Note: Descriptions are shown in the official language in which they were submitted.
CA 02683024 2009-10-20
INSULATING THIN-BRICK, THIN-STONE, AND THIN-BLOCK SIDING SYSTEM
BACKGROUND
[0001] The present invention relates generally to materials used to cover
exterior walls and, more particularly, to a system providing for insulating,
light
weight, and moisture resistant units of thin-brick, thin-stone, and thin-block
facing
materials for exterior and interior use.
[0002] The background information discussed below is presented to better
illustrate the novelty and usefulness of the present invention. This
background
information is not admitted prior art.
[0003] Inefficient home heating and cooling systems often account for up to
one-half of a home's energy expenditures. Additionally, emissions generated
from
the unnecessary heating and cooling of buildings not properly insulated,
negatively impact the environment. It is easy to understand the importance of
reducing both heating and cooling costs and of decreasing the environmentally
deleterious emissions that result from cooling and heating energy use that is
coupled with inefficient home insulation. One of the most effective ways of
minimizing energy use is through effective use of building insulation. In
winter,
insulation can greatly reduce the flow of heat from the interior to the
exterior of a
building and, conversely, in the summer, insulation can greatly reduce the
flow of
heat from the outside to the inside of a building.
[0004] Insulation materials are rated by how well they can reduce heat flow.
A material ability to resist heat flow is commonly indicated by a number
referred to
as an R-value. R-values are based on the thermal conductivity, the density,
and
the thickness of a given material. The higher the R-value, the less heat will
flow
through the material. Importantly, R-values can be additive. When additional
insulation is installed, the R-value of each of insulation materials is added
to
obtain the total R-value.
[0005] There are many well-known insulating materials, including insulation
blankets that are sometimes sold in rolls, such as fiber-glass and rock-wool;
loose
(blown-in) materials encompass rock wool, fiberglass, and cellulose, among
others; examples of foamed-in-place insulating material are polyurethane or
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CA 02683024 2009-10-20
isocyanurate foam, and rigid insulation materials include extruded polystyrene
foam (XPS), expanded polystyrene foam (EPS or bead board), polyurethane
foam, and polyisocyanurate foam. Rigid insulation, made from fibrous materials
or
plastic foams, is pressed or extruded into board-like forms. Rigid insulation
materials provide thermal insulation having strength, low weight, and provide
for
coverage with few heat-loss paths. Such boards, additionally, may be faced
with a
reflective foil that reduces heat flow when next to an air space. These boards
generally have high R-values of 4 to 7 per inch. Rigid board insulation may be
manufactured to be used in confined spaces such as exterior walls, basements,
foundation and stem walls, concrete slabs, and cathedral ceilings.
Polyurethane
and polyisocyanurate insulations are usually double-faced with foil, or can be
bonded with an interior or exterior finishing material. Such facing boards
typically
have an R-value of 5.8 per inch to 7.2 per inch. Extruded polystyrene (XPS) is
a
lightweight foam plastic board manufactured in low and high densities suitable
for
both above- and below-grade applications. Low-density extruded polystyrene has
an R-value of 4.7 per inch while high-density XPS has an R-value of 5.0 per
inch.
Expanded polystyrene (EPS) or "bead board," as it is often called, also comes
in
low- and high-density boards. This high-density board is more moisture
resistant
and can be used on the exterior of a foundation, providing the surrounding
soil is
dry, sandy, and properly drained. Low-density expanded polystyrene has an R-
value of 3.7 per inch while the high-density type has an R-value of 4.0 per
inch. In
general, expanded polystyrene is less expensive than extruded polystyrene or
other rigid insulations.
[0006] In addition to wanting the most thermally efficient home possible,
many homeowners are deeply concerned about the aesthetic appeal of their
home and about cost and time effective ways of maintaining the home's appeal.
Brick provides home owners with a maintenance-free siding that offers a
classic
and timeless look unequaled by any other exterior building product. Brick
siding
symbolizes prestige, elegance, strength, value, and comfort. For these
reasons,
brick homes are very much desired.
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CA 02683024 2009-10-20
SUMMARY
[0007] The present Inventor recognized that the high cost of standard brick
and brick-laying labor often makes brick-sided homes unaffordable for most.
Standard load-bearing bricks are expensive for several reasons; or example,
bricks are larger, thus, require more material to form, and are heavier.
Furthermore, laying brick is time-consuming and requires highly trained
masons.
A compromise made by many homeowners is to limit their use brick to certain
areas, such as the front of the house. This design choice is frequently seen
in
new development homes where the sides and backs of the brick-fronted homes
are finished using vinyl siding. The present Inventor knew that an alternative
to
using traditional brick and vinyl as siding is to use thin-bricks as a siding.
