tntroduction The present invention relates to a brick alignment device for bricklaying comprising a brick support and a spacer member projecting orthogonally from one side of the brick support, the depth of the brick support and spacer member being substantially the same as the desired spacing between adjacent bricks for the reception of grouting mortar therebetween.

Such a brick alignment device facilitates the accurate laying of bricks and blocks, hereinafter generally bricks, both by the professional and amateur bricklayer. Such brick alignment devices have been known for some considerable time. Typical examples are those disclosed in, for example, British Patent Specification No. GB 2047768 (Wilson) and in PCT Patent Specification No. WO 94/28271 (Tweedy).

PCT Patent Specification No. WO 02/35027 (Herbison) discloses another such brick alignment device and the specification discusses in some detail the problems in relation to known brick alignment devices where there is particular reference to the possibility of cracking of mortar as it shrinks and on drying out. While undoubtedly the problem of mortar drying out is one that causes some difficulty and is one that needs to be addressed, an even more important problem is the difficulty in handling such brick alignment devices and embedding them successfully in the mortar. They would work very satisfactorily if mortar was of a coherent and consistent quality.

Unfortunately, while mortar is made from what is supposed to be relatively fine sand, very often, the mortar includes sand or, more often, crushed stone, which can have dimensions as large as 5mm. Thus, it has been found to be very difficult to embed such brick alignment devices successfully in mortar and they have not worked very satisfactorily. Indeed, this difficulty of embedding the brick or, more properly, the alignment device or spacer element, into the mortar, has been a major problem.

Misalignment of the bricks often occurs.

The present invention is directed towards overcoming this problem.

Statements of Invention According to the invention, there is provided a brick alignment device for bricklaying comprising a brick support and a spacer member projecting orthogonally from one side of the brick support, the depth of the brick support and spacer member being substantially the same as the desired spacing between adjacent bricks for the reception of grouting mortar therebetween, characterised in that the brick support comprises an elongate upstanding wall having, in plan, a non-linear configuration for support of a brick, the wall comprising a plurality of opposed depending and upstanding spaced-apart brick engaging teeth, the thickness of each tooth reducing in cross-section to form a narrow brick engaging edge. The advantage of these brick engaging teeth is that they are relatively sharp and will project easily through the mortar and because they are relatively small in cross-sectional area, they will be able to either slice through any obstructions in the mortar or push and bypass such obstructions, for example, a slightly larger grain of aggregate or sand so as to ensure that the alignment device contacts the brick that it should contact. Further, because the brick engaging surface of each tooth is relatively small, the tooth will engage in recesses and accommodate irregularities in the brick.

In one embodiment of the invention, the device is formed from a pliable material whereby the teeth bend under a loading of the weight of more than one brick to facilitate natural bedding of the bricks in the mortar as the bricks are laid. This has two major advantages. Firstly, it is relatively easy to provide a brick alignment device which will easily support a brick when laid on top of it without any distortion.

However, as more bricks are laid on top of the wall and the bricks will then be allowed to bed down into the mortar without obstruction by the alignment device, thus overcoming the problems hereinbefore referred to. Further, because the teeth will bend, they will naturally bend and twist to accommodate irregularities within the bricks. They will also ensure that there are no cracks in the mortar.

In one embodiment of the invention, the spacer member comprises a plate projecting upwards from the wall, the plate reducing in thickness to form opposed narrow side edges. The advantage of this is that again the spacer element will cut neatly into the mortar and thus impinge against the face of the bricks.

In one embodiment of the invention, the support wall forms an enclosed frame which may be substantially circular. This is a relatively simple construction of a brick alignment device and is particularly useful with the present construction in which the brick support has relatively sharp brick engaging teeth.

In another embodiment of the invention, there are two diametrically opposed spacer members. This is useful to fix the brick alignment device in position.

In another embodiment of the invention, the spacer member forms an enclosed upstanding open frame projecting upwardly from two diametrically opposed locations on the wall. The advantage of this is that firstly it is easy to hold and secondly, it allows the facing bricks to be secured together in suitable parallel facing fashion.

