Note: Descriptions are shown in the official language in which they were submitted.
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TITLE
Thin Wall Veneer Brick and Manufacturing Assembly Therefor
BACKGROUND
[0001] Thin Wall veneer brick constructions are well known in the art
of exterior and interior wall covering. Conventional bricks are generally laid
with mortar provided between adjacent bricks and between adjacent brick rows.
This may be viewed as a drawback since it is difficult to keep brick rows
level.
Furthermore, the task of laying out bricks with mortar is time consuming,
costly
and labour intensive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] In the appended drawings:
[0003] Figure 1 is a front elevation of a brick wall made with different
sizes of thin wall veneer bricks according to illustrated embodiment of the
present invention;
[0004] Figure 2 is a close-up view of two adjacent thin wall veneer
bricks of the brick wall of Figure 1;
[0005] Figure 3 is a sectional view taken along line 3-3 of Figure 2;
[0006] Figure 4 is a schematic side elevation of part of a brick edge
aging machine illustrated in the operation of aging a brick according to an
illustrated embodiment;
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[0007] Figures 5A to 5H illustrate the dimensions of the bricks used
in the brick wall of Figure 1;
[0008] Figure 6 is an exploded side elevation of an assembly for
manufacturing thin wall veneer bricks according to illustrated embodiments;
[0009] Figure 7 is a side elevation of the assembly of Figure 6 ready
to mold bricks of different sizes;
[0010] Figure 8 is a side elevation similar to Figure 7, illustrating the
assembly when it contacts the concrete provided in the molds;
[0011] Figure 9 is a side elevation similar to Figure 7, illustrating the
assembly partially compressing the concrete provided in the molds;
[0012] Figure 10 is a side elevation similar to Figure 7, illustrating
the assembly totally compressing the concrete provided in the molds;
[0013] Figure 11 is a side elevation similar to Figure 7, illustrating
the assembly when the brick shoulders are formed;
[0014] Figure 12 is a side elevation similar to Figure 7, illustrating
the assembly when the newly formed bricks are released therefrom;
[0015] Figures 13A and 13B are respectively side elevation and top
plan views of a thin wall veneer corner brick according to an illustrated
embodiment;
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[0016] Figure 14A is a front elevation of a brick wall made with
different sizes of bricks according to another embodiment of the present
invention;
[0017] Figure 14B is a sectional view taken along line 14B-14B of
Figure 14A;
[0018] Figure 15 is a front elevation of a brick wall made with
identical bricks according to another embodiment; and
[0019] Figures 16A-16G are front elevations of bricks provided with
different peripheral flange configurations according to embodiments of the
present invention.
DETAILED DESCRIPTION
[0020] In accordance with an illustrative embodiment, there is
provided a thin brick comprising:
[0021] a generally rectangular body having a first thickness; the
rectangular body defining four sides; and
[0022] a flange provided on at least two of the four sides of the
generally rectangular body and integral therewith for receiving at least one
fastener for mounting the brick to a wall substrate; the flange having a
second
thickness smaller than the first thickness to allow the flange and the at
least
one fastener to be covered.
[0023] The use of the word "a" or "an" when used in conjunction with
the term "comprising" in the claims and/or the specification may mean "one",
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but it is also consistent with the meaning of "one or more", "at least one",
and
"one or more than one". Similarly, the word "another" may mean at least a
second or more.
[0024] As used in this specification and claim(s), the words
"comprising" (and any form of comprising, such as "comprise" and
"comprises"), "having" (and any form of having, such as "have" and "has"),
"including" (and any form of including, such as "include" and "includes") or
"containing" (and any form of containing, such as "contain" and "contains"),
are
inclusive or open-ended and do not exclude additional, unrecited elements or
process steps.
[0025] The term "about" is used to indicate that a value includes an
inherent variation of error for the device or the method being employed to
determine the value.
