Masonry support panel and associated methods of use

Abstract

Support panels for masonry objects and associated methods of use are disclosed herein. A support panel for masonry objects may include an inner surface, an outer surface, at least one stiffening channel formed longitudinally along the support panel, and a plurality of substantially C-shaped tabs extending from the outer surface, the tabs being disposed in spaced apart relation to one another to form a grid, wherein the tabs are configured to contactingly support at least a portion of a masonry object.

Claims

1. A support panel for masonry objects, comprising: an inner surface; an outer surface; a plurality of tabs extending from the outer surface, wherein the tabs are disposed in spaced apart relation to one another to form a grid, wherein the tabs each include a pair of opposing arms that are mirror images of one another and separated by an aperture to define an opening that functions as a pathway for the communication of fluid; and wherein the tabs are configured to contactingly support at least a portion of a masonry object, and wherein each of the tabs are at least partially cut out from the support panel and bent outwardly to define a substantially hemispherical aperture adapted to communicate fluids through the support panel into the conduits between adjacent stiffening channels; at least one stiffening channel that is substantially U-shaped and includes a substantially flattened medial portion that is disposed substantially parallel to the outer surface of the support panel; and wherein the support panel is attachable to a wall of a structure.

2. The support panel according to claim 1, wherein the tabs are planar.

3. The support panel according to claim 1, wherein the substantially flattened medial portion of the at least one stiffening channel is adapted to receive at least one fastener for joining the support panel to the wall of the structure, wherein the support panel and the wall cooperate to form a conduit between adjacent stiffening channels.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Certain embodiments of the present invention are illustrated by the accompanying figures. It will be understood that the figures are not necessarily to scale and that details not necessary for an understanding of the invention or that render other details difficult to perceive may be omitted. It will be understood that the invention is not necessarily limited to the particular embodiments illustrated herein.

(2) The invention will now be described with reference to the drawings wherein:

(3) FIG. 1 of the drawings is an exploded perspective view of an exemplary environment illustrating the installation of a support panel for masonry objects;

(4) FIG. 2 of the drawings is a cross-sectional view of a support panel in combination with masonry objects, the support panel installed on the wall of a structure;

(5) FIG. 3A of the drawings is a top plan view of a support panel for masonry objects;

(6) FIG. 3B of the drawings is a top plan view of a substantially C-shaped tab;

(7) FIG. 4 of the drawings is a cross-sectional view of a lower end of the support panel spaced apart from a flashing;

(8) FIG. 5 is a front perspective view of one embodiment of a support panel fabricated in accordance with the present invention;

(9) FIG. 6 is a top plan view of the support panel of FIG. 5;

(10) FIG. 7 is a bottom plan view of the support panel of FIG. 5;

(11) FIG. 8 is a left side elevation view of the support panel of FIG. 5;

(12) FIG. 9 is a right side elevation view of the support panel of FIG. 5;

(13) FIG. 10 is a front end view of the support panel of FIG. 5; and

(14) FIG. 11 is a rear end view of the support panel of FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

(15) While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail several specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated.

(16) It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings with like reference characters.

(17) Referring now to the drawings, and more particularly to FIGS. 1 and 2 collectively, an exploded perspective view of exemplary environment 100 is shown. Environment 100 preferably includes wall 10, support panel 12, flashing 14, and masonry objects 16. According to some embodiments, membrane 18 may be disposed between wall 10 and support panel 12 to act as an insulating and/or moisture barrier for protecting wall 10. Although not shown, a layer of insulation may be disposed between wall 10 and support panel 12, either alone or in combination with membrane 18.

(18) It will be understood that wall 10 may include any one of a number of substrates such as plywood, concrete, cinderblock, stucco, wood slats, and the like.

