US20010023559A1 - Process for making brick-faced construction material and brick-faced block made by this process - Google Patents
Process for making brick-faced construction material and brick-faced block made by this process Download PDFInfo
- Publication number
- US20010023559A1 US20010023559A1 US09/864,572 US86457201A US2001023559A1 US 20010023559 A1 US20010023559 A1 US 20010023559A1 US 86457201 A US86457201 A US 86457201A US 2001023559 A1 US2001023559 A1 US 2001023559A1
- Authority
- US
- United States
- Prior art keywords
- bricks
- brick
- colored
- adhesive layer
- faced
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/002—Producing shaped prefabricated articles from the material assembled from preformed elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/0064—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces
- B28B7/0073—Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces with moulding surfaces simulating assembled bricks or blocks with mortar joints
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/36—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article
- B28B7/364—Linings or coatings, e.g. removable, absorbent linings, permanent anti-stick coatings; Linings becoming a non-permanent layer of the moulded article of plastic material or rubber
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C1/00—Building elements of block or other shape for the construction of parts of buildings
- E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/02—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
- E04B2002/0256—Special features of building elements
- E04B2002/0267—Building elements with the appearance of several bricks
Definitions
- This invention relates to a process for making brick-faced construction material in the form of blocks or panels useful for various interior and exterior works such as construction of fencing and/or gateposts and to brick-faced blocks suitable for said applications.
- first object of this invention to provide a process for efficiently and reliably making brick-faced construction material, for example, brick-faced block or panel, through a series of steps inclusive of a brick molding step so that interior and/or exterior works such as construction of fencing and gateposts may be quickly done and labor saving at the construction site may be achieved. It is a second object of this invention to provide brick-faced block particularly suitable for construction of fencing and/or gateposts.
- the first object set forth above is achieved, according to one aspect of this invention, by a process for making brick-faced construction material comprising steps of: molding a plurality of bricks with a predetermined space between each pair of adjacent bricks at once by laying colored brick material such as colored mortar or a mixture of inorganic material and binder into a plurality of individual molds distributed on a molding unit; placing and pressing a base coated on its surface with still uncured adhesive layer formed by suitable adhesive such as mortar- or resin-based adhesive against said plurality of bricks arranged with said predetermined space between each of adjacent bricks so that said base may be bonded to said plurality of bricks at once and at the same time joints are formed by said still uncured adhesive layer in accordance with said predetermined space between each pair of adjacent bricks; stripping said bricks bonded to the base by means of said adhesive layer from said molding unit at once; and aging said bricks and adhesive layer and thereby curing them.
- said process for making brick-faced construction material defined by claim 1 further comprises immediately before said step of molding the bricks, a step of coating said individual molds with inorganic pigment having a tone differing from the tone of said colored brick material by applying or spraying said inorganic pigment.
- said step of molding the bricks is carried out placing a jig on the molding unit so that its mortar permeable zones defined by through-holes, meshes, stripes or parallel lines lie over the individual molds and its masking zones cover ribs defining peripheries of the individual molds arranged with said predetermined space between each pair of adjacent bricks, laying the colored brick material on said jig and smoothing said colored brick material with a smoothing tool so that said colored brick material may be evenly laid into the plurality of individual molds.
- said step of placing and pressing the base against the bricks includes a step of vibrating the molding unit after placement of said base or during pressing said base.
- said base comprises a block or a panel made of organic or inorganic material.
- brick-faced block comprising: a base block made of foamed resin; an adhesive layer formed by adhesive such as mortar- or resin-based adhesive; and a plurality of bricks molded from colored brick material such as colored mortar or a mixture of inorganic material and binder and bonded to said base block by means of said adhesive layer with a predetermined space between each pair of bricks so that said adhesive layer may be partially exposed to form joints in accordance with said predetermined space between each pair of adjacent bricks.
- said plurality of bricks of said colored brick material arranged with said predetermined space between each pair of adjacent bricks are molded at once utilizing the molding unit including the individual molds arranged in accordance with positions at which said bricks being still uncured will be bonded at once to said adhesive layer being also still uncured.
- FIG. 1 is a perspective view of brick-faced blocks
- FIG. 2 is a partially enlarged perspective view of such brick-faced blocks
- FIG. 3 is a block diagram illustrating basic steps of a process according to this invention.
- FIG. 4 is a block diagram illustrating specific substeps of the respective basic steps in one preferred embodiment of this invention.
- FIG. 5 is a perspective view showing, by way of example, a relationship between a molding unit and a jig;
- FIG. 6 is a perspective view showing, by way of example, a relationship between colored brick material immediately after laid on the molding unit and a smoothing tool as partially in a longitudinal section;
- FIG. 7 is a longitudinal sectional view showing, by way of example, a phase in which colored brick material has been laid in and pressed against individual molds ;
- FIG. 8 is a perspective view showing, by way of example, a relationship between the bricks having been molded from colored brick material and a base coated with an adhesive layer.
- Reference letter A designates a brick-faced block comprising a base block 1 made of foamed resin, an adhesive layer 4 of mortar-based type, resin-based type or the other type laid on a surface of said base block 1 , and a plurality of bricks 5 adhesively laid on said adhesive layer 4 .
- Said bricks 5 are molded from colored brick material such as colored mortar or a mixture of inorganic material and binder and laid on said adhesive layer 4 with a predetermined space left between each pair of adjacent bricks 5 in such a manner in which said adhesive layer 4 are partially exposed to form joints 6 .
- reinforcement may be inserted into the filling hole 2 of the base block 1 and then the filling hole 2 may be filled with concrete at the site of the work to construct a fence or a gate.
- said plurality of colored bricks to be laid on the base block 1 with a predetermined space left between each pair of adjacent bricks 5 are molded at once using a molding unit 7 including individual molds 8 arranged in accordance with the placement of said bricks on said base block 1 .
- these bricks 5 which have been molded but yet uncured are adhesively set at once on the base block 1 with interposition of said adhesive layer 4 which is also still uncured in this phase.
- said block A is obtained, according to this invention, as illustrated by FIG. 3, by a method basically comprising steps of: a step of molding the bricks wherein a plurality of individual molds 8 distributed on the molding unit 7 with a predetermined space between each pair of adjacent individual molds 8 are filled with colored brick material 11 such as colored mortar or a mixture of inorganic material and binder and thereby the bricks 5 distributed with said predetermined space between each pair of adjacent bricks 5 are molded at once; a step of placing and pressing the base block against the unit mold wherein the base block 1 is placed and pressed against said molding unit 7 with interposition of the adhesive layer 4 applied said base block such as mortar- or resin-based adhesive and facing the uncured bricks 5 so that said plurality of bricks 5 may be bonded to the base block 1 at once and at the same time the joints 6 may be formed by a partial amount of said adhesive layer exposed between each pair of adjacent bricks 5 by said adhesive layer 4 ; a step of stripping the molding unit 7 wherein the molding
- the molding unit 7 used for said brick molding step is of a relatively large-size, for example, in order of 800 ⁇ 300 cm and made of suitable synthetic rubber such as urethane rubber or silicone rubber.
