CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This is a PCT international application that claims priority to, and the benefit of the filing date of, U.S. provisional application No. 62/893,400, filed on August 29, 2019, entitled “AN INSULATED MODULAR BRICK SYSTEM AND METHODS,” which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] The present disclosure discloses an insulated modular brick system and method for fabricating and installing the insulated modular brick system.

BACKGROUND

[0001] The conventional method of installing masonry is one brick at a time, which requires a large amount of in-site materials, labor and additional costs. Attempts have been made to develop systems that provide the same aesthetic appearance as traditional brick systems while reducing materials, labor and costs associated with traditional brick masonry. For example, “thin brick” systems and “brick veneer” systems exist that are marketed as light-weight alternatives to traditional brick systems. Such systems can be combined with insulating materials for improved energy efficiency. Installing such systems, however, is a fairly labor-intensive process in that it requires individually attaching the thin bricks or brick veneers to a base that has been mechanically attached to a framed structure. Some of these thin brick systems can be prone to bricks popping off in severe weather conditions.

[0002] A need exists for a system that overcomes the aforementioned disadvantages of existing thin brick systems, that has the aesthetic qualities of a traditional brick system, that is cost effective, that has insulating characteristics, and that requires less labor to install than traditional brick systems and the aforementioned thin brick or brick veneer alternatives.

SUMMARY

[0003] The present disclosure relates to an insulated modular brick panel designed to be installed on a substrate of a building structure, an insulated modular brick system comprising the panel, a method for making the panels. The panel comprises an insulating foam core having a preselected thickness, an encapsulating material encapsulating the insulating foam core on at least first, second and third sides of the insulating foam core, and a plurality of thin bricks partially embedded in at least a front face of the encapsulating material at preselected locations.

[0004] In accordance with an embodiment, the encapsulating material has at least a first clip attachment formed in an upper surface thereof. The first clip attachment can be configured to receive a first clip for attaching the panel to a second insulated modular brick panel.

[0005] In accordance with an embodiment, the encapsulating material has at least a second clip attachment formed in a lower surface thereof. The second clip attachment can be configured to receive a second clip for attaching the panel having the second clip attachment to a third insulated modular brick panel.

[0006] In accordance with an embodiment, the encapsulating material has a J-track formed therein. The J-track can be configured to receive an attachment mechanism for attaching the panel to the building structure such that a weight of the panel is supported by the building structure.

[0007] In accordance with an embodiment, the plurality of thin bricks comprises multiple rows of thin bricks partially embedded in the front face of the encapsulating material at preselected locations. Each row of thin bricks is laterally offset from an adjacent rows of thin bricks by a preselected distance, L/2, where L is equal to the length of each thin brick.

[0008] In accordance with an embodiment, the panel has at least first and second joints for joining the panel laterally with first and second panels, respectively. The panel comprises preselected locations in the rows that are empty of thin bricks. The preselected locations that are empty of thin bricks have lengths equal to L/2. The preselected locations of length L/2 that are empty of thin bricks align with preselected locations of length L/2 that are empty of thin bricks in an adjoining panel such that the aligned empty locations, once joined, are sized to receive a full thin brick of length L.

[0009] In accordance with an embodiment, the panel has at least first and second interlocking joints on first and second sides, respectively, of the panel for joining the panel laterally with first and second panels that each have the first and second interlocking joints on first and second sides of the first and second panels.

[0010] In accordance with an embodiment, the first interlocking joint has interlocking pockets and interlocking legs and the second interlocking joint has interlocking pockets and interlocking legs.

[0011] In accordance with an embodiment, the interlocking pockets and interlocking legs of the first interlocking joint alternate row by row such that each row of the panel that ends with an interlocking pocket on the first side of the panel is adjacent to a row on the first side of the panel that ends with an interlocking leg.

[0012] In accordance with an embodiment, the interlocking pockets and interlocking legs of the second interlocking joint alternate row by row such that each row of the panel that ends with an interlocking pocket on the second side of the panel is adjacent to a row on the second side of the panel that ends with an interlocking leg.