(19) Flashing 14 may be installed proximate the lower end of wall 10. Flashing 14 may be a substantially L-shaped elongated member that is adapted to be installed such that at least a portion of membrane 18 overlaps at least a portion of flashing 14 contacting wall 10. Fluid contacting membrane 18 is preferably directed downwardly via gravity and diverted away from wall 10 via flashing 14. It will be understood that in some embodiments, support panel 12 may be spaced apart from flashing 14 so as to create a gap between the end of support panel 12 and flashing 14 allowing fluid to communicate outwardly and away from wall 10 rather than being retained behind support panel 12, as will be discussed in greater detail infra.

(20) Support panel 12 may be fabricated from, for example, a 27-gauge architectural grade steel panel. According to some embodiments, the size of support panel 12 may be nominally 48 inches by 48 inches, although it is envisioned to be within the scope of the present invention to form support panels 12 having different sizes and utilizing different gauge steel. According to some embodiments, support panel 12 may be formed from a plastic, a polymer, a resin, a composite, a natural product such as wood, rubber, or any combinations thereof.

(21) It is noteworthy that in some embodiments, at least one of outer surface 20 and inner surface 22 of support panel 12 may be at least partially provided with a coating (not shown) such as a paint, powder coating, sealant, resin, and the like, adapted to substantially reduce or eliminate oxidation of support panel 12. One of ordinary skill in the art with the present disclosure before them will appreciate that the coating chosen may depend, in part, upon the material from which support panel 12 is fabricated.

(22) According to additional embodiments, at least one of outer surface 20 and inner surface 22 may include texturing (not shown) adapted to further enhance the bond between support panel 12 and masonry objects 16 via adhesive 24 applied to at least one of support panel 12 and masonry objects 16.

(23) Support panel 12 may include a plurality of substantially C-shaped tabs 26 that are formed during fabrication of support panel 12. Tabs 26 may be arranged into a grid having a plurality of rows 28 and columns 30.

(24) It will be understood that when support panel 12 is fabricated, each tab 26 may be created via punching and/or laser cutting, and the like leaving tabs 26 at least partially connected to support panel 12. Therefore, tabs 26 are initially coplanar with the rest of support panel 12 until tabs 26 are bent outwardly so as to extend at an angle relative to outer surface 20. According to some embodiments, angle may include approximately 76 degrees relative to outer surface 20 of support panel 12, although one of ordinary skill in the art will appreciate that other angles may be utilized in accordance with the present inventionincluding, but not limited to, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, and 90 degrees.

(25) Referring now to FIGS. 3A, 3B, and 4 collectively, each tab 26 includes a particular geometrical configuration that in some embodiments may include opposing arms 32 and 34 that are mirror images of one another and cooperate to define opening 36 that functions as a pathway for the communication of fluid, as will be discussed in greater detail infra. Moreover, as each tab 26 is bent outwardly, a substantially hemispherical aperture 38 (see FIG. 5) is left that corresponds in size to the outer peripheral geometry of tab 26.

(26) Support panel 12 may also include a plurality of stiffening ribs 40 that extend longitudinally along the length of support panel 12 from top to bottom. Ribs 40 are formed integrally and preferably comprise a substantially U-shaped configuration that optionally includes substantially flat medial portion 42. Medial portion 42 may be substantially parallel to outer surface 20 of support panel 12 and functions as a level contact surface for attaching support panel 12 to wall 10. Moreover, support panel 12 may be securely attached to wall 10 via fasteners inserted through ribs 40. In some embodiments, ribs 40 may include apertures (not shown) adapted to receive any one of a number of fasteners such as nails, screws, pins, clips, or the like. It is noteworthy that fasteners may be fabricated from a substantially non-corrosive and/or non-reactive material such as stainless steel.

(27) According to some embodiments, support panel 12 may include a plurality of ribs 40, each rib 40 subdividing tabs 26 into columns 30 of two, although it will be understood that ribs 40 may subdivide tabs 26 into columns 30 of varying numbers.

(28) As is best shown in FIG. 4, when support panel 12 is attached to wall 10, sections of support panel 12 between ribs 40 are spaced apart from wall 10 to form conduits 44 that are adapted to facilitate the communication of fluids therethrough.

