Masonary Panel Assembly

Abstract

A masonry panel assembly for enhancing quality and efficiency of masonry work includes a panel that that has a pre-dried layer. The panel has a plurality of ridges thereon and the process of fastening the panel to the wall replaces applying a scratch coat for masonry work on site. A mortar is applied to masonry units to attach the masonry units to the panel after the panel is fastened to the wall. Additionally, the mortar engages each of the ridges such that the mortar resists running downwardly on the panel when the masonry units are adhered to the panel by the mortar.

Claims

1. A masonry panel assembly being configured to have masonry units adhered thereto during construction and remodeling, said assembly comprising: a panel being configured to be fastened to a wall, said panel having a plurality of ridges thereon, a pre-dried layer of thinset concrete covering said panel; and a mortar covering a masonry unit, said masonry unit being pressable against said panel wherein said mortar covering engages and is adhered to said thinset concrete.

2. The assembly of claim 1, further comprising said mortar engaging each of said ridges wherein said mortar is configured to resist running downwardly on said panel.

3. The assembly according to claim 1, wherein said panel has a first surface, a second surface and a peripheral edge extending therebetween, said peripheral edge having a first lateral side, a second lateral side, a top side and a bottom side, said first surface being configured to be fastened to the wall, each of said ridges extending outwardly from said second surface.

4. The assembly according to claim 3, wherein each of said ridges extends between said first lateral side and said second lateral side, said ridges being spaced apart from each other and being distributed between said top side and said bottom side.

5. The assembly according to claim 3, wherein each of said ridges is oriented parallel with each other and with said top side and said bottom side, said panel being oriented such that each of said ridges is horizontally oriented on the wall.

6. The assembly of claim 3, further comprising each of said ridges extending outwardly from said second surface, each of said ridges having a distal surface relative to said second surface, said distal surface being planar and parallel to said second surface.

7. A masonry panel assembly being configured to have masonry units adhered thereto during construction and remodeling, said assembly comprising: a panel being configured to be fastened to a wall, said panel having a plurality of ridges thereon, a pre-dried layer of thinset concrete covering said panel; a mortar covering a masonry unit, said masonry unit being pressable against said panel wherein said mortar covering engages and is adhered to said thinset concrete; said panel having a first surface, a second surface and a peripheral edge extending therebetween, said peripheral edge having a first lateral side, a second lateral side, a top side and a bottom side, said first surface being configured to be fastened to the wall, each of said ridges extending outwardly from said second surface; each of said ridges extending between said first lateral side and said second lateral side, said ridges being spaced apart from each other and being distributed between said top side and said bottom side; each of said ridges being oriented parallel with each other and with said top side and said bottom side, said panel being oriented such that each of said ridges is horizontally oriented on the wall; and each of said ridges extending outwardly from said second surface, each of said ridges having a distal surface relative to said second surface, said distal surface being planar and parallel to said second surface.

8. A method of adhering masonry to an underlying panel, the steps of the method comprising: having a panel; applying a scratch coat and thinset concrete to the panel to form a pre-dried layer on the panel; allowing the scratch coat and thinset to dry on the panel prior to attaching the panel to a structure; attaching the panel to a structure; and applying mortar to a masonry unit; and pressing the masonry unit against the panel wherein the mortar interacts with the pre-dried layer on the panel to adhere the masonry unit to the panel.

9. The method of claim 8, wherein the pre-dried layer provides a plurality of ridges on the panel.

Description

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING(S)

[0010] The disclosure will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

[0011] FIG. 1 is a top perspective view of a panel of a masonry panel assembly according to an embodiment of the disclosure.

[0012] FIG. 2 is a bottom view of a panel of an embodiment of the disclosure.

[0013] FIG. 3 is a right side view of a panel an embodiment of the disclosure.

[0014] FIG. 4 is a top view of a panel of an embodiment of the disclosure.

[0015] FIG. 5 is a front perspective in-use view of an embodiment of the disclosure.

[0016] FIG. 6 is a cross sectional view taken along line 6-6 of FIG. 5 of an embodiment of the disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0017] With reference now to the drawings, and in particular to FIGS. 1 through 6 thereof, a new masonry device embodying the principles and concepts of an embodiment of the disclosure and generally designated by the reference numeral 10 will be described.

[0018] As best illustrated in FIGS. 1 through 6, the masonry panel assembly 10 generally comprises a panel 12 that may be fastened to a wall 14. The panel 12 has a plurality of ridges 16 thereon and the panel 12 has a first surface 18, a second surface 20 and a peripheral edge 22 extending therebetween. The peripheral edge 22 has a first lateral side 24, a second lateral side 26, a top side 28 and a bottom side 30. The first surface 18 is fastened to the wall 14 and each of the ridges 16 extends outwardly from the second surface 20.

[0019] Each of the ridges 16 extends between the first lateral side 24 and the second lateral side 26. Moreover, the ridges 16 are spaced apart from each other and are distributed between the top side 28 and the bottom side 30. Each of the ridges 16 are oriented parallel with each other, with the top side 28 and with the bottom side 30. Additionally, the panel 12 is oriented such that each of the ridges 16 is horizontally oriented on the wall 14. A scratch coat, typically thinset concrete, is applied to the panel 12 and allowed to dry to form a pre-dried layer 87 on the panel 12 before installation of the panel 12. After the pre-dried layer 87 is delivered to a work site, the panel 12 is fastened to the wall 14 to prepare the wall 14 for masonry work. A plurality of panels 12 may each be attached to the wall 14 in sufficient numbers to cover the wall 14.

[0020] A mortar 32 is provided and the mortar 32 is applied to masonry units 34 for application onto the panel 12 after the panel 12 is fastened to the wall 14. A plurality of the masonry units 34, such as stone veneer, brick, tile and other heavy masonry units 34, are adhered to the panel 12 by the mortar 32 when the mortar 32. The mortar 32 engages each of the ridges 16 such that the mortar 32 resists running downwardly on the panel 12. Moreover, the mortar 32 may be a fluid masonry mortar 32 of any conventional design.

[0021] In use, the panel 12 is attached to the wall 14 after formation of the pre-dried layer 87 such that the panel 12 is immediately ready for use of mortar 32 to adhere the masonry units 34. The traditional process of applying a scratch coat to the wall 14 to prepare the wall 14 for masonry work involves 24 hours of cure time before mortar 32 can be applied to the scratch coat. Thus, the panel 12 having the pre-dried layer 87 reduces the amount of time required to complete the masonry work.

[0022] With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of an embodiment enabled by the disclosure, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by an embodiment of the disclosure.

[0023] Therefore, the foregoing is considered as illustrative only of the principles of the disclosure. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the disclosure. In this patent document, the word comprising is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article a does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be only one of the elements.