[0026] Other objects, advantages and features will become more
apparent upon reading of the following non-restrictive description of
illustrative
embodiments thereof, given by way of example only with reference to the
accompanying drawings.
[0027] Generally stated, illustrative embodiments are concerned with
concrete bricks having a shoulder defining a peripheral flange configured for
receiving the heads of fasteners used to mount the concrete bricks to a wall
substrate. Optionally, the peripheral flange is provided with indentations
allowing fasteners to be inserted therein when two adjacent bricks have
aligned
indentations. The peripheral flange of the bricks, which is thinner than the
body
of the concrete brick, allows mortar, or other covering material, to be
inserted
thereonto to create the conventional brick look while hiding the fasteners.
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Another aspect is concerned with an assembly to manufacture such concrete
bricks.
[0028] Turning now to Figures 1 to 3 of the appended drawings, a
wall 20 covered with thin bricks according to an illustrative embodiment will
be
described. The wall 20 is covered with thin concrete bricks defining eight
brick
sizes 22A-22H.
[0029] Figure 2 illustrates two adjacent bricks 22D and 22E. As can
be seen from this figure, each brick is generally rectangular, thereby
provided
with four corners 26, and includes a peripheral shoulder defining a peripheral
flange 24 provided with eight semi-cylindrical indentations 28A-28H. Each
indentation 28A-28H is located at the same distance from a corner 26 of the
brick. Accordingly, since the bricks 22D and 22E are of the same height, the
two indentations 28C and 28D of brick 22E are respectively aligned with the
two indentations 28H and 28G of brick 22D. Fasteners 30 are driven through
the aligned indentations to enter the wall substrate (not shown) to mount the
bricks 22D and 22E to the wall. As can be better seen from Figure 3, the
fasteners 30 include a head portion 32 abutting the flanges 24 to adequately
mount the bricks to the wall. The width of the flanges 24 define the distance
separating the brick faces since the flanges of one brick abuts the flanges of
adjacent bricks.
[0030] Once the bricks are mounted to the wall via fasteners 30,
mortar can be used to cover the flanges 24, hiding the fasteners 30, to give
the
brick wall a conventional look.
[0031] Figures 5A to 5H give illustrative dimensions for the bricks
22A to 22H. As can be seen from Figure 1, given those brick dimensions, each
brick has four of its eight indentations aligned with indentations of adjacent
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bricks therefore allowing four fasteners 30 to contact the flange of each
brick to
adequately mount the bricks to the wall.
[0032] It is to be noted that the dimensions of Figures 5A to 5H are
given for illustration purpose only. Similarly, the number of different size
bricks
may also vary. Alternatively, all the bricks could be the same as will be
discussed hereinbelow.
[0033] Turning now to Figures 6 to 12 of the appended drawings, an
assembly 100 for manufacturing thin wall veneer bricks will be described.
[0034] The assembly 100 is shown in an exploded side view in
Figure 6.
[0035] The assembly 100 includes a mold 102 provided with cavities
104 each having a brick dimension and defining an aperture through the mold
102. The mold 102 is designed to be pressed against a flat surface 106. Each
cavity 104 is so shaped as to define the eight indentations of the particular
brick
size.
[0036] The assembly 100 also includes a flange making
assembly 108 including flange sized walls 110 configured and sized to enter
the cavities 104 to shape the flanges 24 as will be described hereinbelow. It
is
to be noted that the walls 110 also define apertures 111 in the assembly 108
to
allow the brick pressing elements therethrough as will be described
hereinbelow.
[0037] A brick pressing assembly 112 is also part of the assembly
100. The pressing assembly 112 includes plungers 114 each provided with an
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adequately sized brick pressing element 116 that may pass through a
corresponding apertures 111 in the flange making assembly 108. The plungers
114 are mounted to a plate 115 that includes stoppers 117 the purpose of
which will be described hereinbelow.
