Title:
TEMPLATE FOR BRICK-FACED MASONRY PANEL
United States Patent 3602476
Abstract:
Masonry panels of concrete or other casting material are to be faced with brick, tile, or other blocks of facing material. An elastomeric template is molded with recesses which are defined and separated by upstanding ridges; these ridges form the pattern of the grouting grooves between the bricks of a conventional masonry wall. The ridges are undercut so that the opening of each recess is slightly smaller than the nominal dimensions of each brick, but the bottom surfaces of the recesses are the same size or larger than the nominal dimensions of the brick. A series of bricks are seated in these recesses, the template being placed in a mold. A panel of reinforced concrete or other casting material is poured over the template and cured to bond the rear surfaces of the bricks to the panel. The template is subsequently removed. The resulting brick-faced panel is a close replica in appearance to a conventional masonry wall. The configuration and dimensioning of the template ridges prevents flow of the casting material onto the front faces of the bricks, which would ruin the panels, and also accommodates normally wide tolerance variations of the bricks from nominal dimensions.
US Patent References:
Method and apparatus for making brick-faced concrete walls
Willson - October 1939 - 2178535
Faced monolithic building wall
Hardie et al. - March 1949 - 2465871
Method of precasting masonry panels
Conder et al. - January 1966 - 3231646
Apparatus for erecting a brick building
Boeglen - March 1966 - 3242549
Apparatus for making tile panels
Kastenbein - October 1958 - 2855653
Method and apparatus for making brick-faced concrete walls
Willson - October 1939 - 2178535
Faced monolithic building wall
Hardie et al. - March 1949 - 2465871
Method of precasting masonry panels
Conder et al. - January 1966 - 3231646
Apparatus for erecting a brick building
Boeglen - March 1966 - 3242549
Apparatus for making tile panels
Kastenbein - October 1958 - 2855653
Application Number:
04/813821
Publication Date:
08/31/1971
Filing Date:
04/07/1969
View Patent Images:
Export Citation:
Assignee:
San-Vel Concrete Corporation (Littleton, MA)
Primary Class:
Other Classes:
425/195, 264/219, 249/15, 425/117
International Classes:
B28B19/00; E04C2/04; E04F13/08; E04G11/06
Field of Search:
249/15,96,91,83,205 25/123,1F,131
Primary Examiner:
Schran, Donald R.
Claims:
I claim
1. A template for use in molding brick-faced masonry panels, said template being formed of elastomeric material, and having a series of recesses molded integrally into one face thereof, each of said recesses having a planar bottom surface, said recesses being separated and each peripherally enclosed by intersecting upstanding ridges which are molded into said template with integral joints at their intersections, said ridges extending from bases adjoining said bottom surfaces into apices, each recess forming an opening peripherally bounded by said intersecting ridges, each said opening being similar in form to a selected brick but having dimensions smaller than the nominal dimensions of the brick, whereby the seating of said brick in one of said recesses results in liquid-sealing engagement of the ridges about the periphery of the brick.
2. A template as recited in claim 1, in which the dimensions of said opening of each of said recesses are equal to the nominal dimensions of the brick to be seated therein minus a maximum brick tolerance.
3. A template as recited in claim 1, in which said ridges have decreasing thickness from said apices to said bases thereof, and said bottom surfaces have dimensions larger than those of said openings.
4. A template as recited in claim 1, in which the dimensions of said bottom surface are at least equal to the nominal dimensions of the brick.
5. A template as recited in claim 4, in which the dimensions of said bottom surface are equal to the nominal dimensions of the brick plus a maximum brick tolerance.
6. A template is recited in claim 1, in which sidewalls of ridges opposed within each of said recesses are inclined away from one another from the apices of said ridges toward said bottom surface.
7. A template as recited in claim 1, in which said ridges are formed with convexly curved apices.
8. A template as recited in claim 1, together with a rigid backing plate bonded to said template on a face thereof opposite to said recesses.
1. A template for use in molding brick-faced masonry panels, said template being formed of elastomeric material, and having a series of recesses molded integrally into one face thereof, each of said recesses having a planar bottom surface, said recesses being separated and each peripherally enclosed by intersecting upstanding ridges which are molded into said template with integral joints at their intersections, said ridges extending from bases adjoining said bottom surfaces into apices, each recess forming an opening peripherally bounded by said intersecting ridges, each said opening being similar in form to a selected brick but having dimensions smaller than the nominal dimensions of the brick, whereby the seating of said brick in one of said recesses results in liquid-sealing engagement of the ridges about the periphery of the brick.
2. A template as recited in claim 1, in which the dimensions of said opening of each of said recesses are equal to the nominal dimensions of the brick to be seated therein minus a maximum brick tolerance.
3. A template as recited in claim 1, in which said ridges have decreasing thickness from said apices to said bases thereof, and said bottom surfaces have dimensions larger than those of said openings.
4. A template as recited in claim 1, in which the dimensions of said bottom surface are at least equal to the nominal dimensions of the brick.