Thin-
bricks, as a substitute for standard bricks, are known to be used to create
brick
facings. Some benefits offered by thin-bricks are that they are less
expensive,
weigh less, and may be easier to install. Thin-bricks can be mounted on a
backing board that previously has been attached to a building. In order to
save
installation time and cost, "brick-panels" are pre-fabricated by gluing thin-
bricks to
a backing board. The bricked board is referred to as a bricking-panel. The
backing board part of the brick-panel is what is used to attach brick-panels
to a
structure. The pre-fabricated brick-panels are transported to the job site
ready to
be attached to a building.
[0008] The present Inventor, recognized that although pre-fabricated brick-
panels are, as compared to real brick, an improvement in many respects, they
still
are of unwieldy size and weight and, thus, difficult to handle for transport,
difficult
to cut into desired shapes, and difficult to install. Moreover, even after the
application of mortar as part of the installation process, unsightly seam-line
gaps
usually appear. For non-professional installers, installation of the pre-
fabricated
brick panels is particularly burdensome as special installation tools, support
structures, and skill are required.
[0009] Accordingly, the present inventor formulated a set of principles that
make possible the creation of a wide variety of insulating building siding
materials,
all having the look and feel of traditional materials, such as brick, stone,
or block,
~
but all having the properties of being insulating, light-weight facing
material, cost
3
CA 02683024 2009-10-20
effective, and easy to use. In the interest of conciseness, the terms "thin-
brick
siding" and "thin-brick" will be used herein, but it should be understood that
the
terms include thin-stone, thin-block, and all other facing materials that will
work
within the principles of the present system. The insulated building siding, as
taught herein, eliminates unsightly seam lines, is water resistant, light
weight,
sized for ease of handling even for a single person of average or less
strength,
and is insulating. A basic bricked-siding panel of the present invention
comprises
a row of thin-bricks positioned short end to short end securely attached to an
elongate, insulating backing-panel sized to accept a single row of bricks. It
should
be understood though, that depending on the size and shape of the bricks,
multiple rows of the specialty sized-bricks attached to a backing-panel could
be
encompassed by the present invention. For example, if each brick were
considerably longer and narrower than an average-sized thin-brick, it would be
within the principles of the present invention to attach at least two rows of
the
narrower bricks to a backing-panel and attain the same weight and ease of
handling. Each insulating basic bricked-siding panel is fabricated by
attaching a
plurality of individual thin-bricks to a backing-panel so that the bottom long
edge of
each brick is aligned with the bottom long edge of the backing-panel, so that
each
horizontal row of bricks positioned on a wall casts a shadow on the basic
bricked-
siding panel directly beneath it. The shadow so created hides any seam line
that
might appear, or seem to appear. Thus, each insulating backing-panel is sized
to
accept a single row of thin-bricks positioned short end to short end, keeping
in
mind the exceptions discussed above. The principles of the present invention
thus provide for a system that insures that each basic bricked-siding panel is
always perfectly aligned providing for seams having a constant spacing, is
lightweight, easy to install, and is cost effective, in addition to being
insulating for
both sound and heat.
[0010] The size of each panel is determined mainly by a desired workable
size, weight, and ease of installation. Although, as mentioned, the height of
each
backing-panel is generally limited to accept one row of brick aligned short
end to
short end across the width of each backing-panel, if desired, backing-panels
can
be manufactured to accept more than one row. The number of thin-bricks aligned
end to end per panel is about five, but can be more or less depending on
required
4
CA 02683024 2009-10-20
backing-panel design and the facing material used if not brick. The thin-
bricks, or
units of other facing material, are affixed to the outwardly facing face of
each
backing-panel using a suitable adhesive-type material, for example, the grout
or
mortar that is placed between the bricks once the bricks are laid, although
any
adhesive that will perform according to the principles of the invention is
contemplated by this invention. Once the grout is dried, the bricked-backing-
panels are ready to be installed. After each bricked-backing-panel is affixed
to a
building wall or building support structure, grout is again applied to the
spacing
between and around the bricks to complete the look of natural brick, stone, or
other material with which grout would be used.