- the molding unit 7 includes a plurality of individual molds (cavities) 8 in the form of depressions and ribs 9 protruding upward so as to define peripheries of the respective individual molds 8 .
- the molding unit 7 inclusive of the individual molds 8 is provided with micro pores (not shown) for the purpose of degassing.
- the molding unit 7 includes the individual molds 8 of used brick tone which were made in accordance with actually available used bricks to mold a plurality of bricks 5 of so-called used brick tone at once.
- the molding unit 7 utilizes thermoplastic resin film 10 adapted to stick to a molding surface of said molding unit 7 under vacuum suction and the individual molds 8 are filled with the colored material 11 with interposition of said film 10 to perform the operation of molding. More specifically, said thermoplastic resin film 10 is preformed by heating this and placed, while it is continued to be heated, upon the molding surface of the molding unit 7 which is, for example, immovably supported by a table 16 provided with a suction device. Vacuum suction performed by this suction device through said degassing micro pores causes a single sheet of said film 10 to cover and stick to a plurality of individual molds 8 . In the course of this step, said vacuum suction may be continued until the later step of stripping in order to prevent said film from being deformed and/or shifting. The step of stripping will be described later more in detail.
- a mixture of inorganic material and binder is used as the colored brick material 11 and pulverulent material obtained by pulverizing ceramic tile, roof tile or the like is used as said inorganic material.
- such colored brick material 11 may be further added with pigment prepared in the form of the similar pulverulent material or inorganic pigment prepared in the form of colored grains or the like and mixed with suitable binder such as silicone-modified acrylic emulsion.
- said inorganic pigment serves to adjust a tone of said pulverulent material so that said used brick's tone can be obtained.
- Pigment of two or more different colors for example, red, black and white may be simultaneously added to the base components and mixed together to obtained the colored brick material 11 , or pigment of single or plural colors may be added to the said components and mixed together to obtain separate batches of the colored brick material 11 so that the brick 5 of varicolored fashion can be obtained by partially using these separate batches.
- the process according to this embodiment includes an earlier step of pigment placement wherein inorganic pigment having a tone differing from that of the colored brick material 11 itself is applied or sprayed to the individual molds 8 which are closely coated with, in this embodiment, said film 10 .
- Transfer of this inorganic pigment on the surface of the colored brick material 11 i.e., surface of each brick 5
- the tone of the colored brick material 11 itself to emphasize said used brick tone.
- Aesthetic appearance of the brick can be improved in this manner particularly using appropriate pigment, for example, of black, yellow, white etc.
- the colored brick material 11 is laid in the individual molds 8 with interposition of said film 10 from a single batch of the colored brick material 11 or from two or more batches of the colored brick material 11 so as to obtain the varicolored effect. Then the colored brick material 11 filling the individual molds 8 is placed under a pressure to mold the bricks having said inorganic pigment(s) transferred to their top surfaces.
- the jig 12 is placed upon the molding unit 7 and the colored brick material 11 is smoothed by a suitable smoothing tool so that a plurality of individual molds 8 distributed over the molding unit 7 with a predetermined space between each pair of adjacent individual molds 8 may be evenly filled with the colored brick material 11 .
- Said jig 12 defines mortar permeable zones 13 formed by through-holes, meshes, stripes, parallel lines or the like and masking zones 14 corresponding to the ribs 9 which define, in turn, the outer peripheries of the individual molds 8 .
- the colored brick material 11 If the colored brick material 11 is laid in the individual molds 8 without use of said jig 12 , the colored brick material 11 would sometimes remain on the ribs 9 (i.e., on the film 10 covering these ribs 9 ) and cling to the adhesive layer 4 . Consequently, boundaries of the colored brick material 11 would become indefinite and the bricks 5 would be partially forced out onto or cover the joints 6 .
- said jig 12 may be placed upon the molding unit 7 and a predetermined amount of the colored brick material 11 supplied on said jig 12 may be smoothed by a smoothing tool 15 such as spatula or brush to ensure that the masking zones 14 prevent the colored brick material 11 from partially clinging to the ribs 9 and the mortar permeable zones 13 assist the colored brick material 11 to be evenly distributed into the individual molds 8 . In this way, it is possible to fill the individual molds 8 with the colored brick material 11 reliably and smoothly.
- a smoothing tool 15 such as spatula or brush
- the jig 12 comprising a frame formed by blank layout of sheet metal so as to define the masking zones 14 and metallic mesh material laid across the mortar permeable zones 13 .
- the smoothing tool 15 comprises, for example, a brush having bristles each of a diameter corresponding to a mesh size of said mortar permeable zones 13 .
- the jib 12 may be used with the smoothing tool 15 to ensure that the individual molds 8 are evenly filled with the colored brick material 11 and, at the same time, to prevent the colored brick material 11 from clinging to the ribs 9 (i.e., to the film 10 covering these ribs 9 ) in efficient and reliable manner. In this way, the bricks 5 and the joints 6 presenting tones different from each other can be formed with high aesthetic effect as if the bricks 5 have been individually laid and thereafter the joints 6 have been finished.
- the step of molding the bricks 6 from the colored brick material 11 is carried out using said molding unit 7 so that a plurality of bricks 5 arranged with a predetermined space between each pair of adjacent bricks 5 may be molded at once.
- said jig 12 is removed from the molding unit 7 .
- the colored brick material 11 is manually or mechanically pressed together utilizing suitable means such as panel, cloth, pressure jig or the like simultaneously for all of the individual molds 8 or separately for every individual mold 8 or several individual molds 8 .
- the base block 1 to placed against the molding unit 7 at the step of placing and pressing the substrate 1 against the molding unit 7 may be organic or inorganic block or panel, preferably said organic block.
- this base block 1 comprises a lightweight block obtained by expansion-molding expandable resin such as polystyrene resin at an expansion ratio of 25 ⁇ 30.
- the base block 1 is relatively thick and provided with the filling hole 2 vertically extending therethrough.
- the filling hole 2 is not limited to such through-hole but may be a blind hole of which the longitudinally opposite ends are breakably covered.
- Said base block 1 is coated on its one side with a predetermined thickness of adhesive such as mortar- or resin-based adhesive, particularly according to the present embodiment, resin-based adhesive colored in black by mixing with corresponding pigment powder to form the adhesive layer 4 .
- Said base block 1 is placed against the unit mold 7 with said adhesive layer 4 facing the bricks 5 to bond said adhesive layer 4 to the colored brick material 11 laid in the individual units 8 and the ribs 9 (i.e., the surface of the film 10 covering these ribs 9 ) of the molding unit 7 .
- an appropriate pressure is exerted on the base block 1 so that a plurality of bricks 5 arranged with a predetermined space between each pair of adjacent bricks 5 may be bonded to the substrate, i.e., the base block 1 and simultaneously the joints 6 may be formed by a part of said adhesive layer 4 in accordance with said space between each pair of adjacent bricks 5 .
