Press lock system

Abstract

An interlocking installation panel for masonry objects comprising a base rail having a top edge, bottom edge, a wall-facing surface, and a masonry-facing surface; a top support unit comprising one or more resilient elements. The resilient elements have a top wall and a downwardly extending engagement member that is engaged to the top wall outer edge and that extends away from the top wall and towards the base rail. There is a bottom support unit comprising a bottom wall, a plurality of teeth proximate the bottom wall outer edge and that extends away from the bottom wall and towards the base rail. The bottom support unit further comprises a first downwardly extending flange proximate to the bottom wall inner edge and is directed generally downwards and a second downwardly extending flange proximate to the bottom wall outer edge and is directed generally downwards.

Description

BACKGROUND

[0001] The present invention generally relates to building materials and structures. In particular, it relates to a formed panel for supporting and maintaining a brick or other masonry unit thereon.

[0002] The process of installing stone or thin bricks on a vertical surface is laborious, time consuming, and inefficient. It often times takes more than one individual to work on the task. The use of support panels has gained popularity to aid in the effort to install and maintain stone / thin brick precisely and efficiently on a vertical surface.

[0003] In building construction, it has become common to provide a wall with a thin brick façade for improved appearance and enhanced durability. These brick facades are traditionally achieved using metal lath sheets which are mounted to the wall, covered with a cement based coating or multiple cement based coating, then adhering the tile to the wall by pressing them into the wet cement-based coating, whereby the entire wall is covered with brick tile to achieve a wall that appears to be made with full bed depth brick. More recently, thin brick applications have been achieved through the application of large metal panels to the wall. While these metal panels have punched and bent outward pieces of steel (tangs in other words) that properly space and align the tiles, the tiles are affixed to the steel panel by an adhesive.

[0004] Some mounting apparatuses provide a mounting apparatus comprising a series of grooves attached to a wall. The brick or tiles are initially fitted under friction into the grooves and adhered to the board. Subsequently, a construction worker applies mortar into the gaps between the brick slips to simulate the aesthetics of traditional brickwork. However, the tolerances of the dimensions of brick slips are typically relatively large. As a result, if the brick slip is relatively small, the friction fit can have limited, if any, strength and the brick slip is held in place by the adhesive only where necessary if the tiles are smaller than the apparatus is able to accommodate. If the adhesive does not dry quickly enough, or is not strong enough, the brick slip can fall out before the mortar is applied. Furthermore, the mortar provides little structural support to the finished façade. As a result, this weak adhesive connection can result in brick slips falling from the finished façade.

[0005] It is therefore an object of the present invention to provide an improved arrangement for the positioning of masonry elements, bricks, or tiles on a wall.

[0006] Still another object of the present invention is to provide an inexpensive and easily installed wall covering which may be used in new construction as well as retrofitted on existing structures.

[0007] A further object of the present invention is to provide an improved arrangement for the placing of a brick facade on a flat structural member such as a wall.

[0008] Another object of the present invention is to provide a support structure for bricks, masonry or tile that does not require the use of external fasteners, mortar, or grout to hold the tiles securely in place.

[0009] Still another object of the present invention is to provide a support structure for bricks and other masonry that eliminates the need for grooving of the masonry for solid attachment into the rails.

[0010] Another object of the present invention is to provide a support structure for bricks that provides additional strength to the connection between rails by the interleaving of rails together.

[0011] Yet another object of the present invention is to provide a wall covering having high strength and durability of a full bed depth brick masonry wall using a thin brick system that can be installed with lower skilled laborers than required to build with full bed depth brick (i.e. masons) and have the traditional look and attractiveness of full bed depth brick, masonry or tile.

[0012] These and other objects will be described in the following description.SUMMARY OF THE INVENTION

[0013] The present invention therefore provides a masonry or façade unit mounting apparatus comprising a rail having multiple evenly spaced supports, whereby the top portion of the support comprises a first row of first and second supports attached to a wall and gripping at least one masonry object mounted therebetween. The first support comprises at least one resilient element configured to bias the at least one masonry object against the second support. The first support may comprise a first base extending outwardly from the wall and including a plurality of resilient elements. The plurality of resilient elements may be mounted to the first base and comprise a plurality of projections extending from the first base, said plurality of projections configured to extend at least partially inwardly towards the wall. The second support is for securing the masonry unit(s) and away from the first base for, in use, gripping the at least one facade unit against outward movement from the wall.

