GB2624007A

GB2624007A - A method of manufacturing a ceramic brickwork member

Info

Publication number: GB2624007A
Application number: GB2216414.9A
Authority: GB
Inventors: Simons Jeremy
Original assignee: Ibstock Brick Ltd
Current assignee: Ibstock Brick Ltd
Priority date: 2022-11-04
Filing date: 2022-11-04
Publication date: 2024-05-08
Also published as: GB202216414D0

Abstract

A method of manufacturing a ceramic brickwork member, the method comprising the steps of: a) providing a container defining a base and four walls extending around said base so as to define a receptacle; b) providing a first material in the receptacle; c) imparting a textured surface onto an upper surface of the first material; d) applying a second material onto the textured surface; e) curing the second material to create a flexible mould comprising the textured surface; f) arranging the flexible mould to form a substantially tubular mould comprising the textured surface on an internal surface thereof; g) at least partially filling the tubular mould with a third material; h) curing the third material to form a substantially cylindrical mould comprising the textured surface on an external surface thereof; i) imparting the textured surface on a clay building material. The first material may be deformable and may be deformable clay material. The first material may be rolled or flattened.

Description

A Method of Manufacturing a Ceramic Brickwork Member FIELD The present teachings relate to a method of manufacturing a ceramic brickwork member, and a method of manufacturing a textured roller stamp.

BACKGROUND

Brickwork members, such as bricks or brick slips, are widely used in the construction of building structures, such as walls. A brick is a type of block used to build walls that is composed of dried clay. Bricks can be joined using mortar, adhesives or by interlocking them to construct the wall. Brick slips are thin sections of brick that are provided on external (or internal) surfaces of a building structure (i.e. a wall) to replicate the appearance of a conventional brick. An array of brick slips are typically mounted onto the surface in order to cover said surface, and provide a quick, and cost-effective route to providing a traditional 'brick' surface finish. In addition to being mounted to a building structure for aesthetic purposes, brick slips are also often used as they are durable and require low maintenance. Bricks and brick slips may be manufactured via an extrusion process. However, the extruded clay material is generally devoid of any surface texture, which may be undesirable for bricks and brick slips.

The present teachings seek to overcome or at least mitigate one or more problems

associated with the prior art.

SUMMARY

According to an aspect of the disclosure, there is provided a method of manufacturing a ceramic brickwork member, the method comprising the steps of: a) providing a container defining a base and four walls extending around said base so as to define a receptacle; b) providing a first material in the receptacle; c) imparting a textured surface onto an upper surface of the first material; d) applying a second material onto the textured surface; e) curing the second material to create a flexible mould comprising the textured surface; f) arranging the flexible mould to form a substantially tubular mould comprising the textured surface on an internal surface thereof; g) at least partially filling the tubular mould with a third material; h) curing the third material to form a substantially cylindrical mould comprising the textured surface on an external surface thereof; i) imparting the textured surface on a clay building material.

Through the present method of manufacture outlined above, a clay brickwork member (i.e. a brick or a brick slip) is able to be produced with a desired surface texture relatively quickly. This method of manufacture replicates or duplicates a custom textured surface.

The production of the cylindrical mould enables this custom textured surfaced to then be applied to a large number of clay brickwork members. This advantageously improves the ability of a brick slip to be manufactured with a custom surface texture.

Transferring the textured surface produces a cast of the custom textured brick surface, which provides an effective way to replicate the surface features of the first mould.

Optionally, the first material is a deformable material.

This enables surface textured to be imparted onto the first material. Optionally, the first material comprises a deformable clay material.

Optionally, the method comprises the step after step b) of rolling or flattening the first material.

This helps to provide a smooth and level surface prior to the surface texture being applied to ensure that the resulting brick or brick slip that is created has a level outer face.

Optionally, the step of imparting surface texture onto the first material comprises imprinting an object onto the first material and/or comprises creating surface texture with a work tool.

Optionally, the object is a natural object, for example selected from one or more of an animal shell, a part of a tree such as branches or bark, and/or a leaf.

Optionally, the object is an existing brick.

Optionally, the method comprises the step after step c) of drying or curing the first material such that the textured surface is substantially rigid.

Providing a rigid textured surface has been found to facilitate the transfer of the textured surface to the second material.

The first material may be allowed to dry for 24 hours.

Optionally, each of the four walls project upwardly above the upper surface of the first material to define a receptacle for receiving the second material.