- Operation of pressing the base block 1 is carried out, for example, by a hydraulic press adapted to press the base block 1 from its upper surface (i.e., the surface not coated with the resin-based adhesive) against the table 16 , i.e., against the molding unit 7 .
- a hydraulic press adapted to press the base block 1 from its upper surface (i.e., the surface not coated with the resin-based adhesive) against the table 16 , i.e., against the molding unit 7 .
- the step of placing and pressing the base block 1 against the molding unit 7 further includes a step of vibrating the unit mold 7 after placement of the base block 1 or during the operation of pressing the base block 1 . Vibration of the molding unit 7 reliably fills the individual molds 8 with the colored brick material 11 without voids and/or pits and prevents the bricks 5 from getting out of their desired shapes. In this way, said step of molding the bricks 5 can be reliably achieved and, in the case of the present embodiment, the molding unit 7 intending to realize said used brick tone can be faithfully reproduced with desired aesthetic appearance.
- operation of vibrating the molding unit 7 is carried out after the base block 1 has been placed against the molding unit 7 and before or during pressing said base block 1 against said molding unit 7 using a vibrator adapted to vibrate the table 16 immovably supporting said molding unit 7 at a high frequency.
- the bricks 5 bonded to the base block by means of said adhesive layer 4 are stripped at once from the molding unit 7 and, at the subsequent step of aging, the colored brick material 11 as well as the adhesive layer 4 is aged and thereby cured.
- the step of stripping may be started, for example, by turning over the table 16 immovably supporting the molding unit 7 and at the same time removing the vacuum suction on said film 10 .
- the table 16 is lifted together with the molding unit 7 immovably supported thereon so that the brick-faced block A may be transferred on a separate table 16 adapted to be turned over in operative association with said table 16 supporting the molding unit 7 and provided for the purpose of receiving said brick-faced block A.
- the step of aging is carried out at the normal temperature so that the colored brick material 11 and the adhesive layer 4 may be cured under the film 10 remaining to cover them.
- the film 10 can be peeled off even in the course of the aging, it is apprehended, if the film 10 is prematurely peeled off, that the inorganic pigment applied or sprayed on the film 10 at the earlier stage might remain on the film 10 and the bricks might fail to obtain the tone expected to be produced by said inorganic pigment.
- step of molding the bricks 5 includes a step of sucking the thermoplastic resin film 10 so as to stick to the molding unit 7 , a step of placing the inorganic pigment on the molding unit 7 , a step of placing the jig 12 on the molding unit 7 , a step of smoothing the colored brick material 11 with the smoothing tool 15 and a subsequent step of pressing the colored brick material 11 against the molding unit 7 .
- the step of placing and pressing the base block 1 upon and against the bricks 5 includes a step of placing the base block 1 coated with the adhesive layer 4 upon the molding unit 7 and a step of vibrating and pressing the substrate 1 .
- the step of stripping includes a step of turning over the table 16 , a step of removing the vacuum suction from the film 10 and a step of taking out the brick-faced block a as a final product.
- the step of aging a step of curing the colored brick material 11 as well as the adhesive layer 4 by aging them and a subsequent step of peeling off the film 10 from said brick-faced block A.
- the brick-faced construction material particularly the brick-faced blocks A, after they have been shipped and delivered to a construction site, may be used with reinforcing bars and mortar to construct gateposts or fencing by the same construction method as in the case of concrete blocks more easily and more reliably than in the case of said concrete blocks.
- the gateposts or fencing will have not only the bricks 5 of so-called used brick tone offered by the colored brick material but also the joints 6 formed by the adhesive layer 4 . In this manner, said brick-faced blocks A well contribute to labor saving at the construction site.
- a pair of blocks A may be assembled back to back to form said fencing or gateposts or the side of said block A having neither bricks 5 nor joints 6 may be also provided with said bricks 5 or coated with suitable paint to finish such fencing or gateposts.
- Said blocks A are made of lightweight foamed resin facilitating not only transport but also execution of work and contribute to labor saving.
- said blocks A offer mortar- or inorganic-based brick-finished construction of desired aesthetic appearance.
- reference numeral 3 designates a tongued-and-grooved joint of the base block 1 to join two or more base blocks 1 in vertical direction.
- the jig In use of the jig, it is possible to provide the mortar permeable zones corresponding to the bricks in the form of a plurality of through-holes, stripes or parallel lines. It is possible to mold the bricks under a sufficient pressing effect to eliminate use of vibration. It is possible to place the jig on the molding unit after the colored brick material has been laid in the individual molds and then to smooth said colored brick material. It is possible to carry out the step of stripping manually by turning over only the molding unit supported by the table without turning over said table. It is possible to produce the brick-faced block in the form of the block provided on its both sides with the brick as well as the joints.
- the novel process and the novel product made by this process as have been described hereinabove provide high industrial applicabilities in various aspects.
- the invention defined by claim 1 provides a process for efficiently and reliably making brick-faced construction material, for example, brick-faced block or panel, through a series of steps inclusive of a brick molding step so that interior and/or exterior works such as construction of fencing and gateposts may be quickly done and labor saving at the construction site may be achieved.
- the invention defined by claim 2 enables the surface tone of the bricks to be adjusted to present, for example, an antique tone of used bricks or aesthetic effect of unevenly baked bricks.
- the invention defined by claim 3 effectively prevents the joints formed by the adhesive mortar from being partially covered with the brick materials to make the boundaries between the bricks and the joints definite and thereby to improve an aesthetic appearance of the brick-faced construction material.
- the invention defined by claim 4 enables the individual brick molds to be properly filled with the colored mortar and eliminates an apprehension that voids and pits might remain in said colored mortar and the bricks might get out of their desired shapes.
- the invention defined by claim 5 allows the type of the base to be selected depending on the particular application.
- claims 6 or 7 provides the brick-faced block particularly suitable for construction of fencing and/or gateposts.
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Producing Shaped Articles From Materials (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
Abstract
This invention aims to provide a novel process for making brick-faced block.
Colored brick material 11 is laid into a plurality of individual molds 8 of a molding unit 7 to mold at once a plurality of bricks 5 arranged with a predetermined space between each pair of adjacent bricks 5. Then a base block 1 made of foamed resin and coated with a brick adhesive layer 4 is placed and pressed against the molding unit 7 to bond at once these bricks 5 to the brick adhesive layer 4. Thereupon the brick adhesive layer 4 is partially exposed to form joints 6 in accordance with the predetermined space between each pair of adjacent bricks 5. Thereafter, steps of stripping and aging are carried out to form a brick-faced block A.
Description
- 1. Technical Field of the Invention
- This invention relates to a process for making brick-faced construction material in the form of blocks or panels useful for various interior and exterior works such as construction of fencing and/or gateposts and to brick-faced blocks suitable for said applications.