[0014] The present invention further provides a method of mounting at least one facade unit to a wall, the method comprising: attaching first and second supports to a wall, the first support comprising at least one resilient element; mounting at least one facade unit between the first and second supports such that the first and second supports grip the at least one facade unit, and the at least one resilient element biases the at least one facade unit against the second support. The first support may comprise: a first base extending outwardly from the wall; and a plurality of resilient elements mounted to the first base and comprising a plurality of projections extending from the first base inwardly and away from the first base. The plurality of projections may grip the at least one facade unit against outward movement from the wall.

[0015] The present invention further provides a rail for an apparatus for mounting a plurality of facade units to a wall, the rail comprising: an inner support for attachment to a wall; a common base extending from the inner support to, in use, extend outwardly from the wall, the common base comprising: a first support comprising at least one resilient element extending away from the common base configured to, in use, bias the at least one facade unit of a first row of facade units away from the common base; and a second support for supporting, in use, at least one facade unit of a second row of facade units biased against the second support. The inner support may comprise an inner base and at least one spacer attached to or formed with the inner base, the at least one spacer being configured for providing, in use, at least one second gap between the at least one facade unit of the first row and the inner base.

[0016] The plurality of resilient elements create a friction fit between the first and second supports by pushing the at least one facade unit against the second support. The plurality of resilient elements also allow different sizes of facade units to be mounted to the wall and the friction fit maintained. As a result, for example, brick slips with significantly different dimensions due to large manufacturing tolerances can be fitted to the wall.

[0017] The at least one resilient element may comprise a spring, a compression spring, a resilient wedge, a clip, a spring clip and / or a resilient lever.

[0018] The present invention therefore provides a facade unit mounting apparatus comprising first and second supports for, in use, attachment to a wall and gripping at least one facade unit mounted therebetween, wherein the first support comprises at least one resilient elements configured to, in use, bias the at least one facade unit against the second support. The first support may comprise a first base for, in use, extending outwardly from the wall and a plurality of resilient elements. The plurality of resilient elements may be mounted to the first base and comprise a plurality of projections extending from the first base. The plurality of projections may be configured to extend inwardly and away from the first base for, in use, gripping the at least one facade unit against outward movement from the wall.

[0019] The present invention further provides a method of mounting at least one facade unit to a wall, the method comprising: attaching first and second supports to a wall, the first support comprising at least one resilient element; mounting at least one facade unit between the first and second supports such that the first and second supports grip the at least one facade unit, and the at least one resilient element biases the at least one facade unit against the second support. The first support may comprise: a first base extending outwardly from the wall; and a plurality of resilient elements mounted to the first base and comprising a plurality of projections extending from the first base inwardly and away from the first base. The plurality of projections may grip the at least one facade unit against outward movement from the wall.

[0020] The present invention further provides a rail for an apparatus for mounting a plurality of facade units to a wall, the rail comprising: an inner support for attachment to a wall; a common base extending from the inner support to, in use, extend outwardly from the wall, the common base comprising: a first support comprising at least one resilient element extending away from the common base configured to, in use, bias the at least one facade unit of a first row of facade units away from the common base; and a second support for supporting, in use, at least one facade unit of a second row of facade units biased against the second support. The inner support may comprise an inner base and at least one spacer attached to or formed with the inner base, the at least one spacer being configured for providing, in use, at least one second gap between the at least one facade unit of the first row and the inner base.

[0021] The present invention provides an interlocking installation panel for masonry objects. It has a base rail having a top edge, a bottom edge, a wall-facing surface, and a masonry-facing surface. There is a top support unit comprising one or more resilient elements, each having a top wall with a top wall inner edge and a top wall outer edge. The one or more resilient elements each have a downwardly extending engagement section that extends away from the top wall and towards the base rail. There is a bottom support unit comprising a bottom wall with an bottom wall inner edge and an bottom wall outer edge, a plurality of teeth proximate the bottom wall outer edge and that extend away from the bottom wall and towards the base rail. The bottom support unit further comprises a first downwardly extending flange proximate to the bottom wall inner edge and is directed generally downwards and a second downwardly extending flange proximate to the bottom wall outer edge and is directed generally downwards.

