Brick tray

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 63/341,026 filed on May 12, 2022, and U.S. Provisional Application Ser. No. 63/341,033, filed on May 12, 2022, the disclosures of which, in their entireties, are incorporated herein by reference.

BACKGROUND OF THE INVENTION

In general, brick trays use adhesives to hold brick slips in place. However, the use of adhesives increases the cost of materials and labor. In an effort to provide a more cost-effective solution, numerous prior art brick trays are designed for mechanical installation of cut and uncut bricks. For example, U.S. Pat. No. 10,738,476 teaches the use of horizontal rows of spaced-apart tabs with a removeable horizontal bar attached to the tabs—the upper edge and lower edge of the horizontal bar secure the brick slip. It is believed that with this type of configuration, the brick tray provides less than optimal support for the brick slip.

In an effort to increase support, prior art teaches the use of significant modification of the brick slip. For example, in U.S. Pat. No. 8,973,327, the brick tray has similar upper and lower protruding ribs for securing a row of bricks. However, as shown in FIGS. 1A-1F of the '327 patent, the bricks have substantial cuts along their top and/or back surfaces. The use of a substantially cut brick, like the use of adhesive, increases the cost of materials and labor.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the invention, a brick tray securing a brick slip comprises a C-shaped channel having a length; at least one stiffening bar located along a portion of the length of the C-shaped channel; a top, the top having a downward facing flange, the downward facing flange angled inward toward the C-shaped channel and having a toothed bottom edge, the toothed bottom edge having at least one tooth; and a base, the base having an upward facing flange angled perpendicular to the base and having a smooth top edge. The uncut brick slip sits between the toothed bottom edge of the downward facing flange and the smooth top edge of the upward facing flange.

In accordance with a second embodiment of the invention, the brick tray includes a clip for further securing a brick slip. In this embodiment, the brick slip has vertical cuts along its side edges. The first vertical edge of the clip sits within the vertical cut of one brick slip, and the second vertical edge of the clip sits within the vertical cut of a second brick slip.

In accordance with third embodiment of the invention, a brick tray securing a brick slip comprises a C-shaped channel having a length; at least one stiffening bar located along a portion of the length of the C-shaped channel; a top, the top having a downward facing flange, the downward facing flange angled inward toward the C-shaped channel and having a toothed bottom edge, the toothed bottom edge having at least one tooth; and a base, the base having an outside edge that is hemmed, the hem having at least one angled arm with the angled arm extending either outward (away) from the brick tray or inward (toward) the brick tray. A stiffening bar, which also acts as a spacer, straddles the center line of the base.

In an alternate embodiment of the third embodiment of the invention, the hemmed side edge has two angled arms, a top arm and a bottom arm, the top arm securing a first brick slip and the bottom arm securing a second brick slip.

BRIEF DESCRIPTION OF DRAWINGS

The foregoing features of the invention will be more readily understood by reference to the following detailed description and the accompanying views of drawing, in which:

FIG. 1 is a schematic side view of an exemplary embodiment of a brick tray, in accordance with a first embodiment of the invention.

FIG. 2 is a schematic front view of an exemplary embodiment of a brick tray, in accordance with the first embodiment of the invention.

FIG. 3 is a schematic off-set view of an exemplary embodiment of a brick, in accordance with the first and second embodiments of the invention.

FIG. 4 is a schematic off-set view of an exemplary embodiment of a brick for use in association with a second embodiment of the invention.

FIG. 5A is a schematic off-set view of an exemplary embodiment of a clip for use in association with the second embodiment of the invention.

FIG. 5B is a schematic front view of an exemplary embodiment of the clip positioned for use in association with the second embodiment of the invention.

FIG. 6 is a schematic off-set view of an exemplary embodiment of a brick tray, in accordance with the second embodiment of the invention.

FIG. 7 is a schematic front view of an exemplary embodiment of a brick tray, in accordance with the second embodiment of the invention.

FIG. 8 is a schematic side view of an exemplary embodiment of a brick tray, in accordance with a third embodiment of the invention.

FIGS. 9A and 9B are schematic side views of an exemplary embodiment of a brick tray, in accordance with the third embodiment of the invention

FIG. 10 is a schematic back view of an exemplary embodiment of a brick tray, in accordance with the first, second, and third embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a schematic representation of one embodiment of a brick tray. As shown, tray 100 comprises C-shaped channel 102, which comprises back 106, top 108a and base 108b. Brick slip 300 is uncut. For ease of use, the phrase “brick slip” encompasses other brick industry terminology, for example, brick, brick tile, brick veneer and thin brick. The phrase “uncut brick slip” is used to define a brick slip that has not been modified with, for example, grooves, cuts, kerf cuts, and slots.