[0038] Finally, the assembly 100 includes a pressure applying
assembly 118 that can be powered by a hydraulic press (not shown), for
example. The pressure applying assembly 118 includes a plate 119 provided
with four projecting posts 120 (only two shown) configured and sized to allow
sleeves 122 mounted to the plate 115 of the brick pressing assembly 112
thereunto.
[0039] The projecting posts can be replaced by any other
interconnecting assembly (not shown).
[0040] To assemble the assembly 100, the brick pressing assembly
112 is mounted to the pressure applying assembly 118 by sliding the sleeves
122 onto the posts 120. The flange making assembly 108 is then mounted to
the posts 120 via bolts 126 and nuts 128.
[0041] The assembled assembly 100 is shown in Figure 7. As can
be seen from this figure, the sleeves 122 are about midway on the posts 120.
It is also to be noted that the brick pressing elements 116 are level with the
walls 110.
[0042] Turning now to Figures 7 to 12 of the appended drawings, the
operation of the assembly for manufacturing thin wall veneer bricks 100 will
be
described.
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[0043] Figure 7 illustrates the assembly 100 when the mold 102 is
applied against the flat surface 106. Concrete 130 is provided in each cavity
104 of the mold 102.
[0044] Then, in Figure 8, the pressure applying assembly 118, to
which the brick pressing and shoulder making assemblies are mounted, is
lowered (see arrows 132) so that the brick pressing elements 116 contact the
concrete 130 provided in the cavities 104.
[0045] Figures 9 and 10 illustrate the compression of the
concrete 130 by the continued movement of the brick pressing elements 116
(see arrows 134 and 136). Figure 10 shows the final position of the pressing
elements 116, i.e. when the concrete 130 completely fills the cavities 104.
[0046] Figure 11 shows the position of the assembly 100 following
the relative displacement of the walls 110 with respect to the brick pressing
elements 116 (arrow 138). This displacement is limited by the stoppers 117
that
abut against the plate 119 of the pressure applying assembly 118, preventing
further relative displacement therebetween. The stoppers 117 therefore limit
the depth of the shoulders and therefore the thickness of the flanges 24 of
the
bricks.
[0047] It is also to be noted that the brick pressing elements 116 are
slightly raised (see arrows 140) to the final thickness of the brick by the
displacement of the concrete by the walls 110.
[0048] Figure 12 illustrates the disengagement of the assembly for
manufacturing thin wall veneer bricks 100 from the newly formed bricks 22. To
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do so, the pressure applying assembly 118 and the mold 102 are moved away
from the flat surface 106 (see arrows 141 and 142).
[0049] It is to be noted that the brick pressing elements 116 may
have a textured surface to form texture faced bricks.
[0050] It is also to be noted that the assembly 100 could be used to
form bricks that are thicker than the final desired thickness to allow for
post-
treatment of the bricks in view of enhancing its aesthetics. For example,
thicker
bricks could be subjected to splitting, pitching or other enhancement
treatments.
[0051] To allow forming thicker bricks 22, the posts 120 and
stoppers 117 are sized accordingly. According to another embodiment of the
assembly for manufacturing thin wall veneer bricks, cylinders or other means
are provided to adjust the mounting distance between the brick pressing
assembly 112 and the pressure applying assembly 118.
[0052] Figure 4 of the appended drawings, which illustrates the
process of aging a brick 22, illustrates how the configuration of the brick 22
allows edging the edges and/or top surface thereof by any known edging
process, while preserving intact the peripheral edge 24 thereof.
[0053] Figures 13A and 13B illustrate a comer brick to be used with
any of the bricks 22A to 22H in constructing a wall (not shown).
[0054] It is to be noted that the brick arrangement illustrated in
Figure 1 is for illustration purpose since a plurality of brick patterns can
be
created using some or all of the eight sized of bricks disclosed herein.
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Furthermore, the brick sizes are also given for illustration purpose since any
brick size is possible.