[0022] The present invention provides an interlocking installation panel for masonry objects. It has a base rail having a top edge, a bottom edge, a wall-facing surface, and a masonry-facing surface. There is a top support unit comprising one or more resilient elements, each having a top wall with a top wall inner edge and a top wall outer edge. The one or more resilient elements have a downwardly extending engagement section that extends away from the top wall and towards the base rail. There is a bottom support unit comprising a bottom wall with an bottom wall inner edge and an bottom wall outer edge, a plurality of teeth proximate the bottom wall outer edge and that extend away from the bottom wall and towards the base rail. The bottom support unit further comprises a first downwardly extending flange proximate to the bottom wall inner edge and is directed generally downwards and a second downwardly extending flange proximate to the bottom wall outer edge and is directed generally downwards. The interlocking installation panel includes anoffsetting portion that extends from the top edge of the base rail and is engaged to the top support unit. The offsetting portion is set at a non zero angle relative to the base rail.

[0023] The present invention further comprises a method of installing masonry objects to a wall or vertical surface which includes inserting a brick or similar masonry object into an interlocking installation panel that is already attached to a wall or vertical surface.

[0024] The plurality of resilient elements create a friction fit between the first and second supports by pushing the at least one facade unit against the second support. The plurality of resilient elements also allow different sizes of facade units to be mounted to the wall and the friction fit maintained. As a result, for example, brick slips with significantly different dimensions due to large manufacturing tolerances can be fitted to the wall.

[0025] The at least one resilient element may comprise a spring, a compression spring, a resilient wedge, a clip, a spring clip and / or a resilient lever.

[0026] The present invention contemplates a brick, masonry or tile support structure including a sheet metal panel having a plurality of resilient elements creating a friction fit between first and second supports by pushing the at least one masonry object against the second support. The plurality of resilient elements also allow different sizes of masonries to be mounted to the wall and the friction fit maintained.

[0027] The present invention therefore provides a masonry mounting apparatus comprising a panel which attaches to the wall or other mounting surface. The panel includes at least a top base and a bottom base designed to bias at least one masonry or façade unit in between. Each of the top and bottom bases comprise at least one resilient element configured to bias the at least one masonry or facade unit against the bottom base.

[0028] The top and bottom bases each include a top support and bottom support unit, respectively, each extending outwardly from the wall, said top and bottom support units having a plurality of resilient elements. The plurality of resilient elements may be mounted to the top and bottom support unit and comprise a plurality of projections extending therefrom. The plurality of projections are configured for gripping and securing the at least one masonry or facade unit in the support structure.

[0029] The plurality of resilient elements create a friction fit between the first and second supports by pushing the at least one masonry object into the support structure. The plurality of resilient elements also allow different sizes of facade units to be mounted to the wall and the friction fit maintained. As a result, for example, brick slips with significantly different dimensions due to large manufacturing tolerances can be fitted to the wall.

[0030] The at least one resilient element may comprise a spring, a compression spring, a resilient wedge, a clip, a spring clip and / or a resilient lever. The resilient elements further allow the masonry object to be easily removed by separating or plying the resilient element(s) from the masonry object. The same or different masonry object can then be placed therein.

[0031] In accordance with the invention, the manner in which the thin bricks are affixed to the outer surface of the sheet metal panel should provide secure mounting of the thin bricks thereon for years of use, while facilitating the placement and positioning of the individual brick or masonry elements to allow this form of construction to be economically competitive. Moreover, the sheet metal panel should be inexpensive and should allow flexibility in the variety of brick arrays and configurations positioned thereon. The brick support arrangement should further have the strength to hold a wide variety of bricks of all sizes and weights and also be readily adapted for new construction as well as retrofitting on existing structures. These mounting panels (or rails) also interlock with one another in order to add strength to the overall thin brick wall system and allow for adjustment of the spacing of the rails and tiles to achieve a more appealing appearance by allowing coursing adjustment to meet tops of windows doors and walls with full brick course the same way that full bed depth brick walls are coursed for this said purpose.BRIEF DESCRIPTION OF FIGURES

[0032] Certain embodiments of the present invention are illustrated by 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.

[0033] FIG. 1 presents a front perspective view of an individual interlocking installation panel.

[0034] FIG. 2 presents a front view of the interlocking installation panel.

[0035] FIG. 3 presents a perspective view of multiple interlocking installation panels stacked together and engaged to bricks.

[0036] FIG. 4 presents a front perspective view of the interlocking installation panel showing the resilient elements with differing lengths.

[0037] FIG. 5 presents a side view of an embodiment interlocking installation panel.

[0038] FIG. 6 presents a side view of multiple interlocking installation panels of FIG. 5 stacked on top of one another.