- 2. Description of the Related Art
- It is well known to fill individual brick molds with colored brick material such as colored mortar to mold bricks and to cure these bricks after stripping. Such process of prior art typically uses the brick molds made of synthetic rubber such as urethane rubber or silicone rubber or made of metal such as aluminum and provided with micro pores for degassing in order to ensure that the brick can be free from need for any surface finishing after molded and the step of stripping can be facilitated. The molding surface of each brick mold is usually covered with film or sheet of thermoplastic resin, silicone resin or the like. In some cases, the colored brick material is laid into the individual brick molds while these molds are heated and vacuum sucked through said degassing micro pores.
- While such process of prior art can offer individual bricks each having a desired shape, an applicability of the brick obtained in this manner is substantially similar to the applicability of the conventional brick, for example, of ceramic type. In other words, the bricks obtained by said process of prior art should be laid on the concrete block or the base panel at the site of construction. Therefore, said process of prior art is certainly effective to reduce a cost of the brick but has not merit other than such merit of cost reduction.
- In view of the problem as has been described above, it is a first object of this invention to provide a process for efficiently and reliably making brick-faced construction material, for example, brick-faced block or panel, through a series of steps inclusive of a brick molding step so that interior and/or exterior works such as construction of fencing and gateposts may be quickly done and labor saving at the construction site may be achieved. It is a second object of this invention to provide brick-faced block particularly suitable for construction of fencing and/or gateposts.
- The first object set forth above is achieved, according to one aspect of this invention, by a process for making brick-faced construction material comprising steps of: molding a plurality of bricks with a predetermined space between each pair of adjacent bricks at once by laying colored brick material such as colored mortar or a mixture of inorganic material and binder into a plurality of individual molds distributed on a molding unit; placing and pressing a base coated on its surface with still uncured adhesive layer formed by suitable adhesive such as mortar- or resin-based adhesive against said plurality of bricks arranged with said predetermined space between each of adjacent bricks so that said base may be bonded to said plurality of bricks at once and at the same time joints are formed by said still uncured adhesive layer in accordance with said predetermined space between each pair of adjacent bricks; stripping said bricks bonded to the base by means of said adhesive layer from said molding unit at once; and aging said bricks and adhesive layer and thereby curing them.
- According to one preferred embodiment of this first invention, said process for making brick-faced construction material defined by
claim 1 further comprises immediately before said step of molding the bricks, a step of coating said individual molds with inorganic pigment having a tone differing from the tone of said colored brick material by applying or spraying said inorganic pigment. - According to another preferred embodiment of this invention, said step of molding the bricks is carried out placing a jig on the molding unit so that its mortar permeable zones defined by through-holes, meshes, stripes or parallel lines lie over the individual molds and its masking zones cover ribs defining peripheries of the individual molds arranged with said predetermined space between each pair of adjacent bricks, laying the colored brick material on said jig and smoothing said colored brick material with a smoothing tool so that said colored brick material may be evenly laid into the plurality of individual molds.
- According to still another preferred embodiment of this invention, said step of placing and pressing the base against the bricks includes a step of vibrating the molding unit after placement of said base or during pressing said base.
- According to further another preferred embodiment of this invention, said base comprises a block or a panel made of organic or inorganic material.
- The second object set forth above is achieved, according to another aspect of this invention, by brick-faced block comprising: a base block made of foamed resin; an adhesive layer formed by adhesive such as mortar- or resin-based adhesive; and a plurality of bricks molded from colored brick material such as colored mortar or a mixture of inorganic material and binder and bonded to said base block by means of said adhesive layer with a predetermined space between each pair of bricks so that said adhesive layer may be partially exposed to form joints in accordance with said predetermined space between each pair of adjacent bricks.
- According to one preferred embodiment of this second invention, said plurality of bricks of said colored brick material arranged with said predetermined space between each pair of adjacent bricks are molded at once utilizing the molding unit including the individual molds arranged in accordance with positions at which said bricks being still uncured will be bonded at once to said adhesive layer being also still uncured.
- FIG. 1 is a perspective view of brick-faced blocks;
- FIG. 2 is a partially enlarged perspective view of such brick-faced blocks;
- FIG. 3 is a block diagram illustrating basic steps of a process according to this invention;
- FIG. 4 is a block diagram illustrating specific substeps of the respective basic steps in one preferred embodiment of this invention;
- FIG. 5 is a perspective view showing, by way of example, a relationship between a molding unit and a jig;
- FIG. 6 is a perspective view showing, by way of example, a relationship between colored brick material immediately after laid on the molding unit and a smoothing tool as partially in a longitudinal section;
- FIG. 7 is a longitudinal sectional view showing, by way of example, a phase in which colored brick material has been laid in and pressed against individual molds ; and
- FIG. 8 is a perspective view showing, by way of example, a relationship between the bricks having been molded from colored brick material and a base coated with an adhesive layer.
- Details of this invention will be more fully understood from the description given hereunder in reference with the accompanying drawings. Reference letter A designates a brick-faced block comprising a
base block 1 made of foamed resin, anadhesive layer 4 of mortar-based type, resin-based type or the other type laid on a surface ofsaid base block 1, and a plurality ofbricks 5 adhesively laid on saidadhesive layer 4. Saidbricks 5 are molded from colored brick material such as colored mortar or a mixture of inorganic material and binder and laid on saidadhesive layer 4 with a predetermined space left between each pair ofadjacent bricks 5 in such a manner in which saidadhesive layer 4 are partially exposed toform joints 6. As in the case of concrete block, reinforcement may be inserted into thefilling hole 2 of thebase block 1 and then thefilling hole 2 may be filled with concrete at the site of the work to construct a fence or a gate. According to the embodiment of this invention described here in reference with the drawings, said plurality of colored bricks to be laid on thebase block 1 with a predetermined space left between each pair ofadjacent bricks 5 are molded at once using amolding unit 7 includingindividual molds 8 arranged in accordance with the placement of said bricks on saidbase block 1. Then, thesebricks 5 which have been molded but yet uncured are adhesively set at once on thebase block 1 with interposition of saidadhesive layer 4 which is also still uncured in this phase. - More definitely to describe, said block A is obtained, according to this invention, as illustrated by FIG. 3, by a method basically comprising steps of: a step of molding the bricks wherein a plurality of