[0011] In the one preferred embodiment that is illustrated herein, each
insulating backing-panel is formed during a molding process to provide for
tongue
and groove construction of the backing-panels. Tongue and groove construction
in this case means that the upper surface of each panel has a tongue extension
that fits into a groove on a bottom surface of a panel above it. Or,
conversely each
bricked-backing-panel could have a tongue extension on its bottom surface that
fits into a groove on a top surface of a panel below it. Thus, each bricked-
backing-
panel is able to securely interdigitate with both a previously bricked-backing-
panel
over which the current backing-panel is installed and a bricked-backing-panel
installed over the backing-panel currently being installed providing for
maximum
strength panel to panel attachment. Additionally, each backing-panel may be
provided with interdigitating end connectors. In the example provided below,
each
backing panel is designed to have a male-connector end and a fQmale-connector
end, providing for secure, tight, and strong connections between the ends of
adjacent panels. Besides ensuring that the panels fit together in an
apparently
seamless manner and providing for secure attachment of each panel to adjacent
panels, the interlocking tongue and groove fitting of the panels to each other
provides for maximizing the insulating thin-brick siding R-value by preventing
air
leakage. Because each panel is designed to be of a limited sized, the
insulating
thin-brick siding panels are extremely light-weight and, thus, easy to handle
making installation possible by do-it-yourself handy men, women, and mature
children, as well as by, professionals. Moreover, the insulating brick-faced
siding
has an R-value of about 20, is also acoustically insulating, and is suitable
for both
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CA 02683024 2009-10-20
indoor and outdoor installation. As will be seen the principles of the present
invention provide for more than just elongate bricked-backing-panels. There
are,
additionally, backing-panels that are corner-shaped making installation around
the
corners of structures not only easy, but providing for the insulating
properties at
the corners than would be if the panels were to end at the corner edge of a
building and had to be connected only using grout. There are also trim
features,
such as window sills, lintels, and corner blocks that all continue the
insulating and
light-weight character of the siding and the interdigitating connectors where
relevant. The corner blocks are different form the corner-shaped bricked-
panels.
The corner-shaped bricked panels are bricked-panels that are formed as one
piece having two sides at 90 degrees from each other. The corner blocks are
designed to look like a large block of stone that has been shaped to be a
corner
stone. Each panel is also provided with small protuberances, herein referred
to as
"weep spacers" to provide a space between the backing-panels and the building
surface to prevent problems occurring from condensation. Problems caused by
condensation include growth of mold and mildew, corrosion of metal, and
degrading of insulation R-values do exist. Air normally contains water vapor
in
varying quantities and its capacity to do so is related to its temperature,
that is
warm air can hold more water than cold air. Air is saturated when it cannot
contain
any more water vapor at its existing temperature and under these conditions it
is
said to have a relative humidity (RH) of 100%, and at this point condensation
of
water vapor on surfaces will begin. Condensed water usually appears as water
droplets or water film on non-absorbent surfaces such as the building's walls.
[0012] The principles of the present invention provide for a system,
comprising:
a system of surface facing materials structured for facing indoor and
outdoor surfaces, comprising;
facing sections having:
interdigitating connectors on opposing first and second surfaces so as to
securely connect a long connecting-side of a section to a long connecting-side
of
an adjacent section and/or
.~
interdigitating connectors on each end so as to securely connect each section
end
to an end of an adjacent section, so as to provide light weight, moisture
resistant,
6
CA 02683024 2009-10-20
sound and heat insulating facing. Where one style of the facing sections
comprise
a single row of thin-bricks positioned short end to short end securely adhered
to
an elongate, lightweight, insulating backing-panel having interdigitating
connectors
sized so as to accept a single row of bricks so as to result in a thin-bricked
panel.
In one preferred embodiment from 2 to 10 thin-bricks adhered end to end to a
backing-panel forming an elongated row of thin-bricks on a backing panel.
[0013] The thin-bricks are adhered to the lightweight insulating backing-
panel using grout or mortar or any other material that would perform the
adherence desired.
[0014] Instead of thin-brick could be replaced by thin-stone or thin-block,
and the facing section could further include multiple rows of thin-bricks.
[0015] The backing-panels are attached to each other in an air-tight manner
using interdigitating connectors on the opposing first and second surfaces
that
could be tongue and groove connectors, and by using interdigitating connectors
on the ends of each panel that could be male and female connectors.
[0016] The principles of the present invention include several facing section
styles, one style of the facing section including both window sills and window
lentils. Another style including various sizes of thin-bricked panels shaped
to fit
about surface corners. Yet, another style includes various sized and shaped
corner blocks.
[0017] The facing sections are supplied with spacers protruding from their
back surface so as provide for a space between the back of each facing section
and the surface that is being faced by the facing sections to prevent a build-
up of
moisture.
wherein the facing section is structured so that the bottom edge of each brick
of
each
[0018] The principles of the present invention include such aesthetic
features as providing for the bottom edge of each brick to be even with the
bottom
edge of the backing-panel to which it is adhered, so that each row of bricks
positioned on a wall casts a shadow on another bricked-panel directly beneath
it
so as to hide any seam lines.