[0039] FIG. 7 presents a side view of an embodiment of the interlocking installation panel having a rearward ridge.

[0040] FIG. 8 presents a side view of the multiple interlocking installation panels of FIG. 7 connected to one another.

[0041] FIG. 9 presents a side view of the interlocking installation panel holding bricks with several different dimensions.DETAILED DESCRIPTION OF THE INVENTION

[0042] While this invention is susceptible of embodiments 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 specific embodiments illustrated.

[0043] 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.

[0044] As used herein, the term “brick” is used throughout the application for convenience. However, the panel invention is intended to encompass the application of any masonry object including, but not limited to, thin bricks, tiles, building stone such as marble, granite, and limestone, cast stone, concrete blocks, glass blocks and adobe.

[0045] As used herein, “generally horizontal / horizontally” or “generally vertical / vertically” indicates the direction does not need to be exactly horizontal or exactly vertical with respect to a fixed point, but includes those situations where is a small amount of variance for example, ±10 degrees of variance. Other degrees of variance are included, for example ±5, ±15 and ±20 and all intermediate ranges and values therein. Likewise, “generally angled” or “generally perpendicular” as used herein indicates the element is at least partially angled or partially perpendicular whereby there may be a small amount of variance, for example, ±5, ±10, ±15 and ±20 and all intermediate ranges and values therein.

[0046] As shown in FIG. 1, the interlocking installation panel 100 comprises an elongated base rail 108 having an installation side 102, which faces a masonry object 106 attached to the interlocking installation panel 100, and a wall side 104, which faces and is engaged to a wall or other vertical surface. The interlocking installation panel 100 further includes a top support unit 110 attached to an upper end of the elongated base rail 108 and that provides a frictional engagement to an upper surface of the masonry object 106. There is also a bottom support unit 112 attached to the bottom and of the elongated base rail 108 that provides a frictional engagement to the bottom end of the masonry object 106 as it is secured within the interlocking installation panel 100. The masonry object 106 is inserted into the interlocking installation panel 100 on the installation side 102 and is locked into position by the top support unit 110 and bottom support units 112. The interlocking installation panel 100 is typically longer than it is tall, and is generally installed to a wall or other vertical surface horizontally or generally horizontally. The bottom support unit 112 and the top support unit 110 both extend outwards from the elongated base rail 108 and the wall / vertical surface, defining a masonry holding space 114 adjacent to the installation side 102.

[0047] The interlocking installation panel 100 has an installation side 102 and a wall side 104. The interlocking installation panel 100 may be made of any desired material. This could include, but is not limited to, metals, polymer, resin, composite, rubber, plastics, wood, fiber, and combinations thereof. It is envisioned to be within the scope of the present invention to form installation panels 100 having different sizes and utilizing different gauge steel, for instance. An offsetting portion 105 is attached to the upper edge of the elongated base rail 108 and to the top support unit 110. The offsetting portion 105 has a non-zero angle relative to the elongated base rail 108 and keeps the top support unit 110 further away from a wall or vertical surface than the elongated base rail 108.

[0048] In some embodiments of the invention, the interlocking installation panel 100 may be at least partially coated with a coating (not shown) including, but not limited to, paint, powder coating, sealant, resin, galvanized coating, ZAM coating (Zinc, Aluminum, Magnesium) and the like, to substantially reduce or eliminate oxidation of installation panel 100.

[0049] According to other embodiments, the installation panel 100 may be at least partially texturized on the installation side 102 or wall side 104 to further enhance the bond between the interlocking installation panel 100 and masonry objects 106 and / or the interlocking installation panel 100 and the wall via fasteners and / or adhesive to the installation panel 100 and / or the masonry objects 106 and wall.

[0050] The top support unit 110 comprises a generally vertical wall 111 that is engaged to the offsetting portion 105, and a plurality of resilient elements 113. In a preferred embodiment, each resilient element 113 includes a generally horizontal or horizontal member 116, the inner portion of which is engaged to the generally vertical wall, and the outer portion of which is opposite to the inner edge. A downwardly extending engagement member 118 is attached to, or proximate to, the outer portion of the horizontal member 116. The downwardly extended engagement member 118 is directed downwards and is generally vertically oriented and, optionally, inwards towards the installation side 102. When viewed from the side, the top support unit 110 has a hook-like shape. When the masonry object 106 is positioned in the interlocking installation panel 100, the masonry object 106 is prevented from sliding outwards by the downwardly extended engagement members 118. Because they are bent inwards when a masonry object 106 is inside the masonry holding space 114 they effectively oppose the motion of the masonry object 106 outwards. The resilient elements 113 are biased towards a rest position where they are perpendicular or generally perpendicular with the top wall or generally angled towards the interlocking installation panel. When not under pressure from an outside source, a restoring force pulls the resilient elements 113 back into their rest position if they are not currently in their rest position. When a masonry object 106 is in the masonry holding space 114, the resilient elements 113 are forced out of the rest position. The restoring force acts on the resilient elements 113 and creates a downwards force on the masonry objects 106, which in turn press into the bottom support unit 112 and securing the masonry object 106 from the top and bottom.