In another embodiment of the invention, the wall incorporates a weakened snap-off portion on one side of the spacer member. The advantage of this is that the brick support can then be reduced in size so asito accommodate end walls abutting bricks and laying bricks against abutting walls.

Detailed Description of the n ion The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which : - Fig. 1 is a perspective view of a brick alignment device according to the invention, Fig. 2 is a front view of the device, Fig. 3 is a side view of the device, Fig. 4 is a side view showing a brick alignment device and brick about to be placed in position,

Fig. 5 is a side view showing the brick alignment device and brick in position, Fig. 6 is a perspective view of the brick alignment device and brick in position, Fig. 7 is a view similar to Fig. 6 showing another way of using the brick alignment device, Fig. 8 is a front view of another construction of brick alignment device, Fig. 9 is a perspective view of a still further construction of brick alignment device, Fig. 10 is a perspective view of another brick alignment device, Fig. 11 is a perspective view of a still further brick alignment device, and Fig. 12 is a perspective view of another brick alignment device according to the invention.

Referring to the drawings and initially to Figs. 1 to 6 thereof, there is provided a brick alignment device, indicated generally by the reference numeral 1, which comprises two elements, namely, a brick support, indicated generally by the reference numeral 2, and formed in this embodiment by a substantially circular enclosed frame 4. The other element is a spacer member 3. The frame 4 comprises an elongate upstanding wall 5 comprising a plurality of upstanding spaced-apart brick engaging teeth 6 and depending brick engaging teeth 7. The brick engaging teeth 6 and 7 reduce in cross- section towards their free edge to form a narrow brick engaging edge 8 and 9 respectively. The spacer member 3 comprises a narrow plate 15 projecting orthogonally from one side of the brick support 2, the plate 15 reducing in cross- section to form narrow brick engaging side edges 16.

Ideally, the brick alignment device 1 is manufactured from a pliable materiat and generally a pliable plastics material.

Referring to Figs. 4 to 6; there is illustrated a plurality of bricks, each identified by the reference numeral 20 and suitable subscript letters. In the embodiment, there is shown a plurality of bricks 20 (a), 20 (b), on which have been laid bricks 20 (d) and 20 (c) (see Figs. 5 and 6). Mortar is identified by the reference numeral 21 and suitable subscript letters, as appropriate. There is illustrated a number of brick alignment devices 1.

Referring now to Fig. 4, there is illustrated a wall with the brick 20 (d) already laid on bricks 20 (a), 20 (b) and 20 (c) which have been laid on a base 23. Mortar 21 (a) and 21 (b) is shown placed in position as is normal in bricklaying and the brick 20 (c) is held in the bricklayer's hand, which is not shown. The bricklayer carries a brick alignment device, here identified as 1 (a), on a trowel 22, only portion of the blade of which is shown. It will be appreciated that the bricklayer holds the device under the brick 20 (e) by the trowel 22 while grasping the brick in his or her other hand. Then, the brick is moved in the direction of the arrow A into the position on top of the mortar, as illustrated in Fig. 4.

It will be also noted that an alignment device 1 (b) was placed in position adjacent the end of the wall to align the brick 20 (d) above the brick 20 (a). When more than three or four courses of brick have been laid, the teeth 6 and 7 will start to bend slightly under the weight of the bricks 20 which are now on top of them. Thus, there will be some settling of the alignment device 1. This will further prevent cracking of the mortar 21. It will also allow the teeth 6 and 7 to flex and thus further overcome the problems that arise with imperfections in the mortar and in the bricks.

Referring now to Fig. 7, there is illustrated an alternative way of using the brick alignment devices 1 which might be used by a professional or more skilled bricklayer.

In this embodiment, the spacer members 3 are mounted depending rather than upstanding. In Fig. 7, again parts similar to those described with reference to Fig. 6, are identified by the same reference numerals. This would allow the skilled person to proceed at a more rapid rate as it would allow the unimpeded spreading of the next mortar bed. Thus, the bricklayer would lay one bed of mortar and then carry on as before. It should be noted that for ease of understanding, not all the mortar is shown

spread.

