Sheet of articulated masonry-like units and method for producing the same

Abstract

The present invention provides a sheet of articulated masonry-like units (SAMU) and a method for producing the same. The method comprises obtaining masonry-like units prepared from one or more hardening materials; placing said masonry-like units into an articulating structure; interconnecting the masonry-like units to each other using a mesh-adhesive thereby generating a SAMU. Kits for preparing such sheets and methods of installing the same are also provided.

I claim:  
     
         1 . A method of forming a sheet of articulated masonry-like units using the sequential steps comprising: 
 a) obtaining masonry-like units having a base portion ranging in size from about ⅛ to 2 ½ inches in thickness prepared from one or more hardening materials selected from the group gypsum cement, plaster of Paris, Portland cement, an acrylic-based resin with cementitious material and cementitious material;    b) placing said masonry-like units into an articulating structure with a plurality of separate holding cavities to hold one or more masonry-like units at least {fraction (1/16)} of an inch above the height of the upper edge of said articulating structure;    c) interconnecting the masonry-like units to each other using a mesh-adhesive thereby generating a sheet of articulated masonry-like units, wherein sufficient space is present between each masonry-like unit sufficient to enable an installation or filler material to enter between adjacent masonry-like units and pass through the open weave portions of said mesh adhesive.    
     
     
         2 . The method of forming a sheet of articulated masonry-like units according to  claim 1 , wherein said masonry-like units comprise a high definition front face shaped to look like masonry material selected from the group of bricks, stones, flagstones, marble and any type of masonry work or millwork, and wherein said masonry-like units comprise a generally flat back face and sides necessary for attachment to the mesh adhesive.  
     
     
         3 . The method of forming a sheet of articulated masonry-like units according to  claim 1 , wherein said masonry-like units are brick-like units.  
     
     
         4 . The method according to  claim 2 , wherein said mesh-adhesive is formed by: 
 placing a mesh selected from the group of glass fiber, nylon, fiberglass and any material that is resistant to the alkalinity of said hardening material over said masonry-like units; and    b) applying an adhesive over said mesh to form said mesh-adhesive.    
     
     
         5 . The method according to  claim 4 , wherein said mesh-adhesive is formed by placing an adhesive onto and over said masonry-like units in a random pattern.  
     
     
         6 . The method according to  claim 5 , wherein said adhesive is latex glue or a polymer-based glue.  
     
     
         7 . A sheet of articulated masonry-like units produced according to the method of  claim 1 .  
     
     
         8 . A sheet of articulated masonry-like units produced according to the method of  claim 3 .  
     
     
         9 . A kit to produce a sheet of articulated masonry-like units comprising separately; 
 a) an articulating structure shaped to simulate any wall, ceiling, or building type structure constructed with masonry units;    b) masonry-like units;    c) mesh netting means;    d) adhesive;    e) adhesive application means;    f) mortar material(s); and    g) instructions for use.    
     
     
         10 . A kit having a sheet of articulated masonry-like units comprising separately; 
 a) a sheet of articulated masonry-like units;    b) mortar material(s); and    c) instructions for use.