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Fiber Enforced Thin Brick Sheet and Process
| Content Provider | The Lens |
|---|---|
| Abstract | A fiber enforced sheet for use as a wall or floor covering which comprises of adhered thin bricks bonded to a fiber-reinforced, backing layer. Thin brick is adhered to the fiber enforced sheet. The fiber enforced backing increases strength and rigidity to the thin brick during handling, and installation permits the thin bricks to be adhered to proper specification and spacing to be cut using ordinary tile or thin brick tools. |
| Related Links | https://www.lens.org/lens/patent/014-475-604-683-533/frontpage |
| Language | English |
| Publisher Date | 2017-06-08 |
| Access Restriction | Open |
| Content Type | Text |
| Resource Type | Patent |
| Jurisdiction | United States of America |
| Date Applied | 2016-12-15 |
| Applicant | Old Mill Brick Incorporated |
| Application No. | 201615380733 |
| Claim | 1 - 41 . (canceled) A method of installing thin brick sheets, comprising: applying a first thin brick sheet to a wall or floor surface, wherein the first thin brick sheet comprises: a first backing layer that comprises a first edge and a second edge that are at opposite sides of the first backing layer; and a first plurality of thin bricks that are bonded to the first backing layer, wherein each thin brick of the first plurality of thin bricks comprises: a first portion that extends in a first direction; and a second portion that extends in a second direction; wherein the first portions of the thin bricks of the first plurality are staggered such that some of the first portions are recessed from the first edge of the first backing layer; applying a second thin brick sheet to the wall or floor surface, wherein the second thin brick sheet comprises: a second backing layer; and a second plurality of thin bricks that are bonded to the second backing layer such that a portion of some of the thin bricks of the second plurality overhang the second backing layer at a first edge of the second backing layer; and joining the overhanging portion of the thin bricks of the second plurality to the first thin brick sheet. The method of claim 42 , wherein the first backing layer comprises regions that extend beyond some of the first portions of the thin bricks of the first plurality, and wherein the regions of the first backing layer are configured to be coupled with overhanging portions of thin bricks of the second plurality. The method of claim 42 , wherein the first backing layer defines a grid that comprises holes, and wherein each thin brick of the first plurality is bonded to the first backing layer such that a portion of the rear surface of the thin brick is free from an adhesive, wherein the portion of the rear surface of the thin brick that is free from the adhesive overlaps one or more holes in the first backing layer such that a construction adhesive can penetrate through the first backing layer to adhere to the portion of the rear surface of each of the thin bricks of the first plurality that is free from the adhesive to bond the thin brick to the wall or floor surface. The method of claim 42 , wherein the first backing layer is flexible and substantially non-stretchable. The method of claim 42 , wherein the first backing layer comprises reinforcing fibers that comprise one or more of graphite fibers, aramid fibers, carbon fibers, fiberglass fibers, and poly fibers. The method of claim 42 , wherein the second thin brick sheet further comprises: a third plurality of thin bricks that are bonded to the second backing layer, wherein each thin brick of the third plurality of thin bricks comprises: a first portion that extends in a first direction; and a second portion that extends in a second direction; wherein the first portions of the thin bricks of the third plurality are staggered such that some of the first portions are recessed from an edge of the second backing layer. The method of claim 42 , wherein the thin bricks of the first plurality are rectangular. The method of claim 42 , wherein the first thin brick sheet is a prefabricated thin brick sheet. The method of claim 42 , wherein the thin bricks of the first plurality are between 0.125 inches and 3 inches thick. The method of claim 42 , wherein the first plurality of thin bricks are spaced from one another to provide spaces between adjacent bricks that are configured to be filled with mortar or grout. The method of claim 42 , wherein the first thin brick sheet defines an elongated corner, wherein the first thin brick sheet comprises a first portion that extends away from the corner in the first direction, wherein the first thin brick sheet comprises a second portion that extends away from the corner in the second direction that is different from the first direction. A method of installing prefabricated thin brick sheets, comprising: applying a first prefabricated thin brick sheet to a wall or floor surface, wherein the first prefabricated thin brick sheet comprises: a first backing layer that comprises a first edge and a second edge that are at opposite sides of the first backing layer; and a first plurality of thin bricks that are bonded to the first backing layer with an adhesive, wherein each thin brick of the first plurality of thin bricks comprises: a first portion that extends in a first direction; and a second portion that extends in a second