[0013] In accordance with an embodiment, the encapsulating material is a glass fiber reinforced concrete (GFRC) coating.

[0014] The insulated modular brick system comprises a plurality of the insulated modular brick panels that are attached to one another by clips.

[0015] The process for fabricating an insulated modular brick system, the process comprises: placing thin brick tiles in respective pockets of a customized mold, the pockets being sized and shaped to receive the thin brick tiles; pouring an encapsulating matrix material into the mold such that the encapsulating matric material is in contact with back surfaces of the thin brick tiles and is disposed in between sides of adjacent thin brick tiles; placing a foam core comprising insulating material in the mold in contact with the encapsulating matrix material such that a front face of the foam core is substantially parallel with the back surfaces of the brick tiles; and allowing the encapsulating matrix material to cure or harden.

[0016] These and other features and advantages will become apparent from the following description, drawings and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Many aspects of the invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.

[0018] Figs. 1 and 2 show straight and return insulated modular brick panels, respectively, in accordance with a representative embodiment.

[0019] Fig. 3 is a cross-sectional side view of the panel shown in Fig. 1.

[0020] Figs. 4 and 5 show straight and return insulated modular brick panels, respectively, in accordance with a representative embodiment.

[0021] Fig. 6 is a cross-sectional side view of the panel shown in Fig. 4.

[0022] Figs. 7 and 8 show straight and return insulated modular brick panels, respectively, in accordance with a representative embodiment.

[0023] Fig. 9 is a cross-sectional side view of the panel shown in Fig. 7.

[0024] Figs. 10 and 11 show straight and return insulated modular brick panels, respectively, in accordance with a representative embodiment.

[0025] Fig. 12 is a cross-sectional side view of the panel shown in Fig. 10.

[0026] Figs. 13A and 13B show front perspective and side cross-sectional views, respectively, of an insulated modular brick system in accordance with a representative embodiment that has been constructed using one of the panels shown in Fig. 7, three of the panels shown in Fig. 1 and one of the panels shown in Fig. 10.

[0027] Fig. 14 shows an elevation view of the insulated modular brick system in accordance with a representative embodiment that has been constructed using six insulated modular brick panels.

[0028] Fig. 15 shows a table of test data for a few representative embodiments of the insulated modular brick panels.

[0029] Figs. 16A and 16B show front perspective and side cross-sectional views, respectively, of a straight insulated modular brick panel in accordance with another representative embodiment having an interlocking configuration. [0030] Fig. 17 shows a front perspective view of a return insulated modular brick panel in accordance with another representative embodiment having an interlocking configuration that is configured to interlock with the panel shown in Fig. 16 A.

[0031] Fig. 18 is a plan view of an example of the insulated modular brick system 150 comprising a plurality of the panels 130 and 131 shown in Figs. 16A - 17 showing the manner in which they can be joined.

DETAILED DESCRIPTION

[0032] The present disclosure discloses an insulated modular brick system that has the aesthetic qualities of a traditional brick system, that is cost effective, that has insulating characteristics, and that requires less labor to install than traditional brick systems and the aforementioned thin brick or brick veneer alternatives. The system comprises one or more insulated modular brick panels designed to be installed on a substrate of a building structure. The panel comprises an insulating foam core having a preselected thickness, an encapsulating material encapsulating the insulating foam core on at least first, second and third sides of the insulating foam core, and a plurality of thin bricks partially embedded in at least a front face of the encapsulating material at preselected locations.

[0033] The panels preferably are made via a casting process during which an insulating foam core is encapsulated in an encapsulating material along with a thin-brick pattern that gives the panel the aesthetic look of a solid brick wall. Custom molds can be used during the casting process for casting the panels. The panels are then allowed to cure. Once the panels are cured to the desired strengths, they can be inspected and reviewed for quality control prior to being released for shipment.

