FIBER ENFORCED THIN BRICK SHEET AND PROCESS

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.

Claims

1-41. (canceled)

42. A method of installing thin brick sheets, comprising: applying a first adhesive to a wall or floor surface; and applying a thin brick sheet to the wall or floor surface, wherein the thin brick sheet comprises a backing layer and a plurality of thin bricks that are bonded to the backing layer via a second adhesive, wherein the backing layer defines a grid that comprises a plurality of holes, and wherein the plurality of thin bricks are bonded to the backing layer such that the first adhesive penetrates through the plurality of holes to hold the brick sheet to the wall or floor surface.

43. The method of claim 42, wherein the backing layer is non-stretchable.

44. The method of claim 42, wherein the backing layer comprises at least one of fiberglass, polyester, graphite, aramid, or carbon.

45. The method of claim 44, wherein the backing layer comprises fiberglass.

46. The method of claim 42, wherein the plurality of bricks are adhered to the backing layer in a running bond pattern or a stack bond pattern.

47. The method of claim 46, wherein the plurality of bricks are adhered to the backing layer in a stack bond pattern.

48. The method of claim 42, wherein the adhesive penetrates through a plurality of holes disposed behind the plurality of thin bricks to bond the thin bricks to the wall or floor surface.

49. The method of claim 42, wherein the plurality of thin bricks comprise one or more of clay bricks, cast bricks, or wire cut bricks.

50. The method of claim 42, wherein the thin brick sheet consists of four rows of thin bricks.

51. The method of claim 50, wherein the thin brick sheet consists of three thin bricks per row.

52. A method of installing thin brick sheets, comprising: applying a first adhesive to a wall or floor surface; and applying a thin brick sheet to the wall or floor surface, wherein the thin brick sheet comprises a backing layer and a plurality of thin bricks that are bonded to the backing layer via a second adhesive, wherein the backing layer defines a grid that comprises a plurality of holes, and wherein the plurality of thin bricks are bonded to the backing layer such that the first adhesive penetrates through the plurality of holes to hold a rear surface of the brick sheet to the wall or floor surface.

53. The method of claim 52, wherein the backing layer is non-stretchable.

54. The method of claim 52, wherein the backing layer comprises at least one of fiberglass, polyester, graphite, aramid, or carbon.

55. The method of claim 54, wherein the backing layer comprises fiberglass.

56. The method of claim 52, wherein the adhesive penetrates through a plurality of holes disposed behind the plurality of thin bricks to bond the thin bricks to the wall or floor surface.

57. The method of claim 52, wherein the plurality of thin bricks comprise one or more of clay bricks, cast bricks, or wire cut bricks.

58. The method of claim 52, wherein the thin brick sheet consists of four rows of thin bricks.

59. The method of claim 58, wherein the thin brick sheet consists of three thin bricks per row.

60. A method of installing thin brick sheets, comprising: applying a first adhesive to a wall or floor surface; and applying a thin brick sheet to the wall or floor surface, wherein the thin brick sheet comprises a backing layer and a plurality of thin bricks that are bonded to the backing layer via a second adhesive, wherein the plurality of thin bricks comprise one or more of clay bricks, cast bricks, or wire cut bricks, wherein the backing layer defines a grid that comprises a plurality of holes, wherein the plurality of thin bricks are bonded to the backing layer such that the first adhesive penetrates through the plurality of holes to hold a rear surface of the brick sheet to the wall or floor surface, and wherein the thin brick sheet consists of four rows of thin bricks.

61. The method of claim 60, wherein the thin brick sheet consists of three thin bricks per row.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 Is a cross-sectional view of fiber enforced thin brick sheets of the said invention.

[0016] FIG. 2 Cut thru order of fiber enforced thin brick process.

[0017] FIG. 3 Is a cross-sectional view of corner brick using fiber enforced thin brick sheets in the process of the said invention.

[0018] FIG. 4 View of an example layout of the corner thin brick sheets of said invention showing application arrangement and edges of such a sheet.

DETAILED DESCRIPTION OF THE DRAWINGS

[0019] The invention will best be understood by referring to the drawings.

[0020] FIG. 1 shows a portion of a thin brick sheet in cross section. Individual thin brick elements (5) are supported by adhesive (6) on a fiber-reinforced backing layer (7). Anti-adhesive paper on back of thin brick sheets for separation and adhesive release (8).

[0021] FIG. 2 schematically it a cut thru fabricated thin brick sheets. Thin layer of anti-adhesive paper to prevent bonding of the backing layer adhesive (9). Reinforcing fabric (10) for the backing layer. Adhesive at a high temperature is then impregnated or applied to either brick or fiber-reinforced backing layer (11). Individual thin brick elements (12).

[0022] FIG. 3 schematically illustrates corner thin brick sheets. Thin layer of anti-adhesive paper to prevent bonding of the backing layer adhesive that is curved in the same position of a typical thin brick corner (13). Reinforced fabric sheet that is curved in the same position of a typical thin brick corner (14). Adhesive at a high temperature is then impregnated or applied to either corner brick or fiber-reinforced backing layer (15). Thin corner brick positioner (16) helps in the proper spacing and alignment process.

[0023] FIG. 4 shows in detail the layout of an optional embodiment of the thin brick sheets and corner sheets of the present invention. Corner sheets are typically applied first (17) were brick are placed opposite of each other. The thin bricks are staggered in typical brick patterns (18) and fiber-reinforced backing layer extends beyond the thin brick elements on one edge of the sheet (19), while on the opposite edge the thin brick elements overhang the fiber-reinforced backing layer by an equal distance (20). This permits abutting thin brick sheets to be joined together in such a way that the joint between bricks are the proper space to adjacent thin brick sheets.

SUMMARY

[0024] Alternatively, the sheets of the present invention may be manufactured individually in multiple sizes. Thin bricks are placed face down or face up within the confines of a frame designed to hold the loose thin bricks in a rectangular array. Gaps are left between the edges of adjacent thin bricks to permit the subsequent insertion of grout as is well known in the art.

[0025] Reinforcing fabric for the hacking layer is then placed over the exposed rear surfaces of the thin brick elements in the array. A adhesive is then applied to the fabric first or brick first, saturating it and extending through it to contact the thin bricks or sheets. As the adhesive cures it bonds the backing layer to the thin bricks. This process may be accelerated by the application of heat to raise the temperature of the adhesive/catalyst mixture thereby increasing its cure rate.

[0026] When the adhesive of the backing layer has substantially cured, the hacking layer with the thin brick elements bonded to it is inverted, exposing the front face of the thin brick elements. Grout or mortar other suitable or alike material is applied to the spaces between the thin bricks.

[0027] In use, the thin brick sheets are mounted to conventional floor or wall surfaces using construction adhesives of the type previously mentioned.

[0028] While one specific embodiment of the invention has been disclosed herein, it should be understood that this disclosure is made by way of illustration rather than limitation. Numerous changes may be made by those skilled in the art, particularly with reference to the dimensions, materials and configuration disclosed herein. Changes of this nature would not depart from the spirit of the invention or the scope of the appended claims.