individual molds 8 distributed on themolding unit 7 with a predetermined space between each pair of adjacentindividual molds 8 are filled withcolored brick material 11 such as colored mortar or a mixture of inorganic material and binder and thereby thebricks 5 distributed with said predetermined space between each pair ofadjacent bricks 5 are molded at once; a step of placing and pressing the base block against the unit mold wherein thebase block 1 is placed and pressed against saidmolding unit 7 with interposition of theadhesive layer 4 applied said base block such as mortar- or resin-based adhesive and facing theuncured bricks 5 so that said plurality ofbricks 5 may be bonded to thebase block 1 at once and at the same time thejoints 6 may be formed by a partial amount of said adhesive layer exposed between each pair ofadjacent bricks 5 by saidadhesive layer 4; a step of stripping themolding unit 7 wherein themolding unit 7 is stripped from thebricks 5 bonded to thebase block 1 by means of theadhesive layer 4; and a step of aging wherein thebricks 5 and theadhesive layer 4 are aged and thereby cured. - The
molding unit 7 used for said brick molding step is of a relatively large-size, for example, in order of 800×300 cm and made of suitable synthetic rubber such as urethane rubber or silicone rubber. Themolding unit 7 includes a plurality of individual molds (cavities) 8 in the form of depressions andribs 9 protruding upward so as to define peripheries of the respectiveindividual molds 8. Themolding unit 7 inclusive of theindividual molds 8 is provided with micro pores (not shown) for the purpose of degassing. Themolding unit 7 includes theindividual molds 8 of used brick tone which were made in accordance with actually available used bricks to mold a plurality ofbricks 5 of so-called used brick tone at once. - The
molding unit 7 utilizesthermoplastic resin film 10 adapted to stick to a molding surface of saidmolding unit 7 under vacuum suction and theindividual molds 8 are filled with thecolored material 11 with interposition of saidfilm 10 to perform the operation of molding. More specifically, saidthermoplastic resin film 10 is preformed by heating this and placed, while it is continued to be heated, upon the molding surface of themolding unit 7 which is, for example, immovably supported by a table 16 provided with a suction device. Vacuum suction performed by this suction device through said degassing micro pores causes a single sheet of saidfilm 10 to cover and stick to a plurality ofindividual molds 8. In the course of this step, said vacuum suction may be continued until the later step of stripping in order to prevent said film from being deformed and/or shifting. The step of stripping will be described later more in detail. - A mixture of inorganic material and binder is used as the
colored brick material 11 and pulverulent material obtained by pulverizing ceramic tile, roof tile or the like is used as said inorganic material. Depending on a desired effect, such coloredbrick material 11 may be further added with pigment prepared in the form of the similar pulverulent material or inorganic pigment prepared in the form of colored grains or the like and mixed with suitable binder such as silicone-modified acrylic emulsion. In this case, said inorganic pigment serves to adjust a tone of said pulverulent material so that said used brick's tone can be obtained. Pigment of two or more different colors, for example, red, black and white may be simultaneously added to the base components and mixed together to obtained thecolored brick material 11, or pigment of single or plural colors may be added to the said components and mixed together to obtain separate batches of thecolored brick material 11 so that thebrick 5 of varicolored fashion can be obtained by partially using these separate batches. - The process according to this embodiment includes an earlier step of pigment placement wherein inorganic pigment having a tone differing from that of the
colored brick material 11 itself is applied or sprayed to theindividual molds 8 which are closely coated with, in this embodiment, saidfilm 10. Transfer of this inorganic pigment on the surface of the colored brick material 11 (i.e., surface of each brick 5) which is subsequently laid into theindividual molds 8 cooperates with the tone of thecolored brick material 11 itself to emphasize said used brick tone. Aesthetic appearance of the brick can be improved in this manner particularly using appropriate pigment, for example, of black, yellow, white etc. - The
colored brick material 11 is laid in theindividual molds 8 with interposition of saidfilm 10 from a single batch of thecolored brick material 11 or from two or more batches of thecolored brick material 11 so as to obtain the varicolored effect. Then the coloredbrick material 11 filling theindividual molds 8 is placed under a pressure to mold the bricks having said inorganic pigment(s) transferred to their top surfaces. - In the course of laying the
colored brick material 11 in theindividual molds 8, thejig 12 is placed upon themolding unit 7 and thecolored brick material 11 is smoothed by a suitable smoothing tool so that a plurality ofindividual molds 8 distributed over themolding unit 7 with a predetermined space between each pair of adjacentindividual molds 8 may be evenly filled with thecolored brick material 11. Saidjig 12 defines mortarpermeable zones 13 formed by through-holes, meshes, stripes, parallel lines or the like andmasking zones 14 corresponding to theribs 9 which define, in turn, the outer peripheries of theindividual molds 8. - If the
colored brick material 11 is laid in theindividual molds 8 without use of saidjig 12, thecolored brick material 11 would sometimes remain on the ribs 9 (i.e., on thefilm 10 covering these ribs 9) and cling to theadhesive layer 4. Consequently, boundaries of thecolored brick material 11 would become indefinite and thebricks 5 would be partially forced out onto or cover thejoints 6. On the contrary, saidjig 12 may be placed upon themolding unit 7 and a predetermined amount of thecolored brick material 11 supplied on saidjig 12 may be smoothed by asmoothing tool 15 such as spatula or brush to ensure that themasking zones 14 prevent thecolored brick material 11 from partially clinging to theribs 9 and the mortarpermeable zones 13 assist thecolored brick material 11 to be evenly distributed into theindividual molds 8. In this way, it is possible to fill theindividual molds 8 with thecolored brick material 11 reliably and smoothly. - According to the present embodiment, the
jig 12 comprising a frame formed by blank layout of sheet metal so as to define themasking zones 14 and metallic mesh material laid across the mortarpermeable zones 13. The smoothingtool 15 comprises, for example, a brush having bristles each of a diameter corresponding to a mesh size of said mortarpermeable zones 13. Thejib 12 may be used with the smoothingtool 15 to ensure that theindividual molds 8 are evenly filled with thecolored brick material 11 and, at the same time, to prevent thecolored brick material 11 from clinging to the ribs 9 (i.e., to thefilm 10 covering these ribs 9) in efficient and reliable manner. In this way, thebricks 5 and thejoints 6 presenting tones different from each other can be formed with high aesthetic effect as if thebricks 5 have been individually laid and thereafter thejoints 6 have been finished. - As will be apparent from the foregoing description, the step of molding the
bricks 6 from thecolored brick material 11 is carried out using saidmolding unit 7 so that a plurality ofbricks 5 arranged with a predetermined space between each pair ofadjacent bricks 5 may be molded at once. Specifically, after saidcolored brick material 11 has been laid in theindividual molds 8, saidjig 12 is removed from themolding unit 7. Then thecolored brick material 11 is manually or mechanically pressed together utilizing suitable means such as panel, cloth, pressure jig or the like simultaneously for all of theindividual molds 8 or separately for everyindividual mold 8 or severalindividual molds 8. - The
