Firebrick Liner Panel Device

Abstract

A firebrick liner panel device is disclosed, which is used to expedite the brick liner installation in fireplaces in a more conventional fashion. The firebrick liner panel device comprises a panel component made of a fire brick liner and constructed in different sizes to fit a variety of fireplace walls to be lined. The panel component is constructed using a cement board or other planer surface. The brick is then placed in a pattern with spacers in between to create even separation of the bricks. Users then fill the joint spaces with mud, then a sheet of diamond mesh lath is positioned over the bricks. The user with a trowel, adds a 0.25 mud bed over the mesh and lets it dry. Once completed, the panel component is installed within the fireplace by a user with minimal mason experience.

Claims

1. A firebrick liner panel device that provides a user with a prefabricated liner panel which can be installed quickly, the firebrick liner panel device comprising: a panel component; wherein the panel component is constructed using a planar surface, with a plurality of firebricks positioned on a surface; wherein mortar is applied to the plurality of firebricks; and further wherein the panel component is then installed within a fireplace.

2. The firebrick liner panel device of claim 1, wherein the planar surface is a cement board.

3. The firebrick liner panel device of claim 2, wherein the plurality of firebrick are arranged in a pattern over the cement board.

4. The firebrick liner panel device of claim 3, wherein spacers are positioned in between the plurality of firebricks to create an even separation of the plurality of firebricks.

5. The firebrick liner panel device of claim 4, wherein the spacers are utilized to create recesses between the plurality of firebricks.

6. The firebrick liner panel device of claim 5, wherein users fill the recesses with mortar.

7. The firebrick liner panel device of claim 6, wherein a sheet of diamond mesh lath is positioned over the plurality of firebricks and mortar.

8. The firebrick liner panel device of claim 7, wherein the cement board is treated with a protective layer of paper with a release agent, thus enabling the protective layer of paper to be peeled away when applied to the fireplace.

9. The firebrick liner panel device of claim 8, wherein the user with a trowel adds an approximately 0.25 mortar bed over the sheet of diamond mesh lath and lets it dry.

10. The firebrick liner panel device of claim 9, wherein once completed, the panel component has a maximum thickness of one and half inches but no less than 1.25 inches thick as required by code.

11. The firebrick liner panel device of claim 10, wherein the panel component is cured sufficiently before tilting vertically and separating from the cement board for adhesion to the fireplace.

12. A firebrick liner panel device that provides a user with a prefabricated liner panel which can be installed quickly, the method comprising the following steps: a panel component; a cement board; wherein the panel component is constructed using the cement board, with a plurality of firebricks positioned on a surface of the cement board; wherein spacers are positioned in between the plurality of firebricks to create an even separation and recesses between the plurality of firebricks; wherein mortar is applied to the recesses; wherein a sheet of diamond mesh lath is positioned over the plurality of firebricks and mortar is applied over the sheet of diamond mesh lath; wherein the panel component is then installed within a fireplace; and further wherein the panel component makes it easy for users to install a perfectly even set of fire bricks within the fireplace.

13. The firebrick liner panel device of claim 12, wherein the user with a trowel adds an approximately 0.25 mortar bed over the sheet of diamond mesh lath and lets it dry.

14. The firebrick liner panel device of claim 12, wherein once completed, the panel component has a maximum thickness of one and half inches but no less than 1.25 inches thick as required by code.

15. The firebrick liner panel device of claim 12, wherein multiple panel components can be prepared by the user then easily installed on the fireplace.

16. The firebrick liner panel device of claim 15, wherein installation of the multiple panel components can be performed by a user with minimal mason experience.

17. The firebrick liner panel device of claim 16, wherein after installation of the multiple panel components, spaces between adjacent firebricks of adjacent panel components are filled with mortar to complete installation, and to render the fireplace wall indistinguishable from a conventionally bricked fireplace wall.

18. The firebrick liner panel device of claim 12, wherein the panel components may be made in different sizes and shapes to fit a variety of fireplace walls to be lined.