Optionally, each of the side walls project upwardly above the upper surface of the first mould by a distance in the range 5mm to 15mm, for example 8mm to 12mm, for example approximately lOmm.

Optionally, the second material is resiliently deformable.

Optionally, the second material comprises silicone.

The silicone may be allowed to set for 24 hours. Optionally, the flexible mould is resiliently deformable. Optionally, the third material comprises a plastics material.

These materials have been found to have the desired viscosity to enable it to produce an accurate cast of the traditionally manufactured brick surface, whilst also having sufficient structural strength to withstand the brickwork member manufacturing process.

Optionally, the third material comprises a resin material.

Optionally, the third material comprises a polyurethane resin material.

Optionally, the third material comprises a filler material configured to increase the structural strength of the cylindrical mould.

This increased structural strength helps the mould insert to withstand the brickwork member manufacturing process.

Optionally, the step of forming the substantially tubular mould comprises arranging the flexible mould into a substantially tubular shape and applying the flexible mould to an internal surface of a tubular body.

Optionally, the step of forming the substantially cylindrical mould comprises attaching two edges of the flexible mould together, for example with an adhesive.

Optionally, the method comprises the step of applying surface texture across the boundary between attached edges.

This helps to provide a continuous textured surface on the cylindrical mould, and so on the clay brickwork member.

Optionally, the cylindrical mould is substantially rigid.

Providing a rigid cylindrical mould has been found to facilitate the transfer of the textured surface to the clay brickwork member.

Optionally, the method comprises forming a roller stamp with the cylindrical mould for imparting the textured surface to the clay building material.

Optionally, the method comprises the step of extruding an elongate length of the clay building material and imparting the textured surface along the elongate length of the extruded clay building material with the roller stamp.

Optionally, the method comprises the step of cutting the extruded clay building material after the textured surface has been imparted to form a plurality of clay building material units comprising the textured surface thereon.

Optionally, the method comprises firing the clay building material to form a clay brickwork member.

Optionally, the clay building material comprises a water content in the range of 18% to 24%.

Such a clay material has been found to be particularly beneficial for manufacturing brickwork members, since it is plastic in nature making it suitable for shaping, imparting and retaining a texture on a brickwork member. It will be understood that if the clay material has a water content that is too high (e.g. much greater than 24%) the clay material would be too viscous for the shape of the mould to be imparted on the brickwork member (e.g. the clay material may not maintain its shape after removal from the mould).

Furthermore, a high clay water content requires more energy when firing the brickwork member in a kiln or similar apparatus. It will also be understood that if the clay material has a water content that is too low, the clay material may not be plastic enough for the shape of the mould to be imparted on the brickwork member (e.g. the clay material may not conform to the shape of the mould even under the application of pressure).

Optionally, the flexible mould is a cast of the textured surface.

Optionally, the method comprises the step of depositing sand onto the clay building material prior to imparting the textured surface thereon.

According to an aspect of the disclosure, a method of manufacturing a roller stamp for the manufacture of ceramic brickwork members is provided, the method comprising the steps of: a) providing a container defining a base and four walls extending around said base so as to define a receptacle; b) providing a first material in the receptacle; c) imparting a textured surface onto an upper surface of the first material; d) applying a second material onto the textured surface; e) curing the second material to create a flexible mould comprising the textured surface; f) arranging the flexible mould to form a substantially cylindrical mould comprising the textured surface on an internal surface thereof; g) at least partially filling the cylindrical mould with a third material; h) curing the third material to form a substantially cylindrical mould comprising the textured surface on an external surface thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described with reference to the accompanying drawings, in which: Figure 1 is a schematic cross-sectional view of a mould containing a first mould material therein having a textured upper surface; Figure 2 is a schematic cross-sectional view of the mould of Figure 1 with a second mould material applied to the first mould material; Figure 3 is a schematic cross-sectional view of a second mould formed from the second mould material of Figure 2; Figure 4 is a schematic cross-sectional view of a tubular mould with the second mould of Figure 3 on an internal surface thereof; Figure 5 is a schematic cross-sectional view of a cylindrical mould; and Figure 6 is a schematic view of a stamping assembly including the cylindrica mould of Figure 5.

DETAILED DESCRIPTION OF EMBODIMENT(S)

The present teachings relate to a method of producing a textured surface on a ceramic brickwork member.