base block 1 to placed against themolding unit 7 at the step of placing and pressing thesubstrate 1 against themolding unit 7 may be organic or inorganic block or panel, preferably said organic block. According to the present embodiment, thisbase block 1 comprises a lightweight block obtained by expansion-molding expandable resin such as polystyrene resin at an expansion ratio of 25˜30. Thebase block 1 is relatively thick and provided with the fillinghole 2 vertically extending therethrough. The fillinghole 2 is not limited to such through-hole but may be a blind hole of which the longitudinally opposite ends are breakably covered. Saidbase block 1 is coated on its one side with a predetermined thickness of adhesive such as mortar- or resin-based adhesive, particularly according to the present embodiment, resin-based adhesive colored in black by mixing with corresponding pigment powder to form theadhesive layer 4. Saidbase block 1 is placed against theunit mold 7 with saidadhesive layer 4 facing thebricks 5 to bond saidadhesive layer 4 to thecolored brick material 11 laid in theindividual units 8 and the ribs 9 (i.e., the surface of thefilm 10 covering these ribs 9) of themolding unit 7. From this state, an appropriate pressure is exerted on thebase block 1 so that a plurality ofbricks 5 arranged with a predetermined space between each pair ofadjacent bricks 5 may be bonded to the substrate, i.e., thebase block 1 and simultaneously thejoints 6 may be formed by a part of saidadhesive layer 4 in accordance with said space between each pair ofadjacent bricks 5. - Operation of pressing the
base block 1 is carried out, for example, by a hydraulic press adapted to press thebase block 1 from its upper surface (i.e., the surface not coated with the resin-based adhesive) against the table 16, i.e., against themolding unit 7. - The step of placing and pressing the
base block 1 against themolding unit 7 further includes a step of vibrating theunit mold 7 after placement of thebase block 1 or during the operation of pressing thebase block 1. Vibration of themolding unit 7 reliably fills theindividual molds 8 with thecolored brick material 11 without voids and/or pits and prevents thebricks 5 from getting out of their desired shapes. In this way, said step of molding thebricks 5 can be reliably achieved and, in the case of the present embodiment, themolding unit 7 intending to realize said used brick tone can be faithfully reproduced with desired aesthetic appearance. - According to the present embodiment, operation of vibrating the
molding unit 7 is carried out after thebase block 1 has been placed against themolding unit 7 and before or during pressing saidbase block 1 against saidmolding unit 7 using a vibrator adapted to vibrate the table 16 immovably supporting saidmolding unit 7 at a high frequency. - At the step of stripping subsequent to the step of placing and pressing the
base block 1 against themolding unit 7, thebricks 5 bonded to the base block by means of saidadhesive layer 4 are stripped at once from themolding unit 7 and, at the subsequent step of aging, thecolored brick material 11 as well as theadhesive layer 4 is aged and thereby cured. The step of stripping may be started, for example, by turning over the table 16 immovably supporting themolding unit 7 and at the same time removing the vacuum suction on saidfilm 10. Then the table 16 is lifted together with themolding unit 7 immovably supported thereon so that the brick-faced block A may be transferred on a separate table 16 adapted to be turned over in operative association with said table 16 supporting themolding unit 7 and provided for the purpose of receiving said brick-faced block A. The step of aging is carried out at the normal temperature so that thecolored brick material 11 and theadhesive layer 4 may be cured under thefilm 10 remaining to cover them. While thefilm 10 can be peeled off even in the course of the aging, it is apprehended, if thefilm 10 is prematurely peeled off, that the inorganic pigment applied or sprayed on thefilm 10 at the earlier stage might remain on thefilm 10 and the bricks might fail to obtain the tone expected to be produced by said inorganic pigment. - The basic steps of the process for making the brick-faced block A has been described above. Now these steps of molding the
bricks 5, placing and pressing thebase block 1 against themolding unit 7, stripping and aging will be more specifically described in reference with FIG. 4. Said step of molding thebricks 5 includes a step of sucking thethermoplastic resin film 10 so as to stick to themolding unit 7, a step of placing the inorganic pigment on themolding unit 7, a step of placing thejig 12 on themolding unit 7, a step of smoothing thecolored brick material 11 with the smoothingtool 15 and a subsequent step of pressing thecolored brick material 11 against themolding unit 7. The step of placing and pressing thebase block 1 upon and against thebricks 5 includes a step of placing thebase block 1 coated with theadhesive layer 4 upon themolding unit 7 and a step of vibrating and pressing thesubstrate 1. The step of stripping includes a step of turning over the table 16, a step of removing the vacuum suction from thefilm 10 and a step of taking out the brick-faced block a as a final product. The step of aging a step of curing thecolored brick material 11 as well as theadhesive layer 4 by aging them and a subsequent step of peeling off thefilm 10 from said brick-faced block A. - The brick-faced construction material, particularly the brick-faced blocks A, after they have been shipped and delivered to a construction site, may be used with reinforcing bars and mortar to construct gateposts or fencing by the same construction method as in the case of concrete blocks more easily and more reliably than in the case of said concrete blocks. The gateposts or fencing will have not only the
bricks 5 of so-called used brick tone offered by the colored brick material but also thejoints 6 formed by theadhesive layer 4. In this manner, said brick-faced blocks A well contribute to labor saving at the construction site. Since the block A according to the embodiment described and illustrated herein is provided only on its one side with thebricks 5 as well as thejoints 6, a pair of blocks A may be assembled back to back to form said fencing or gateposts or the side of said block A having neitherbricks 5 norjoints 6 may be also provided with saidbricks 5 or coated with suitable paint to finish such fencing or gateposts. Said blocks A are made of lightweight foamed resin facilitating not only transport but also execution of work and contribute to labor saving. In addition, said blocks A offer mortar- or inorganic-based brick-finished construction of desired aesthetic appearance. - Referring to FIG. 3,
reference numeral 3 designates a tongued-and-grooved joint of thebase block 1 to join two or more base blocks 1 in vertical direction. - While the typical embodiment of this invention has been described hereinabove, various variations and modifications will be apparent those skilled in the art in the light of the foregoing description. For example, it is possible to fill the individual molds directly and one by one with the colored brick material or to use the jig and to lay the colored brick material onto the molding unit via said jig without use of the film. It is also to replace the base block made of said foamed resin by a block or a panel made of organic material such as synthetic resin or a block made of inorganic material such as mortar or a panel made of metallic material depending on particular applications. In use of the jig, it is possible to provide the mortar permeable zones corresponding to the bricks in the form of a plurality of through-holes, stripes or parallel lines. It is possible to mold the bricks under a sufficient pressing effect to eliminate use of vibration. It is possible to place the jig on the molding unit after the colored brick material has been laid in the individual molds and then to smooth said colored brick material. It is possible to carry out the step of stripping manually by turning over only the molding unit supported by the table without turning over said table. It is possible to produce the brick-faced block in the form of the block provided on its both sides with the brick as well as the joints. Without departing from the spirit of this invention, additional variations and modifications are possible with respect to specific manners to implement various features such as the step of molding the bricks, the step of placing and pressing on and against the molding unit, the step of stripping, the step of aging, the molding unit used for these steps, the colored brick material, the base and the adhesive layer. Furthermore, sequential steps of the process; materials, shapes and structures, correlation of these factors and possible additions to them; specific materials, shapes and structures of the foamed resin base block, the joints and the bricks, correlation of these factors and possible additions to these them; and possible applications of the brick-faced block as the construction materials.