[0051] The resilient elements 113 may be any shape, but shapes that provide enough frictional contact with the surface of the masonry object 106 to prevent it from falling from the interlocking installation panels 100 are preferred. In a preferred embodiment, the resilient element 113 tapers towards the end of its length, giving it a generally triangular or trapezoidal shape. In particular, the downwardly extending engagement member 118 may taper to a point or to a straight edge. The downwardly extending member may be triangular, trapeziodal, or any number of other shapes. In some embodiments, the resilient element 113 may be rectangular, and not taper at any point along its length. In another possible embodiment, the downwardly extending engagement member 118 is rounded. The resilient elements 113 may optionally comprise a spring, a compression spring, a resilient wedge, a clip, a spring clip and / or a resilient lever.

[0052] The resilient elements 113 allow for masonry objects 106 with different dimensions to be held without having to use differently sized interlocking installation panels 100. As shown in FIG. 9, taller bricks will simply cause the the downwardly extending engagement members 118 to bend further inwards towards the elongated base rail 108. No other modification of the interlocking installation panels 100 is required. If desired, a user may use differently sized and shaped masonry objects 106 simultaneously on a single elongated base rail 108.

[0053] The resilient elements 113 further alleviate the necessity of using mortar or grout to hold the masonry objects 106 to the installation panel 100. This provides numerous advantages, including cost savings, less mess, less skill needed to apply the masonry objects, no time needed to dry, etc. As such, the masonry objects 106 may be removed and / or replaced by simply releasing the resilient elements 113 from the masonry items by, for example, placing a wedge and / or by forcing a “Tile Extractor” (a thin, high carbo, sheet metal tool) between the masonry unit and the locking teeth to allow the release of the tile or other impediment between the masonry object 106 and the resilient elements 113. Additionally, unlike certain other installation panels known in the art, the present invention does not require the use of spacers for containing mortar and / or grout between the panel and the installation panel and the wall.

[0054] The resilient elements 113, in particular the downwardly extending engagement members 118, may differ in length from one another. In one embodiment, the different downwardly extending engagement members 118 bend to different angles from one another when a masonry object 106 has been placed into the interlocking installation panel 100, as shown in FIG. 4. With the downwardly extending engagement members 118 at different angles, they can directly resist movement of the masonry objects 106 over a broad range of possible angular directions.

[0055] The bottom support unit 112 includes a bottom wall 120 which extends outwards from the installation side 102 of the elongated base rail 108, and the bottom wall 120 includes an inner edge 121 and an outer edge 123. A first downwardly extending flange 122 is engaged to the inner edge 121 and a second downwardly extending flange 124 is engaged to the outer edge 123. Each downwardly extending flange 122 and 124 is directed generally straight down and is perpendicular or generally perpendicular to the bottom wall 120. A support holding space is defined between the downwardly extending flanges 122 and 124 and below the bottom wall 120. The support holding space 126 is configured to fit over a top support unit 110 for a corresponding interlocking installation panel 100. A top support unit 110 fits within the support holding space 126 with the generally vertical wall in contact with the inside surface of the first downwardly extending flange 122 and the downwardly extending engagement member in partial contact with the second downwardly extending flange 124. The upper surface of the top support unit 110 is in contact with the bottom surface of the bottom wall 120. The interlocking nature of the installation panels 100 adds to their strength and ability to support the installation panel 100 and masonry objects 106 contained therein.

[0056] The bottom support unit 112 further comprises a plurality of teeth 125 or similar resilient elements 113 along the outer edge of the bottom wall 120. The plurality of teeth 125 are generally angled inwards towards the installation side 102. Similar to the resilient elements 113 of the top support unit 110, the plurality of teeth 125 provide a oppositional frictional force against any movement of masonry objects 106 out of the interlocking installation panel 100. In one embodiment of the invention, the teeth 125 and the resilient elements 113 are “flipped” and the teeth extend downwards from the top support unit 110 and the resilient elements 113 extend upwards from the bottom support unit 112.