5. A template as recited in claim 4, in which the dimensions of said bottom surface are equal to the nominal dimensions of the brick plus a maximum brick tolerance.
6. A template is recited in claim 1, in which sidewalls of ridges opposed within each of said recesses are inclined away from one another from the apices of said ridges toward said bottom surface.
7. A template as recited in claim 1, in which said ridges are formed with convexly curved apices.
8. A template as recited in claim 1, together with a rigid backing plate bonded to said template on a face thereof opposite to said recesses.
Description:
BACKGROUND AND BRIEF DESCRIPTION OF THE INVENTION
The laying of bricks one course at a time is a time-consuming and expensive method of construction. Attempts have been made to produce a satisfactory simulation by laying bricks in a template and pouring a concrete panel as a backing for the bricks. A method previously attempted involved the use of a template made up of strips of rectangular cross sections, forming a series of recesses each having the nominal dimensions of a brick. The template took the form of the grouting pattern that normally appears in the face of a conventional brick wall. THe process did not prove commercially satisfactory. Panels made in this fashion characteristically suffer from the flow of concrete around the bricks, into the recesses of the template, and onto the faces of the bricks, which spoils the appearance of the panel and therefore renders it practically unusable. This problem is aggravated by the necessity to tamp or vibrate the concrete prior to curing; the bricks tend to jump from the recesses. Furthermore, the rigidity of materials previously used in the templates and the necessity to size the recesses uniformly, coupled with the normal variation of bricks from nominal dimensions, prevents uniform engagement of the bricks in the recesses. Commercially produced bricks and tiles have a tolerance of at least ±1/8 inch from nominal dimensions.
It is the primary object of my invention to provide an improved brick-faced masonry panel and a method of manufacture thereof which greatly reduces the cost of these panels as compared with conventional methods of construction, yet produces a panel of high quality and strength with a uniformly attractive appearance and no concrete leakage onto the brick faces. Further objects and advantages of the invention will appear as the following description proceeds.
According to the present invention, I form a template from rubber or other elastomeric material. The template has undercut ridges surrounding and dividing the brick-receiving recesses. These recesses have openings slightly smaller in size than the nominal dimensions of the bricks to be used. The walls of opposed ridges in each recess are inclined away from one another from the opening toward the bottom of the recess, and preferably attain at least the nominal dimensions of the bricks at their bottoms. Consequently, any brick that falls within the normal tolerance limits will cause more or less compression of the ridges near the opening, and will consequently form a tight seal around the periphery of the brick. This holds the brick firmly in place when tamping or vibrating the concrete which is later poured, and prevents leakage onto the brick face at the bottom of the recess.
Having filled the recess of the template with bricks, and seated the template in a mold, I pour a panel of concrete or other casting material, which may be reinforced in a conventional manner by steel mesh or rods. After curing, the template and mold are removed and the brick-faced panel is ready for use. I have found that extremely large panels may be made in this way, up to at least 10 by 40 feet in size, and that these panels fully satisfy A.S.T.M. standards for outdoor construction use. The panels have a uniformly attractive appearance with no grout leaks on the exposed brick faces.
DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out the subject matter which I regard as my invention, it is believed that a clearer understanding may be gained from the following detailed description of a preferred embodiment and mode of practice thereof, referring to the accompanying drawings, in which:
FIG. 1 is a fragmentary sectional view in end elevation showing a template and parts of a mold used in its fabrication;
FIG. 2 is a fragmentary plan view of the template and mold of FIG. 1;
FIG. 3 is a fragmentary view in perspective showing the template;
FIG. 4 is a fragmentary sectional view in end elevation showing the use of the template in the casing of a masonry panel; and
FIG. 5 is a fragmentary perspective view of a completed masonry panel.
Referring to FIGS. 1 and 2, I first assemble a mold which includes a top plate 24 and a series of caps 16 and 17 which have frustoconical locating pins 18 and are preferably made of aluminum. These pins are received in recesses 27 formed in the top plate to position the caps in lateral and longitudinal rows, and in spaced-apart relation as shown. The caps have trapezoidal cross sections so that their longitudinal edges 20 are inclined toward one another from the base of each cap toward its upper portion. The lateral edges of the caps are similarly inclined.
A sandblasted steel backing plate 28 is inserted in a molding press (not shown) in spaced relation to the top plate 24 and the caps 16 and 17. Gum rubber or other uncured elastomeric material is then injected under pressure into the mold, which is then pressed and heated as required to cure and harden the rubber material to form a template 10.
