US20230257999A1

US20230257999A1 - Masonry Support Structure

Info

Publication number: US20230257999A1
Application number: US17/674,423
Authority: US
Inventors: Caleb Ezra King
Original assignee: Rocketbox LLC; King Stoneworks LLC
Current assignee: Rocketbox LLC
Priority date: 2022-02-17
Filing date: 2022-02-17
Publication date: 2023-08-17

Abstract

The present invention is a masonry support structure and kit. The support structure includes at least a block of cellular glass insulation whose exterior surface is coated in a scratch coat. The support structure may be used to support the application of masonry veneers. The kit includes at least one support structure and may also include masonry veneers, veneer mortar, masonry wall ties, and post brackets.

Description

FIELD OF THE INVENTION

The present invention related generally to masonry support structures.

BACKGROUND

Cellular glass insulation is a thermal insulation that has recycled glass and sand as base materials, supplemented by mineral substances and other natural materials. It is inorganic insulation material that is composed of millions of sealed glass cells. The closed cell structure captures gas produced in the cells, giving the material an insulative property and ensuring a stable thermal conductivity. No water molecules can diffuse in the glass cells and internal condensation is impossible. The result is a vapor-tight, incombustible material with very high compressive strength. (What is cellular glass insulation? [online] [retrieved on 2022-02-16]. Retrieved from the Internet <URL: https://www.foamglas.com/en/advice-center/general-advice/what-is-cellular-glass-production-process>) A common cellular glass insulation, and the preferred cellular glass insulation most commonly referenced herein, is that sold under the trademark FOAMGLAS® sold by Pittsburgh Corning. FOAMGLAS® cellular glass insulation is waterproof, dimensionally stable, and acid-resistant because it consists of pure glass; pest-proof because it is inorganic and cannot rot; compression-proof without deformation even with longterm loads due to its cell geometry; incombustible because it consists of pure glass; and vapor-tight because it consists of hermetically sealed glass cells.
Cellular glass insulation is used in many applications as an excellent insulator. Cellular glass insulation is easily cut into any desired measurement with a simple tool, such as a saw blade or hand saw. In this way, sections of cellular glass insulation may be customized and fabricated for elements such as pipe insulation, curved sidewall segments, specialty tank heads, and detailed pipe insulation, such as elbow and T sections. Applications include insulation for cryogenic systems, heated and chilled water systems, underground piping, and any application that requires fire-resistant insulation. Cellular glass insulation is sometimes referred to as foam glass gravel or foamed glass aggregate. Cellular glass insulation is sometimes used as an inert, non-leaching fill in civil and infrastructure applications. (What is Cellular Glass? [online blog] [retrieved on 2022-02-16]. Retrieved from the Internet <URL: https://www.glavel.com/what-is-cellular-glass-insulation/>) Cellular glass insulation may, for example, act as a thermal bridge behind masonry veneer walls. (TOMASULO, Katy, Owens Corning Foamglas Perinsul SIB. Jan. 20, 2022 [online] [retrieved on 2022-02-16]. Retrieved from the Internet <URL: https://www.woc360.com/masonry/owens-corning-foamglas-perinsul-sib>)
As used herein, the term “cellular glass insulation” refers to a material as described above and may specifically refer to FOAMGLAS® cellular glass insulation.
A scratch coat is a textured coating applied to a surface to which a masonry hanging will be applied and is commonly used in the field of masonry. A scratch coat is typically made of plaster or mortar of the type used in masonry. Once applied and dried, the scratch coat provides a rough surface with many small tiny indentions. When it is time for a masonry hanging, such as a masonry veneer, to be applied to the surface, a second layer of masonry plaster or mortar is applied and adheres to the scratch coat by filling those tiny indentations. The scratch coat therefore primes the surface to be a structural support for a masonry hanging.