19. The firebrick liner panel device of claim 12 further comprising a plurality of indicia.

20. A method of expediting firebrick liner installation in fireplaces, the method comprising the following steps: providing a firebrick liner panel device comprising a panel component constructed in a variety of sizes; positioning a plurality of bricks in a pattern on a cement board; placing spacers between the bricks to create even separation; filling the joint spaces with mud; laying a sheet of diamond mesh lath over the bricks; adding a mud bed over the mesh and letting it dry; and installing the panel component within a fireplace.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The description refers to provided drawings in which similar reference characters refer to similar parts throughout the different views, and in which:

[0028] FIG. 1 illustrates a perspective view of one embodiment of the firebrick liner panel device of the present invention in accordance with the disclosed architecture;

[0029] FIG. 2 illustrates a perspective view of one embodiment of the firebrick liner panel device of the present invention showing the panel component assembled with bricks in accordance with the disclosed architecture;

[0030] FIG. 3 illustrates a perspective view of one embodiment of the firebrick liner panel device of the present invention showing the thickness of the panel component in accordance with the disclosed architecture;

[0031] FIG. 4 illustrates a perspective view of one embodiment of the firebrick liner panel device of the present invention showing the multiple panel components in accordance with the disclosed architecture;

[0032] FIG. 5 illustrates a perspective view of one embodiment of the firebrick liner panel device of the present invention showing the panel components applied to a fireplace in accordance with the disclosed architecture; and

[0033] FIG. 6 illustrates a flowchart showing the method of expediting firebrick liner installation in fireplaces in accordance with the disclosed architecture.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0034] The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof. Various embodiments are discussed hereinafter. It should be noted that the figures are described only to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention and do not limit the scope of the invention. Additionally, an illustrated embodiment need not have all the aspects or advantages shown. Thus, in other embodiments, any of the features described herein from different embodiments may be combined.

[0035] As noted above, there is a long felt need in the art for a firebrick liner panel device that provides users with an improved liner device for expediting brick liner installation in fireplaces. There is also a long felt need in the art for a firebrick liner panel device that features a masonry panel constructed using bricks. Further, there is a long felt need in the art for a firebrick liner panel device that allows users to install a perfectly even set of bricks into the fireplace rather than installing bricks one by one. Moreover, there is a long felt need in the art for a device that includes different sizes to accommodate various fireplace walls being lined with bricks. Further, there is a long felt need in the art for a firebrick liner panel device that allows users to prefabricate the liner panels and install them quickly, saving extensive time and effort on a worksite. Finally, there is a long felt need in the art for a firebrick liner panel device that eliminates the need for workers to be on their hands and knees installing individual bricks within a fireplace.

[0036] The present invention, in one exemplary embodiment, is a novel firebrick liner panel device. The firebrick liner panel device comprises a panel component constructed in a variety of sizes to fit a variety of fireplace walls to be lined. The panel component is constructed using a cement board or other planer surface. The brick is then placed in a pattern with spacers in between to create even separation of the bricks. Users then fill the joint spaces with mud, then a sheet of diamond mesh lath is positioned over the bricks. The user with a trowel, adds a 0.25 mud bed over the mesh and lets it dry. Once completed, the panel component is installed within the fireplace by a user. The present invention also includes a novel method of expediting firebrick liner installation in fireplaces. The method includes the steps of providing a firebrick liner panel device comprising a panel component constructed in a variety of sizes. The method also comprises positioning a plurality of bricks in a pattern on a cement board. Further, the method comprises placing spacers between the bricks to create even separation. The method also comprises filling the joint spaces with mud. The method also comprises laying a sheet of diamond mesh lath over the bricks. The method comprises adding a mud bed over the mesh and letting it dry. Finally, the method comprises installing the panel component within a fireplace.