Top 108a has a downward facing flange, denoted as 110a. Top 108a and base 108b may be between 0.649-0.75 inches-in-depth, and may be longer to accommodate other brick slip sizes. Stiffening bars 112a and 112b straddle the center line of back 106 and run the length of C-shaped channel 102. The center line of stiffening bar 112a may be placed approximately 0.771 inches from base 308b, and the center line of second stiffening bar 112a may be placed approximately 1.125 inches from the center line of stiffening bar 112b. In operation, stiffening bars 112a and 112b add strength to the tray and serve as contact points for back side 326 of brick slip 300 (shown in FIG. 3) for vertical alignment.

Brick slip 300 sits under, and is secured by, inward facing flange 110a. The inward facing flange may be 0.250 inches-in-length. Flange 110a may be angled downward at 90 degrees, with an angle of tolerance between 0 degrees and minus 15 degrees. Flange 110b is angled upward at 90 degrees, with an angle tolerance between 0 degrees and minus 15 degrees.

The edge of flange 110a is toothed and the tooth depths may range between 2.0 mm and 6.0 mm in depth. As a person of ordinary skill understands, the teeth may have varying widths and lengths. The teeth, when in contact with brick slip 300, may be slightly flexed. The edge of flange 110b is smooth and provides a uniform seat for brick slip 300.

As shown in FIG. 2, each tray may hold several brick slips stacked in several rows. At least one tooth may grip each brick slip. The teeth may be spaced in even intervals, or staggered intervals, along the edge of the top flange.

FIG. 3 is a schematic representation of brick slip 300. Brick slip 300, which is uncut, comprises top 322, bottom 324, back 326, and sides 328a and 328b.

In placing brick slip 300 between flanges 110a and 110b, an operator positions, for example, bottom side 324 of brick slip 300 atop the smooth edge of flange 110b and top side 322 of brick slip 300 against the toothed edge of flange 110a. Then, the operator uses a mallet to hit brick slip 300 with a downward and inward striking blow, driving top side 322 against the toothed edge of flange 110a. Once brick slip 300 is in place, the teeth of flange 110a may be flexed and gripping top side 322 of brick slip 300, securing brick slip 300 into place. The striking blow also causes back side 326 of brick slip 300 to rest against contact points 104a and 104b of stiffening arms 112a and 112b. As understood by a person of ordinary skill in the art, mortar may be used to further secure the brick slips or to achieve the traditional look of brick veneer.

FIG. 4 is a schematic representation of brick slip 400. Brick slip 400, which has two nominal vertical cuts, comprises top 422, bottom 424, back 426, sides 428a and 428b and vertical cut 430a down side 428a, and vertical cut 430b down side 428b. The width of vertical cuts 430a and 430b may be 0.25 inches+/−0.0625 inches. The vertical cut is located 0.1875 inches+/−0.0625 inches from back 426, and may extend the height of brick slip 400.

FIG. 5A is a schematic representation of clip 500. Clip 500 comprises front 532, top 534a, and base 534b. As shown, top 534a is located at the top edge of front 532. It comprises flange 536, which may be angled downward at a 90-degree angle from top 534a. Further, top 534a may be perpendicular to, and narrower than, front 532. In general, top 534a may be positioned in line with the vertical centerline of front 532. As understood by a person of skill in the art, the narrower width of top 534a, as compared to front 532, forms two horizontal surfaces, denoted as 538a and 538b, on the top edge of front 532. In turn, base 534b is located at the bottom edge of front 532. It may be perpendicular to front 532, or angled inward toward front 532. Base 534b may be similar in width to front 532.

FIG. 5B is a schematic representation of clip 500 with horizontal surface 538a sitting in vertical cut 430a of one brick slip and horizontal surface 538b sitting in vertical cut 430b of another brick slip.

FIG. 6 is a schematic representation of a second embodiment of the invention. With the exception of clip 500, tray 600 is similar in structure to tray 100. As shown, clip 500 sits between top 608a and base 608b of tray 600, with front 532 facing away from tray 600 (that is, toward the brick slips). When positioned, top 608a and base 608b of tray 600 secure clip 500 in tray 600, and clip 500 secures brick slip 400 in place. As described above, the vertical cuts are located 0.1875 inches+/−0.0625 inches from back 426. Thus, in FIG. 6, this posterior portion of brick tray 400 is not visible. Further, in a manner similar to tray 100, brick slip 400 may be secured by the toothed edge of a flange, such a flanges 610a and 610b.