[0034] Figs. 1 - 13B and 16A - 18 show several representative embodiments of insulated modular brick panels that can be used to construct the insulated modular brick system. The inventive principles and concepts are not limited to insulated modular brick panels having the configurations shown in Figs. 1 - 13B and 16A - 18. The representative embodiments of the panels shown in Figs. 1 - 13B and 16A - 18 are examples of possible configurations from which the insulated modular brick system can be constructed. Figs. 14 and 18 provide examples of the insulated modular brick systems. [0035] Figs. 1 and 2 show straight and return insulated modular brick panels 1 and 2, respectively, each having a clip attachment portion 3. Fig. 3 is a cross-sectional side view of the panel 1 shown in Fig. 1. As can best be seen in Fig. 3, the insulating foam core 4 is encapsulated on at least three sides of the core 4 in an encapsulating material 5. The encapsulating material 5 has a thin-brick pattern 6 embedded in a front face 5a of the panel 1. In Fig. 2, the thin-brick pattern 6 is also embedded in a side face 5b of the encapsulating material 5. The thin- brick pattern 6 comprises a plurality of thin bricks arranged in rows at preselected locations, with each row of thin bricks being laterally offset relative to the adjacent row(s) of thin bricks. For example, if each thin brick has a length, L, the adjacent row(s) of thin bricks will typically be laterally offset by an amount equal to L/2.

[0036] At the joints of each panel, there are preselected locations that are absent of thin bricks. With reference to Fig. 1, the panel 1 has first and second joints 7a and 7b, respectively, at which the panel 1 is intended to be joined with adjoining panels (not shown). At these joints 7a and 7b, the locations 8 and 9, respectively, having lengths equal to L/2 are left empty of thin bricks so that once the panel 1 is joined at joints 7a and 7b with adjoining panels (not shown), the empty locations 8 and 9 will align with empty locations in the adjoining panels that are also of length L/2. The aligned empty locations, once joined, are sized to receive a full thin brick (i.e., a thin brick of length L) after the panels have been adjoined. In this manner, the joints are “hidden,” or “blended,” i.e., they appear seamless.

If the panel 1 is not intended to be joined with adjoining panels, thin bricks of length L/2 will be embedded in the encapsulating material 5 at the locations 8 and 9 during the casting process.

[0037] A variety of encapsulating materials are suitable for use as the encapsulating material 5. The encapsulating material is typically a glass fiber reinforced concrete (GFRC) coating. A few examples of suitable encapsulating materials include, but are not limited to, cementitious or acrylic and polymer-based materials.

[0038] The insulating foam core 4 is typically 4 inches thick and has a standard R-16 insulation value. It should be noted, however, that the inventive principles and concepts are not limited with respect to the type, thickness or insulating value of the insulating core 4.

The core thickness can be sized to meet any local codes requirements. [0039] Figs. 4 and 5 show straight and return insulated modular brick panels 11 and 12, respectively, each having a clip attachment portion 3. Fig. 6 is a cross-sectional side view of the panel 11 shown in Fig. 4. The panels 11 and 12 are identical to the panels 1 and 2, respectively, except that the panels 11 and 12 include a feature 13 known in the industry as a bullnose.

[0040] Figs. 7 and 8 show straight and return insulated modular brick panels 21 and 22, respectively, each having a clip attachment portion 3. Fig. 9 is a cross-sectional side view of the panel 21 shown in Fig. 7. The panels 21 and 22 are identical to the panels 1 and 2, respectively, except that the panels 21 and 22 include a J-track 23. The purpose of the J- track is described below in detail in the description of the installation process for installing an insulated modular brick system.

[0041] Figs. 10 and 11 show straight and return insulated modular brick panels 31 and 32, respectively, each having a clip attachment portion 3. Fig. 12 is a cross-sectional side view of the panel 31 shown in Fig. 10. The panels 31 and 32 are identical to the panels 21 and 22, respectively, except that the panels 31 and 32 include the bullnose feature 13. Like the panels 21 and 22, the panels 31 and 32 include the J-tracks 23.

