Masonry structure

Abstract

A factory-build masonry fireplace includes a firebox, casing, and chimney system, where the firebox defines a cavity. Masonry panels are removably attached to the periphery of the cavity. Each masonry panel has firebrick housings configured to hold a corresponding firebrick, wherein the housings can optionally be arranged in a running bond and herringbone patterns, among others. Additionally, the base masonry panel defines an opening configured to hold a removable ash dump, the opening covered with a removable cover. In another arrangement, masonry panels have protruding walls that are configured to hold a corresponding firebrick. The masonry panels are used to build traditionally site built masonry structures.

Description

RELATED APPLICATIONS [0001]This application relates to and claims the benefit of the provisional application 60 / 452,478, filed Mar. 5, 2003, which is hereby incorporated by reference in its entirety.BACKGROUND OF THE INVENTION [0002]1. Field of the Invention[0003]The present invention is directed to masonry, and in particular to factory built masonry.[0004]2. Description of the Related Art[0005]Masonry structures have are well known in the art and have existed for many years. Many traditionally site built masonry structures (e.g., fireplaces, countertops, brick walls, and the like) may have to be constructed by a mason and thus can be expensive. Traditional site built masonry structures can also require significant installation time. For example, site built masonry fireplaces commonly found in residential structures and can be expensive and require substantial installation time.[0006]Over the years, factory built fireplaces have grown in popularity due to the increased cost of site ...

AI Technical Summary

Benefits of technology

[0013]The panel disposed over the base of the firebox cavity optionally defines an opening therethrough. The opening is preferably disposed near a front edge of the base of the firebox, wherein the front edge of the base is near the front end of the firebox. Additionally, a removable cover can optionally be disposed over the opening. The opening is preferably sized to receive a removable ash dump, which is capable of receiving ashes produced during the burning of logs or other material in the fireplace. The ash dump is preferably configured to be easily removed from the opening and to be easily emptied. The cover and the ash dump are preferably configured to be removed and replaced without the use of any tools.

[0017]In accordance with another embodiment, factory-built masonry structures are able to be constructed at significantly less cost than traditional masonry structures. The masonry panels are preferably constructed such that the costly layout of the brick pattern is eliminated. Additionally, individual brick housings are preferably incorporated into the panel to advantageously allow fast and accurate construction. For example, the panels can be constructed having the firebrick housings pre-arranged in a specific pattern, such as running bond or herringbone. Moreover, the firebricks supplied with the fireplace are preferably pre-cut and identified as corresponding to a particular housing, advantageously reducing the time, and thus the cost, of construction. For example, the fireplace can be constructed by an individual who may not normally have expert masonry skills, again reducing the construction costs. For example, the fireplace can be constructed by a certified fireplace installer or a homeowner Accordingly, a factory-built masonry fireplace can be constructed to resemble a traditional masonry fireplace at less than 20% of the cost and significant savings in installation time.

[0019]The kit enables the user to easily install the plurality of firebrick housings onto the masonry panels and arrange the housings in a desired pattern, such as running bond or herringbone. Alternatively, the housings can be pre-installed and arranged at a factory prior to delivery of the kit to the user. The user then installs the masonry panels on the side areas, rear area, and base area of the cavity frame. Optionally, the masonry panels and the cavity frame are assembled and pre-installed at the factory. The user can mix the high-temperature cement to prepare mortar material. The user can place the bricks into the housings of the panel, where the firebrick preferably corresponds to the housing. The user can repeat this process with the remaining firebrick housings. Once the user has installed the plurality of firebricks in the plurality of housings, the user can apply mortar material into any gaps between any adjacent firebricks to grout the firebrick assembly. The user can then allow the masonry fireplace cure for a desired amount of time before use. Once the masonry fireplace is properly cured, the user can optionally install a facade around the fireplace, as desired. The facade can be formed of masonry panels having housing configured to receive and hold firebricks. Firebricks can be coupled to the masonry panels to achieve a site built masonry appearance.

Problems solved by technology

Many traditionally site built masonry structures (e.g., fireplaces, countertops, brick walls, and the like) may have to be constructed by a mason and thus can be expensive.

Traditional site built masonry structures can also require significant installation time.

For example, site built masonry fireplaces commonly found in residential structures and can be expensive and require substantial installation time.

Over the years, factory built fireplaces have grown in popularity due to the increased cost of site constructed masonry structures.

Moreover, factory built fireplaces are capable of being installed in multi-level buildings, where construction of traditional masonry units is not feasible.

Even where the construction of masonry fireplaces is feasible, construction usually requires a significant amount of time and costs, significantly more than a factory-built fireplace.

Additionally, installation of tradition masonry fireplaces generally requires the services of a licensed mason or other construction professional, adding to the cost of construction.

However, such refractory panels, and other similar designs, have been incapable of achieving the desired masonry look.

However, such construction design has proved structurally unstable, often falling and breaking, and thus unable to provide adequate retention of bricks.

Additionally, such designs have provided poor alignment of bricks and have not been capable of providing multiple brick pattern arrangements.

However, as noted above, some localities restrict or prohibit the use of masonry fireplaces due to, for example, the risk of seismic activity in the locality.

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