[0037] Referring initially to the drawings, FIG. 1 illustrates a perspective view of one embodiment of the firebrick liner panel device 100 of the present invention. In the present embodiment, the firebrick liner panel device 100 is an improved firebrick liner panel device 100 that provides a user with a prefabricated liner panel which can be installed quickly. Specifically, the firebrick liner panel device 100 comprises a panel component 102 constructed in a variety of sizes to fit a variety of fireplace walls to be lined. The panel component 102 is constructed using a cement board 104 on which firebricks 106 are placed in a pattern with spacers 108 in between to create even separation of the bricks 106. Users then fill the joint spaces 118 with mud 110, then a sheet of diamond mesh lath 112 is positioned over the bricks 106 and a mud bed 114 applied over top. Once completed, the panel component 102 is installed within the fireplace 116 by a user.

[0038] Generally, the firebrick liner panel device 100 provides users with an improved liner device for expediting brick liner installation in fireplaces 116. Specifically, the firebrick liner panel device 100 provides a masonry panel constructed using bricks 106, allowing users to install a perfectly even set of bricks 106 into the fireplace 116 rather than installing bricks 106 one by one. The device 100 allows users to prefabricate the liner panels and install them quickly, saving extensive time and effort on a worksite.

[0039] Further, the firebrick liner panel device 100 comprises a transportable brick panel component 102 consisting of a plurality of firebricks 106 arranged in a predetermined pattern on a planar surface 104 and filled with mud 110 between the recesses or gaps 118 of the firebricks 106.

[0040] As shown in FIG. 2, the manufacture of the transportable brick panel component 102 is constructed using a cement board 104 or other planer surface. The planar surface 104 can be any suitable shape and size as is known in the art, as long as it's sized to retain a predetermined amount of firebricks 106 in a particular design. Further, the planar surface 104 can be manufactured of any suitable material as is known in the art, although a cement board 104 is typically used. The cement board 104 in its natural state must be flat and not molded to any brick pattern shape as the cement board 104 accommodates many different panel component 102 configurations. Additionally, in the figures, the cement board 104 is shown tilted to a near vertical position for the placing of the firebricks 106 of the panel component 102 on the fireplace 116, as described below. Initially, however, the cement board 104 is positioned horizontally and the plurality of firebricks 106 applied.

[0041] Further, once the cement board 104 is in a horizontal position on the ground, worktable, or other planar surface, the plurality of firebrick 106 are then arranged in a pattern over the cement board 104, any suitable amount of firebricks 106 can be utilized as is known in the art, depending on the wants and/or needs of a user. The firebricks 106 utilized are conventional firebricks 106. Generally, a firebrick 106 is a special type of brick made using fire clay and has a good resistance against high temperatures. These bricks 106 are typically used in kilns, lining furnaces, fireplaces and fireboxes, etc. These bricks 106 are manufactured in a way similar to that of normal bricks, except during the burning process, fire bricks 106 are exposed to very high temperatures.

[0042] Additionally, spacers 108 are positioned in between the firebricks 106 to create an even separation of the bricks 106. Any suitable brick spacers 108 can be utilized as is known in the art, depending on the needs and/or wants of a user. Conventional brick spacers 108 are typically utilized in between the firebricks 106. The brick spacers 108 are utilized to create recesses or joint spaces 118 between the firebricks 106. Users then fill the recesses/joint spaces 118 with mud or mortar 110. Mortar 110 is the essential ingredient that holds the firebricks 106 together and serves as a sealant and buffer between them. Mortar 110 is frequently made up of a sand, gravel, and/or cement mixture. Further, mortar 110 provides excellent adhesion without compromising its ability to remain flexible enough for thermal expansion and contraction of the firebricks 106.

[0043] Furthermore, a sheet of diamond mesh lath 112 is positioned over the bricks 106. Any suitable diamond mesh lath 112 can be utilized as is known in the art. The sheet of diamond mesh lath 112 is a multipurpose expanded steel substrate or other suitable mesh lath as is known in the art. The function of the diamond mesh lath 112 is to prevent the fluid mortar 110 from contaminating the face surface of the bricks 106, as well as to stabilize the firebricks 106 in their preferred position. The compressible resilient nature of the diamond mesh lath 112 allows the bricks 106 to sink in, thus being able to resist lateral forces generated during the preparation or the introduction of the fluid mortar 110.

