Modular Frame System for Thin Brick Installation Alignment
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Solution Overview
Problem
The installation of brick veneers or thin bricks is time-consuming and costly due to the need for unit-by-unit placement, requiring skilled labor and extensive time despite lower material costs compared to traditional bricks.
Innovation Solution
A frame system with a support panel, spacer members, and engagement members that allows for the secure positioning and alignment of thin bricks during installation, enabling faster and more efficient placement by supporting the bricks until they are set in a bonding material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If brick veneers or thin bricks are installed unit by unit using traditional methods, then installation precision and appearance quality are maintained, but installation time and labor costs increase significantly
Solution Approach 1:
The installation system is segmented into modular frame units, each capable of holding multiple thin bricks independently. This allows parallel installation of multiple bricks while maintaining individual positioning precision through dedicated engagement members for each brick unit.
Solution Approach 2:
Thin bricks are pre-positioned within the frame structure before being transferred to the substrate. The frame预先 provides alignment and support, so that when bricks are installed, they are already in the correct position and orientation, eliminating the need for precise manual placement during the installation process.
2Reliability
If traditional unit-by-unit brick installation is performed, then skilled labor can ensure proper positioning and bonding, but installation time and labor costs increase
Solution Approach 1:
The frame system acts as an intermediary device between the installer and the thin bricks. It provides the positioning and support functions traditionally performed by skilled labor, allowing less skilled workers to achieve consistent results by simply placing bricks into the pre-configured frame structure.
Solution Approach 2:
The frame structure with its engagement members automatically holds and positions the thin bricks without requiring continuous manual adjustment. Once bricks are placed in the frame, the system self-maintains their position and alignment, reducing the need for skilled intervention throughout the installation process.
3Productivity
If multiple thin bricks are positioned simultaneously using the frame system, then installation speed increases, but the complexity of the positioning system increases
Solution Approach 1:
The frame system is divided into multiple independent modular units, each capable of holding and positioning a thin brick. This segmentation allows the system to scale in complexity linearly with the number of bricks needed, rather than requiring a single complex positioning mechanism for all bricks.
Solution Approach 2:
Each modular frame unit is designed to be universal and interchangeable with others in the system. The same basic engagement member and support structure can accommodate any thin brick in the set, simplifying the overall system design while enabling simultaneous positioning of multiple bricks through replication of the basic modular unit.
Data Source
AI summary
A frame for supporting at least one of masonry units during installation of the masonry units on a substrate includes a support panel having a front and back surface, first and second spacer members extending transversely from the front surface of the support panel, and engagement members extending from at least one of the following: the front surface of the support panel, the first spacer members, the second spacer members, or any combination thereof. The front surface of the support panel is configured to abut a first face of each of the masonry units. The engagement members are releasably engageable with a second face of each of the masonry units or the second face and a third face of each of the masonry units.