7
CA 02683024 2009-10-20
[0019] Each facing section is attached to the surface it is facing using a
fastener, such as a cleat or anchor, that is first fastened into the facing
section
and then fastened into the surface.
[0020] A particularly favored embodiment is a siding material, comprising:
an insulating, lightweight, interior, exterior siding material,
comprising;
an insulating, lightweight backing-panel structured to have a
length, a top, front, bottom, and back surface,
the top surface having a tongue along its length, the bottom surface having
a grove along its length, the tongue and groove structure providing for tongue
and
groove attachment of one of the backing-panels stacked above another,
the backing-panel having a male connector on one end and a female
connector on another end providing for end to end connection of each siding
panel,
the front surface having one row of thin facing elements adhered across its
length so as to form a lightweight, insulating siding-panel; where the thin-
facing
elements can be thin-bricks or thin-stone, and the backing-panel is a molded,
foam backing-panel to ensure its being light-weight and insulating, and where
the
thin facing elements are fixed to a front surface using mortar.
[0021] The principles of the present invention also include a method of
making the units that comprise the system, where the method is for making a
bricked-panel facing section and comprises the following steps:
a method of making a facing section, comprising
providing for a set of thin-bricks;
providing for a lightweight, insulating backing-panel having
interdigitating connectors on opposing short and long surfaces;
providing for grout;
adhering at least one row of thin-bricks to the backing-panel using
the grout so as to make a thin-brick, light weight, insulating facing sections
for
facing indoor and outdoor surfaces.
[0022] Thus, there has been outlined some of the more important features
of the invention in order that the detailed description thereof that follows
may be
better understood, and in order that the contribution of the present invention
to the
8
CA 02683024 2009-10-20
art may be better appreciated. There are, of course, additional features of
the
invention that will be described hereinafter, such as the fasteners, and which
will
form the subject matter of the claims appended hereto. Those skilled in the
art will
appreciate that the conception, upon which this disclosure is based, may
readily
be utiiized as a basis for designing other structures, methods, and systems
for
carrying out the several purposes of the present invention. It is important,
therefore, that the claims be regarded as including such equivalent
constructions
insofar as they do not depart from the spirit and scope of the present
invention.
Yet still other benefits and advantages of this invention will become apparent
to
those skilled in the art upon reading and understanding the following detailed
specification and related drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In order that these and other objects, features, and advantages of
the present invention may be more fully comprehended and appreciated, the
invention will now be described, by way of example, with reference to specific
embodiments thereof which are illustrated in appended drawings wherein like
reference characters indicate like parts throughout the several figures. It
should
be understood that these drawings only depict preferred embodiments of the
present invention and are not therefore to be considered limiting in scope,
thus,
the invention will be described and explained with additional specificity and
detail
through the use of the accompanying drawings, in which:
FIG. 1A is a plan view of the top of an insulating bricked backing-panel of
the present invention.
FIG. 1 B is an elevation view of the front or outer side (i.e., the side of
the
bricked panel that faces outwardly away from a building and is the side on
which
the thin-bricks are attached) of the insulating bricked backing-panel, as
illustrated
in FIG.1A.
FIG. IC is a plan view of the bottom side of an insulating bricked backing-
panel, as illustrated in FIG. 1A.
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CA 02683024 2009-10-20
FIG. 1 D is an elevation view of the back side of the insulating bricked
backing-panel (i.e., the side that will be attached to a building), as
illustrated in
FIG. 1.
FIG. 1 E is an elevation view of the female connection end of the insulating
bricked backing-panel illustrated in FIG. 1.
FIG. 2 is a perspective view of a basic, insulating, bricked backing-panel
(also referred to as a thin-brick panel).
FIG. 3 is a perspective view of a thin-brick panel about to be installed over
previously installed thin-brick panel and adjacent to another previously
installed
thin-brick panel.
FIG. 4 is a perspective view of a stack of four thin-brick panels.
FIG. 5 is a perspective view of an attachment cleat being readied to attach
the top bricked backing-panel to a wall (not shown).
FIG. 6 is a perspective view of an attachment cleat attached to the top most
panel that is ready to be attached to a wall (not shown).
FIG. 7 is a perspective view of an attachment cleat that has been attached
to the top panel being attached to a wall.
FIG. 8A is a plan view of the top side of a left bricked corner panel.
FIG. 8B is a plan view of the bottom side of the left bricked corner panel, as
illustrated in FIG. 8A.
FIG. 9A is a plan view of the top side of a left block corner.
FIG. 9B is a plan view of the bottom side of the left block corner, as
illustrated in FIG. 9A.