[0044] In one embodiment, the cement board 104 is treated with a protective layer of paper 120 with a cement retardant, or release agent 122 thus enabling the paper 120, which will adhere to the bricks 106, to be peeled away and the brickwork then brushed and any blemishes rectified. Thus, the cement board 104 is removed and then the protective layer of paper 120 removed before applying the panel component 102 to the fireplace 116.

[0045] As shown in FIG. 3, the user with a trowel adds an approximately 0.25 mud or mortar bed 110 over the diamond mesh lath 112 and lets it dry. Any suitable amount of mud or mortar 110 can be used as is known in the art. Once completed, the panel component 102 has a maximum thickness of one and half inches but no less than 1.25 inches thick as required by code. When this is complete, the panel component 102 is cured sufficiently before tilting vertically and separating from the cement board 104.

[0046] As shown in FIG. 4, multiple panel components 102 can be prepared by the user then easily installed on the fireplace 116, as needed. The multiple panel components 102 can be of varying sizes and shapes as is known in the art.

[0047] As shown in FIG. 5, once assembled, the user then installs the panel component 102 within the fireplace 116. Typically, the cement board 104 is removed from the panel component 102 and then the panel component 102 is secured to the fireplace 116 via suitable securing means as is known in the art, such as mud, mortar 110, etc. The panel component 102 makes it easy for users to install a perfectly even set of bricks 106 into the fireplace 116. Thus, installation of the panel components 102 can be performed by a user with minimal mason experience.

[0048] Further, after installation of the panel components 102, the spaces 118 between adjacent firebricks 106 of the adjacent panel components 102 are filled with mortar 110, to complete the installation, and to render the finished fireplace wall indistinguishable from a conventionally bricked fireplace wall.

[0049] In one embodiment, the panel components 102 may be made in different sizes and shapes to fit a variety of fireplace walls to be lined.

[0050] In yet another embodiment, the firebrick liner panel device 100 comprises a plurality of indicia 500. The panel component 102 of the device 100 may include advertising, a trademark, or other letters, designs, or characters, printed, painted, stamped, or integrated into the panel component 102, or any other indicia 500 as is known in the art. Specifically, any suitable indicia 500 as is known in the art can be included, such as but not limited to, patterns, logos, emblems, images, symbols, designs, letters, words, characters, animals, advertisements, brands, etc., that may or may not be firebrick, fireplace, or brand related.

[0051] FIG. 6 illustrates a flowchart of the method of expediting firebrick liner installation in fireplaces. The method includes the steps of at 600, providing a firebrick liner panel device comprising a panel component constructed in a variety of sizes. The method also comprises at 602, positioning a plurality of bricks in a pattern on a cement board. Further, the method comprises at 604, placing spacers between the bricks to create even separation. The method also comprises at 606, filling the joint spaces with mud. The method also comprises at 608, laying a sheet of diamond mesh lath over the bricks. The method comprises at 610, adding a mud bed over the mesh and letting it dry. Finally, the method comprises at 612, installing the panel component within a fireplace.

[0052] Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different users may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not structure or function. As used herein firebrick liner panel device, firebrick device, liner panel device, and device are interchangeable and refer to the firebrick liner panel device 100 of the present invention.

[0053] Notwithstanding the forgoing, the firebrick liner panel device 100 of the present invention can be of any suitable size and configuration as is known in the art without affecting the overall concept of the invention, provided that it accomplishes the above stated objectives. One of ordinary skill in the art will appreciate that the firebrick liner panel device 100 as shown in FIGS. 1-6 is for illustrative purposes only, and that many other sizes and shapes of the firebrick liner panel device 100 are well within the scope of the present disclosure. Although the dimensions of the firebrick liner panel device 100 are important design parameters for user convenience, the firebrick liner panel device 100 may be of any size that ensures optimal performance during use and/or that suits the user's needs and/or preferences.

[0054] Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. While the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.

[0055] What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term includes is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term comprising as comprising is interpreted when employed as a transitional word in a claim.