- The novel process and the novel product made by this process as have been described hereinabove provide high industrial applicabilities in various aspects. The invention defined by
claim 1 provides a process for efficiently and reliably making brick-faced construction material, for example, brick-faced block or panel, through a series of steps inclusive of a brick molding step so that interior and/or exterior works such as construction of fencing and gateposts may be quickly done and labor saving at the construction site may be achieved. The invention defined byclaim 2 enables the surface tone of the bricks to be adjusted to present, for example, an antique tone of used bricks or aesthetic effect of unevenly baked bricks. The invention defined byclaim 3 effectively prevents the joints formed by the adhesive mortar from being partially covered with the brick materials to make the boundaries between the bricks and the joints definite and thereby to improve an aesthetic appearance of the brick-faced construction material. The invention defined byclaim 4 enables the individual brick molds to be properly filled with the colored mortar and eliminates an apprehension that voids and pits might remain in said colored mortar and the bricks might get out of their desired shapes. The invention defined byclaim 5 allows the type of the base to be selected depending on the particular application. The invention defined byclaims
Claims (7)
1. Process for making brick-faced construction material comprising steps of:
molding a plurality of bricks with a predetermined space between each pair of adjacent bricks at once by laying colored brick material such as colored mortar or a mixture of inorganic material and binder into a plurality of individual molds distributed on a molding unit;
placing and pressing a base coated on its surface with still uncured adhesive layer formed by suitable adhesive such as mortar- or resin-based adhesive against said plurality of bricks arranged with said predetermined space between each of adjacent bricks so that said base may be bonded to said plurality of bricks at once and at the same time joints are formed by said still uncured adhesive layer in accordance with said predetermined space between each pair of adjacent bricks;
stripping said bricks bonded to the base by means of said adhesive layer from said molding unit at once; and
aging said bricks and adhesive layer and thereby curing them.
2. Process for making brick-faced construction material as defined by , further comprising, immediately before said step of molding the bricks, a step of coating said individual molds with inorganic pigment having a tone differing from the tone of said colored brick material by applying or spraying said inorganic pigment.
claim 1
3. Process for making brick-faced construction material as defined by or , wherein said step of molding the bricks is carried out placing a jig on the molding unit so that its mortar permeable zones defined by through-holes, meshes, stripes or parallel lines lie over the individual molds and its masking zones cover ribs defining peripheries of the individual molds arranged with said predetermined space between each pair of adjacent bricks, laying the colored brick material on said jig and smoothing said colored brick material with a smoothing tool so that said colored brick material may be evenly laid into the plurality of individual molds.
claim 1
2
4. Process for making brick-faced construction material defined by any one of claims 1-3, wherein said step of placing and pressing the base against the bricks includes a step of vibrating the molding unit after placement of said base or during pressing said base.
5. Process for making brick-faced construction material defined by any one of claims 1-4, wherein said base comprises a block or a panel made of organic or inorganic material.
6. Brick-faced block comprising:
a base block made of foamed resin;
an adhesive layer formed by adhesive such as mortar- or resin-based adhesive; and
a plurality of bricks molded from colored brick material such as colored mortar or a mixture of inorganic material and binder and bonded to said base block by means of said adhesive layer with a predetermined space between each pair of bricks so that said adhesive layer may be partially exposed to form joints in accordance with said predetermined space between each pair of adjacent bricks.
7. Brick-faced block as defined by , wherein said plurality of bricks of said colored brick material arranged with said predetermined space between each pair of adjacent bricks are molded at once utilizing the molding unit including the individual molds arranged in accordance with positions at which said bricks being still uncured will be bonded at once to said adhesive layer being also still uncured.
claim 6
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/864,572 US20010023559A1 (en) | 1999-01-07 | 2001-05-24 | Process for making brick-faced construction material and brick-faced block made by this process |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP1999/2176 | 1999-01-07 | ||
JP11002176A JP3044028B1 (en) | 1999-01-07 | 1999-01-07 | Method for producing building material having brick on substrate surface and block with surface brick |
US47474599A | 1999-12-29 | 1999-12-29 | |
US09/864,572 US20010023559A1 (en) | 1999-01-07 | 2001-05-24 | Process for making brick-faced construction material and brick-faced block made by this process |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US47474599A Division | 1999-01-07 | 1999-12-29 |
Publications (1)
Publication Number | Publication Date |
---|---|
US20010023559A1 true US20010023559A1 (en) | 2001-09-27 |
Family
ID=11522065
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/864,572 Abandoned US20010023559A1 (en) | 1999-01-07 | 2001-05-24 | Process for making brick-faced construction material and brick-faced block made by this process |
Country Status (2)
Country | Link |
---|---|
US (1) | US20010023559A1 (en) |
JP (1) | JP3044028B1 (en) |
Cited By (16)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2003000477A3 (en) * | 2001-06-25 | 2003-11-06 | Shapes & Solutions Ltd | Brick and stone facings |
US20040134154A1 (en) * | 2003-01-09 | 2004-07-15 | Allan Block Corporation | Interlocking building block |
US20050183385A1 (en) * | 2004-02-13 | 2005-08-25 | Viken Ohanesian | Wall system and method |
US7000657B1 (en) | 2005-01-19 | 2006-02-21 | Thorpe Douglas G | Interlocking fuel nozzle |
US20060168907A1 (en) * | 2005-01-19 | 2006-08-03 | Thorpe Douglas G | Decorative, interlocking, mortarless building block |
US20060277851A1 (en) * | 2005-06-13 | 2006-12-14 | Trevi Fabrication Inc. | Under ground swimming pool modular wall structure |
US20070209308A1 (en) * | 2004-07-30 | 2007-09-13 | James Barrett | Faux-stone architectural panel system |
US20100242395A1 (en) * | 2004-12-07 | 2010-09-30 | David Michael Garrett | Insulating concrete form block |
US20110036032A1 (en) * | 2007-07-02 | 2011-02-17 | Sean Smith | Construction element |
US8950137B2 (en) * | 2010-04-02 | 2015-02-10 | Romeo Ilarian Ciuperca | Composite insulated foam panel |