direction; wherein the first portions of the thin bricks of the first plurality are staggered such that some of the first portions are recessed from the first edge of the first backing layer; applying a second prefabricated thin brick sheet to the wall or floor surface, wherein the second prefabricated thin brick sheet comprises: a second backing layer; and a second plurality of thin bricks that are bonded to the second backing layer with an adhesive, wherein a portion of some of the thin bricks of the second plurality overhang the second backing layer at a first edge of the second backing layer; joining the overhanging portion of the thin bricks of the second plurality to the first prefabricated thin brick sheet; applying a third prefabricated thin brick sheet to the wall or floor surface, wherein the third prefabricated thin brick sheet comprises: a third backing layer; and a third plurality of thin bricks that are bonded to the third backing layer with an adhesive, wherein a portion of some of the thin bricks of the third plurality overhang the third backing layer at a first edge of the third backing layer; and joining the overhanging portion of the thin bricks of the third plurality to the second prefabricated thin brick sheet. The method of claim 53 , wherein the first backing layer comprises regions that extend beyond some of the first portions of the thin bricks of the first plurality, and wherein the regions of the first backing layer are configured to be coupled with overhanging portions of thin bricks of the second plurality. The method of claim 53 , wherein the first backing layer defines a grid that comprises holes, and wherein each thin brick of the first plurality is bonded to the first backing layer such that a portion of the rear surface of the thin brick is free from an adhesive, wherein the portion of the rear surface of the thin brick that is free from the adhesive overlaps one or more holes in the first backing layer such that a construction adhesive can penetrate through the first backing layer to adhere to the portion of the rear surface of each of the thin bricks of the first plurality that is free from the adhesive to bond the thin brick to the wall or floor surface. The method of claim 53 , wherein the first backing layer is flexible and substantially non-stretchable. The method of claim 53 , wherein the first plurality of thin bricks are spaced from one another to provide spaces between adjacent bricks that are configured to be filled with mortar or grout. The method of claim 53 , wherein the first prefabricated thin brick sheet defines an elongated corner, wherein the first prefabricated thin brick sheet comprises a first portion that extends away from the corner in the first direction, wherein the first prefabricated thin brick sheet comprises a second portion that extends away from the corner in the second direction that is different from the first direction. A prefabricated thin brick sheet comprising: a backing layer that comprises a first edge and a second edge that are at opposite sides of the backing layer, wherein the backing layer defines a grid that comprises holes; a plurality of thin bricks that are arranged in a staggered pattern, wherein some of the thin bricks overhang the first edge of the backing layer by a first distance, and wherein the backing layer extends beyond some of the thin bricks at the second edge of the backing layer by a second distance; and an adhesive that bonds the plurality of thin bricks to the backing layer as a unitary prefabricated thin brick sheet that is configured to be mounted to a floor or wall surface, wherein each thin brick is bonded to the backing layer such that a portion of the rear surface of the thin brick is free from the adhesive, wherein the portion of the rear surface of the thin brick that is free from the adhesive overlaps one or more holes in the backing layer such that a construction adhesive can penetrate through the backing layer to adhere to the portion of the rear surface of each of the thin bricks of the plurality of thin bricks that is free from the adhesive to bond the thin brick to a wall or floor surface. The sheet of claim 59 , wherein the first and second distances are substantially equa The sheet of claim 59 , wherein the adhesive extends through some of the holes of the backing layer. |
| CPC Classification | FINISHING WORK ON BUILDINGS; e.g. STAIRS; FLOORS TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION |
| Extended Family | 098-636-967-857-522 047-427-527-738-879 110-684-054-743-087 014-475-604-683-533 071-702-108-741-292 089-601-276-067-752 197-701-788-976-849 198-591-314-982-552 196-084-650-792-062 108-518-294-648-235 166-620-790-687-000 |
| Patent ID | 20170159298 |
| Inventor/Author | Hunsaker Jason Walker Jeffrey Hunsaker Garrick |
| IPC | E04F13/09 E04F13/08 E04F13/14 E04F15/08 E04F15/16 |
| Status | Active |
| Owner | Old Mill Brick Llc Old Mill Brick Incorporated |
| Simple Family | 098-636-967-857-522 047-427-527-738-879 110-684-054-743-087 071-702-108-741-292 014-475-604-683-533 089-601-276-067-752 198-591-314-982-552 197-701-788-976-849 196-084-650-792-062 166-620-790-687-000 108-518-294-648-235 |
| CPC (with Group) | E04F13/0862 E04F13/0733 E04F13/0885 E04F13/142 E04F15/08 E04F15/166 Y10T156/1092 E04F13/09 E04F13/147 |
| Issuing Authority | United States Patent and Trademark Office (USPTO) |
| Kind | Patent Application Publication |