[0057] The first downwardly extending flange 122 may be integral with both the bottom wall 120 and the elongated base rail 108. In particular, the elongated base rail 108 may extend below the bottom wall 120, and be folded back upwards alongside itself before integrally merging with the inner edge 121 of the bottom wall 120. The second downwardly extending flange 124 may also be formed by the bottom wall 120. In one embodiment, the outer edge 123 of the bottom wall 120 extends generally downwards before folding back generally upwards alongside itself and integrally merging with the plurality of teeth 125.

[0058] The elongated base rail 108 has a generally rectangular flat base structure with an upper end and a lower end, the upper end further comprises an angled offsetting portion 105 that is engaged to the top support unit 110. The angled offsetting portion 105 holds the top support unit 110 away from the wall so that a downwardly extending flange 122 or 124 of an interlocking installation panel 100 located above the first interlocking installation panel 100 may be slid next to one another while keeping the elongated base rails 108 of the interlocking installation panels 100 aligned. The first downwardly extending flange 122 of the above interlocking installation panel 100 may contact the offsetting portion. The interlocking installation panel 100 can be therefore formed as a single unitary component and folded into the proper shape, which cuts down on manufacturing costs. In other embodiments, the first and second downwardly extending flanges 122 and 124 may be separate members that may be integrally formed with the rest of the interlocking installation panel 100 or affixed to the interlocking installation panel 100.

[0059] In an embodiment of the disclosure shown in FIGS. 5-6, the elongated base rail 108 comprises one or more support ridges 128 that extend outwards from the installation side 102 of the elongated base rail 108. The support ridges 128 prevent the masonry object 106 from being fully pressed against the surface of the installation side 102 and creates a gap 132 between the masonry and the wall / vertical surface. It is envisioned that the gap 132 would allow for the drainage of water and other liquids, as well as to optionally provide space for more layers of insulation and / or fastener heads that attach the rails to the substrate and / or vertical Z-girts or Hat Channels that add rigidity to the panels allowing for greater distances between vertical supports which to the rails will attach. The elongated base rail 108 optionally include a plurality of through holes 134 through which fasteners, such as bolts, screws, nails, etc. may be passed and into the wall / vertical surface to secure the interlocking installation panel 100. The support ridges 128 may be integral with the elongated base rail 128 or they be a separate component that is attached to the elongated base rail 128.

[0060] In a preferred embodiment of the disclosure shown in FIGS. 7-8, the elongated base rail 108 comprises at least one inwardly directed support 130 that extends from the wall side 104 of the elongated base rail 108 and contacts the wall or other vertical surface. The inwardly extending support 130 has a corresponding channel 136 on the installation side 102 that provides a gap 132 between the masonry objects 106 and the wall / vertical surface. When a masonry object 106 is positioned in the interlocking installation panel 100, the masonry object 106 presses against the surface of the elongated base rail 108, or common base / surface, around the channel 136. As shown in FIGS. 1-2, the inwardly extending ridge / channel 136 may comprise a plurality of through holes 134 through which fasteners such as bolts, screws, nails, etc. may be passed into the wall / vertical surface to secure the interlocking installation panel 100.

[0061] Masonry objects 106 are typically cuboid in configuration, resembling a traditionally proportioned brick. In general, masonry objects 106 include a rear surface, a top surface, and a bottom surface (see FIGS. 3-4 and 9). It will be understood that bottom surface of masonry object 106 may contactingly rest upon at least a portion of the plurality of teeth 125, and the top surface will be in contact with at least a portion of the resilient elements 113. The rear surface will be undertood to be in contact with at least a part of the installation side 102 of the elongated base rail 108, or ridges and spacers extended therefrom. Masonry objects 106 may vary in size, and potential sizes may include, but are not limited to, about 2 3 / 16 inches to about 2 5 / 16 inches in height.

[0062] While noting that the unique design of the installation panel 100 of the invention does not require bonding agents or other adhesives, masonry objects 106 may optionally be further attached to the interlocking installation panel 100 and to one another using bonding agents known in the art including, but not limited to, concrete, mortar, grout, adhesive, resin, or combinations thereof. The bonding agent operates to bond masonry objects 106 to the interlocking support panels if a higher pull out resistance is desired and fill in the gaps between them to create a facade that covers at least a portion of installation side 102 of interlocking installation panel 100.

