Abstract
The present invention is a masonry support structure and kit. The support structure includes at least a block of cellular glass insulation whose exterior surface is coated in a scratch coat. The support structure may be used to support the application of masonry veneers. The kit includes at least one support structure and may also include masonry veneers, veneer mortar, masonry wall ties, and post brackets.
Claims
1. A structural support comprising: a block of cellular glass insulation having an exterior surface; and a scratch coat disposed on at least a portion of said exterior surface of said block.
2. The structural support as claimed in claim 1, wherein said scratch coat is exterior veneer mortar.
3. The structural support as claimed in claim 1, wherein said block of cellular glass insulation is a block rectangular prism.
4. The structural support as claimed in claim 3, wherein: said block of cellular glass insulation comprises at least two strata of cellular glass insulation; each of said at least two strata comprises at least one interior surface; and said strata are stacked to form said block, such that adjacent strata are in physical contact within said block; and said structural support further comprises a layer of interior veneer mortar disposed between said interior surfaces of said adjacent strata such that said adjacent strata are adhered to one another.
5. The structural support as claimed in claim 3, wherein said block has dimensions of 12″ by 12″ by 12″.
6. The structural support as claimed in claim 3, wherein said block has dimensions of 12″ by 12″ by 18″.
7. The structural support as claimed in claim 4, wherein said block cellular glass insulation comprises three strata of cellular glass insulation.
8. The structural support as claimed in claim 1, wherein: said block comprises a first leg, a second leg, and a bridge connecting said first and second legs; said first and second legs are parallel to one another; said bridge is perpendicular to said first and second legs; said bridge is a bridge rectangular prism having six bridge sides; said first and second legs each extend from a same first of said bridge sides of said bridge; each of said first and second legs are leg rectangular prisms having six leg sides, wherein said leg rectangular prisms are a same size and shape; said first and second legs extend from said same first of said bridge sides such that: five of said leg sides of said first and second legs form a portion of said exterior surface; a second of said bridge sides forms a first flush surface with one of said leg sides of said first leg; and a third of said bridge sides forms a second flush surface with one of said leg sides of said second leg; and a side view of said block is symmetrical.
9. The structural support as claimed in claim 8, wherein: two of three dimensions of said bridge rectangular prism are 15″ by 12″; said first flush surface has dimensions of 12″ by 7.5″; said second flush surface has dimensions of 12″ by 7.5″; a leg side of said first leg disposed farthest from said bridge has dimensions of 4″ by 12″; and a leg side of said second leg disposed farthest from said bridge has dimensions of 4″ by 12″.
10. The structural support as claimed in claim 8, further comprising a layer of interior veneer mortar disposed between: said first leg and said first of said bridge sides; and said second leg and said first of said bridge sides.
11. A structural support kit comprising: at least one structural support comprising: a block of cellular glass insulation having an exterior surface; and a scratch coat disposed on at least a portion of said exterior surface of said block; and at least one masonry veneer.
12. The kit as claimed in claim 11, further comprising at least one masonry wall tie.
13. The kit as claimed in claim 11, further comprising at least one post bracket.
14. The kit as claimed in claim 11, further comprising a supply of veneer mortar.
15. The kit as claimed in claim 11, wherein said scratch coat of said at least one structural support is exterior veneer mortar.
16. The kit as claimed in claim 11, wherein: said block of cellular glass insulation of said at least one structural support is a block rectangular prism, comprising at least two strata of cellular glass insulation; each of said at least two strata comprises at least one interior surface; and said strata are stacked to form said block, such that adjacent strata are in physical contact within said block; and said structural support further comprises a layer of interior veneer mortar disposed between said interior surfaces of said adjacent strata such that said adjacent strata are adhered to one another.