Referring now to Fig. 8, there is illustrated a still further construction of brick alignment device, again indicated generally by the reference numeral 1, in which a weakened snap-off portion 22 is provided in the wall 5 on either side of the spacer member 3. This allows, for example, if in the wall of Fig. 7, namely, the end of the wall, portion of the brick support 2 to be snapped off and thus not to project beyond the end wall. This could be used, for example, rather than the manner in which the alignment device 1 is used in Fig. 5. Then, simply all that would be left would be portion of the brick support 2 with the spacer member 3 and the projecting portion of the brick support 2 snapped off.

Referring to Fig. 9, there is illustrated another construction of alignment device, again indicated generally by the reference numeral 1. In this embodiment, there is only one spacer member 3.

Referring to Fig. 10, there is illustrated a further construction of alignment device, again indicated generally by the reference numeral 1, in which there are four spacer members 3. These could be used where, for example, four bricks were to meet together or could be used for the laying of slabs or bricks flat on the ground to cover an area. Then, the alignment devices could be laid either on the base with the four spacer members 3 engaging against four bricks or alternatively, they could be placed above the bricks and removed when the bricks had been mortared into position.

Fig. 11 illustrates a still further construction of brick alignment device, again indicated generally by the reference numeral 1. In this embodiment, the spacer member, again indicated generally by the reference numeral 3, comprises an enclosed upstanding frame 24 which projects upwardly from two diametrically opposed locations 25 on the wall 5. It is also constructed in substantially the same way as the wall 5. This can be advantageous for the handling of the alignment device 1. It also allows adjacent bricks to be more clearly butted together.

Finally, in Fig. 12, there is illustrated a still further construction of alignment device, again indicated generally by the reference numeral 1, in which the enclosed frame 4

is now rectangular. The remainder of the parts are substantially similar to those described with reference to the previous drawings and are identified by the same reference numerals.

It will be appreciated that an entire course may be laid"dry", that is to say, without any grouting mortar. The bricks can then be removed and individually bedded in mortar. This method could be useful for the inexperienced or D. I. Y. practitioner as it ensures, before the bricks are finally bedded, that the course is the same length as the preceding one.

It will be appreciated that the professional or experienced bricklayer may only use the alignment device to build the corners of a house or a wall and use a line to build the straight portions in between. This method will allow the skilled tradesman to quickly and accurately ensure that the gauge, that is, the height of a given number of courses, is maintained without incurring the expense of using a device for each brick which, in many instances, might slow down the work, even if the bricklayer were to use the spacing devices upside down, as suggested already.

There are many other ways of carrying out the invention and further, there are many other ways in which the device may be used in accordance with the invention.

It will be appreciated that the spacer could be abutted against an end wall and the remainder of the brick support could be placed underneath the brick.

It will also be appreciated that the particular constructions described above will be particularly useful in that they will allow mortar to be relatively easily placed around the brick alignment device so that the brick alignment device will not in any way interfere with the normal bricklaying and will not interfere with the keying of the bricks together.

It is envisaged that the brick alignment device according to the present invention can be manufactured from many materials but it is envisaged that it could be easily moulded from a plastics material as described above.

It will be appreciated that the present invention will be particularly suitable in maintaining a uniform spacing in brick and block work joints. Further, they will be particularly useful for the do-it-yourself bricklayer to allow he or she to produce brickwork to a near professional standard.

A further advantage of the present invention is that where it is desired to have different spacings of mortar or other grout material between blocks or bricks, different sizes of brick alignment devices according to the invention can be provided to achieve this aim.

A further advantage, particularly for the amateur or do-it-yourself brick or block layer will be that the brick alignment device will essentially define for the bricklayer in a relatively simple way, the amount of mortar required since, once mortar has been laid across the top of the brick support, the brick support will effectively define the amount of mortar required.

In the specification the terms"comprise, comprises, comprised and comprising"or any variation thereof and the terms"include, includes, included and including"or any variation thereof are considered to be totally interchangeable and they should all be afforded the widest possible interpretation.

The invention is not limited to the embodiments hereinbefore described but may be varied in both construction and detail with the scope of the claims.