Referring to Figure 1, a container 10 is illustrated. The container 10 is used in the production of a textured surface for use in the manufacture of clay brickwork members. The container 10 includes a body defining a base 12 and four upstanding walls 14 extending from said base 12 so as to define a receptacle 16.

The receptacle 16 of the container 10 receives a first material 18 therein. The first material 18 defines an upper surface 20 thereof. In some arrangements, the first material 18 (i.e. the upper surface 20) may be rolled or flattened prior to imparting a textured surface thereon. This helps to provide a smooth and level surface prior to the surface texture being applied to ensure that the resulting brick or brick slip that is created has a level outer face.

A textured surface 21 is imparted on the upper surface 20 of the first material 18. It will be appreciated that imparting surface texture onto the first material 18 may be done in a range of different ways. Imparting the textured surface features may include imprinting an object onto the first material 18. The object may be a non-ceramic object or a natural object such as an animal shell, tree bark, leaves etc. onto the first material 18.

Alternatively or additionally, imparting the textured surface features may be performed using a work tool. In some arrangements, the textured surface may be imparted from an existing brick.

In the present arrangement, the textured surface 21 is provided over substantially all (e.g. over an entirety) of the upper surface of the first material 18. In alternative arrangements, however, it will be appreciated that the textured surface 21 may extend over only a part of the upper surface 20 of the first material 18.

The first material 18 may be a deformable material, for example a plastically deformable material. The use of deformable materials has been found to facilitate the formation of the textured surface 21. In some arrangements, the first material 18 may be a deformable clay (e.g. a wet clay) material, but it will be appreciated that any suitable material may be used as the first material 18 to form the textured surface 21, such as a deformable plastics or polymeric material. In some arrangements, the method may include the step of drying or curing the first material 18 after the textured surface 21 has been imparted such that the textured surface 21 becomes substantially rigid. Put another way, the method may include the step of drying or curing the first material 18 after the textured surface 21 has been imparted such that the textured surface 21 is not deformable).

Providing a rigid textured surface 21 has been found to facilitate the transfer of the textured surface 21 to a further material. In arrangements where the first material 18 is clay, the method may include the step of drying the clay material for 24 hours at room temperature. This drying/curing process enables the clay material to fully cure which helps to provide improved definition of the detail of the textured surface and to provide sufficient strength such that it can withstand the subsequent method steps.

Each of the four walls 14 project upwardly above the upper surface 20 of the first material 18 to further define a receptacle for receiving a second material 22. As is illustrated in Figure 2, the second material 22 is applied to the first material 18, i.e. onto the textured surface 21.

Each of the side walls 14 may project upwardly above the upper surface of the first mould by a distance in the range 5mm to 15mm, for example 8mm to 12mm, for example approximately lOmm. This results in thicknesses of the flexible mould in the range 5mm to 15mm, for example 8mm to 12mm, for example approximately 10mm. These have been found to provide an optimum thickness of the second material 22, when the second material 22 fills the receptacle.

Once the second material 22 has been applied to the textured surface 21 of the first material 18, said second material 22 is cured to create a flexible mould 22 comprising the textured surface 21. The flexible mould 22 may then be removed from the first mould material 18. The second material 22 may produce a flexible mould that is resiliently deformable. It will be appreciated that the flexible mould 22 may be considered to be a cast of the textured surface 21.

In the present arrangement, the second material comprises silicone. In such arrangements, the silicone material may be allowed to cut/set for approximately 24 hours.

In alternative arrangements, it will be appreciated that any suitable material may be used such as a gypsum based casting plaster, or any other suitable casting material.

Once the flexible mould 22 has been removed from the first material 18 it can then be arranged as required. The flexible mould 22 is arranged to form a substantially tubular mould or cast 24 comprising the textured surface on an internal surface thereof, as is illustrated in Figure 3.

The flexible mould 22 is arranged into a substantially tubular shape. It will be appreciated that arranging the flexible mould 22 into a substantially tubular shape comprises attaching two edges 26 of the flexible mould 22 together. The edges 26 may then be attached together via an adhesive 28. One example of an adhesive that may be used is silicone, but it will be appreciated that any suitable material may be used. In some arrangements, the method may include the step of applying surface texture across the boundary between attached edges 26. This helps to provide a continuous textured surface on the tubular mould, and so on the clay brickwork member. The tubular mould 22 is then applied to an internal surface of a tubular body 30. The tubular mould 22 defines an internal cavity or chamber for receiving a third material 32.

The method includes the step of least partially or entirely filling the tubular mould 22 with the third material 32. Put another way, the cavity or chamber defied by the tubular mould 22 is at least partially filled with the third material 32, as is illustrated in Figure 4.

The method also includes the step of curing the third material 32 to form a substantially cylindrical mould 32 comprising the textured surface 21 on an external surface thereof, as is illustrated in Figure 5. It will be appreciated that the third material 32 may be cured so as to form a substantially rigid cylindrical mould 32. Providing a rigid cylindrical mould has been found to facilitate the transfer of the textured surface to the clay brickwork member.

The third material 32 may be provided in the form of a plastics material. The plastics material may be a resin material. Resinous plastics materials have been found to have the desired viscosity to enable it to produce an accurate cast of the second material, whilst also having sufficient structural strength (e.g. hardness and shear strength) to withstand the brickwork member manufacturing process. In some arrangements, the third material may comprise a polyurethane resin material. In alternative arrangements, the third material may comprise a polyamide resin, a polycarbonate resin, an epoxy resin or any combination thereof. In further alternative arrangements, the third material may comprise any casting material that is able to be cured so as to be substantially rigid. The third material 32 may contain a filler material configured to increase the structural strength of the cylindrical mould 32. It will be appreciated that any material suitable to produce an accurate cast of the textured surface and then to be cured to be substantially rigid may be used.

Referring now to Figure 6, The method also includes the step of imparting the textured surface 21 onto a clay building material 34.

The cylindrical mould 32 is used as a roller stamp so as to impart the textured surface 21 to the clay building material 34.

The roller stamp 32 may form part of a stamping assembly. The stamping assembly may include one or more roller stamps 32 to impart a textured surface onto one or more faces of the clay building material. In the arrangement shown, the stamping assembly includes three roller stamps, two lateral roller stamps and an upper roller stamp. It will be appreciated, however, that any suitable number of roller stamps may be used in other arrangements.

In exemplary embodiments, the building material is a clay material having a water content in the range of 18% to 24%. Such a clay material has been found to be particularly beneficial for manufacturing brickwork members with imparted textured surfaces, since it is plastic in nature making it suitable for shaping, imparting and retaining a texture on a brickwork member.

The clay building material 34 is dispensed or placed onto a conveyer belt 36 which moves the clay building material 34 relative to the roller stamp(s) 32. As the clay building material 34 moves past, underneath, or between one or more roller stamps 32, said roller stamp applies pressure to the clay building material 34 so as to impart the textured surface (not shown in Figure 6) onto the clay building material 34. Sand may then be deposited so as to cling/adhere to liquid on the surface(s) of the clay building material 34. In this way, sand may be deposited so as to substantially cover the textured surface 21. This helps to reduce sticking between the clay building material 34 and the surface of the roller stamp 32.

In some arrangements, the clay building material 34 may be extruded. As such, the method may include extruding an elongate length of the clay building material 34 and imparting the textured surface along the elongate length of the extruded clay building material 34 with the roller stamp 32. It will be appreciated that the extruded clay building material 34 may be positioned on the conveyer belt discussed above. In arrangements where the clay building material 34 is extruded, it will be appreciated that the clay building material 34 may be cut into desired sizes after the textured surface has been applied to form a plurality of clay building material units comprising the textured surface thereon.

In some embodiments, a longitudinal axis of the roller stamp(s) 32 is movable in relation to a frame of the stamping assembly. This allows the stamping assembly to accommodate different sizes of building material 34 for producing different sizes of brickwork members.

For example, a longitudinal axis of the roller stamp(s) 32 may be movable in a vertical direction to accommodate different heights of building material 34, and/or in a horizontal direction to accommodate different widths of building material 34. In addition, the longitudinal axis of the roller stamp(s) 32 being movable in relation to a frame of the stamping assembly may allow the depth of the textured surface imparted onto the building material 34 to be varied, and/or for the pressure applied to the building material 34 by the roller stamp(s) 32 to be varied.

Following the application of the textured surface, the brickwork member 30 is put into a dryer to reduce its moisture content. It will be appreciated that the drying process may be varied to suit the building material used and the use of the brickwork member. As an example, the brickwork member may be dried for approximately 24 hours at a temperature at or above 100°C. It may be the case that once the brickwork member has been sufficiently dried, it will be placed in a kiln to be fired.

Through the present method of manufacture outlined above, a clay brickwork member (i.e. a brick or a brick slip) is able to be produced with a desired surface texture relatively quickly. This method of manufacture replicates or duplicates a custom textured surface. The production of the cylindrical mould enables this custom textured surfaced to then be applied to a large number of clay brickwork members. This advantageously improves the ability of a brickwork member to be manufactured with a custom surface texture.

Transferring the textured surface produces a cast of the custom textured brick surface, which provides an effective way to replicate the surface features of the original textured surface.

Although the teachings have been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope as defined in the appended claims.

Claims

Claims 1. A method of manufacturing a ceramic brickwork member, the method comprising the steps of: a) providing a container defining a base and four walls extending around said base so as to define a receptacle; b) providing a first material in the receptacle; c) imparting a textured surface onto an upper surface of the first material; d) applying a second material onto the textured surface; e) curing the second material to create a flexible mould comprising the textured surface; f) arranging the flexible mould to form a substantially tubular mould comprising the textured surface on an internal surface thereof; g) at least partially filling the tubular mould with a third material; h) curing the third material to form a substantially cylindrical mould comprising the textured surface on an external surface thereof; i) imparting the textured surface on a clay building material.
2. The method according to claim 1, wherein the first material is a deformable material.
3. The method according to claim 2, wherein the first material comprises a deformable clay material.
4. The method according to any preceding claim, comprising the step after step b) of rolling or flattening the first material.
5. The method according to any preceding claim, wherein imparting surface texture onto the first material comprises imprinting an object onto the first material and/or comprises creating surface texture with a work tool.
6. The method according to claim 5, wherein the object is a natural object, for example selected from one or more of an animal shell, a part of a tree such as branches or bark, and/or a leaf.
7. The method according to claim 5, wherein the object is an existing brick.
8. The method according to any preceding claim, comprising the step after step c) of drying or curing the first material such that the textured surface is substantially rigid.
9. The method according to any preceding claim, wherein each of the four walls project upwardly above the upper surface of the first material to define a receptacle for receiving the second material.
10.The method according to any preceding claim, wherein the second material is resiliently deformable.
11.The method according to any preceding claim, wherein the second material comprises silicone.
12.The method according to any preceding claim, wherein the flexible mould is resiliently deformable.
13.The method according to any preceding claim, wherein the third material comprises a plastics material.
14.The method according to claim 13, wherein the third material comprises a resin material.
15.The method according to claim 14, wherein the third material comprises a polyurethane resin material.
16.The method according to any preceding claim, wherein forming the substantially tubular mould comprises arranging the flexible mould into a substantially tubular shape and applying the flexible mould to an internal surface of a tubular body.
17.The method according to claim 16, wherein forming the substantially cylindrical mould comprises attaching two edges of the flexible mould together, for example with an adhesive.
18.The method according to claim 17, comprising the step of applying surface texture across the boundary between attached edges.
19.The method according to any preceding claim, wherein the cylindrical mould is substantially rigid.
20.The method according to any preceding claim, comprising forming a roller stamp with the cylindrical mould for imparting the textured surface to the clay building material.
21.The method according to claim 20, comprising the step of extruding an elongate length of the clay building material and imparting the textured surface along the elongate length of the extruded clay building material with the roller stamp.
22.The method according to claim 21, comprising the step of cutting the extruded clay building material after the textured surface has been imparted to form a plurality of clay building material units comprising the textured surface thereon.
23.The method according to any preceding claim, comprising firing the clay building material to form a clay brickwork member.
24. The method according to any preceding claim, wherein the clay building material comprises a water content in the range of 18% to 24%.
25.A method of manufacturing a roller stamp for the manufacture of ceramic brickwork members, the method comprising the steps of: a) providing a container defining a base and four walls extending around said base so as to define a receptacle; b) providing a first material in the receptacle; c) imparting a textured surface onto an upper surface of the first material; d) applying a second material onto the textured surface; e) curing the second material to create a flexible mould comprising the textured surface; f) arranging the flexible mould to form a substantially cylindrical mould comprising the textured surface on an internal surface thereof; g) at least partially filling the cylindrical mould with a third material; h) curing the third material to form a substantially cylindrical mould comprising the textured surface on an external surface thereof.