17. The kit as claimed in claim 11, wherein: said block of said at least one structural support comprises a first leg, a second leg, and a bridge connecting said first and second legs; said first and second legs are parallel to one another; said bridge is perpendicular to said first and second legs; said bridge is a bridge rectangular prism having six bridge sides; said first and second legs each extend from a same first of said bridge sides of said bridge; each of said first and second legs are leg rectangular prisms having six leg sides, wherein said leg rectangular prisms are a same size and shape; said first and second legs extend from said same first of said bridge sides such that: five of said leg sides of said first and second legs form a portion of said exterior surface; a second of said bridge sides forms a first flush surface with one of said leg sides of said first leg; and a third of said bridge sides forms a second flush surface with one of said leg sides of said second leg; and a side view of said block is symmetrical.
18. A structural support kit comprising: at least one structural support comprising: a block of cellular glass insulation having an exterior surface; and a scratch coat disposed on at least a portion of said exterior surface of said block; and at least one masonry wall tie.
19. The kit as claimed in claim 18, further comprising at least one post bracket.
20. The kit as claimed in claim 18, further comprising a supply of veneer mortar.
21. The kit as claimed in claim 18, wherein said scratch coat of said at least one structural support is exterior veneer mortar.
22. The kit as claimed in claim 18, wherein: said block of cellular glass insulation of said at least one structural support is a block rectangular prism, comprising at least two strata of cellular glass insulation; each of said at least two strata comprises at least one interior surface; and said strata are stacked to form said block, such that adjacent strata are in physical contact within said block; and said structural support further comprises a layer of interior veneer mortar disposed between said interior surfaces of said adjacent strata such that said adjacent strata are adhered to one another.
23. The kit as claimed in claim 18, wherein: said block of said at least one structural support comprises a first leg, a second leg, and a bridge connecting said first and second legs; said first and second legs are parallel to one another; said bridge is perpendicular to said first and second legs; said bridge is a bridge rectangular prism having six bridge sides; said first and second legs each extend from a same first of said bridge sides of said bridge; each of said first and second legs are leg rectangular prisms having six leg sides, wherein said leg rectangular prisms are a same size and shape; said first and second legs extend from said same first of said bridge sides such that: five of said leg sides of said first and second legs form a portion of said exterior surface; a second of said bridge sides forms a first flush surface with one of said leg sides of said first leg; and a third of said bridge sides forms a second flush surface with one of said leg sides of said second leg; and a side view of said block is symmetrical.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1a is a perspective view of a preferred embodiment of the structural support of the present invention.
[0022] FIGS. 1b and 1c are perspective diagrams of the structural support of the present invention.
[0023] FIG. 2a is a perspective view of an alternate preferred embodiment of the structural support of the present invention.
[0024] FIG. 2b is a perspective diagram of the structural support of the present invention shown in FIG. 2a.
[0025] FIG. 2c is the side view of the structural support of the present invention shown in FIG. 2a.
[0026] FIG. 3 is a block diagram of the components of the kit of the present invention.
[0027] FIG. 4 is a photograph of structural supports of the present invention in use around a barbecue grill.
[0028] FIGS. 5a and 5b are photographs of the kit of the present invention in use around a column.
DETAILED DESCRIPTION
[0029] Referring first to FIG. 1a, a perspective view of a preferred embodiment of structural support 10 of the present invention is provided. Structural support 10 is a block 12 made of cellular glass insulation 14. Block 12 is formed as a block rectangular prism 22 having first dimension 24, second dimension 26, and third dimension 28. The preferred dimensions 24, 26, 28 are each 12″. Block 12 has exterior surface 16 on which is disposed scratch coat 18, which is preferably exterior veneer mortar 20.
[0030] Now referring to FIGS. 1b and 1c, perspective views of structural support 10 separated into strata 30 is provided. It is understood that not all embodiments of block 12 include strata 30 and that some blocks 12 are formed from a single, integrated piece of cellular glass insulation 14. It is further understood that strata 30 of structural support 10 are not typically visible as structural support 10 is block 12 in its final form. FIGS. 1b and 1c are provided for illustrative purposes to indicate interior features of block 12. In FIG. 1b, block 12 has two strata 30. Each stratum 30 has one interior surface 32. A layer of interior veneer mortar 34 has been applied to the interior surface 32 of the lower stratum 30. This interior veneer mortar 34 will adhere the strata 30 together so that their interior surfaces 32 are in physical contact with one another. It is understood that interior veneer mortar 34 may be applied to the interior surface of the upper stratum 30 instead of the lower stratum 30 or to the interior surfaces 32 of both the upper and lower strata 30. In FIG. 1c, block 12 has three strata 30. The upper and lower strata 30 each have one interior surface 32 and the middle stratum 30 has two interior surfaces 32, one of which is in physical contact with the interior surface 32 of the upper stratum 30, and one of which is in physical contact with the interior surface 32 of the lower stratum 30. Layers of interior veneer mortar 34 have been applied to all interior surfaces 32 of all strata 30. Strata 30 may be adhered together when a layer of interior veneer mortar 34 is applied to only one interior surface 32 of adjacent strata 30, as shown in FIG. 1b, or on both interior surfaces 32 of adjacent strata 30, as shown in FIG. 1c. In FIG. 1c, one dimension 24 of block 12 is 18″ so that the dimensions 24, 26, 28 of this embodiment of block 12 are 18″×12″×12″.
[0031] Now referring to FIG. 2a, a perspective view of the “C”/“U” configuration 72 of the structural support 10 of the present invention. Block 12 has bridge 40 connecting first leg 36 and second leg 38. First and second legs 36, 38 each extend perpendicularly out from a first bridge side 42 and are parallel to one another. The dashed lines indicate the delineation between bridge 40 and first and second legs 36, 38, but it is understood that this dashed line is illustrative only and is not visible on block 10. (It is understood that similar dashed lines in other Figures are also illustrative only and are not visible.) A first flush surface 52 is formed across a second bridge side 44 (to the left of the vertical dashed line) and a leg side 56 of first leg 36 (to the right of the vertical dashed line). A similar second flush surface 54 is formed across third bridge side 46 and a leg side 56 of second leg 38, but second flush surface 54 is not visible in this view. This preferred embodiment has first bridge dimension 64 of 15″; second bridge dimension 66, which is also a first dimension of first and second flush surfaces 52, 54, of 12″; second dimension 68 of first and second flush surfaces 52, 54 of 7.5″; and leg side dimension 70 of 4″, where leg side dimension 70 is a dimension of the either leg side 56 that is furthest from bridge 40.
[0032] Now referring to FIG. 2b, a perspective diagram of structural support 10 as shown in FIG. 2a, with bridge 40 and first and second legs 36, 38 separated is provided. It is understood that some blocks 12 in “C”/“U” configuration 72 are formed from a single, integrated piece of cellular glass insulation 14 that has been manufactured into the “C”/“U” shape. FIG. 2b illustrates an embodiment of the “C”/“U” configuration 72 where first and second legs 36, 38 are adhered to bridge 40 to form the “C”/“U” shape. Each of first and second legs 36, 38 is a leg rectangular prism 50 with six leg sides 56. Five of the six of the leg sides 56 of each of first and second legs 36, 38 are part of the exterior surface 16 of block 12. The remaining sixth leg side 56 of each of first and second legs 36, 38 is an interior surface 32. Each of first, second, and third bridge sides 42, 44, 46, discussed above is a bridge side 48. Bridge 40 is a bridge rectangular prism 62 with six bridge sides 48. All of bridge sides 48 form part of the exterior surface 16 of block 12 except for the portions of first bridge side 42 to the left of the left dashed line, which meets with interior surface 32 of first leg 36, and to the right of the right dashed line, which meets with interior surface of second leg 38. Interior surfaces 32 of first and second legs 36, 38 include a layer of interior veneer mortar 34 to adhere first and second legs 36, 38 to first bridge side 42 of bridge 40. It is understood that the layer of interior veneer mortar 34 may be applied instead to the portions of first bridge side 42 that are interior surfaces 32 or to the interior surfaces 32 of both first and second legs 36, 38 and the interior surfaces 32 of first bridge side 42.