FIG. 10A is a plan view of the top side of a block window sill.
FIG. 10B is a plan view of the bottom side of the block window sill, as
illustrated in FIG. 10A.
[0024] List of Reference Characters and Their Corresponding Parts
2 Male connector end of bricked backing-panel 12, also referred to as a
surface facing section.
3 Female connector end of bricked backing-panel 12, also referred to as a
surface facing section.
6 A thin-brick.
CA 02683024 2009-10-20
8 Grout or mortar.
A bricked panel, also referred to as a surface facing section.
12 A lightweight, insulating backing-panel or surface facing backer.
14 Bottom of backing-panel 12.
16 Front side of backing-panel 12.
18 Top side of backing-panel 12.
Rearward surface of backing-panel 12.
22 Tongue, of tongue and groove construction, running along the axial line of
the panel to an equi-distance from each end 2.
24 Space between each end 2 of panel 12 and related end of tongue 22.
26 Groove, of tongue and groove interdigitating connector construction,
extends from male connector end 2 of bricked backing-panel 12 to opposing
female connector end 3 equidistant from each long side.
28 Cleat or anchor used to attach bricked panel 10 to wall 4.
32 End of cleat 28 that is adhered to backing-panel 12.
34 End of cleat 28 that is drilled into structure wall 4.
40 Clip (also referred to as cleat, anchor, or fastener) recess.
42 Weep spacers.
50 Window sill.
BEB Bottom edge of thin-brick 6.
BEP Bottom edge of backing-panel 12.
SO Set-off.
[0025] DEFINITIONS
[0026] Grout, as used herein, refers to a construction material used to seal
joints, such as the spaces found between bricks, to embed rebar in masonry
walls, and to connect sections of pre-cast concrete. Grout is generally
composed
of a mixture of water, cement, sand, and sometimes fine gravel. Color tint may
be
applied as a thick liquid which hardens over time, much like the mortar. Main
varieties of grout include: tilin grout (either cement-based or epoxy),
flooring
grout, resin grout, non-shrink grout and thixotropic grout.
[0027] Insulated backin -q panel, as used herein, refers to a rigid panel made
from insulating material, such as extruded polystyrene foam (XPS), expanded
11
CA 02683024 2009-10-20
polystyrene foam (EPS or bead board), polyurethane foam, and polyisocyanurate
foam, keeping in mind that the present invention contemplates any lightweight,
moisture resistant, insulating backing material.
[0028] Thin-brick, as used herein, refers to a brick that is generally about
1/6 the weight of a standard brick so extra structural support and a brick
ledge are
not needed, resulting in cost savings. Thin-brick is not susceptible to
wetting,
termites, rotting, denting, or burning and it does not require painting.
[0029] Thin brick pre-fabricated facing, cladding, or siding material or
panel,
as used herein, refers to a weather-resistant, non-combustible thin-bricks
directly
adhered to a structural backing material with an adhesive. The ready to be
installed siding benefits includes more efficient and environmentally friendly
use of
natural resources, is light-weight, reduces construction costs, and provides
better
quality assurance.
[0030] It should be understood that the drawings are not necessarily to
scale. In certain instances, details which are not necessary for an
understanding
of the present invention or which render other details difficult to perceive
may
have been omitted.
DETAILED DESCRIPTION
[0031] The principles of the present invention as disclosed herein teach
both the constructions and methods for achieving cost effective, easy to
install,
lightweight, insulated thin brick panel assembly for forming a "brick", or any
other
material-facing on a building structure, comer-panels, corner-stones, window
sills,
and window-lintels. The insulating thin-brick siding, as taught, is light-
weight,
cost-effect, offers an R-factor of about 20, and excellent sound insulation.
In
addition to providing for excellent insulating properties, the insulated thin-
brick
siding, of the present invention, offers the look and feel of traditional
brick, thus
instantly communicates the qualities of standard brick; permanence, warmth,
and
substance. Moreover, the insulating thin-brick siding, according to the
principles of
the present invention, eliminates unsightly seam lines of presently available
bricked-panels, is extremely light weight, and sized for easy handling, even
by one
person, and is structured to prevent any condensation build-up. Furthermore,
the
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principles teach interdigitating connectors to be used on all sides of the
panels
that are to be connected, as well as novel cleats, or anchors that assure a
tight,
secure fit of the panels to a surface. Additionally, thin-brick panels include
thin-
stone, thin-block, and any other building facing material that is suitable for
siding a
building.
[0032] Thin-brick is made to the same exacting criteria and with the same
materials as standard brick, which means that thin-brick has the exact look of
brick with all the advantages, and none of the disadvantages of thin-brick.