[0042] Figs. 13A and 13B show front perspective and side cross-sectional views, respectively, of an insulated modular brick system 100 in accordance with a representative embodiment that has been constructed using one of the panels 21 shown in Fig. 7, three of the panels 1 shown in Fig. 1 and one of the panels 31 shown in Fig. 10.

[0043] Fig. 14 shows an elevation view of the insulated modular brick system 120 in accordance with a representative embodiment that has been constructed using six insulated modular brick panels 120a - 120f. Dashed line 121 indicates where the three upper panels 120a - 120c are joined with the three lower panels 120d - 120f, respectively. The filler thin bricks discussed above that are installed after a panel has been adjoined laterally with another panel are not needed for all laterally adjoining panels in order to provide the visual effect of seamlessness at the joints. For example, in the representative embodiment shown Fig. 14, the filler bricks are only used at the joints where panel 120d is adjoined with panel 120e and where panel 120e is adjoined with panel 120f. The upper panels 120a - 120c are just set in place without using the filler bricks, and yet the entire system has the seamless visual effect of traditional brick masonry. This further reduces the labor, materials and cost associated with installing the system without sacrificing the aesthetic qualities or structural integrity.

The Casting Process

[0044] As indicated above, the insulated modular brick system 100 replaces the old method of installing masonry, one brick at a time, which requires a large amount of on-site materials, labor and additional costs.

[0045] The insulated modular brick panels preferably are cast using the encapsulating material 5, which encapsulates the insulating form core 4 with the thin- brick pattern 6 partially embedded in a front and/or side face of the encapsulating material 5, which gives the panel the aesthetic look of a solid brick wall. Molds having preselected shapes and sizes are used for casting the panels and then the panels are allowed to cure in a temperature- controlled manufacturing facility. Once the panels have been cured to the required strengths, they preferably are inspected and reviewed by quality control personnel and released for shipment if they pass the inspection and review process.

[0046] The mold is customized to receive the thin brick tiles and to create pockets for the thin brick tiles that will be installed on-site at the joints 7a and 7b. Once the thin brick tiles have been placed in the mold, casting of the encapsulating matrix material can begin. The matrix material is cast to a set point in the mold. The foam comprising the foam core 4 is then placed in the mold. Once the foam is set, the excess matrix material is removed. The product is allowed to cure in a controlled environment for eight hours. The cured matrix material functions as the grout in between adjacent thin brick tiles as well as the mechanism that holds the entire panel together. Thus, the need to perform grouting during the installation process is eliminated. The part is then removed from the mold. The quality control inspection and review processes are then performed. The panels are then palletized for shipping.

Site Preparation

[0047] The general contractor or subcontractor for the project will typically process a full pre-install review/checklist of the substrate which includes building verification, shop drawings, and layouts. This pre-installation review/checklist will reduce labor and material costs, waste, and require less alterations to panels on-site.

The Installation Method

[0048] Comprehensive shop and setting drawings, detailing joint layout, fabrication details, setting and part numbers are engineered and stamped to meet local Code requirements. The panels are installed using adhesive and mechanical attachments. The adhesive is applied to the back of the panel, in a pattern detailed by our engineer, then the panel is lined up with the layout/shop drawings. Once the panel is positioned it is mechanically attached/clipped back to the structure.

[0049] At certain levels of the building, a J-track mechanical attachment method is used to carry the weight of the panel. This is the purpose for the J-tracks shown in Figs. 7, 9, 10, 12, 13A and 13B. Preferably the panels will be positioned on a spacer (placed at both horizontal/vertical joints) to control the joint size and maintain uniformity. At panel joints, such as joints 7a and 7b, a bead of latex caulk preferably is installed, which allows for movement in the structure and provides for a water-tight wall system. For multi-story panel applications, preferably all joints are filled with a grout. As seen in Figs. 1 - 13B, there will typically only be two joints on any sized modular panel. Once the installation of all panels is complete, the subcontractor/installer will typically clean the wall surface with approved cleaner, as with traditional brick.

