NL2020610B1 - Thin groove - Google Patents

Abstract

Method for producing a brick, the method comprising the following steps: - provided with an open mold defined by a bottom and several upright walls; - inserting a clay lump into the open mold so that the clay lump mainly fills the mold; - cutting off excess clay at the open side of the open mold so that a mold is formed in the mold with a shape related to the open mold; Removing the clay mold from the mold; - baking from the clay form to the brick; the bottom of the open mold containing at least one raised fin with a width that is smaller than 4 mm.

Description

NL B1 2020610

Patent center

The Netherlands

2?) Application number: 2020610

22) Application submitted: 19 March 2018

Θ 2020610

B1 PATENT @ Int. Cl .:

B28B 7/00 (2018.01) B28B 13/02 (2019.01)

Application registered: (73) Patent holder (s): September 30, 2019 Nelissen Steenfabrieken N.V. in Lanaken, Belgium, BE. (43) Application published: (72) Inventor (s): (47) Patent granted: Roel Vandebeek in Maasmechelen (BE). September 30, 2019 (45) Patent issued: (74) Agent: October 1, 2019 ir. P.J. Hylarides et al. In The Hague.

© Thin groove

57) Method for producing a brick, the method comprising the following steps:

- provided with an open mold that is defined by a bottom and several upright walls;

- inserting a clay lump into the open mold so that the clay lump mainly fills the mold;

- cutting off excess clay at the open side of the open mold so that a mold is formed in the mold with a shape related to the open mold;

- removing the clay mold from the mold;

- baking from the clay form to the brick; the bottom of the open mold containing at least one raised fin with a width that is smaller than 4 mm.

3a

This patent has been granted regardless of the attached result of the research into the state of the art and written opinion. The patent corresponds to the documents originally submitted.

Thin groove

The invention relates to a method for producing a brick according to the hand-forming principle.

The hand-forming principle for producing a brick relates to a method with the following steps:

provided with an open mold defined by a bottom and a plurality of upright walls;

inserting a clay lump into the open mold so that the clay lump mainly fills the mold;

cutting off excess clay at the open side of the open mold so that a mold is formed in the mold with a shape related to the open mold;

removing the clay mold from the mold; baking from the clay form to the brick.

Bricks that are formed by the hand shape principle are called hand shape bricks. Hand-molded bricks are typically used as facing bricks for making houses. Hand-molded bricks are known to create a specific visual impression that is mainly created because each brick is unique. The way in which the mold fills with the clay as a result of the insertion of the clay lump is always different, so that the outer surface of the hand-mold brick always shows imperfections. These imperfections are desirable and ensure a unique character of the brick.

In the past, hand-molded bricks were made entirely by hand. The open mold was usually made from wood. When used, the mold was sprinkled with sand on the inside. A clay lump is then formed which is typically also rolled in sand before throwing the clay lump into the wooden mold with a predetermined force and / or speed. Due to the strength and / or speed of the clay clog, the clay will end up with a predetermined impact on the mold, causing the clay to deform and mainly fill the mold. The clay lump typically has a mass that is noticeably greater than the mass required to fill the mold. A surplus of clay material will therefore protrude above the mold on the open side. In a next step, the excess clay is cut off at the open side so that the mold remains in a mold with a shape that is related to the shape of the mold. Those skilled in the art will understand that the mold is shaped as a negative of the desired brick. In a further step, the clay mold is removed from the mold, typically by inverting the mold so that gravity forces the clay mold out of the mold. Because the mold and the outside of the clay clog are dusted with sand, the clay does not stick appreciably to the mold, and can easily be removed from it. The clay mold thus obtained is then fired into a brick in a shape that is predetermined and related to the shape of the mold.

For many years this process has been at least partially automated, whereby clay clogs are automatically formed and inserted into an open mold by machine. The open molds are typically made from metal or a hard plastic to optimize the service life of the molds. For small runs of bricks with special shapes, a wooden mold is still being made in which clay clogs are inserted manually.

In recent years much experimentation has been carried out with alternative methods for traditional brickwork. In the past, a façade was built by placing bricks on top of each other and connecting them with a layer of mortar. The bricks then typically have a height between 5 cm and 8 cm, and the mortar is applied with a layer thickness between 0.5 cm and 1.5 cm. In recent years, experiments have been conducted with glue to replace mortar, with the layer thickness of the glue being only a few millimeters. In contrast to the mortar, the glue is typically not visible, or not appreciably visible, giving the bricks the appearance of being stacked on top of each other without a joining layer. This creates new possibilities for obtaining optical effects. In addition, architects are demanding to have bricks in dimensions that deviate from traditional dimensions for bricks.

A drawback of the known method for producing a brick according to the hand-forming principle is that bricks with a limited height tend to warp during the baking process and tend to break during the handling of the brick. Architects are demanding for hand-molded bricks with a height of, for example, 2 or 3 centimeters, which is not possible to manufacture using current techniques. A further drawback relates to the realization of a facade with such bricks with a limited height. Because the bricks have a limited height, notably more rows will have to be placed on top of each other in order to obtain a facade with a predetermined height. When the bricks have a limited height, this is very labor-intensive and therefore expensive.

The present invention has for its object to provide a solution for one or more of the disadvantages described above.

To this end, the method according to the invention is characterized in that the bottom of the open mold contains at least one upright fin with a width that is smaller than 4 mm.

The effect of the raised fin with a width that is smaller than 4 mm is unexpected and atypical for hand-molded bricks. In the traditional implementation of the method according to the hand-forming principle, and subsequent use of the hand-molded bricks when measuring a facade, the cut-off side of the clay form forms the final underside of the brick. This means that the visible sides of the brick, which are visible in a façade when the brick is placed with the cut-off side of the clay mold downwards, are formed by the sides of the brick adjacent the upright walls in the open mold. The method for producing a brick according to the invention aims at explicitly departing from this tradition, and aims to form the main view side of the brick via the bottom of the open mold. This is atypical in the domain of hand-shaped bricks.

A special and unexpected effect is obtained by providing an upright fin in the bottom of the open mold that forms the main view side of the brick, the upright fin having a width of less than 4 mm. Due to the thin raised fin in the bottom, the brick will have a corresponding thin groove in its main view side. In particular when bricks in a facade are connected to each other by means of a thin layer of glue, this thin groove visually gives the impression that both sides of the groove are formed by separate bricks. As a result, the impression can be created that thin hand-shaped bricks have been used to form a facade, while several thin hand-shaped bricks are in fact a single hand-shaped brick. The disadvantages described above can hereby be avoided. The bricks can have a shape with a usage height that is equal to or larger than traditional hand-molded bricks, so that the labor required to manufacture a facade with a predetermined height does not increase. Also, due to their conventional thickness, the bricks do not tend to warp during baking. Furthermore, due to their conventional thickness, the bricks can be handled in a normal way without the additional risk of breaking. However, when they are integrated into a façade, the bricks have the effect of giving the impression of having smaller dimensions than is actually the case. This is a direct consequence of the grooves that are created in the main view side by the upright fins with a width of less than 4 mm, which optically subdivides one stone into several stones.

Preferably, the at least one raised fin divides the bottom of the open mold into several bottom segments. When the at least one upright fin subdivides the bottom of the mold into several bottom segments, the groove formed in the brick by the upright fin will also subdivide the main face of the brick corresponding to the bottom of the mold into several segments. This optically creates the effect that the different segments of the visible side of the brick are formed by several separate bricks. This makes it possible to divide the visible side of the brick into several segments with different dimensions and shapes, depending on the wishes of the customer.

Preferably the fin has a height greater than 2 mm. Furthermore, the fin preferably has a height that is smaller than 7 mm. Tests have shown that the height of the fin, which determines the depth of the groove, influences the perception of a person who views the visible side of the brick. By giving the fins a height of more than 2 mm, the groove is typically perceived as a subdivision of the stone. By making the groove smaller than 7 mm, simple realization can be achieved without technical complications while the optical illusion is maximum.

Preferably, the bottom of the mold is substantially rectangular and at least one raised fin extends along the long side of the rectangle. Bricks are typically used in a facade with their long side according to the direction of the rows, this is the mainly horizontal direction of the facade. By also shaping the fins in this direction, the height of the stone is optically reduced. For example, when a fin is formed in the center of the rectangle, the stone gives the impression of being two stones of equal height placed on top of each other. Those skilled in the art will appreciate that the fin can be formed at different positions to create the impression of being stones of different heights.

Preferably the at least one raised fin extends along at least one line from a short side of the rectangle to the opposite short side of the rectangle. Further preferably, the at least one line is straight. Tests have shown that this is on the one hand well achievable when forming the hand-molded brick and on the other hand creates an optimal visual effect when a brick is made with a facade.

Preferably, the at least one raised fin is tapered in the upward direction. Furthermore, preferably the at least one raised fin has a width of approximately 3 mm at the location of its base and a width of approximately 2 mm at the location of its top. By tapering the raised fin, the removal of the clay mold from the mold is considerably simplified, and the clay mold at the location of the raised fin will have little or no tendency to deform, whereby for example an edge of the groove breaks off and / or remains in the mold.

Preferably, mold is formed such that the bottom of the mold forms the main view side of the brick.

The invention further relates to a brick obtained by performing the method according to the invention.

The invention will now be described in more detail with reference to an exemplary embodiment shown in the drawing.

In the drawing:

Figure 1 shows the steps for hand-shaping a brick;

Figure 2 shows an open mold from the method according to the invention;

Figure 3 shows a section of an upright fin; and figure 4 shows some exemplary embodiments of the invention.

In the drawing, the same reference numeral is assigned to the same or analogous element.

Figure 1 illustrates the basic steps of the method for hand-shaping a brick. As already stated above, the present invention is particularly applicable in such a method for producing hand-molded bricks. In the first instance, the traditional method for hand-shaping bricks will be explained with reference to Figure 1. The invention will be explained with reference to the further figures, and it will be explained how the invention is surprisingly compatible with the traditional method for hand-forming bricks. Unless otherwise stated, the features and steps for traditional hand-forming bricks explained with reference to Figure 1 will be an integral part of the method according to the invention.

Figure 1A shows an open mold 1. The open mold 1 comprises at least one bottom 2 and a plurality of side walls 3 which rise with respect to the bottom to form an open cavity. Figure 1A shows a mold 1 in the form of a traditional brick. The open mold 1 from Figure 1A therefore shows a substantially rectangular bottom 2, wherein an upright side wall 3A, 3B, 3C and 3D is formed at each side of the rectangle. The side walls 3A and 3D are thereby formed at the short sides of the rectangle of the bottom 2. The side walls 3B and 3C are formed at the long sides of the rectangular bottom 2. It will be clear to a person skilled in the art that the open mold 1 can have different sizes and shapes, wherein the sizes and shapes of the open mold 1 will determine the final shapes and sizes of the bricks formed therein. As the person skilled in the art will understand, one main condition is preferably met when designing the open mold, this is that the opening at the location of the open side has a shape and dimensions that allow the entire clay form to be able to leave the open mold 1 through the opening be deleted. in line with this condition, the side walls 3 are also preferably formed to allow removal of the brick from the open mold via its open side. The removal step is illustrated in Figure 1D.

Figure 1A further illustrates a clay clog 4. A clog is defined as a shapeless mass. A clay lump 4 is thus defined as a shapeless mass with the mass mainly comprising clay. The clay lump 4 preferably has a volume that is noticeably greater than the volume required to completely fill the open mold. The clay clog 4 is traditionally thrown into the open mold 1, manually or mechanically. Insertion is defined as moving the clay clog 4 to the open mold 1 with a predetermined minimum force and / or speed such that the clay clog 4 at least partially fills the open mold 1. The predetermined force is illustrated in Figure 1A with arrow F. this can easily be realized in practice by bringing the clay clog 4 to a predetermined height h above the open side of the open mold 1, after which the clay clog is released so that it falls into the open mold 1 from the predetermined height h. Thereby, the clay lump 4 can be guided during the fall movement to, for example, optimize the fall direction and / or the fall trajectory for filling the open mold 1. Furthermore, the clay lump can be braked or accelerated during the fall movement to fill the open mold 1 to optimize.

Figure 1B shows a cross-section of an open mold and a clay lump 4, after the clay lump has been thrown into the open mold. The method preferably further comprises applying a sand layer on the inside of the open mold 1 and / or on an outside of the clay mold 4 between the step from Figure 1A and the step from Figure 1B. The sand has several functions. By inserting the clay clog 4 into the open mold 1, the sand is pressed at least partially into the clay, so that it forms part of the final brick. In particular when the clay has a first color and the sand has a second color that deviates from the first color, a unique visual impression is obtained. A second effect relates to the removal of the clay from the open mold 1, wherein the sand significantly reduces the friction between the open mold 1 and the clay. Without a layer of sand on the outside of the clay clog 4 and / or on the inside of the open mold 1, clay has a strong tendency to stick to the bottom 2 and walls 3 of the open mold 1, so that the removal of the clay owl the mold 1 is difficult.

In figure 1B the clay clog 4 is indicated with reference numeral 4 ". Figure 1B illustrates that the clay mold 4 ’has changed in shape compared to the clay mold 4 from figure IA. This is due on the one hand to the deformability of the clay and on the other hand to the force F and / or speed with which the clay lump 4 is thrown into the open mold 1. By inserting the clay lump 4, an impact is created between the clay and the open mold 1 which results in the clay lump 4 being distorted. As a result of the deformation, the clay clog fills almost the entire open mold 1. Figure 1B illustrates how the clay clog 4 "has a first segment 5 and a second segment 6. The clay fills the open mold 1 with the first segment 5. This first segment 5 is also referred to as the clay form because this is the part of the clay lump 4 which assumes the shape of the open mold 1. The second segment 6 is the portion of the clay clog 4 "that extends above the open mold 1. The clay from the second segment 6 is also called the superfluous clay, and is the direct result of the clay lump 4 which is considerably larger in volume than the content of the open mold 1.

Figure 1B illustrates how the clay 5 is pressed against the bottom 2 and the side walls 3B and 3C. There is typically sand between the bottom 2 and the clay and between the side walls 3B and 3C and the clay. Also, the clay does not connect flawlessly everywhere against the bottom 2 and the side walls 3, as a result of the insertion of the clay lump 4. This is because the clay lump 4 does not have a controlled form, and because insertion implies that there is no complete control over it. filling the mold 1. This irregular and uncontrolled aspect of filling the mold 1 is desirable and gives the hand-mold brick a unique character.

Figure 1C illustrates the cutting of the excess clay, indicated by arrow 10. The term cutting is broadly interpreted in the context of this invention, and includes cutting, sawing, grinding, tearing or any other way of separating the first segment 5 and the second segment 6 of the clay clog 4 '. In figure 1C the clay shape is indicated with reference numeral 8, and the redundant clay is indicated with reference numeral 9. The cutting line is indicated in figure 1C with reference numeral 7. As described above, the clay shape 8 at the location of the bottom 2 and the side walls 3 is unique formed by the sand and by the insertion. At the location of the open side 7, the clay form 8 has no significant unique form. In practice, the cutting line 7 forms a regular, typically smooth surface with no sand pressed into the clay. This side 7 typically forms a brick side with an undesirable visual character. The cut-off side 7 of the clay mold 8 is therefore typically used in practice as the bottom of the brick. In this aspect, the method according to the invention differs from the traditional method, as will be explained below.

Figure 1D illustrates with arrow 11 the removal of the clay mold 8 from the open mold

1. In practice, the open mold 1 with the clay mold 8 from Fig. 1C is turned over, whereafter the open mold 1 is lifted, while the clay mold 8 remains lying down due to gravity. By turning over, the cut-off side 7 of the clay mold 8 comes to lie at the bottom, indicated in Figure 1 by brick side 12F. In this position the clay mold 8 can be baked into a brick. Because the clay mold 8 lies downwards with its cut-off side 12F, no noticeable pressure will be exerted during baking on the unique sides of the brick, being side 12A which is related to the bottom of the open mold, being sides 12E, 12D, 12C and 12B which are respectively related to the upright side walls 3A, 3B, 3D and 3C of the open mold 1. As already explained above, these side walls of the brick 1 are formed with a unique character, whereby it is advantageous not to bake any further during baking. exerting force on these sides.

Figure IE shows a facade 13 that is built with several bricks that have been formed according to the method described above. Figure IE in particular illustrates a corner of a facade 13, which makes it clear that two sides of the brick are visible at the location of a corner. More specifically, the longitudinal side 12B and an end side 12C will be visible. According to the traditional method, the longitudinal side 12B which forms the main view side of the brick corresponds to a side which abuts against a long side wall 3B or 3C of the open mold 1 of Fig. IA. The end view side corresponds to a side that abuts against a short side wall 3A or 3D of the open mold 1 of figure IA. As becomes clear below, the invention herein differs from the traditional method.

Figure 2 shows an embodiment of an open mold used in the method according to the invention. The open mold 1 of Fig. 2 corresponds in many respects to the open mold of Fig. 1A such that the open mold of Fig. 2 is compatible with the method described above. The open mold 1 of figure 2 differs in that the bottom 2 is provided with at least one upright vane 14. Preferably, the upright vane 14 extends in one piece to a corresponding upright vane 14 at the location of at least one side wall 3. In the case of Figure 2, two upright fins 14 extend from the bottom 2 to one upright wall 3A. It will be clear here that running through in one piece is a functional feature and not necessarily a physical feature of the mold 1. The upright fin 14 can be made of several parts which are connected to each other and / or cooperate in such a way that the parts functionally as one upright fin 14.

The upright fins 14 have the purpose of forming a groove in the clay mold 8 at the location of the bottom and the side wall 3A. As described above, this groove creates the optical illusion that the shaped brick consists of several individually shaped bricks. The open mold 1 from Fig. 2 further deviates from the open mold from Fig. 1 in its purpose of use. In the open mold of figure 2, the bottom 2 of the mold 1 is formed, this is to say provided with an outer shape and dimensions, to form the main view side of the brick ultimately formed. In contrast, the bottom 2 is formed from the open mold of Figure 1A to form the top of the brick ultimately formed. The effect of this is further explained with reference to the figure

4.

Figure 3 shows a cross-section of a preferred embodiment of an upright vane 14. Figure 3 illustrates that the upright vane 14 extends above the bottom 2 with a height 15. The height 15 is preferably minimum 2 mm, more preferably minimum 3 mm and is preferably maximum 7 mm, more preferably maximum 6 mm. Most preferably, the height is approximately 4 nnn. Figure 3 further illustrates that the upstanding vines tapering upwards. At the location of the bottom 2, the upright fin 14 has a width 16 that is greater than the width 17 at the top of the fin 14. Preferably, the width 16 is approximately 3 mm, while the width 17 at the top of the top is preferably about 2 mm. This is a preferred embodiment, and it will be appreciated that the upright fin 14 in its widest embodiment is not limited in dimensions. Preferably, the raised vane 14 has an average width over its height that is smaller than 7 mm, more preferably smaller than 5 mm.

In figure 3 the upright vane 14 is shown with the bottom 2 as the basis for the upright vane 14. Those skilled in the art will understand that the upright vane 14 is formed analogously at the side wall 3.

The upright fin 14 is preferably formed from metal. Tests have shown that when the raised fin 14 owl metal is formed, a high wear resistance can be obtained. Also, the vane 14 with the dimensions mentioned above can be formed with sufficiently high strength. The metal fin 14 can be integrally formed with a metal bottom 2 or a metal wall 3. Alternatively, the metal fin 14 is embedded in a hard plastic layer, which functions as bottom 2 or as wall 3.

Figure 4 shows three different embodiments of the open mold, and shows its effects on the brick formed with the mold. The brick is herein designated with reference numeral 21. The brick 21 always has a main view side 18 and an end view side 19 which respectively correspond to the brick view sides 12B and 12C of figure IE.

Figure 4A shows an embodiment in which the bottom 2 has two parallel upright fins 14 which run in the longitudinal side of the bottom 2. These fins 14 extend in one piece into a short side wall 3. The effect of this is that a brick 21 can be formed in which grooves 20 extend continuously from a main view side 18 to a front view side

19. As described above, the optical illusion is created that brick 21 of figure 4A consists of three bricks stacked on top of each other. By positioning the upright fins 14 as illustrated in Fig. 4A, removing the clay mold 8 from an open mold 1 (as shown in Fig. 1D) is simple because the removal direction runs parallel to the upright fins 14, in particular on site of the side wall 3. Furthermore, the fins 14 of Fig. 4A are formed substantially parallel to the insertion direction of the clay lump 4 into the open mold, so that the upright fins 14 are loaded substantially straight and uniformly. This significantly increases the service life of the mold 1. It will be clear that the upright fins 14 can continue to extend continuously over the side wall which is opposite to the side wall shown, so that the two face faces of the brick have the grooves.

It is noted in this context that if upright fins were to be placed in the mold of Figure 1A at the sides that form the main view side and the face view side, these are the sides 3B and 3A, on the one hand removing the clay mold from the mold would be virtually impossible. and, on the other hand, filling the mold by inserting the clay would be difficult because the fins would be formed transversely to the throwing direction.

Figure 4B pays off an alternative embodiment in which a storing fin 14 extends diagonally across the bottom and diagonally across a side wall. When ejecting the clay mold from such a mold, the clay mold will at least partially make a rotational movement away from the side wall 3 with the diagonal fin 14. With this mold a brick 21 can be obtained which generates a visual impression of several pyramidal bricks consisting of .

Figure 4C shows a further alternative embodiment, in which not only storing fins 14 are placed in the longitudinal direction, but also in the transverse direction, at least at the location of the bottom 2. This allows a brick 21 to be obtained with the main side showing a pattern, in this case example is divided into several segments, both horizontal and vertical.

The examples from Figure 4 have been added for illustrative purposes only, and will make it clear to those skilled in the art that there are many possibilities for designing and creating visual impressions in manual mold containers. Horizontal, vertical and transverse fins 14 can thereby be combined depending on the intended visual effect. Because the bottom 2 of the open mold forms the main side, which is atypical in the method for hand-forming bricks, these optical effects can be obtained without the efficiency of the method for forming bricks, illustrated in Figures 1A to 1D, is reduced. In particular, no significant post-processing or intermediate steps will be required. Provided with a modified mold as illustrated in Figure 2 and in Figures 4A-4C, existing machines can be used for manufacturing bricks according to the invention.

On the basis of the above description, it will be understood by those skilled in the art that the invention can be practiced in different ways and on different principles. In addition, the invention is not limited to the embodiments described above. The embodiments described above, as well as the figures, are merely illustrative and serve only to increase the understanding of the invention. The invention will therefore not be limited to the embodiments described herein, but is defined in the claims.

Legend of the figures

1. open mold

2. bottom

3. side walls

4. clay lump

5. first segment of clay clog

6. Second segment clay clog

7. cut side

8. clay form

9. surplus clay

10. cut off

11. remove

12. sides of brick

13. facade

14. raised fin

15. height of the raised fin

16. width of base upstanding fin

17. width top storing fin

18. main view side

19. front view side

20. grooves

21. brick

Claims (11)

Conclusions A method for producing a brick, the method comprising the following steps: provided with an open mold defined by a bottom and a plurality of upright walls; inserting a clay lump into the open mold so that the clay lump mainly fills the mold; cutting off excess clay at the open side of the open mold so that a mold is formed in the mold with a shape related to the open mold; removing the clay mold from the mold; baking from the clay form to the brick; characterized in that the bottom of the open mold contains at least one raised fin with a width that is smaller than 4 mm. The method of claim 1, wherein the at least one raised fin subdivides the bottom of the open mold into a plurality of bottom segments. Method according to one of the preceding claims, wherein the raised fin has a height that is greater than 2 mm. Method according to one of the preceding claims, wherein the raised fin has a height that is smaller than 7 mm. A method according to any one of the preceding claims, wherein the bottom of the mold is substantially rectangular and wherein at least one raised fin extends along the long side of the rectangle. The method of claim 5, wherein the at least one raised fin extends along at least one line from a short side of the rectangle to an opposite short side of the rectangle. The method of claim 6, wherein the at least one line is straight. A method according to any one of the preceding claims, wherein the at least one upright fin is tapered in the upward direction. The method of claim 8, wherein the at least one raised fin has a width of about 3 mm at its base and has a width of about 2 mm at its top. A method according to any one of the preceding claims, wherein the mold is formed such that the bottom of the mold forms the main view side of the brick. A brick obtained by performing the method according to any one of the preceding claims. 2/3