FIELD OF THE INVENTION

The invention relates generally to a masonry veneer system and particularly, although not exclusively, to a masonry veneer system constructed on a frame with connectors.

BACKGROUND TO THE INVENTION

Masonry veneer walls may consist of a decorative or other non-structural layer applied to a structural frame or wall. The masonry veneer wall may be built adjacent to the structural frame or wall. ^" -The masonry veneer wall may be constructed from bricks and may use mortar between horizontally and vertically adjacent bricks. Brick ties may be used to secure the masonry veneer wall to the structural frame or wall. Additionally, shelf angles or relieving supports may be used to support the masonry veneer wall vertically.

It is an object of the present invention to provide an improved masonry veneer system, or at least to provide the public with a useful choice.

SUMMARY OF THE INVENTION

In a first aspect the invention broadly consists in a masonry veneer system comprising: one or more longitudinal connectors having a back member arranged to be secured to a frame or surface and having a protrusion extending from the back member; and one or more blocks having one or more recesses in a back side shaped to receive a protrusion of a connector, the protrusion of the connector(s) being arranged to snap into the recess in the block(s) to support the blocks(s) on the frame or surface.

Preferably, the connector(s) have a constant cross-section along their length.

Preferably, the protrusion comprises two arms extending from the back member.

Preferably, the arms are resiliently flexible towards one another for snap fitting into a recess in a block. Preferably, a finger extends from at or towards a distal end of each arm.

Preferably, the connector comprises one or more spacers extending forward from the back member.

Preferably, the recess extends from one edge of a back side of the block to an opposing edge of the back side of the block.

Preferably, the recess has a constant cross section.

Preferably, the recess comprises two opposing sloping portions that originate on the back side of the block.

Preferably, the distance between the sloping portions at their origin is greater than the distance between the arms of the connector.

Preferably, the recess comprises flanges for receiving the fingers when the connector is snap fitted with the block (s).

Preferably, the block(s) comprise two recesses with one recess provided at or towards each end of the block and the recesses provided substantially parallel to one another.

Preferably, the masonry veneer system comprises one or more horizontal spacers for providing between the top face and bottom face of adjacent blocks.

Preferably, the masonry veneer system comprises one or more vertical insets provided between the side faces of adjacent blocks.

Preferably, the block(s) have a width and height across a major plane of the block(s) greater than a depth though the plane of the block(s).

In a second aspect the invention broadly consists in a longitudinal connector having a back member arranged to be secured to a frame or surface and having a protrusion extending from the back member arranged to snap into a recess in a block to support the blocks on the frame or surface. Preferably, the longitudinal connector has a constant cross-section along its length.

Preferably, the protrusion comprises two arms extending from the back member.

Preferably, the arms are resiliently flexible towards one another for snap fitting into a recess in a block.

Preferably, a finger extends from at or towards a distal end of each arm.

Preferably, the connector comprises one or more spacers extending forward from the back member.

In a third aspect the invention consists in a block having one or more recesses in a back side shaped to receive a protrusion of a connector.

Preferably, the recess extends from one edge of a back side of the block to an opposing edge of the back side of die block.

Preferably, the recess has a constant cross section.

Preferably, the recess comprises two opposing sloping portions that originate on the back side of the block.

Preferably, the distance between the sloping portions at their origin is greater than the distance between the arms of the connector.

Preferably, the recess comprises flanges for receiving the fingers of a connector when the connector is snap fitted with the block.

Preferably, the block comprises two recesses with one recess provided at or towards each end of the block and the recesses provided substantially parallel to one another

Preferably, the block has a width and height across a major plane of the block greater than a depth though the plane of the block. In a fourth aspect the invention broadly consists in a kit for forming a masonry veneer wall comprising- one or more longitudinal connectors having a back member arranged to be secured to a frame and having a protrusion extending from the back member arranged to snap into a recess; and one or more blocks having one or more recesses in the back side that are arranged to receive the protrusion, so that in use the block(s) are supported by the connector(s).