[0055] Turning now to Figures 14A and 14B of the appended
drawings a dry-stack wall 200 covered with thin bricks according to another
illustrative embodiment will be described. The wall 200 is covered with thin
concrete bricks defining two brick sizes 202A-202B.
[0056] As can be seen from Figure 14A, the bricks 202A and 202B
have flanges 204 on two contiguous sides (shown as the left and the bottom
sides in the appended figures) and overhangs 206 on the other two contiguous
sides. Accordingly, this allows fasteners 208 to mount the bricks to a wall
substrate (not shown) via the two sides provided with flanges 204 while hiding
the fasteners with the overhangs of adjacent bricks. Accordingly, no mortar is
required to hide the fasteners 208 and the flanges 204, thereby creating a dry-
stack wall 200.
[0057] Of course, one skilled in the art will be in a position to
dimension the flanges and overhangs so as to create an adequate dry-stack
wall while allowing fasteners to adequately mount the bricks to a wall
substrate.
[0058] The expression "dry-stack wall" should be construed herein
as including any wall construction wherein the veneer bricks or more generally
the wall elements are assembled without using mortar or another similar
compound.
[0059] Turning now to Figure 15 of the appended drawings a wall
300 covered with thin bricks according to another illustrative embodiment will
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be described. The wall 300 is covered with thin concrete bricks defining a
single brick size 302.
[0060] As can be seen from this figure, the peripheral flanges 304 of
the bricks 302 have no indentations to receive the fasteners. Accordingly, the
spacing between adjacent bricks and adjacent row of bricks is determined and
maintained by the shank of the fasteners 306 provided therebetween.
Accordingly, the distance between the adjacent installed bricks is not
determined by the width of the flange 304. Again, once the bricks 302 are
mounted to the wall substrate (not shown) via the fasteners 306, mortar (not
shown) can be used to hide the peripheral flanges 304 and the fasteners 306.
[0061] Figures 16A to 16G illustrate examples of shapes that can be
imparted to the peripheral flanges.
[0062] It is to be noted that even though the bricks have been shown
herein as being mounted to a wall, the same bricks could be used on other
surfaces such as a floor.
[0063] One skilled in the art will understand that when an indentation
is present in the peripheral flange of the bricks, the shape of the
indentation is
not critical, as long as two aligned indentations allow passage of a fastener
therein.
[0064] It is also to be noted that should appropriately smaller
fastener (not shown) be used, these smaller fastener could be inserted in any
indentation of the bricks, not only in the indentations aligned with another
indentation of an adjacent brick. Thin Wall veneer bricks according to
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embodiments of the present invention can be used in constructing any well-
known types of wall, including ashlar pattern, herringbones, etc.
[0065] The manufacturing process of wall veneer bricks according to
embodiments of the present invention as described herein may further include
any well-known secondary process such as aging, splitting and pitching.
[0066] While concrete has been described herein as the material of
choice to make bricks as described herein, other materials could be used.
[0067] Similarly, while nails are illustrated as the fastener entering
the indentations, other types of fasteners could be used such as, without
limitations, screws with washers.
[0068] It is to be noted that while the peripheral flange has been
shown as being at right angle, other angles could be used.
[0069] It is also to be noted that while bricks and corner bricks have
been illustrated and described herein, other standard masonry elements such
as lintel, for example, could be made according to the general principles
described herein.
[0070] It is finally to be noted that while the flanges are shown as
having 90 degrees edges, a chamfer could be provided thereon. When this is
the case, flat head or oval head screws, or any other fastener having a
countersunk head bottom, can be used to mount the bricks to the wall
substrate. Alternatively, a triangular washer matching the chamfer could be
used.
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[0071] It is to be understood that the invention is not limited in its
application to the details of construction and parts illustrated in the
accompanying drawings and described hereinabove. The invention is capable
of other embodiments and of being practiced in various ways. It is also to be
understood that the phraseology or terminology used herein is for the purpose
of description and not limitation.