Thin-
brick is extremely cost effective as its light-weight means low transportation
cost,
as compared to real brick. Additionally, light-weight and sized for handling
by
men, women, and children thin-brick is easy to handle and install even by one
person, thus reducing labor costs. Moreover, thin-brick panels install quickly
reducing labor time. Thin-brick is generally about 1/6 the weight of standard
brick
so extra structural support and a brick ledge are not required for
installation,
resulting in additional cost savings. Thin brick is virtually maintenance
free. It
doesn't rot, dent, burn, or need to be painted. And it won't be eaten by
termites.
[0033] The siding, as taught herein, comprises a method of producing thin-
brick siding panels, the product so produced, and the use of the product. Thin-
bricked siding panels are manufactured by securely and permanently attaching a
number of individual durable, thin-bricks to a mating, elongate, lightweight,
insulating backing-panel. To keep manufacturing costs to a minimum, each
backing-panel is generally a molded product that may be, if desired, molded
with
protruding contours which allow the thin brick tiles to be positioned
uniformly
across each row. Each backing-panel is molded to provide for tongue and groove
attachment of the backing-panels to each other's long sides and
interdigitating
connection means at each end of a panel to provide for interdigitating end
connections. The height of each panel is generally limited to accept one
horizontal row of thin-bricks, but could just as well accept two or three,
rows of
brick aligned short end to short end, depending on the height dimension of the
bricks. The number of bricks aligned end to end per panel is about five, but
can
be more or less depending on the desired design. After the bricks are affixed
to
the insulating, light-weight foam backing using an adhesive-like material,
such as
grout, a layer of grout is applied to the spacing between and around the
bricks to
13
CA 02683024 2009-10-20
give the appearance of actual, grouted brick. Once the grout affixing the
bricks to
the backing and the grout deposited between the bricks are dried, the basic
unit is
ready for installation on a surface of a building.
[0034] Referring now to the drawings, how to make and how to use the
invention will be described with more particularity. The structure of one
favored
embodiment of the principles of the present invention is illustrated as an
elongate
bricked-backing-panel in FIGS. 1A to IE. FIG. IA, a plan view, illustrates top
surface 18 of backing-panel 12 having tongue 22, of tongue and groove
interdigitating connector construction, running the axial length of panel 12
from
male connector end 2 to female connector end 3. Tongue 22 is sized to fit into
groove 26 of bottom surface 14 of an adjacent backing-panel (see FIG. IC). The
top surfaces of a series of weep spacers 42 can also be seen in FIG. 1 A. The
weep spacers provide a series of spaces between the back of panel 12 and the
surface to which the panels are attached. Furthermore, slight indentations 40
can
be seen on surface 18 of panel 12. Indentations 40 provide the space needed
for
the anchor cleat or clip that is used to secure panel 12 to a surface. More
about
the anchor cleat will be provided below.
[0035] FIG. 113, an elevation view, illustrates front surface 16 of insulating
backing-panel 12. It is onto front surface 16 that thin-bricks 6, or other
desired
facing material, are attached. Thin-bricks 6 can be attached to backing-panel
12
using the same grout that is used to attach real bricks to a surface. Just as
in the
installation of real brick, grout 8 is spread over the entire attachment
surface so
that grout 8 is present behind, between, above, and below each thin-brick 6 to
present the appearance of real brick. A side view of tongue 22 extending
upwards
from top surface 18 of panel 12 also can be seen. The two dashed lines near
the
top of the front surface indicate the presence of recesses 40, as seen in FIG.
1,
that provide an indented platform for anchor installation.
[0036] FIG. 1C, a plan view, illustrates bottom surface 14 of panel 12 with
groove 26, of tongue and groove interdigitating connector construction,
extending
from male connector end 2 of bricked backing-panel 12 to opposing female
connector end 3 equidistant from each long side. The two dashed lines near the
bottom edge of the bottom surface indicate the presence of recesses 40, as
seen
in FIGS.1A and 1B, that provide an indented platform for anchor installation.
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CA 02683024 2009-10-20
[0037] FIG. 1 D, an elevation view, illustrates rearward surface 20 of
insulating backing-panel 12. The back (rearward) side is the side that is
situated
facing and attached to the surface to which backing-panel 12 will be attached,
such as a building wall. Backing-panel 12 can be attached to a wall using
grout,
mortar, adhesive, or any known, or as yet unknown, fastening device.
[0038] FIG. I E, an elevation end view of female connector end 3, illustrates
the structural relationship of groove 26 to tongue 22 to backing-panel 12.