SUMMARY OF THE INVENTION

The present invention is a structural support and structural support kit.
In its most basic form, the structural support of the present invention is a block of cellular glass insulation having an exterior surface with a scratch coat disposed on at least a portion of the exterior surface of the block.
While cellular glass insulation has been used in many applications for insulation, it has not been used as a support structure for masonry veneers before the present invention. The inclusion of the scratch coat on the exterior surface of the block of cellular glass insulation is a physical component that indicates and is required by this intended use. As discussed above, although sheets of cellular glass insulation have been used as a thermal bridge behind masonry veneer walls, the cellular glass insulation in that application were not used as a support structure on which masonry veneers were applied, but only as a thermal bridge. Heretofore, the innate qualities of cellular glass insulation, including being lightweight, easy to cut and shape, compression-proof, waterproof, and vermin-resistant, have only been harnessed in using the material in its insulative capacity. The present invention uses these qualities in a new way.
It is preferred that the scratch coat consist of veneer mortar. As veneer mortar will be mentioned in regards to several aspects of the present invention, the veneer mortar that may form the scratch coat is referred to herein as “exterior veneer mortar,” as it is disposed on the exterior surface of the block. The scratch coat may be disposed on the entire exterior surface of the block or only a portion of the exterior surface. In some applications of the structural support of the present invention, it may make sense for the base of the block to remain uncoated with scratch coat, for example.
The block may be any shape but has at least two preferred configurations, the first of which is when the block takes the form of a rectangular prism. As rectangular prisms will be mentioned in regards to several aspects of the present invention, the rectangular prism that is that shape of the preferred block is referred to herein as “block rectangular prism.” Preferred dimensions of the block rectangular prism include 12″×12″×12″ and 12″×12″×18″. While the block rectangular prism may be formed of a single block of cellular glass insulation, in some embodiments, the block is formed by at least two strata of cellular glass insulation. Each of these strata will have at least one interior surface that will be in physical contact with an interior surface of an adjacent stratum. As used herein, “interior surface” refers to the one or more surfaces of the strata (or other structural components of the block, as discussed below) that will be within the block and that form no part of the exterior surface of the block. A stratum is considered “adjacent” to another stratum when it is directly below or above the other stratum in the stack of strata that is forming the block. When the block is formed by strata, a layer of veneer mortar is disposed between the interior surfaces of the strata so that the strata are adhered to one another. When veneer mortar is used between interior surfaces, it is referred to herein as “interior veneer mortar.” Given standard sizing of cellular glass insulation, it is preferred that the block include three strata. In this configuration, the middle stratum has two interior surfaces and is sandwiched between the outer strata, each of which has one interior surface in physical contact with the interior surfaces of the middle stratum.
The second preferred configuration of the block of the present invention has a “C” or “U” shape. The shape is formed by a bridge connecting first and second legs. The first and second legs are parallel to one another and perpendicular to the bridge. The bridge is a rectangular prism, referred to specifically herein as “bridge rectangular prism,” having six bridge sides, which are the six surfaces of the bridge rectangular prism. Each of the first and second legs is also a rectangular prism, referred to specifically herein as “leg rectangular prisms,” having the same size and shape so that the first and second legs are identical. Each leg rectangular prism has six leg sides, which are the six surfaces of the respective leg rectangular prism. The first and second legs extend from the same bridge side such that five of the six legs of each of the first and second legs form part of the exterior surface of the block. The first and second legs extend from and edge of that same bridge side so that a first flush surface is formed between a second bridge side and one of the leg sides of the first leg and a second flush surface is formed between a third bridge side and one of the leg sides of the second leg. Two opposite surfaces of the block therefore form a “U” or “C” shape. A top down view of one of these surfaces is referred to herein as a “side view” of the block in this configuration. The two-dimensional side view has a single line of symmetry and is therefore symmetrical.
