Fiber enforced thin brick sheet and process

Abstract

A fiber enforced sheet for use as a wall or floor covering which comprises of adhered thin bricks bonded to a fiber-reinforced, backing layer. Thin brick is adhered to the fiber enforced sheet. The fiber enforced backing increases strength and rigidity to the thin brick during handling, and installation permits the thin bricks to be adhered to proper specification and spacing to be cut using ordinary tile or thin brick tools.

1 - 41 . (canceled) 
     
     
         42 . A thin brick sheet, comprising:
 a plurality of thin bricks adhered to a first side of a backing layer with an adhesive, wherein the backing layer defines a grid that comprises a plurality of holes, wherein the backing layer is non-stretchable, and wherein the plurality of thin bricks are adhered to the backing layer such that a portion of a rear surface of each thin brick overlaps one or more of the plurality of holes in the backing layer.   
     
     
         43 . The thin brick sheet of  claim 42 , wherein the plurality of thin bricks are adhered to the backing layer with spaces of about ¼ inch to about ¾ inch between adjacent thin bricks. 
     
     
         44 . The thin brick sheet of  claim 42 , wherein the backing layer comprises at least one of fiberglass, polyester, graphite, aramid, or carbon. 
     
     
         45 . The thin brick sheet of  claim 42 , wherein the backing layer is impregnated or saturated with the adhesive. 
     
     
         46 . The thin brick sheet of  claim 42 , further comprising an anti-adhesive paper disposed on a second side of the backing layer. 
     
     
         47 . The thin brick sheet of  claim 42 , wherein the plurality of thin bricks are adhered to the backing layer in a running bond pattern or a stack bond pattern. 
     
     
         48 . The thin brick sheet of  claim 42 , wherein a portion of a rear surface of each thin brick is free from the adhesive. 
     
     
         49 . The thin brick sheet of  claim 42 , wherein the plurality of thin bricks comprise one or more of clay bricks, cast bricks, or wire cut bricks. 
     
     
         50 . The thin brick sheet of  claim 42 , wherein the thin brick sheet consists of four rows of thin bricks. 
     
     
         51 . The thin brick sheet of  claim 50 , wherein the thin brick sheet consists of three thin bricks per row. 
     
     
         52 . A thin brick sheet, comprising:
 a plurality of thin bricks adhered to a first side of a backing layer with a first adhesive, wherein adjacent thin bricks are spaced about ¼ inch to about ¾ inch from each other, wherein the backing layer defines a grid that comprises a plurality of holes, and wherein the plurality of thin bricks are adhered to the backing layer such that a portion of a rear surface of each thin brick overlaps one or more of the plurality of holes in the backing layer such that a second adhesive can extend through the one or more of the plurality of holes to bond each brick to a wall or floor surface.   
     
     
         53 . The thin brick sheet of  claim 52 , wherein the backing layer comprises at least one of fiberglass, polyester, graphite, aramid, or carbon. 
     
     
         54 . The thin brick sheet of  claim 52 , wherein the backing layer is impregnated or saturated with the first adhesive. 
     
     
         55 . The thin brick sheet of  claim 52 , further comprising an anti-adhesive paper disposed on a second side of the backing layer. 
     
     
         56 . The thin brick sheet of  claim 52 , wherein a portion of a rear surface of each thin brick is free from the first adhesive. 
     
     
         57 . The thin brick sheet of  claim 52 , wherein the plurality of thin bricks comprise one or more of clay bricks, cast bricks, or wire cut bricks. 
     
     
         58 . The thin brick sheet of  claim 52 , wherein the thin brick sheet consists of four rows of thin bricks. 
     
     
         59 . The thin brick sheet of  claim 58 , wherein the thin brick sheet consists of three thin bricks per row. 
     
     
         60 . A thin brick sheet, comprising:
 a plurality of thin bricks adhered to a first side of a backing layer with a first adhesive, wherein adjacent thin bricks are spaced about ¼ inch to about ¾ inch from each other, wherein the thin brick sheet consists of four rows of thin bricks, wherein the backing layer defines a grid that comprises a plurality of holes, and wherein the plurality of thin bricks are adhered to the backing layer such that a portion of a rear surface of each brick overlaps one or more of the plurality of holes in the backing layer such that a second adhesive can extend through the one or more of the plurality of holes to bond each brick to a wall or floor surface.   
     
     
         61 . The thin brick sheet of  claim 60 , wherein the thin brick sheet consists of three thin bricks per row.