[0063] The interlocking support panels 102 are interlocked with one another, one on top of another, in additional to being secured to a wall or other vertical surface. The top support unit 110 of a first interlocking installation panel 100 is fit within the bottom support unit 112 of a second, higher interlocking installation panel 100, and so on. The interlocking installation panels 100 are not generally affixed to one another, but optionally be further adhered together with adhesives or grout after the masonry objects 106 have been attached. In some embodiments, the interlocking installation panels 100 may be affixed to one another with fasteners, glue, grout, etc. after they have been interlocked.

[0064] To install the interlocking installation panels 100, a user first engages a first interlocking installation panel 100 to a wall of a generally vertical surface. The first interlocking installation panel 100 is typically secured generally horizontally, but may be set at a different angle if desired. The first interlocking installation panel 100 is then fixed to the wall / vertical surface with fasteners or adhesives. A second interlocking installation panel 100 is slid down over the first interlocking panel such that the bottom support unit 112 of the second interlocking installation panel 100 fits over the top support unit 110 of the first interlocking installation panel 100. The front and rear downwardly extending flanges 122 and 124 fit on either side of the top support unit 110 and prevent side forwards and backwards relative motion thereby adding rigidity to one another and to the entire wall. The bottom wall 120 of the second interlocking installation panel 100 comes to rest on the top wall of the first interlocking installation panel 100 and cannot move further down. Once the second interlocking installation panel 100 is settled into position, then it is secured with fasteners to the wall or subframing (vertical z-girt or hat channel). Once the second interlocking installation panel 100 has been attached, then a user can attach a third or more interconnecting installation panels 100 onto the second and above. A user may attach a panel and secure it with fasteners before adding another panel, or they may stack a series of panels together before securing all of them with fasteners. In some embodiment, the user may attach a plurality of interlocking installation panels 100 to form a facade prior to attachment of the entire plurality at once to a wall.

[0065] To attach a masonry object 106, such as a rectangular brick, the user presses the masonry object 106 into the masonry holding space 114 defined by the top and bottom support units 110 and 112 between the plurality of teeth 125 and the resilient elements 113. The plurality of teeth and the resilient elements provide some resistance to the masonry object 106 because the space between them is slightly smaller than the dimensions of the masonry object 106. The resilient elements 113 will be bent in order to allow entry of the masonry object 106. A user may use blunt force, as applied by a rubber mallet or similar tool, to fully force the masonry object 106 into the masonry holding space. In some case, only pressure applied by a human hand is needed, and the masonry object 106 can be installed by hand and without the use of tools.

[0066] As previously discussed, to remove the masonry object 106, a user may first push a wedge or a “Tile Extractor” (a thin, high carbo, sheet metal tool) between the masonry unit and the locking teeth to allow the release of the tile or similar tool between the resilient elements 113 and the upper surface of the masonry object 106. The resilient elements 113 are brought out of direct contact with the masonry object 106 by the wedge and there will be significantly reduced resistance to movment of the masonry object 106. The plurality of teeth 125 will still dig into the masonry object 106 if it moves so, the user may then rotate the masonry object 106 about the plurality of teeth 125 until the top end of the masonry object 106 is free of the resilient elements 113.

[0067] 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.

Claims

1. An interlocking installation panel for masonry objects comprising:a base rail having a top edge, a bottom edge, a wall-facing surface, and a masonry-facing surface;a top support unit comprising one or more resilient elements having a top wall with a top wall inner edge and a top wall outer edge, and wherein the one or more resilient elements have a downwardly extending engagement member that is engaged to the top wall outer edge and that extends away from the top wall and towards the base rail; anda bottom support unit comprising a bottom wall with an bottom wall inner edge and an bottom wall outer edge, a plurality of teeth proximate the bottom wall outer edge and that extends away from the bottom wall and towards the base rail, and wherein the bottom support unit further comprises a first downwardly extending flange proximate to the bottom wall inner edge and is directed generally downwards and a second downwardly extending flange proximate to the bottom wall outer edge and is directed generally downwards.

2. The interlocking installation panel of claim 1 further comprising an offsetting portion that extends from the top edge of the base rail and is engaged to the top support unit, and wherein the offsetting portion is set at a non-zero angle relative to the base rail.

3. The interlocking installation panel of claim 2, wherein the top wall of each of the one ore more resilient elements is nearly perpendicular with the base rail.