(29) Masonry objects 16 may be substantially cuboid in configuration, resembling a traditionally proportioned brick, but having smaller thickness than a traditional brick. Among other surfaces, masonry object 16 includes rear surface 46 and bottom surface 48 (see FIG. 2). It will be understood that bottom surface 48 of masonry objects 16 may contactingly rest upon at least a portion of one or more tabs 26.

(30) Adhesive 24 may be applied to at least a portion of rear surface 46 of masonry objects 16. According to some embodiments, adhesive 24 may include any number of products capable of bonding masonry objects 16 to support panel 12.

(31) It will be understood that the spacing of vertically adjacent rows 28 of tabs 26 and the horizontal spacing of laterally adjacent masonry objects 16 form voids 50 adapted to receive bonding agent 52 therein. According to some embodiments, bonding agent 52 may include, for example, concrete, mortar, grout, adhesive, resin, or combinations thereof. It is noteworthy that bonding agent 52 disposed within voids 50 operates to bond adjacent masonry objects 16 together to create a facade that covers at least a portion of the outer surface of support panel 12.

(32) Generally speaking, the force generated by air directed against the outer surface of a brick wall may drive moisture between any spaces that may exist between masonry objects 16 and bonding agent 52, cracks that may exist in bonding agent 52 or masonry objects 16, and the like. As such, conduits 44 function to regulate the pressure across the outer surface of the facade of masonry objects 16 to prevent moisture from being driven inwardly through any imperfections in the facade of masonry objects 16.

(33) Referring now to FIG. 4, support panel 12 may be spaced apart from flashing 14 such that gap 54 is formed therebetween. Lower row 28 of tabs 26 are exposed along gap 54 such that air flowing into gap 54 communicates through openings 36 of tabs 26, into apertures 38, passing upwardly into conduits 44, and ultimately out of conduits 44 into the soffit, eave, or ceiling of the structure (not shown). Therefore, the pressure of the air flowing through conduits 44 is substantially equal to the pressure of the air contacting the outer surface of the facade of masonry objects 16. Moreover, as support panel 12 is spaced apart from flashing 14, any fluids that may build up behind masonry objects 16 may pass through apertures 38, downwardly through conduits 44, and outwardly from wall 10 via flashing 14.

(34) In operation, flashing 14 may be securely attached to the lower end of wall 10 such that at least a portion of flashing 14 contacting wall 10 is covered by membrane 18. One or more support panels 12 may be securely attached to wall 10 via fasteners inserted through ribs 40. According to some embodiments, support panels 12 may be spaced apart from flashing 14 to form gap 54. It will be understood that all, or at least a portion of tabs 26 of support panels 12 may be bent outwardly before support panels 12 are secured to wall 10.

(35) Once support panels 12 are secured to wall 10, a predetermined amount of adhesive 24 may applied to rear surface 46 of masonry objects 16 during installation. Adhesive 24 may be applied to only a portion of rear surface 46 of masonry objects 16 such as the four corners of masonry objects 16. Masonry objects 16 are applied to outer surface 20 of support panels 12 within spaces between vertically adjacent rows 28 of tabs 26. It will be understood that application of adhesive 24 between outer surface 20 and masonry objects 16 preferably creates a space therebetween. As adhesive 24 may only be applied to a portion of rear surface 46 of masonry objects 16, fluid building up between masonry objects 16 and support panel 12 may communicate through apertures 38 and into conduits 44.

(36) Additionally, bottom surface 48 of masonry objects 16 may contact at least a portion of one or more tabs 26 disposed on the lower row such that masonry objects 16 are supported thereby. The vertical and horizontal spacing of adjacent masonry objects 16 form voids 50 adapted to receive a predetermined amount of bonding agent 52 therein.

(37) Referring now to FIGS. 5-11, additional views of support panels 12 are shown in accordance with the present invention.

(38) The foregoing description merely explains and illustrates the invention, and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the invention.