Some Benefits of the Insulated Modular Brick Panel [0050] In accordance with some embodiments, some of the benefits are: Standard R-16 insulation value, e.g., 4” insulation thickness - each panel provides standard R-16 value and eliminates the need for an additional 2” rigid insulation. Additional insulation thickness can be added for local Code requirements. Lightweight Panels - panels can be only 15 lbs. per square foot vs. precast panels at 52 lbs. psf. and traditional brick at 24 lbs. psf. Reduced Structural Load - panels are lightweight and reduce the overall load on the building structure and simplify connections. Reduced Labor and Installation Costs - panels can be pre- fabricated, lightweight, and require less equipment and manpower for installation. Detailing issues can be resolved with architect and subcontractor prior to fabrication. Faster Installation On-Site - fast-track schedules can be maintained by pre fabricating the panels in advance while the foundation and structure are under construction. Panel installation can be completed rapidly, even in inclement weather. Panels directly applied to substrate - panels are watertight and fully encapsulated and can be applied directly over an approved water-borne weather barrier. Factory Controlled manufacturing - all panels can be manufactured in a factory/temperature-controlled environment with comprehensive quality control standards. Design Freedom - brick panels offer the architect freedom of design. Custom colors, textures, and special designs are available. Panels are pre-fabricated per detail requirements of individual projects. Wide Variety of Standard panels - Examples include pre-fabricated soldier courses, window headers, water tables, pilasters, column wraps, corners, custom pieces, and large cornice panels are available for project requirements. Sustainability - panel production produces less waste than traditional brick systems with fewer natural resources. Prefabrication is done in a controlled facility and less on-site waste is produced. By producing the panel system in a controlled facility, it is possible to reduce the amount of waste sand, brick and cement that is typically put into the jobsite dumpster. Reducing waste onsite reduces the environmental foot print and costs. Wind Resistance - panels have been tested and maintain a high degree of peak pull- off standards and perform well in high wind or hurricane zones. The pull-out strength can be, for example, 181 lbs per sq inch. This type of bond strength will prevent any brick from popping off during severe weather conditions. Durable Long-Lasting Design - panels are durable, low maintenance, and watertight. Panels are considered a 75-year product (.01% degradation in 300 cycle freeze/thaw test).

Examples of Insulated Modular Brick Panel and System Applications [0051] Public/Government - Panels provide a durable and quality exterior for City Hall and other public buildings which require economical exteriors. Healthcare - Panels provide the aesthetic details designers want for their health services facilities. High - Tech Facilities - Panels provide designers with high-tech finishes and aesthetics for office buildings and campuses which accentuate their brand. Hotels - Hospitality - Hotels, resorts, and casinos benefit from the pre fabricated panel installation and custom designs. Fast - Food Restaurant Chains - Panels make fast-track schedules possible and restaurant units can be fabricated in advance and shipped to job-sites regardless of location when needed. Retail - Panels provide creative and unique details required for high-end, strip centers, big box, and specialty store unique designs. Housing - Panels provide high-quality exteriors for multi-family, college dormitories, and government housing. Residential - Panels provide a low-cost, energy efficient exterior for both new and retrofit applications. Brick patterns on existing exteriors can be “cloned” and matched in texture and color for retrofit or additions. Stadiums/Sports and Entertainment Complexes - Panels provide a great source of speed and flexibility of design for these venues. Steel/Metal Buildings - Panels provide a “brick” exterior for steel/metal buildings where code requires masonry exterior. Custom Applications/Exteriors - Panels can be fabricated to meet the custom design requirements for existing buildings, restoration of historic buildings, parking structures, and custom artwork.