CN105155755A (en) * | 2015-09-18 | 2015-12-16 | 熊柚姣 | Multilayer brick |
US20160010346A1 (en) * | 2014-07-11 | 2016-01-14 | Advanced Formliners, Llc | Visually Enhanced Concrete |
IT201600076304A1 (en) * | 2016-07-20 | 2018-01-20 | Luca Toncelli | Plant and method for forming slabs from a mix of conglomerate |
WO2018140197A1 (en) | 2017-01-25 | 2018-08-02 | E.P. Henry Corporation | Method and apparatus for double faced wall |
US10843377B2 (en) | 2016-07-20 | 2020-11-24 | Luca Toncelli | Method, plant and molds for forming slabs of agglomerate |
US11192278B2 (en) * | 2014-05-13 | 2021-12-07 | Criaterra Innovations Ltd. | Mixture, a process and a mold for manufacturing recyclable and degradable articles |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN101008279B (en) * | 2006-01-24 | 2011-06-29 | 宁波荣山新型材料有限公司 | Production technology of composite thermal-insulating face tile |
CN105786052B (en) | 2014-12-16 | 2020-09-08 | 艺康美国股份有限公司 | Online control and reaction method for pH adjustment |
CN115256607A (en) * | 2022-08-23 | 2022-11-01 | 国网河北省电力有限公司沧州供电分公司 | Baffle plate processing device for reserved expansion joint of concrete |
-
1999
- 1999-01-07 JP JP11002176A patent/JP3044028B1/en not_active Expired - Fee Related
-
2001
- 2001-05-24 US US09/864,572 patent/US20010023559A1/en not_active Abandoned
Cited By (28)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2003000477A3 (en) * | 2001-06-25 | 2003-11-06 | Shapes & Solutions Ltd | Brick and stone facings |
US20040182026A1 (en) * | 2001-06-25 | 2004-09-23 | Clarke Cameron J.R. | Brick and stone facings |
US20040134154A1 (en) * | 2003-01-09 | 2004-07-15 | Allan Block Corporation | Interlocking building block |
US7712281B2 (en) | 2003-01-09 | 2010-05-11 | Allan Block Corporation | Interlocking building block |
US6948282B2 (en) * | 2003-01-09 | 2005-09-27 | Allan Block Corporation | Interlocking building block |
US20070113501A1 (en) * | 2004-02-13 | 2007-05-24 | Viken Ohanesian | Wall system and method |
US7165374B2 (en) * | 2004-02-13 | 2007-01-23 | Viken Ohanesian | Wall system and method |
US20050183385A1 (en) * | 2004-02-13 | 2005-08-25 | Viken Ohanesian | Wall system and method |
US20070209308A1 (en) * | 2004-07-30 | 2007-09-13 | James Barrett | Faux-stone architectural panel system |
US8112960B2 (en) * | 2004-12-07 | 2012-02-14 | Buildblock Building Systems, L.L.C. | Insulating concrete form block including foam panel having inner row projections flush with and inner row projections set back from inner edge and different in size from outer row projections |
US20100242395A1 (en) * | 2004-12-07 | 2010-09-30 | David Michael Garrett | Insulating concrete form block |
US20060168907A1 (en) * | 2005-01-19 | 2006-08-03 | Thorpe Douglas G | Decorative, interlocking, mortarless building block |
US7000657B1 (en) | 2005-01-19 | 2006-02-21 | Thorpe Douglas G | Interlocking fuel nozzle |
US20060277851A1 (en) * | 2005-06-13 | 2006-12-14 | Trevi Fabrication Inc. | Under ground swimming pool modular wall structure |
US20110036032A1 (en) * | 2007-07-02 | 2011-02-17 | Sean Smith | Construction element |
US8950137B2 (en) * | 2010-04-02 | 2015-02-10 | Romeo Ilarian Ciuperca | Composite insulated foam panel |
US11192278B2 (en) * | 2014-05-13 | 2021-12-07 | Criaterra Innovations Ltd. | Mixture, a process and a mold for manufacturing recyclable and degradable articles |
US10119280B2 (en) * | 2014-07-11 | 2018-11-06 | Advanced Formliners, Llc | Form liner for visually enhanced concrete |
US20160010346A1 (en) * | 2014-07-11 | 2016-01-14 | Advanced Formliners, Llc | Visually Enhanced Concrete |
CN105155755A (en) * | 2015-09-18 | 2015-12-16 | 熊柚姣 | Multilayer brick |
US10843377B2 (en) | 2016-07-20 | 2020-11-24 | Luca Toncelli | Method, plant and molds for forming slabs of agglomerate |
WO2018015893A1 (en) * | 2016-07-20 | 2018-01-25 | Luca Toncelli | Plant and method for forming slabs from a mixture of conglomerate |
IT201600076304A1 (en) * | 2016-07-20 | 2018-01-20 | Luca Toncelli | Plant and method for forming slabs from a mix of conglomerate |
WO2018140197A1 (en) | 2017-01-25 | 2018-08-02 | E.P. Henry Corporation | Method and apparatus for double faced wall |
EP3574162A4 (en) * | 2017-01-25 | 2020-10-28 | E.P. Henry Corporation | Method and apparatus for double faced wall |
US10883267B2 (en) | 2017-01-25 | 2021-01-05 | E.P. Henry Corporation | Method and apparatus for double faced wall |
US11802406B2 (en) | 2017-01-25 | 2023-10-31 | Since 1903, Inc. | Method and apparatus for double faced wall |
US11879248B2 (en) | 2017-01-25 | 2024-01-23 | Since 1903, Inc. | Method and apparatus for double faced wall |
Also Published As
Publication number | Publication date |
---|---|
JP3044028B1 (en) | 2000-05-22 |
JP2000198105A (en) | 2000-07-18 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20010023559A1 (en) | Process for making brick-faced construction material and brick-faced block made by this process | |
US5735094A (en) | Method for producing an ornamental concrete surface | |
US5603878A (en) | Process for preparing a decorative transfer sheet with foam layer | |
US5209949A (en) | Method for treating a structural surface with a coating of stones | |
CA1232743A (en) | Method of producing composite boards | |
JPH032450A (en) | Concrete panel having grain surface and its production | |
JP2001001482A (en) | Production of surface decorative material and surface decorative material having archtectural-concrete-like finish feeling | |
EP1319525B1 (en) | Mural reproductions | |
JPH03287901A (en) | Exterior material and manufacture thereof | |
JP3342274B2 (en) | Manufacturing method of surface material | |
JPH02299833A (en) | Stone paper and preparation thereof | |
JPH10121695A (en) | Fine grain inorganic aggregate impregnating sheet and concrete surface finishing construction method using the sheet, and decorated plate | |
JPH01259902A (en) | Decorative material unit used for concrete structure surface, manufacture of this unit and decoration of concrete structure surface using this decorative material unit | |
JPH02116688A (en) | Production of cement-based tile and device therefor | |
JP4119558B2 (en) | Manufacturing method of building material brick and building material brick | |
JP2842410B2 (en) | Surface finishing method for precast concrete plate | |
JPS63267509A (en) | Manufacture of inorganic molded sheet in mode of tilelike panel | |
JPH03271429A (en) | Stone form and manufacture thereof and wall face construction method using stone form | |
JPS62259803A (en) | Manufacture of concrete product having buffer layer | |
JP2003103509A (en) | Method for decoration on hydration hardened material | |
JP2000256050A (en) | Molded brick | |
JP2000301509A (en) | Natural-stonelike artificial rubble or panel with joint thereof | |
JPH05169410A (en) | Preparation of colored concrete block and preparation of colored concrete construction | |
KR100355100B1 (en) | Block type floor panel united ascon and plastics astile and processing method thereof | |
JPH10102723A (en) | Exterior material with sandstone split skin pattern |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |