Thin brick matrix panel and related methods and systems

Abstract

A thin brick system and method for forming a thin brick wall includes a matrix in which channels are formed for receiving a plurality of thin brick units. The thin brick units are bonded to the matrix using mortar and the same mortar can be used to fill spaces between adjacent bricks. The matrix may be attached to a substrate using fasteners. The channels can be formed in the matrix on-site.

1 . A matrix panel for use in a thin brick panel system with thin bricks,
 wherein the matrix panel comprises a front side, a back side, a left side, a right side, a top side, and a bottom side,   wherein the front side has a plurality of laterally oriented channels that each are sized and configured to receive a plurality of thin brick units that are adhered to the channel by mortar,   wherein the channels are each defined by a pair of laterally extending protrusions that are integrally formed with the matrix panel,   wherein the plurality of laterally extending protrusions are positioned to provide proper spacing between the thing brick units to enable the thin brick units to form rows, and   wherein each laterally extending protrusion has a height that is less than the thickness of the thin brick units and each laterally extending protrusion has a width that is sufficient to enable a mortar joint to be formed on each laterally extending protrusions between rows of thin brick units and between horizontally adjacent thin brick units.   
   
   
       2 . The matrix panel of  claim 1 , wherein each laterally extending protrusion has a substantially square transverse cross section. 
   
   
       3 . The matrix panel of  claim 1 , wherein the matrix panel comprises a steel diamond lath. 
   
   
       4 . The matrix panel of  claim 3 , wherein the matrix panel comprises 2.5 gage steel diamond lath. 
   
   
       5 . The matrix panel of  claim 3 , wherein the matrix panel comprises 3.5 gage steel diamond lath. 
   
   
       6 . The matrix panel of  claim 3 , wherein the panel has a height of about 2 feet and a width of about 8 feet. 
   
   
       7 . The matrix panel of  claim 3 , wherein the plurality of laterally extending protrusions each have a height of about 0.25 inches to about 1.5 inches. 
   
   
       8 . The matrix panel of  claim 3 , wherein the plurality of laterally extending protrusions each have a depth of about 0.2 inches to about 2.0 inches. 
   
   
       9 . The matrix panel of  claim 3 , wherein the plurality of laterally oriented channels each have a height of about 2.5 inches to about 3.5 inches. 
   
   
       10 . A thin brick panel system, comprising:
 a matrix panel for use with thin bricks;
 wherein the matrix panel comprises a front side, a back side, a left side, a right side, a top side, and a bottom side; 
   a plurality of mechanical fasteners for securing the panel to a substrate; and,   a plurality of thin brick units,
 wherein the front side of the matrix panel has a plurality of laterally oriented channels that each are sized and configured to receive some of the plurality of thin brick units, wherein the thin brick units are adhered to the channels by mortar, 
 wherein the channels are each defined by a pair of laterally extending protrusions that are integrally formed with the matrix panel, 
 wherein the plurality of laterally extending protrusions are positioned to provide proper spacing between the thin brick units to enable the thin brick units to form rows, and 
 wherein each laterally extending protrusions has a height that is less than the thickness of the thin brick units and each laterally extending protrusion has a width that is sufficient to enable a mortar joint to be formed on each laterally extending protrusions between rows of thin brick units and between horizontally adjacent thin brick units. 
   
   
   
       11 . The system of  claim 6 , wherein each laterally extending protrusion has a substantially square transverse cross section. 
   
   
       12 . The system of  claim 7 , wherein the matrix panel comprises 2.5 gage steel diamond lath. 
   
   
       13 . The system of  claim 7 , wherein the matrix panel comprises 3.5 gage steel diamond lath. 
   
   
       14 . A method for forming a section of thin bricks, comprising:
 providing a matrix panel having a front side and a back side, the front side defining a plurality of laterally oriented channels,   the channels each defined by a pair of laterally extending protrusions that are integrally formed with the matrix panel;   wherein the laterally extending protrusions are positioned to provide proper spacing between the thin brick units to enable the thin brick units to form rows, and   fastening the matrix panel to a substrate via one or more mechanical fasteners;   applying mortar to the panel within the plurality of channels; and,   pressing a plurality of thin brick units into the mortar;
 wherein each laterally extending protrusion has a height that is less than the thickness of the thin brick units and each laterally extending protrusion has a width that is sufficient to enable a mortar joint to be formed on each laterally extending protrusion between rows of thin brick units. 
   
   
   
       15 . The method of  claim 10 , wherein the method further comprises applying mortar within the mortar joint. 
   
   
       16 . The method of  claim 10 , wherein the method further comprises mechanically fastening the matrix panel to a substrate. 
   
   
       17 . A thin brick wall comprising:
 a plurality of thin brick units adhered to a matrix panel and each other by mortar,
 wherein the mortar is enmeshed with cross members and apertures in the matrix panel and the mortar forms mortar joints between rows and horizontally adjacent thin brick units, 
 wherein the matrix panel comprises a plurality of laterally oriented channels that are defined by a pair of laterally extending protrusions and the matrix panel is anchored to a substrate via a plurality of mechanical fasteners. 
   
   
   
       18 . The thin brick wall of  claim 13 , wherein the matrix panel comprises diamond steel lath. 
   
   
       19 . The thin brick wall of  claim 13 , wherein each of the laterally extending protrusions comprise a substantially square transverse cross section. 
   
   
       20 . The thin brick wall of  claim 13 , wherein each thin brick unit has a front face, a rear face, a top side, a bottom side,
 wherein the wall comprises some thin brick units that have other thin brick units immediately adjacent to them on their top side, bottom side left side and right side such that they can be said to be surrounded by other thin brick units, and   wherein those thin brick units that are surrounded by other thin brick units are each contacted by mortar on their back face, top side, bottom side, left side and right side.   
   
   
       21 . A method for forming a section of thin bricks, comprising:
 providing a matrix panel having a front side and a back side;   forming a plurality of laterally extending protrusions such that a pair of laterally extending protrusions defines a laterally extending channel;   wherein the laterally extending protrusions are positioned to provide proper spacing between the thin brick units to enable the tin brick units to form rows,   fastening the matrix panel to a substrate via one or more mechanical fasteners;   applying mortar to the panel within the plurality of channels; and, pressing a plurality of thin brick units into the mortar;   wherein each laterally extending protrusion has a height that is less than the thickness of the thin brick units and each laterally extending protrusion has a width that is sufficient to enable a mortar joint to be formed on each laterally extending protrusion between rows of thin brick units.   
   
   
       22 . The method of  claim 17 , wherein the plurality of laterally extending protrusions are formed in the matrix panel by employing a press, the press comprising:
 a first portion that has at least one recess, and   a second portion that has at least one protrusion;
 wherein the protrusion of the first portion forces a portion of the matrix panel into the recess of the second portion. 
   
   
   
       23 . The method of  claim 17 , wherein the plurality of laterally extending protrusions are formed in the matrix panel by feeding the matrix panel through a roller apparatus, the roller apparatus comprising:
 a first roller that has at least one recess, and   a second roller that has at least one protrusion;
 wherein the protrusion of the first roller forces a portion of the matrix panel into the recess of the second roller.