Artificial masonry unit, a masonry wall, a kit and a method for forming a masonry wall

Abstract

An artificial masonry unit suitable for use with a panel made of a compressible material having masonry unit receiving depressions in a front face thereof and protruding ribs defining and bordering the depressions. The depressions are sized to receive respective artificial masonry units in a close-fitting relationship. The artificial masonry unit comprises a body bounded by a front face, a back face, and a lateral face providing a thickness to the unit, and a back peripheral edge joining the back face and the lateral face. A tooth projection is projecting from the lateral face next to and parallel to the back peripheral edge for thrusting into the protruding rib when the masonry unit is inserted in a respective depression. Thanks to the tooth projection that is thrusting into the rib of a respective depression and that helps retaining the masonry unit within the depression prior to mortaring the wall, there is no need for using a mixture of cement to temporarily retain the masonry units within the depression. A method and a kit for making a masonry wall with the above described masonry unit is also disclosed.

1 . An artificial masonry unit suitable for use with a panel having masonry unit receiving depressions in a front face thereof and protruding ribs defining and bordering said depressions, said depressions being sized to receive respective artificial masonry units in a close-fitting relationship, said artificial masonry unit comprising: 
 a body bounded by a front face, a back face, and a lateral face providing a thickness to the unit, and a back peripheral edge joining the back face and the lateral face; and    a tooth projection projecting from the lateral face next to and parallel to the back peripheral edge for thrusting into the protruding rib when the masonry unit is inserted in a respective depression.    
   
   
       2 . An artificial masonry unit according to  claim 1 , having a rectangular shape and wherein the lateral face divides into a top face, a bottom face and two opposite side faces.  
   
   
       3 . An artificial masonry unit according to  claim 2 , wherein the tooth projection is projecting from at least one of the top face and side faces.  
   
   
       4 . An artificial masonry unit according to  claim 3 , wherein the tooth projection is a ridge-shaped projection spanning said at least one of the top face and side faces.  
   
   
       5 . An artificial masonry unit according to  claim 4 , wherein the tooth projection is spanning the top face.  
   
   
       6 . An artificial masonry unit according to  claim 5 , wherein the tooth projection is projecting from the back edge of the unit.  
   
   
       7 . An artificial masonry unit according to  claim 6 , comprising a groove extending along the tooth projection.  
   
   
       8 . An artificial masonry unit according to  claim 4 , comprising a series of spaced reinforcing structures along the tooth projection to prevent the tooth projection from being chipped off.  
   
   
       9 . An artificial masonry unit according to  claim 8 , wherein each of the reinforcing structures has the shape of a sloping projection.  
   
   
       10 . A masonry wall covering a building surface, comprising: 
 a plurality of panels mounted side by side on the building surface, each panel comprising: 
 a back face covering the building surface; and  
 a front face with a plurality of depressions defined and bordered by protruding ribs, said depressions being shaped and sized to receive respective artificial masonry units;  
   a plurality of artificial masonry units inserted into said depressions, each artificial masonry unit comprising: 
 a body bounded by a front face, a back face, and a lateral face that provides a thickness to the unit, and a back peripheral edge joining the back face and the lateral face, each of said masonry units further comprising:  
 a tooth projection projecting from the lateral face next to and parallel to the back peripheral edge, said tooth projection thrusting into an adjacent protruding rib of a respective one of said depressions; and  
   mortar material binding the masonry units together.    
   
   
       11 . A masonry wall as claimed in  claim 10 , comprising a plurality of wall-ties for securing the masonry wall to the building surface, each of said wall-ties consisting of a generally L-shaped bracket mounted in a corner of a respective one of said depressions of the panel between the masonry unit inserted therein and the respective depression, said corner being defined by a bottom face and the rib of the depression, said L-shaped bracket comprising: 
 a first flange screwed to the bottom face of the depression and the building surface; and    a second flange extending at right angle to the first flange along the rib and having an end projecting out of the depression embedded in the mortar material.    
   
   
       12 . A masonry wall as claimed in  claim 11 , wherein said bracket comprises: 
 at least one hook extending at right angle to the first flange in a direction opposite to the second flange, said hook being inserted in the panel.    
   
   
       13 . A kit for making a masonry wall on a building surface, the kit comprising: 
 a set of panels to be mounted side by side on the building surface, each one of said panels comprising: 
 a back face for covering the building surface; and  
 a front face with a plurality of depressions defined and bordered by protruding ribs, said depressions being shaped and sized to receive respective artificial masonry units;  
   a set of artificial masonry units to be inserted and secured into said depressions, each one of said artificial masonry units comprising: 
 a body bounded by a front face, a back face, and a lateral face that provides a thickness to the unit, and a back peripheral edge joining the back face and the lateral face, each one of said masonry units further comprising:  
 a tooth projection projecting from the lateral face next to and parallel to the back peripheral edge so that when each one of said masonry units is inserted into a respective one of said depressions, each one of said tooth projections thrusts into an adjacent protruding rib of a respective one of said depressions and is secured in place; and  
   mortar material for binding the masonry units together.    
   
   
       14 . A kit as claimed in  claim 13 , comprising: 
 a set of wall-ties for securing the masonry wall to the building surface, each of said wall-ties comprising: 
 a generally L-shaped bracket to be mounted in a corner of a respective one of said depressions of the panel between the masonry unit inserted therein and the respective depression, said corner being defined by a bottom face and the rib of the depression, said L-shaped bracket comprising: 
 a) a first flange screwable to the bottom face of the depression and the building surface; and  
 b) a second flange extending at right angle to the first flange along the rib and having an end devised to project out of the depression and to be embedded in the mortar material when a masonry unit is inserted in the depression and mortared.  
 
   
   
   
       15 . A method for making a masonry wall covering a building surface, comprising the steps of: 
 a) mounting side by side on said building surface a plurality of panels, each one of said panels having a front face with a plurality of depressions defined and bordered by protruding ribs, said depressions being shaped and sized to receive respective artificial masonry units;    b) providing a set of artificial masonry units, each unit comprising: 
 a body bounded by a front face, a back face, and a lateral face that provides a thickness to the unit, and a back peripheral edge joining the back face and the lateral face, each one of said masonry units further comprising: 
 a tooth projection projecting from the lateral face next to and parallel to the back peripheral edge so that when each one of said masonry units is inserted into a respective one of said depressions, each one of said tooth projections is thrusting into an adjacent protruding rib of a respective one of said depressions;  
 
   c) inserting in each of said depressions one of said artificial masonry unit and retaining said unit by thrusting the tooth projection into the adjacent protruding rib of the respective depression; and    d) mortaring the masonry units.    
   
   
       16 . A method according to  claim 15 , comprising, before step c), the step of tying the masonry wall to the building surface, comprising the steps of: 
 mounting in a corner of a plurality of said depressions a generally L-shaped bracket, said corner being defined by a bottom face and a rib of the depressions, said bracket comprising: 
 a first flange screwable to the bottom face of the depression and the building surface; and  
 a second flange extending at right angle to the first flange along the rib and having an end devised to project out of the depression and to be embedded in the mortar material; and  
   screwing said brackets to the panel and the building surface.