referring to either one of figures 2, 3 or 13, an artificial masonry unit (10)
according
to the invention comprises a body (11 ) with a front face (12), a back face
(13) and a
lateral face which divides into four edge faces including a top face (15), a
bottom
face (17), and two opposite side faces (19). The front face (12) is the face
hat is still
visible to people once the artificial masonry unit (10) has been inserted in a
masonry
unit receiving depression (2) of a panel (1 ). The masonry unit (10) is
characterized
in that it further comprises a tooth projection (20) projecting from the
lateral face
next to and parallel to the back peripheral edge (14) for thrusting into the
protruding
rib (4) of the depression (2) when the masonry unit (10) is inserted in a
respective
depression (2).
As best shown in figure 8, the tooth projection (20) thrusts into the rib (4)
of the
depression (2), and thereby helps retaining the masonry unit (10) within the
depression (2) prior to mortaring the whole structure. There is no more need
for
using a mixture of cemenfi to temporarily retain the masonry units (10) within
the
depression (2).
The tooth projection (20) is preferably a ridge-shaped projection spanning the
top
face (15) of the unit (10). More preferably, the tooth projection (20) is
projecting from
fihe back edge (14) of the unit (10).
In accordance with the first preferred embodiment shown in figure 2, the
masonry
unit (10) comprises a series of spaced reinforcing structures (22) along the
tooth
projection (20) to prevent the same from being chipped off, as for example,
during
handling and shipping. Preferably, each of the reinforcing structures (22) has
the
shape of a sloping projection. This first preferred embodiment, with its
natural stone
look, is preferably used~with the panel (1) of figure 5, which is adapted to
build a
stonework.
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In accordance with the second preferred embodiment shown in figures 3 and 4, a
groove (23) is extending along the tooth projection (20). This preferred
embodiment,
with its brick look, is preferably used with the panel (1 ) of figure 6, which
is adapted
to build a brickwork.
As shown in either one of figures 2, 3 or 13, the tooth projection (20} is
preferably
projecting from the top face (15) of the unit (10). It is however worth
mentioning that
in another embodiment of the invention, not illustrated, it may project from
the side
faces (19) or from both the top face (15) and the side faces (19), as long as
it is
adapted to retain the masonry unit (10) and prevent the same from falling out
of the
depression (2).
Panels (1 ) suitable for use with masonry units (10) according to the
invention are
illustrated in figures 5 and 6. The panel (1 ) shown in figure 5 is used for
making a
stonework and the panel (1 ) of figure 6 is used for making a brickwork. Each
of
these panels (1 ) has a front face {9) with masonry unit receiving depressions
(2)
each adapted to receive a respective masonry unit (10). These panels (1 ) are
preferably made of foam, or any compressible material. The foam preferably
used
has no memory, meaning that once it has been compressed, it does not regain
its
original shape. The tooth projection (20) provided on the lateral face (15,19)
of the
unit is thus important to retain the unit within the depression. Because the
foam has
no memory, a simple angled lateral face would not be suitable for retaining
the unit
(10) in a respective depression (2).
Referring to figure 5, a predetermined pattern of depressions (2) is cut in
the front
face (9) of the panel (1 ) in a staggered fashion, to provide a masonry wall
that looks
like a stonework, whereas the depressions (2) of the panel (1 ) shown in
figure 6 are
linear, so as to provide a masonry wall that looks like a brickwork .
Preferably, the depressions {2) are pre-cut in the panel (1 ), or pre-moulded,
as the
panel (1 ) is being moulded. They are shaped to fit artificial masonry units
(10) as
described above, either bricks or pre-cast concrete simile-stones or masonry
pieces
made of plastic. The depressions (2) may have a symmetrical shape, for example
rectangular, or an irregular shape to fit the natural curved outline of a
stone. More
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preferably, the masonry units are pre-cast concrete simile-stones having
predetermined shapes and sizes.
In accordance with a preferred aspect, best shown in figures 5, 6 and 7, the
pane!
(1 ) comprises a series of compressible projections (30) made of a resilient
material
projecting from the ribs (4) outlining the depressions (2). The compressible
projections (30) are adapted to cooperate with the tooth projections (20)
provided on
the masonry units (10) to temporarily retain these pieces (10) within the
depressions
(2) before they have been bound together with the mortar.
Referring to figure 7, the compressible projections (30) are preferably
projecting
from a top rib (4) of each depression (2).