The preferred “C”/“U” configuration of the block has dimensions that are fulfilled when each of the following conditions are met: two of the three dimensions of the bridge rectangular prism are 15″×12″; the first flush surface is 12″×7.5″; the second flush surface is 12″×7.5″; a leg side of the first leg that is as far from the bridge as possible is 4″×12″; and a leg side of the second leg that is as from the bridge as possible is also 4″×12″. In some embodiments of the “C”/“U” configuration of the block, the block is formed from a single piece of cellular glass insulation that has been cut into the “C”/“U” shape as described above. In some embodiments, the first and second legs are adhered to the bridge with a layer of interior veneer mortar between the first or second leg and the first bridge side from which it extends.
It is understood that while two preferred embodiments of the structural support of the present invention, as a block rectangular prism and in a “C”/“U” configuration, have been described in detail above, the structural support of the present invention may be of any shape or size. Cellular glass insulation is easily shaped into any shape or size and the structural support of the present invention only requires a block of cellular glass insulation (of any shape or size) with a scratch coat disposed on at least a portion of the exterior surface of that block.
In one embodiment of its most basic form, the structural support kit of the present invention includes at least one structural support of the present invention, as described above, and at least one masonry veneer. The masonry veneer may be any commonly used in the art, such as brick or stone, or other decorative sheet or surface. A masonry veneer is a non-structural external layer that will be applied to the structural support of the present invention.
The kit may also include a supply of veneer mortar. This supply of veneer mortar is a separate aspect of the invention from either the exterior veneer mortar that may be used for the scratch coat of the structural support or the interior veneer mortar that may be used to adhere parts of the block of the structural support together. It is understood that as used herein, the term “supply of veneer mortar” is referring to a separate component of the kit from the block and the interior and/or exterior veneer mortar that may be used therein or thereon. In practice, the supply of veneer mortar will be used to apply a second coating of veneer mortar on top of the scratch coat of the structural support and the masonry veneer will be adhered to and applied on top of this second coating.
Any veneer mortar used within the present invention, whether it is interior veneer mortar, exterior veneer mortar, or a supply of veneer mortar may be any masonry veneer mortar commonly used in the art, such as any of those designated as Type N, O, S, or M mortars and that are typically a blend of sand, Portland cement, and lime. The preferred veneer mortar, however, is that sold under the trademark The Original Thin-Stone Veneer Mortar™ by Umaco. This masonry mortar is a blend of aggregates, Portland cement, dry polymers, and additives.
The kit may also include at least one masonry wall tie. The masonry wall tie may be any commonly used in the art of masonry. A masonry wall tie is typically a wire or sheet metal device used to connect two or more masonry wythes or to connect masonry veneers to a structural backing system. Examples of common masonry wall ties include stainless steel cable ties; crimped lengths of galvanized steel; and/or lengths of stamped or other patterned metal. In practice, the masonry wall tie may be used to affix the block of the structural support to an existing structure or to secure two blocks of the structural support together.
The kit may also include at least one post bracket. The post bracket may be any commonly used in the art of masonry. A post bracket is typically a wood or metal bracket having at least one 90° angle. In this way, one surface of the post bracket may be affixed to one object and the perpendicular surface of the post bracket may be affixed to another object such that the two objects are held in position relative to one another. In practice, the post bracket may be used to affix the block of the structural support to an existing structure and position the block securely in relation to the existing structure.
In another embodiment of its most basic form, the structural support kit of the present invention includes at least one structural support of the present invention, as described above, and at least one masonry wall tie. This kit may also include at least one masonry veneer. This kit may also include a supply of veneer mortar. This kit may also include at least one post bracket.
These aspects of the present invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the following description, claims, and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a perspective view of a preferred embodiment of the structural support of the present invention.