Preferably, the kit comprises one or more horizontal spacers.

Preferably, the kit comprises one or more vertical insets.

In a fifth aspect the invention broadly consists in a method of constructing a masonry veneer wall comprising. securing a longitudinal connector to a frame by a back member, the connector having a protrusion extending from the back member that is arranged to snap into a recess; aligning the protrusion with a recess provided on the back side of a block that is arranged to receive the protrusion, and applying pressure to the front side of the block so that the protrusion snap connects into the recess so that the block is supported by the connector on the frame

The term "comprising" as used in this specification and claims means "consisting at least in part of When interpreting each statement in this specification and claims that includes the term "comprising", features other than that or those prefaced by the term may also be present Related terms such as "comprise" and "comprises" are to be interpreted in the same manner.

As used herein, "(s)" following a noun means the plural, or singular, or both forms of the noun.

The invention consists in the foregoing and also envisages constructions of which the following gives examples only BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention will be described by way of example only and with reference to the drawings, in which:

Figure 1 is a perspective view of a masonry veneer system of the invention; Figure 2 is a cross-section view of a connector used in the masonry veneer system of Figure 1;

Figure 3 is a perspective view of the connector of Figure 2; Figure 4 is a cross-section view of a block used in the masonry veneer system of Figure 1 ;

Figure 5 is a cross-section view of the connector of Figures 2 and 3 engaged with the block of Figure 4;

Figure 6 is a perspective view of several horizontal spacers and one vertical inset that are provided between the blocks in some embodiments of the invention; and Figure 7 is a perspective view of a masonry veneer system of the invention including the horizontal spacers and vertical insets of Figure 6.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The invention generally relates to a masonry veneer system for constructing a masonry veneer wall over a frame or surface. The system comprises one or more connectors secured to a frame or surface, and one or more blocks arranged to be engaged with the connector in order to be supported on the frame or surface.

Referring to Figure 1, a longitudinal connector 2 is provided in a length and is arranged to be secured to and fully or partially traverse a frame 1 or surface. The frame 1 or surface may be an external or internal housing frame or wall, fence, or building or any other suitable frame or surface. The frame 1 or surface may be covered for example by wood or gibboard, plasterwall, drywall or the like, or covered with any other suitable material or provided in any other suitable manner. The connector 2 may be formed from metal such as aluminium or an allo ₎ , plastic, or any other suitable material. The connector 2 may be formed by extruding, sheet metal forming, casting, injection molding, or in any other suitable manner.

Referring to Figures 2 and 3, the connector 2 preferably has a constant cross-section. The connector 2 has a back member 4 arranged to abut and be secured to the frame 1. There may be two spacers 6 extending forward from the back member 4 and at an angle away from the back member and diverging from one another, however any suitable spacing device may be used. The spacers 6 may be arranged so that in use they abut the back side of the blocks and hold the blocks away from the frame 1 to provide an air gap between the frame 1 and blocks. This may improve heat or sound insulation in the system. The spacers 6 may also act as a damper or buffer to absorb energy if a block is sub _j ected to a force. The connector 2 has a protrusion arranged to engage with a recess on the back side of a block in order to support the block on the frame 1. The connector 2 engages with a recess by snap fitting or press fitting into the recess. In the preferred embodiment, there are two arms 8 extending substantially perpendicularly and forward from the back member 4. The arms 8 may extend from the back 4 parallel to one another. Alternatively, the arms 8 may converge or diverge from one another. There may be a finger 10 extending at an angle such as substantially perpendicularly from at or towards the end of each arm 8 being arranged to enter and grip a recess in a block. Preferably, the arms 8, or at least sections near the bases of the arms 8, are resilient and operable to flex towards one another or may be able to resikently flex towards or away from one another. This may allow the arms 8 to flex towards or away from one anodier when a block is being engaged with the connector 2. In other embodiments, any suitable protrusion mat snap fits with a recess on the back side of a block may be used. Any suitable number and configuration of arms 8 and fingers 10 may be used in order to grip a recess in a block. Any suitable connector 2 may be used.