[0052] Fig. 15 shows a table of test data for a few representative embodiments of the insulated modular brick panels. The ASTM test methods shown in the table are based on results received through independent testing. All insulated modular brick panels comprise a minimal 1/2” thick glass fiber reinforced concrete (GFRC) coating that fully encapsulates EPS foam core. J-tracks and metal clip attachment methods are designed by a Registered Engineer. Shop and setting drawings, indicating jointing, fabrication details, setting details, and location of pieces will be provided per specific requirements of project. [0053] Figs. 16A and 16B show front perspective and side cross-sectional views, respectively, of a straight insulated modular brick panel 130 in accordance with another representative embodiment having an interlocking configuration. Fig. 17 shows a front perspective view of a return insulated modular brick panel 131 in accordance with another representative embodiment having an interlocking configuration that is configured to interlock with the panel 130 shown in Fig. 16A. Each panel 130, 131 has a clip attachment portion 3 to allow straight panels 130 to be vertically stacked on like straight panels 130 and to allow return panels 131 to be stacked on like return panels 131. The panels 130 and 131 can be fabricated using the casting process described above, except that the casting process will use molds that are configured to produce the interlocking configurations.

[0054] The interlocking configuration of panel 130 comprises first and second interlocking joints 137a and 137b, respectively, that are configured to be joined with interlocking joints of either other straight panels 130 or of return panels 131, depending on the design of the insulated modular brick system. In other words, if the insulated modular brick system is designed to be more than one panel 130 in width, then a plurality of the panels 130 will be joined in the lateral direction. If the insulated modular brick system is designed to be more than one panel 130 in height, then a plurality of the panels 130 will be joined in the vertical direction. The panels 131 will interlocked with the panels 130 at the corners of the system and the panels 131 will be stacked one atop the other in the vertical direction to achieve the desired height of the system. Stacking in the vertical direction can be accomplished using the aforementioned clips and clip attachment portions in the manner described above in the installation method section. The J-track 23 are used to couple the panels 130 to the substrate of the building structure in the manner described above in the installation method section.

[0055] The interlocking joint 137a has interlocking pockets 138a and interlocking legs 138b that alternate row by row such that each row that ends with an interlocking pocket 138a is adjacent to a row that ends with an interlocking leg 138b. Likewise, the opposite interlocking joint 137b has interlocking pockets 139a and interlocking legs 139b that alternate row by row such that each row that ends with an interlocking pocket 139a is adjacent to a row that ends with an interlocking leg 139b. For each row that ends with an interlocking pocket 138a of interlocking joint 137a, the opposite end of the row ends with an interlocking leg 139b. Likewise, for each row that ends with an interlocking leg 138b of interlocking joint 137a, the opposite end of the row ends with an interlocking pocket 139a. To join two panels 130, the interlocking pockets 138a of a first panel 130 interlock with interlocking legs 139b of a second panel 130.

[0056] With reference to the return panel 131, the interlocking joints 140a and 140b are identical to the interlocking joints 137a and 137b, respectively. To join two panels 130 with the return panel 131, the interlocking pockets 138a of a first panel 130 interlock with interlocking legs 142b of the return panel 131 and the interlocking legs 139b of a second panel 130 interlock with interlocking pockets 141a of the return panel 131.

[0057] It should be noted that modifications can be made to the interlocking joints shown in Figs. 16A - 17 that enable the joints to blend and be hidden. In all other respects, the panels 130, 131 may be manufactured and installed in the manner described above, with the exception that the need for the filler bricks discussed above with reference to Fig. 14 is obviated because the interlocking joints blend or are hidden when they are joined. Some grouting will typically be performed at the joints in order to improve seamlessness.

[0058] Fig. 18 is a plan view of an example of the insulated modular brick system 150 comprising a plurality of the panels 130 and 131 showing the manner in which they are joined. In this example, twelve straight panels 130 and eight return panels 131 are used to construct the system 150, although the inventive principles and concepts are not limited to using any particular number or combination of the panels or with respect to the manner in which they are vertically joined or attached to a substrate of a building.

[0059] It should be noted that the inventive principles and concepts have been described herein with reference to a few representative embodiments, experiments and computer simulations. It will be understood by those skilled in the art in view of the description provided herein that the inventive principles and concepts are not limited to these embodiments or examples. Many modifications may be made to the systems and methods described herein within the scope of the invention, as will be understood by those of skill in the art.