FIGS. 1 b and 1 c are perspective diagrams of the structural support of the present invention.

FIG. 2 a is a perspective view of an alternate preferred embodiment of the structural support of the present invention.

FIG. 2 b is a perspective diagram of the structural support of the present invention shown in FIG. 2 a.

FIG. 2 c is the side view of the structural support of the present invention shown in FIG. 2 a.

FIG. 3 is a block diagram of the components of the kit of the present invention.

FIG. 4 is a photograph of structural supports of the present invention in use around a barbecue grill.

FIGS. 5 a and 5 b are photographs of the kit of the present invention in use around a column.

DETAILED DESCRIPTION

Referring first to FIG. 1 a , a perspective view of a preferred embodiment of structural support 10 of the present invention is provided. Structural support 10 is a block 12 made of cellular glass insulation 14. Block 12 is formed as a block rectangular prism 22 having first dimension 24, second dimension 26, and third dimension 28. The preferred dimensions 24, 26, 28 are each 12″. Block 12 has exterior surface 16 on which is disposed scratch coat 18, which is preferably exterior veneer mortar 20.
Now referring to FIGS. 1 b and 1 c , perspective views of structural support 10 separated into strata 30 is provided. It is understood that not all embodiments of block 12 include strata 30 and that some blocks 12 are formed from a single, integrated piece of cellular glass insulation 14. It is further understood that strata 30 of structural support 10 are not typically visible as structural support 10 is block 12 in its final form. FIGS. 1 b and 1 c are provided for illustrative purposes to indicate interior features of block 12. In FIG. 1 b , block 12 has two strata 30. Each stratum 30 has one interior surface 32. A layer of interior veneer mortar 34 has been applied to the interior surface 32 of the lower stratum 30. This interior veneer mortar 34 will adhere the strata 30 together so that their interior surfaces 32 are in physical contact with one another. It is understood that interior veneer mortar 34 may be applied to the interior surface of the upper stratum 30 instead of the lower stratum 30 or to the interior surfaces 32 of both the upper and lower strata 30. In FIG. 1 c , block 12 has three strata 30. The upper and lower strata 30 each have one interior surface 32 and the middle stratum 30 has two interior surfaces 32, one of which is in physical contact with the interior surface 32 of the upper stratum 30, and one of which is in physical contact with the interior surface 32 of the lower stratum 30. Layers of interior veneer mortar 34 have been applied to all interior surfaces 32 of all strata 30. Strata 30 may be adhered together when a layer of interior veneer mortar 34 is applied to only one interior surface 32 of adjacent strata 30, as shown in FIG. 1 b , or on both interior surfaces 32 of adjacent strata 30, as shown in FIG. 1 c . In FIG. 1 c , one dimension 24 of block 12 is 18″ so that the dimensions 24, 26, 28 of this embodiment of block 12 are 18″×12″×12″.
Now referring to FIG. 2 a , a perspective view of the “C”/“U” configuration 72 of the structural support 10 of the present invention. Block 12 has bridge 40 connecting first leg 36 and second leg 38. First and second legs 36, 38 each extend perpendicularly out from a first bridge side 42 and are parallel to one another. The dashed lines indicate the delineation between bridge 40 and first and second legs 36, 38, but it is understood that this dashed line is illustrative only and is not visible on block 10. (It is understood that similar dashed lines in other Figures are also illustrative only and are not visible.) A first flush surface 52 is formed across a second bridge side 44 (to the left of the vertical dashed line) and a leg side 56 of first leg 36 (to the right of the vertical dashed line). A similar second flush surface 54 is formed across third bridge side 46 and a leg side 56 of second leg 38, but second flush surface 54 is not visible in this view. This preferred embodiment has first bridge dimension 64 of 15″; second bridge dimension 66, which is also a first dimension of first and second flush surfaces 52, 54, of 12″; second dimension 68 of first and second flush surfaces 52, 54 of 7.5″; and leg side dimension 70 of 4″, where leg side dimension 70 is a dimension of the either leg side 56 that is furthest from bridge 40.
Now referring to FIG. 2 b , a perspective diagram of structural support 10 as shown in FIG. 2 a , with bridge 40 and first and second legs 36, 38 separated is provided. It is understood that some blocks 12 in “C”/“U” configuration 72 are formed from a single, integrated piece of cellular glass insulation 14 that has been manufactured into the “C”/“U” shape. FIG. 2 b illustrates an embodiment of the “C”/“U” configuration 72 where first and second legs 36, 38 are adhered to bridge 40 to form the “C”/“U” shape. Each of first and second legs 36, 38 is a leg rectangular prism 50 with six leg sides 56. Five of the six of the leg sides 56 of each of first and second legs 36, 38 are part of the exterior surface 16 of block 12. The remaining sixth leg side 56 of each of first and second legs 36, 38 is an interior