Tongue
22 is shown extending upwards from top surface 18 and groove 26 extending up
into the backing-panel from bottom surface 14.
[0039] FIG. 2 is a perspective view of a ready-to-install, insulating, single
row, thin-bricked panel 10 showing thin-bricks 6 attached to backing-panel 12.
Thin-bricks 6 are attached to front surface 16 of backing-panel 12 so that
bottom
edge BEB of each thin-brick 6 is aligned with the bottom edge BEP of the
backing-panel 12 to provide for each fully bricked panel to cast a shadow over
the
connection line between itself and the thin-bricked panel it overlies. Thin-
bricks
are attached to the insulating backing-panel using any material compatible
grout,
cement adhesive, and the like. In this example, thin-bricks 6 are attached to
backing-panel 12 using the same type of grout or mortar that is used to
install real
brick. The color of the bricks in this example are brick red and the grout is
gray,
but any color brick and any color grout is within the scope of the principles
of the
present invention. In the embodiment illustrated, the outward-facing surface
of the
backing-panel was first coated with a layer of mortar. Thin-bricks were then
positioned on the mortar that acts as an adhesive to fixedly attach the thin-
bricks
to the backing-panel. To maximize the "real brick" appearance of the thin-
bricked
panel, once the thin-bricks are attached to the backing-panel, additional
mortar is
placed about the perhipery of each thin-brick. At this point, the thin-bricked
panel
is ready for use. One example of a thin brick that works well to form the
present
invention is Flexi-BrickT"". Flexi-BrickT"" thin-bricks are available, for
example, in
what are referred to as "brickettes" that are 7.5" x 2.25" x.5" thick. Each
Flexi-
BrickT"" brickette weights 0.75 pound. This example should not be taken as
limiting. It is but one type of brick that may be used.
[0040] FIG. 3, a perspective view, illustrates how a thin-bricked panel is
interdigitatedly connected to adjacent bricked-panels that may be above,
below, or
-- - --_ --- ___- __- ----------___..._--___..- _ _ _---- _ _. . _ __ _ __ ----
- - - ---- _ - ----_----- ---- -- ---___._ __-- -__ _- _ __ ___._~..- -- __ _
.
CA 02683024 2009-10-20
next to it. In FIG. 3 a first and second row of thin-bricked panels are shown
in the
position they would be as affixed to a wall (that is not shown). A third row
of thin-
bricked panels is in the process of being installed. The thin-bricked panel on
the
left side of the drawing (facing the drawing) is situated against and fixedly
attached to the top surface of a panel that was secured previously to a panel
below it, a second thin-bricked panel (the panel on the right) is in the
process of
being installed so that its groove 26 is being interdigitated with tongue 22
of the
panel onto which it is being positioned. This interlocking fitting of the
panels to
each other locks the panels in position, providing for lower panels to assist
in the
support of upper panels, and, importantly, helps to maintain the high R-value
of
the insulating thin-brick siding. Furthermore, the male connector end of the
panel
on the right that is in the process of being installed is in the process of
being fitted
into the female connector end of the panel on the left. The interlocking
fitting of
the tongue and groove connectors and the male and female connectors of thin-
bricked panels eliminates the occurrence of unsightly seams and open spaces
that would undermine the insulating properties of the bricked-panels.
Moreover,
because each panel is of a pre-determined limited sized, the insulating thin-
brick
siding panels are extremely light-weight and, thus, easy to handle making
installation possible by do-it-yourself handy men, women, and mature children,
as
well as by, experienced professionals. Labor costs are greatly reduced, as one
experienced installer can easily manage a job with untrained labor.
[0041] FIG. 4 is a perspective view of four thin-brick panels installed onto a
surface (not shown) to illustrate how each row is set-off SO relative to the
row
above and below. The set-off installation provides for interdigitating-end
coupling
of one bricked-panel to another, which provides for both greater coupling
strength,
the elimination of unsightly seam lines, and for retaining a higher "R"
insulation
factor. FIG. 4 also shows that a wall "bricked" using thin-bricked panels has
the
appearance of a wall bricked with real bricks. Besides providing for the
appearance of real brick, the insulating thin-brick panel siding has an R-
value of
about 20, is acoustically insulating, and is suitable for indoor and outdoor
installation by professionals or do-it-yourselfers.
[0042] FIG. 5, a perspective view, illustrates one example of how the
bricked-panels may be attached to a surface, such a wall of a structure (not
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CA 02683024 2009-10-20
shown). In this example, attachment cleat or anchor 28 is going to be used to
attach a bricked-panel to a wall. Although not required, attachment cleats
provide
for additional attachment security. In this example, cleat 28 may be described
as
having pointed insert portion 32 for vertical insertion into a bricked-panel
that is of
a density to accept the pointed insert portion of the cleat. There is a middle
cleat
portion that rests on the bricked-panel and a surface attachment segment that
lies
flat against the surface to which the panel is being attached.