In placing brick slip 400 between flanges 610a and 610b, an operator positions, for example, bottom side 424 of brick slip 400 atop the smooth edge of flange 610b and top side 422 of brick slip 400 against the toothed edge of flange 610a. Then, the operator uses a mallet to hit brick slip 400 with a downward and inward striking blow, driving top side 422 against the toothed edge of flange 610a. For the first brick slip in a tray, the operator positions clip 500 between top 608a and base 608b and near brick slip 400, then slides clip 500 into vertical cut 430a (or 430b) of the brick slip. For additional brick slips in the tray, the operator positions clip 500 between top 608a and base 608b and near brick slip 400, then uses the mallet to tap clip 500 into vertical cut 430a (or 430b) of the brick slip.

As shown in FIG. 7, each tray may hold several brick slips stacked in several rows with clip 500 securing two brick slips (as also shown in FIG. 5B). In an alternate embodiment, brick slip 400 may be secured to tray 700 using clip 500 without the use of flanges, such as flange 710a.

FIG. 8 is a schematic representation of a third embodiment of a brick tray. As shown, tray 800 comprises C-shaped channel 802, which comprises back 806, top 808a and base 808b. Brick slip 300 is uncut.

Top 808a has an inward facing flange, denoted as 810a. Stiffening bars 812a and 812b straddle the center line of back 806 and run the length of C-shaped channel 802. Stiffening bar 812c, which also acts as a spacer, straddles the center line of base 608b.

Brick slip 300 sits atop stiffening bar 812c (at contact point 804c) and is secured by inward facing flange 810a. The inward facing flange may be 0.250 inches-in-length, and may be angled inward at angles between 3 degrees and 15 degrees.

The bottom edge of flange 810a is toothed and the tooth depths may range between 2.0 mm and 6.0 mm. As a person of ordinary skill understands, the teeth may have varying widths and lengths. The teeth, when in contact with brick slip 300, may be slightly flexed.

Flange 810b, which is parallel to base 808b, comprises a hemmed edge with an angled arm extending below flange 810b. The hemmed edge may be flexible, and its angled arm may extend outward—away from the tray (concave) (see FIG. 9A) or it may extend inward-toward the tray (convex) (see FIG. 9B).

As shown in FIG. 9A, flange 910ba holds brick slip 300a within tray 900 and secures brick slip 300b within the tray 900. In turn, flange 910bb holds brick slip 300b within tray 900 and secures brick slip 300c within tray 900, flange 110bc holds brick slip 300c within tray 900 and secures brick slip 300d within tray 900, and flange 110bd holds brick slip 300d within tray 900d etc. Thus, when all the trays are in place, all of the brick slips may be secured at their respective top and bottom edges.

As shown in FIG. 9B, flange 910be holds brick slip 300e within tray 900 and secures brick slip 300f within the tray 900. In turn, flange 910bf holds brick slip 300f within tray 900 and secures brick slip 300g within tray 900, flange 110bg holds brick slip 300g within tray 900 and secures brick slip 300h within tray 900, and flange 110bh holds brick slip 300h within tray 900 etc. Thus, when all the trays are in place, all of the brick slips may be secured at their respective top and bottom edges.

In placing brick slip 300, an operator positions, for example, bottom side 324 of brick slip 300 into the well formed by base 808b and flange 810b. Then, the operator uses a mallet to hit brick slip 300 with a downward striking blow, driving brick slip 300 against the toothed edge of flange 810a. Once brick slip 300 is in place, the teeth of flange 810a are flexed and gripping top 322 of brick slip 300, securing brick slip 300 into place. The striking blow also causes back 426 of brick slip 300 to rest against contact points 804a and 804b of stiffening arms 812a and 812b. Bottom 424 rests against contact point 804c of stiffening arm 812c.

FIG. 10 is a schematic representation of the back side of the brick trays described herein. As shown, tray 1000 comprises a C-shaped channel with back 1006 and stiffening bars 1012a and 1012b. In this embodiment, the C-shaped channel further comprises attachment holes 1014 spaced along the center line of back 1006, and weep holes 1016 spaced along the seam formed by the base of the C-shaped channel and back 1006. The weep holes allow for egress of incidental moisture to maintain water management. The attachment holes and the weep holes may be spaced in even or staggered intervals.

As understood by a person of ordinary skill in the art, one or more measurements of the brick tray described herein may be changed to accommodate brick slips with varying heights and thickness. For example, the brick tray may be configured to accommodate brick slip heights between 1.625 to 3.625 inches-in-height, and/or to accommodate various brick slip thicknesses between 0.5 to 1.0 inches-in-thickness.

The C-shaped channels in the three embodiments of the invention may be made from galvanized steel, coated steel, stainless steel, aluminum or any combination these metals or alloys of these metals.