surface 32. Each of first, second, and third bridge sides 42, 44, 46, discussed above is a bridge side 48. Bridge 40 is a bridge rectangular prism 62 with six bridge sides 48. All of bridge sides 48 form part of the exterior surface 16 of block 12 except for the portions of first bridge side 42 to the left of the left dashed line, which meets with interior surface 32 of first leg 36, and to the right of the right dashed line, which meets with interior surface of second leg 38. Interior surfaces 32 of first and second legs 36, 38 include a layer of interior veneer mortar 34 to adhere first and second legs 36, 38 to first bridge side 42 of bridge 40. It is understood that the layer of interior veneer mortar 34 may be applied instead to the portions of first bridge side 42 that are interior surfaces 32 or to the interior surfaces 32 of both first and second legs 36, 38 and the interior surfaces 32 of first bridge side 42.
Now referring to FIG. 2 c , the side view 58 of the structural support 10 of the present invention shown in FIG. 2 a is provided. The side view 58 is a top down view of either two-dimensional surface of block 10 in “C”/“U” configuration 72 where the “U” or “C” shape is most obvious. Side view 58 has line of symmetry 60 and is therefore symmetrical.
Now referring to FIG. 3 , a block diagram illustrating various components of kit 100 of the present invention are provided. Each kit 100 includes at least one structural support 10 of the present invention, which may take the form or block rectangular prism 22, as described above with reference to FIGS. 1 a-1 c ; “C”/“U” configuration 72, as described above with reference to FIGS. 2 a-2 c ; or any other shape and/or size. One embodiment of kit 100 also includes at least one masonry veneer 74. Although masonry veneer 74 is illustrated herein as a brick façade, it is understood that masonry veneer 74 may be any masonry veneer commonly used in the art or a selection of masonry veneers commonly used in the art. Another embodiment of kit 100 also includes at least one masonry wall tie 78. Although masonry wall tie 78 is illustrated herein as a crimped length of steel, it is understood that masonry wall tie 78 may be any masonry wall tie commonly used in the art or a selection of masonry wall ties commonly used in the art. Kit 100 may also include a supply of veneer mortar 76, which may be any veneer mortar commonly used in the art and any quantity thereof. Kit 100 may also include at least one post bracket 80. Although post bracket 80 is illustrated herein as a simple 90° metal bracket, it is understood that post bracket 80 may be any post bracket commonly used in the art. The various components of kit 100 are illustrated in use in FIGS. 4, 5 a, and 5 b below.
Now referring to FIG. 4 , a photograph of structural supports 10 used around a barbecue grill 82 is provided. Barbecue grill 82 is surrounded by structural supports 10 in the form of block rectangular prisms 22. Although not visible, a supply of veneer mortar 76 from kit 100 was used to adhere blocks 12 of structural supports 10 together. Masonry wall ties 78 from kit 100 may also have been used to secure blocks 12 together (as shown in FIGS. 5 a and 5 b below). Moreover, one or more post brackets 80 from kit 100 may have been deployed with one side attached to the bottom of grill 82 and one side attached to the bases of the lower layer of blocks 12. The owner of the grill 82 now need only apply some of her supply of veneer mortar 76 to the visible surfaces of blocks 12 and then apply the masonry veneer 74 of her choice to make a beautiful outdoor structure.
Now referring to FIGS. 5 a and 5 b , photographs of structural supports 10 in two stages of application used around column 84 are provided. The structural supports 10 are in the “C”/“U” configuration 72. In FIG. 5 a , two structural supports 10 are disposed around column 84 so that column 84 is encapsulated in the space provided by the “C”/“U” shape. Masonry wall ties 78 from kit 100 are used to hold the two structural supports 10 in place with respect to one another and with respect to column 84. Although not visible, one or more post brackets 80 are disposed at the bottom of column 84 so that one side is attached to column 84 and one side is attached to the bases of the structural supports 10. Some of the supply of veneer mortar 76 has been used to adhere the two structural supports 10 together down their lengths. FIG. 5 b illustrates the same application a little farther along. A second layer of structural supports 10 are being applied on top of that which we see in FIG. 5 a . The second layer is being applied in a 90° orientation from the first layer so that the seams between the structural supports 10 on the respective layers are not directly atop one another. Again, once completely installed, the owner of column 84 may apply some of her supply of veneer mortar 76 to the outer surfaces of blocks 10 and then apply the masonry veneer 74 of her choice, making a simple wooden post into a much more attractive outdoor feature.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions would be readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the description should not be limited to the description of the preferred versions contained herein.