4. The interlocking installation panel of claim 2, wherein the bottom wall is nearly perpendicular with the base rail.

5. The interlocking installation panel of claim 2, wherein the offsetting portion has an angle relative to the base rail of about 25 degrees to about 65 degrees.

6. The interlocking installation panel of claim 5, wherein the offsetting portion has an angle relative to the base rail of about 45 degrees.

7. The interlocking installation panel of claim 2, wherein the interlocking installation panel comprises one or more materials selected from the group consisting of metal, wood, rubber, polymer, resin, composite, plastic, fiber, and combinations thereof.

8. The interlocking installation panel of claim 2, wherein the interlocking installation panel is at least partially coated with a coating selected from the group consisting of paint, powder coating, sealant, and resin.

9. The interlocking installation panel of claim 2, wherein the interlocking installation panel is at least partially texturized on the wall-facing surface or the masonry-facing surface.

10. The interlocking installation panel of claim 2, wherein the masonry objects are comprised of one or more materials selected from the group consisting of brick, marble, granite, limestone, cast stone, concrete blocks, glass blocks and adobe.

11. The interlocking installation panel of claim 2, wherein the base rail further comprises at least one outwardly extending ridge that extends from the masonry-facing surface.

12. The interlocking installation panel of claim 2, wherein the base rail further comprises an inwardly extending support that extends from the wall-facing surface and which contacts a wall or vertical surface.

13. An interlocking installation panel for masonry objects comprising:a base rail having a top edge, a bottom edge, a wall-facing surface, and a masonry-facing surface;a top support unit comprising one or more resilient elements having a top wall with a top wall inner edge and a top wall outer edge, and wherein the one or more resilient elements have a downwardly extending engagement member that is engaged to the top wall outer edge and that extends away from the top wall and towards the base rail;a bottom support unit comprising a bottom wall with an bottom wall inner edge and an bottom wall outer edge, a plurality of teeth proximate the bottom wall outer edge and that extends away from the bottom wall and towards the base rail, and wherein the bottom support unit further comprises a first downwardly extending flange proximate to the bottom wall inner edge and is directed generally downwards and a second downwardly extending flange proximate to the bottom wall outer edge and is directed generally downwards; andan offsetting portion that extends from the top edge of the base rail and is engaged to the top support unit, and wherein the offsetting portion is set at a non zero angle relative to the base rail.

14. The interlocking installation panel of claim 13, wherein the top wall of the one ore more resilient elements is nearly perpendicular with the base rail.

15. The interlocking installation panel of claim 13, wherein the bottom wall is nearly perpendicular with the base rail.

16. The interlocking installation panel of claim 13, wherein the one or more resilient elements are flexible and configured to resist movement in a direction away from the base rail.

17. The interlocking installation panel of claim 13, wherein the base rail further comprises an inwardly extending support that extends from the wall-facing surface and which contacts a wall or vertical surface.

18. A method of installing at least one masonry object to a wall or façade comprising the steps of:inserting a masonry object to a interlocking installation panel which is attached to a wall or vertical surface, the interlocking installation panel comprising:a base rail having a top edge, a bottom edge, a wall-facing surface, and a masonry-facing surface;a top support unit comprising one or more resilient elements having a top wall with a top wall inner edge and a top wall outer edge, and wherein the one or more resilient elements have a downwardly extending engagement member that is engaged to the top wall outer edge and that extends away from the top wall and towards the base rail;a bottom support unit comprising a bottom wall with an bottom wall inner edge and an bottom wall outer edge, a plurality of teeth proximate the bottom wall outer edge and that extends away from the bottom wall and towards the base rail, and wherein the bottom support unit further comprises a first downwardly extending flange proximate to the bottom wall inner edge and is directed generally downwards and a second downwardly extending flange proximate to the bottom wall outer edge and is directed generally downwards;an offsetting portion that extends from the top edge of the base rail and is engaged to the top support unit; andwherein the masonry object comprises at least a top end and a bottom end, and wherein the top end of the masonry object is in contact with the one or more resilient elements, and the bottom wall is in contact with the plurality of teeth.

19. The method of claim 18, wherein the step of inserting the masonry object to an interlocking installation panel comprises applying pressure to the masonry object towards a direction of the base rail.

20. The interlocking installation panel of claim 18 further comprising an offsetting portion that extends from the top edge of the base rail and is engaged to the top support unit, and wherein the offsetting portion is set at a non-zero angle relative to the base rail.

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