Turning now to figure 8, when a masonry unit (10) is inserted into a
depression (2),
the side wall of the rib (4) or the above-defined optional compressible
projections
(30) of the panel (1 ), are compressed by the ooth projections (20) provided
on the
masonry unit (10). Furthermore, thanks to the fact that the tooth projection
is located
near and parallel to the back edge (14) of the unit (10), the unit (10) is
held tight
within each depression (2).
The compressible projections (30) of the pane! (1 ) are formed during the
cutting or
the moulding of the depressions (2), whereas the tooth projections (20) of the
masonry unit (10) are preferably moulded with the same.
Referring to figure 11, the masonry wall (40) according to the invention
comprises
masonry units (10) as described above inserted in fihe depressions (2) of the
panels
(1 ) described above mounted side by side on a building surface (42). The
units (10)
are mortared together by means of conventional mortar material (43). In
accordance
with a preferred embodiment, the wall (40) further comprises a plurality of
wall-ties
(44) for securing the masonry wail (40) to the building surface (42).
Referring more
particularly to figures 9 and 10, each of the wall-ties (44) consists of a
generally L-
shaped bracket (44) mounted in a corner (6) of a respective one of the
depressions
(2) of the panel (1 ) between the masonry unit (10) inserted therein and the
respective depression (2). The L-shaped bracket (44) comprises a first flange
(46),
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provided with a screw receiving hole (47), screwed to the bottom face (8) of
the
depression (2) and the building surface (42), and a second flange (48)
extending at
right angle to the first flange (46) along the rib (4). The second flange (48)
has an
end (50), also referred herein as an extension, projecting out of the
depression (2).
5 This extension (50) is embedded in the mortar material (43).
Preferably, the bracket (44) further comprises at least one hook (52), more
preferably two, which extends at right angle to the first flange (46) in a
direction
opposite to the second flange (48). Thanks to these hooks (52) which are
insertable
in the panel (1 ), it is possible to install at once all the brackets
required, and then to
10 install the masonry units (10) in the depressions (2).
Referring to figure 12, an accessory bracket (54) that can be used with the
above
system is illustrated. This bracket (54) which comprises hooks (58) projecting
from a
back face (57) thereof, and a front face (56) with a ledge (60), can be used
to retain
a masonry unit (10) on a planar surface of a panel (1 ) where there are no
depressions (2). To this end, the front face (56) and the ledge (60) are
covered with
a bonding material such as glue. Thus, in order to install a masonry unit (10)
on a
planar foam panel (1 ), the accessory bracket (54) is hooked to the panel (1 )
and the
masonry unit (10) is bonded to the front face (56) of the bracket (54).
The present invention also concerns a method for making a masonry wall (40)
covering a building surface (42). The method comprises the steps of:
a) mounting side by side on the building surface (42) a plurality of panels (1
),
each one of the panels (1 ) having a front face (9) with a plurality of
depressions (2)
defined and bordered by protruding ribs (4), the depressions (2) being shaped
and
sized to receive respective artificial masonry units (10);
b) providing a set of artificial masonry units (10) as defined above;
c) inserting in each of the depressions (2) one of the artificial masonry unit
(10) and securing the unit (10) by thrusting the tooth projection (20) into
the adjacent
protruding rib (4) of the respective depression (2); and
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d) mortaring the masonry units (10).
Preferably, the method , further comprises, before step c), the step of tying
the
masonry wall (40) to the building surface (42). Referring to figure 10, this
tying step
comprises the steps of:
- mounting, in a corner (6) of a plurality of the depressions (2), a generally
L-shaped
bracket (44), as described.above and shown in figure 9; and
- screwing the brackets (44) to both the panel (1 ) and the building surface
(42).
The present invention also concerns a kit for making a masonry wall (40) on a
building surface (42), the kit comprising:
- a set of panels (1 ) to be mounted side by side on the building surface
(42),
each one of the panels comprising:
- a back face (7) for covering the building surface (42); and
- a front face (9) with a plurality of depressions (2) defined and bordered by
protruding ribs (4), the depressions (2) being shaped and sized to receive
respective
artificial masonry units (10);
- a set of artificial masonry units (10) as defined above to be inserted and
retained into said depressions (2); and
- mortar material (43) for binding the masonry units (10) together.
Preferably, the kit further comprises a set of wall-ties (44) as defined
above.
Although preferred embodiments of the present invention have been described in
detail herein and illustrated in the accompanying drawings, it is to be
understood
that the invention is not limited to these precise embodiments and that
various
changes and modifications may be effected therein without departing from the
scope or spirit of the present invention.
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As for example, the unit according to the invention may also be used with a
stencil
panel, that is to say a panel wherein the depressions are bottomless. In such
a case
the ribs defining the depressions comprise a groove matable with the tooth
projection of the masonry unit.