Referring to Figure 4, a block 12 comprises a front side 14 and a back side 16. Preferably, the block 12 is veneer shaped which may mean that it has a width and height across a major plane of the that is greater than a depth though the plane of the block. The blocks 12 may be made from concrete, wetcast concrete, metal such as aluminium, wood, polystyrene, glass, natural stone such as marble or schist, polycarbonate, kevlar, plastic, or any other suitable material. The blocks 12 may be formed by casting, molding, extrusion, cutting such as hotwire cutting, or in any other suitable manner Alternatively, the blocks 12 may be produced using a masonry block machine. The back side 16 of the block 12 has one or more recesses 18 arranged to be engaged with and supported by a connector 2. Preferably, the block 12 comprises at least two recesses 18 with one recess 18 provided at or towards each end of the block 18 and provided substantially parallel to one another. However, the block 12 may have more than two recesses 18. Alternatively, the block 12 may have one recess 18. The recesses 18 are complementary in internal shape to the protrusions of the connectors 2. The recesses 18 are arranged so that they may be engaged by snap fitting or press fitting with the connectors 2. Preferably, each recess 18 extends from one face or edge to an opposing face or edge along the entire back side 16 of the block 12 with a constant cross section. For example, the recess 18 may extend from the top back edge of the block 1 _' 2-to the bottom back edge of the block 12. Alternatively, the recess 18 may extend from one back side edge of the block 12 to the other. The recess 18 may be provided on the block in any suitable manner. Generally when the masonry veneer system is in use, the back side 16 may be concealed from view and the front side 14 may be exposed. The front side 14 may be provided with any suitable pattern, design, colour, or combination thereof.

In the preferred embodiment, a recess 18 comprises two opposing sloping portions 20 that originate on the back side 16 of the block 12, slope towards one another, and terminate within the block 12. Preferably, the distance between the two sloping portions 20 at die origin is wider than the distance between die arms 8 of the connector 2. Preferably, the sloping portions 20 terminate at a distance apart from one anodier equal to or less than the distance between the outer edges of the two arms 8. Preferably, the sloping portions 20 terminate into a head portion 22, which extends beyond the termination points of the sloping portions 20. Preferably, the head portion 22 extends beyond the termination portion of die two sloping portions 20 which provides two flanges 24. Any suitably shaped recess 18 that engages with the connector 2 may be used.

Referring again to Figure 1, in use the connectors 2 are secured to the frame 1. The connectors 2 are preferably nailed, screwed, or adhered to the frame 1, however they may be secured in any suitable manner. Preferably, the connectors 2 are secured to the frame 1 by the back member 4. Preferably, the connectors 2 traverse the entire length L of the frame 1, however connectors 2 of any length may be used, such as connectors that are half the length L of the frame 1. The connectors 2 may be secured vertically along the frame's 1 lengdi L. Alternatively, the connectors 2 may be secured horizontally along the frame's width W, or in any other suitable orientation.

Preferably, multiple connectors 2 are secured to the frame 1 substantially parallel with one anodier. The connectors 2 may be suitably spaced apart from one another so that one or more connectors 2 may support a block 12 on the frame 1. Preferably, at least two connectors 2 support each block 12. In embodiments where the blocks 12 are provided with three or more recesses 18, preferably the connectors 2 are arranged to support the two outer recesses 18. However, the connectors 2 may be arranged to alternatively or additionally support inner recesses 18 also.

Referring to Figures 4 and 5, in constructing the masonry veneer wall, the blocks 12 are connected to the connectors 2. The back side 16 of a block 12 may be brought into close proximity with the connectors 2, and the connectors 2 and recesses 18 may be aligned. The blocks 12 may be snap fitted or press fitted to the connectors 2." 'Particularly, the sloping portions 20 of the recesses 18 may be lined up with the arms 8 and fingers 10 of the connectors 2. Pressure may be applied to the front side 14 of the block 12 so that the connectors 2 and recesses 18 come into contact and, upon application of further pressure, snap engage with one another. The arms 8 may bend towards each other and the fingers may 10 slide down the sloping portions 20. When the block 12 is moved far enough towards the back member 4, the fingers 10 will slip under and engage with the flanges 24. The fingers 10 may be contained in the head portion 22. Preferably, when the connector 2 and recess 18 are engaged, the ends of the spacers 6 abut the back side 16 of the block to hold it away from the frame 1 to create an air gap 26 between the block 12 and frame 1. The air gap 26 may contain a material such as an insulator.