[0033] Now referring to FIG. 2c, the side view 58 of the structural support 10 of the present invention shown in FIG. 2a is provided. The side view 58 is a top down view of either two-dimensional surface of block 10 in “C”/“U” configuration 72 where the “U” or “C” shape is most obvious. Side view 58 has line of symmetry 60 and is therefore symmetrical.
[0034] Now referring to FIG. 3, a block diagram illustrating various components of kit 100 of the present invention are provided. Each kit 100 includes at least one structural support 10 of the present invention, which may take the form or block rectangular prism 22, as described above with reference to FIGS. 1a-1c; “C”/“U” configuration 72, as described above with reference to FIGS. 2a-2c; or any other shape and/or size. One embodiment of kit 100 also includes at least one masonry veneer 74. Although masonry veneer 74 is illustrated herein as a brick façade, it is understood that masonry veneer 74 may be any masonry veneer commonly used in the art or a selection of masonry veneers commonly used in the art. Another embodiment of kit 100 also includes at least one masonry wall tie 78. Although masonry wall tie 78 is illustrated herein as a crimped length of steel, it is understood that masonry wall tie 78 may be any masonry wall tie commonly used in the art or a selection of masonry wall ties commonly used in the art. Kit 100 may also include a supply of veneer mortar 76, which may be any veneer mortar commonly used in the art and any quantity thereof. Kit 100 may also include at least one post bracket 80. Although post bracket 80 is illustrated herein as a simple 90° metal bracket, it is understood that post bracket 80 may be any post bracket commonly used in the art. The various components of kit 100 are illustrated in use in FIGS. 4, 5a, and 5b below.
[0035] Now referring to FIG. 4, a photograph of structural supports 10 used around a barbecue grill 82 is provided. Barbecue grill 82 is surrounded by structural supports 10 in the form of block rectangular prisms 22. Although not visible, a supply of veneer mortar 76 from kit 100 was used to adhere blocks 12 of structural supports 10 together. Masonry wall ties 78 from kit 100 may also have been used to secure blocks 12 together (as shown in FIGS. 5a and 5b below). Moreover, one or more post brackets 80 from kit 100 may have been deployed with one side attached to the bottom of grill 82 and one side attached to the bases of the lower layer of blocks 12. The owner of the grill 82 now need only apply some of her supply of veneer mortar 76 to the visible surfaces of blocks 12 and then apply the masonry veneer 74 of her choice to make a beautiful outdoor structure.
[0036] Now referring to FIGS. 5a and 5b, photographs of structural supports 10 in two stages of application used around column 84 are provided. The structural supports 10 are in the “C”/“U” configuration 72. In FIG. 5a, two structural supports 10 are disposed around column 84 so that column 84 is encapsulated in the space provided by the “C”/“U” shape. Masonry wall ties 78 from kit 100 are used to hold the two structural supports 10 in place with respect to one another and with respect to column 84. Although not visible, one or more post brackets 80 are disposed at the bottom of column 84 so that one side is attached to column 84 and one side is attached to the bases of the structural supports 10. Some of the supply of veneer mortar 76 has been used to adhere the two structural supports 10 together down their lengths. FIG. 5b illustrates the same application a little farther along. A second layer of structural supports 10 are being applied on top of that which we see in FIG. 5a. The second layer is being applied in a 90° orientation from the first layer so that the seams between the structural supports 10 on the respective layers are not directly atop one another. Again, once completely installed, the owner of column 84 may apply some of her supply of veneer mortar 76 to the outer surfaces of blocks 10 and then apply the masonry veneer 74 of her choice, making a simple wooden post into a much more attractive outdoor feature.
[0037] Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the description should not be limited to the description of the preferred versions contained herein.