Claims

We claim:

1. A structural support comprising:

a block of cellular glass insulation having an exterior surface; and

a scratch coat disposed on at least a portion of said exterior surface of said block.

2. The structural support as claimed in claim 1, wherein said scratch coat is exterior veneer mortar.

3. The structural support as claimed in claim 1, wherein said block of cellular glass insulation is a block rectangular prism.

4. The structural support as claimed in claim 3, wherein:

said block of cellular glass insulation comprises at least two strata of cellular glass insulation;

each of said at least two strata comprises at least one interior surface; and

said strata are stacked to form said block, such that adjacent strata are in physical contact within said block; and

said structural support further comprises a layer of interior veneer mortar disposed between said interior surfaces of said adjacent strata such that said adjacent strata are adhered to one another.

5. The structural support as claimed in claim 3, wherein said block has dimensions of 12″ by 12″ by 12″.

6. The structural support as claimed in claim 3, wherein said block has dimensions of 12″ by 12″ by 18″.

7. The structural support as claimed in claim 4, wherein said block cellular glass insulation comprises three strata of cellular glass insulation.

8. The structural support as claimed in claim 1, wherein:

said block comprises a first leg, a second leg, and a bridge connecting said first and second legs;

said first and second legs are parallel to one another;

said bridge is perpendicular to said first and second legs;

said bridge is a bridge rectangular prism having six bridge sides;

said first and second legs each extend from a same first of said bridge sides of said bridge;

each of said first and second legs are leg rectangular prisms having six leg sides, wherein said leg rectangular prisms are a same size and shape;

said first and second legs extend from said same first of said bridge sides such that:

five of said leg sides of said first and second legs form a portion of said exterior surface;

a second of said bridge sides forms a first flush surface with one of said leg sides of said first leg; and

a third of said bridge sides forms a second flush surface with one of said leg sides of said second leg; and

a side view of said block is symmetrical.

9. The structural support as claimed in claim 8, wherein:

two of three dimensions of said bridge rectangular prism are 15″ by 12″;

said first flush surface has dimensions of 12″ by 7.5″;

said second flush surface has dimensions of 12″ by 7.5″;

a leg side of said first leg disposed farthest from said bridge has dimensions of 4″ by 12″; and

a leg side of said second leg disposed farthest from said bridge has dimensions of 4″ by 12″.

10. The structural support as claimed in claim 8, further comprising a layer of interior veneer mortar disposed between:

said first leg and said first of said bridge sides; and

said second leg and said first of said bridge sides.

11. A structural support kit comprising:

at least one structural support comprising:

a block of cellular glass insulation having an exterior surface; and

a scratch coat disposed on at least a portion of said exterior surface of said block; and

at least one masonry veneer.

12. The kit as claimed in claim 11, further comprising at least one masonry wall tie.

13. The kit as claimed in claim 11, further comprising at least one post bracket.

14. The kit as claimed in claim 11, further comprising a supply of veneer mortar.

15. The kit as claimed in claim 11, wherein said scratch coat of said at least one structural support is exterior veneer mortar.

16. The kit as claimed in claim 11, wherein:

said block of cellular glass insulation of said at least one structural support is a block rectangular prism, comprising at least two strata of cellular glass insulation;

each of said at least two strata comprises at least one interior surface; and

17. The kit as claimed in claim 11, wherein:

said block of said at least one structural support comprises a first leg, a second leg, and a bridge connecting said first and second legs;

said first and second legs are parallel to one another;

said bridge is perpendicular to said first and second legs;

said bridge is a bridge rectangular prism having six bridge sides;

a side view of said block is symmetrical.

18. A structural support kit comprising:

at least one structural support comprising:

a block of cellular glass insulation having an exterior surface; and

at least one masonry wall tie.

19. The kit as claimed in claim 18, further comprising at least one post bracket.

20. The kit as claimed in claim 18, further comprising a supply of veneer mortar.

21. The kit as claimed in claim 18, wherein said scratch coat of said at least one structural support is exterior veneer mortar.

22. The kit as claimed in claim 18, wherein:

each of said at least two strata comprises at least one interior surface; and

23. The kit as claimed in claim 18, wherein:

said first and second legs are parallel to one another;

said bridge is perpendicular to said first and second legs;

said bridge is a bridge rectangular prism having six bridge sides;

a side view of said block is symmetrical.