A block 12 that has been engaged with one or more connectors 2 may be slid up or down or along the connectors 2 until it is at a suitable position or elevation on the frame 1. Additional blocks 12 may be fitted to the same connectors 2 so that higher blocks 12 may rest on lower blocks 12 in to order cover the frame 1 and construct the masonry veneer wall. Additional blocks 12 may also be fitted to adjacent connectors 2 in order cover to the frame 1 and construct the masonry veneer wall Preferably, the faces or edges of adjacent blocks 12 abut one another to provide a complete covering over the frame 1. Alternatively, a gap may be provided between adjacent blocks 12. Alternatively, the blocks 12 may be engaged with the connectors 2 at their desired height. Blocks 12 may be cut into desired dimensions or shapes in order to completely cover the frame 1. A layer of blocks 12 may be staggered relative to the layer above or below it to give the effect of a brick configuration or bond, such as half bond, quarter bond, English bond, stretcher bond, or any other suitable configuration. The front side 14 may also be provided with a pattern to give to give the effect of a brick configuration or bond, such as herring bond, basket bond, or any other suitable configuration

Referring to Figures 6 and 7, one or more horizontal spacers 30 may be provided between the top and bottom faces or edges of one or more rows of the assembled blocks 12. The horizontal spacers 30 may hold the top and bottom faces or edges of adjacent blocks 12 apart from one another and may be visible between the blocks 12. The horizontal spacers 12 may have an T shaped cross-section, or a 'T' shaped cross-section, or any other suitable cross-section The horizontal spacers 30 may be made from plastic, metal, or any other suitable material. The horizontal spacers 30 may look like or give the illusion of a traditional mortar _j oint when provided between the blocks 12. The horizontal spacers 30 may be designed on their visible side to look like a mortar joint. The horizontal spacers 30 may be laid on top of the blocks 12 during construction. The horizontal spacers 30 may be connected to the frame 1. Alternatively, the horizontal spacers 30 may sit between the top and bottom sides of the blocks 12 and be held in place by the weight of the blocks 12 above. The blocks 12 may be provided with slits on their top and bottom faces or edges arranged to receive a part of the horizontal spacers 30 to locate them between the blocks 12.

One or more vertical insets 32 may also be provided between one or more columns of the blocks 12 and may be used to hold in place or stabilise the horizontal spacers 30. The vertical insets 32 may be flat strips of material, or any other suitable shape. The vertical insets 32 may be made from metal, plastic, or any other suitable material. The vertical insets 32 may be provided between the left and right faces or edges of adjacent blocks 12. The vertical insets 32 may be visible between adjacent blocks 12 and may look like a traditional mortar joint. Alternatively, the blocks 12 may entirely cover or obscure the vertical insets 32. Slits may be provided in the side faces or edges of the blocks to locate the insets 32, which may fully or partially obscure the vertical insets 32.

The horizontal spacers 30 may have a slit in each end arranged to engage with a vertical inset 32. When a vertical inset 32 is inserted into a slit on a horizontal spacer 30, the two may be prevented from moving relative to one anodier. Alternatively, slits may be provided in suitable locations along the length of the vertical insets 32 such that the horizontal spacers 30 can engage with them. However, die horizontal spacers 30 and vertical insets 32 may engage with one another in any suitable manner.

The masonry veneer system may be used on internal walls or external walls of houses or buildings, fences, or any other suitable frame or surface.

The foregoing description of the invention includes preferred forms thereof. Modifications may be made thereto without departing from the scope of the invention as defined by the accompanying claims.