[0043] FIG. 6 illustrates how cleat 28 is used. After foam-compliant
adhesive is applied to end 32 of cleat 28, end 32 is pressed into the backing-
panel
top surface 18 the middle portion of cleat 28 is press-fitted onto one of clip
recesses 40 on top surface 18 of backing-panel 12. Clip recesses 40 provides
for
the top surface of cleat 28 to be at the same elevation as top surface 18.
This
assures that the interdigitating connection formed by the tongue/groove
connectors is as tight as can possibly be. The attachment of the cleat to the
foam
backing can be done before or after a bricked-panel is placed into position
for
attachment to the wall. Once the panel and cleat are attached to the panel and
the panel is in place, surface attachment end 34 of cleat 28 is attached to a
surface, such as into a structural wall, using a drill, as illustrated in FIG.
7.
[0044] FIG. 8A, a plan view, illustrates the top side of a left bricked corner
panel and FIG. 8B, a plan view, illustrates the bottom side of the left
bricked
corner panel, as illustrated in FIG. 8A. These corner-shaped backing-panels
provide for installation of bricked-panels around the corners of structures
not only
easy, but ensure that the panel's insulating properties are at the same level
of
insulating ability at the corners of a structure than at surfaces requiring
only
straight-run panel. The corner-shaped bricked-backing-panels, as illustrated
in
FIG. 8A and FIG. 8B, are corner extensions of the bricked-panels illustrated
in
FIGS. 1a - 7. These corner extensions provide for corners of bricked-panels
that
have no ends that require attachment at the corners. Extending straight-line
panels to each corner and attaching the ends of the straight-line panels at
the
corner join using grout would create a potential weakness. If, for instance,
the
ground upon which the building was built, suffered settling and thus, the
building
suffered settling, it would be fairly easy for the stress created on the
building by
the settling to be released at the grouted corners. However, with the corners
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constructed as solid sections of cornered panels, the weakness would not
reside
at the corners, keeping the corners intact.
[0045] FIG. 9A, a plan view, illustrates a top side of a left block corner and
FIG. 9B, another plan view, illustrates a bottom side of the left block corner
that is
illustrated in FIG. 9A. Right block corners would be mirror images of the left
block
corners. Block corners differ from corner-shaped bricked-backing-panels in
that
the blocks are designed to look as if they were solid blocks of stone that
were
shaped as a corner. To accomplish this, each panel has its typically short
vertical
dimension enlarged to that of a corner stone. So instead of an individual
panel of
several inches in height, the stone corner panel might be a foot or more in
height
with corresponding dimensions of width on each side of the corner apex. The
corner-stone backing panel would usually be faced with thin-stone large-sized
slabs instead of thin-bricks. In other structural respects, both the corner-
shaped
bricked-backing-panels, as illustrated in FIG. 8A and FIG. 8B, and the block
corners as illustrated in FIG. 9A and FIG. 9B, are designed to have weeping
spacers 42, clip recesses 40, the interdigitating tongue 22 and groove 26
connector construction, and the interdigitating male 2 and female 3 connector
construction.
As illustrated in FIG. 10A and FIG. 10B the principles of the present
invention also
provide for trim features, such as window sills 50 and lintels (not shown)
that offer
the same insulating and light-weight properties of the bricked-panels. Each
trim
feature, as well as the window sill and lentil, is provided with weep spacers
42, to
provide a space between the panels and the building surface to prevent
problems
occurring from condensation. All of the trim features come in a plurality of
shapes
and sizes to complement whatever facing style is chosen, whether it be modern,
colonial, Greek, or any other.
[0046] The foregoing description, for purposes of explanation, uses
specific and defined nomenclature to provide a thorough understanding of the
invention. However, it will be apparent to one skilled in the art that the
specific
details are not required in order to practice the invention. Thus, the
foregoing
description of the specific embodiment is presented for purposes of
illustration and
description and is not intended to be exhaustive or to limit the invention to
the
precise form disclosed. Those skilled in the art will recognize that many
changes
18
CA 02683024 2009-10-20
may be made to the features, embodiments, and methods of making the
embodiments of the invention described herein without departing from the
spirit
and scope of the invention. Furthermore, the present invention is not limited
to
the described methods, embodiments, features or combinations of features but
include all the variation, methods, modifications, and combinations of
features
within the scope of the appended claims. The invention is limited only by the
claims.
19