The template is formed with a series of recesses 23, 25 which are separated by longitudinal ridges 14 and interconnecting lateral ridges 15, the latter being staggered like the grouting in courses of brick. These ridges are undercut as a result of the form of the caps 16 and 17, with the opposed peripheral walls 22 of each recess inclined away from one another toward the flat bottom surface of the recess. The dimensions of the bottom surface of the recess are preferably at least equal to the nominal face dimensions of the selected bricks, and may have the nominal dimensions plus the brick tolerance. The top opening 19 of each recess 23 is slightly smaller than the nominal dimensions. This insures that a brick of even the minimum size, when placed in the recess, will interfere with the ridges at the opening, so that the template will form a secure liquid seal completely around the edges of the brick. The openings 19 preferably have the nominal brick dimensions less the tolerance. For example, if brick 2 1/4 by 8 inches are used, having a tolerance of ±1/8 inch, the dimensions of the bottom of the recess may be 2 154 by 81/8 inches, while the opening 19 are 21/8 by 7 7/8 inches. The ridges may be 1/2-inch thick at the level of the openings 19, and 1/4-inch thick where they join the bottoms of the recesses.
The top plate 24 is provided with a network of grooves 26 running between the caps 16, 17 so that the top surface of each ridge 14, 15 will have a convexly rounded form as shown, for the purpose of simulating grouting grooves between bricks.
At the lateral edges of the template, a ridge 12 is formed which has the form of half of a ridge 14 divided on a vertical plane of symmetry. A suitable mold part (not shown) forms the vertical edge. The longitudinal ends of the template are provided with similar half ridges 13, but only at the ends of those alternate recesses 23 which are the size of a complete brick. To conform to the staggered pattern in which bricks are conventionally laid, half-recesses 25 are formed in alternate courses of the template by suitably abbreviated caps 17. The bottom surfaces of these recesses intersect the longitudinal ends. This variation provides for joints between separately cast masonry panels which will form a smooth transition, not revealing the presence of the joint to casual observation.
The longitudinal and lateral edges of the template are molded with a depending apron 30. The plate 28 is bonded to the rear face of the template 10 in the curing process, and the apron 30 encloses and seals the edges of this plate.
After curing is completed, the plate 24 and the caps 16, 17 are stripped from the template. The finished template is shown in FIG. 3, one corner being stripped away from the backing plate 28 to more clearly illustrate the construction.
One or more of the templates 10 are secured to a flat bed (not shown), whose edges and ends are enclosed by a suitable framework of steel channels 38 having a depth sufficient for casting a masonary panel 40 of any desired thickness. A series of bricks, tiles, stone slabs or other selected blocks are then inserted in the recesses 23, 25, as shown in FIGS. 3 and 4. Ordinarily, it is desired to cast relatively large panels, typically on the order 10 by 40 feet, and a number of the templates 10 are butted together. The half-recesses 25 are aligned longitudinally with mating-half recesses in an adjacent template, for receiving bricks of standard size in overlapping relation to the abutting templates. The half-ridges 12 and 13 abut mating half-ridges in adjoining templates to form a full ridge of the standard thickness, except at the edges of the entire panel which is to be cast. After the complete series of templates has been butted and leveled properly, the bricks 34 are inserted in place by hand, or with the help of jigs or placing machines.
Commercially produced bricks have a tolerance of at least ±1/8 inch. A brick of the minimum size within the tolerance range will be slightly smaller than the width or length of the bottoms of the recesses 23, 25, but will nevertheless fit tightly into the openings at the tops of the ridges, since the dimensions of the openings are made equal to the nominal size minus the maximum tolerance. A brick which is oversized will fit tightly at the bottom as well as the top of the recess, compressing the adjacent ridges 14 to some extent.
It is preferred, in making panels of substantial size, to provide steel-reinforcing rods or mesh 36, and this is next laid within the frame 38. Finally, the concrete or other casting material 40 is poured, tamped or vibrated and cured for a suitable time.
After curing, the panel 40 with the bricks 34 bonded thereto is removed from the frame 38 and the template 10. The completed panel is shown in FIG. 5. Because of the rounded form of the top surfaces of the ridges 12, 13, 14, and 15, concave grooves 42 and 44 appear between the bricks, simulating the grouting grooves which appear in conventional brick construction. At the longitudinal and lateral edges of the panel, half-grooves 43 and 45 appear, the latter occurring only at the ends of alternate, full bricks. Upon assembling the panel with other panels to form a building wall, these half-grooves mate with similar half-grooves of the abutting panels to conceal the joints. Half-bricks 35 are used in alternate courses only at the ends of the panel, to mate with adjoining half-bricks of an adjacent panel.
The primary advantage of my improved panel and method of construction is that the faces of the bricks are uniformly clean and free of cement, which is prevented from leaking onto the faces by the compression fit between the bricks and the undersized recesses. The elastomeric template also makes it practical to use bricks which vary considerably in size from nominal dimensions, such as are commercially available at minimum cost. While I have illustrated and described a preferred embodiment and mode of practice of my invention, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the true spirit and scope of the invention, which I intend to define in the appended claims without limitation to the details of the foregoing embodiment and mode of practice.
The laying of bricks one course at a time is a time-consuming and expensive method of construction. Attempts have been made to produce a satisfactory simulation by laying bricks in a template and pouring a concrete panel as a backing for the bricks. A method previously attempted involved the use of a template made up of strips of rectangular cross sections, forming a series of recesses each having the nominal dimensions of a brick. The template took the form of the grouting pattern that normally appears in the face of a conventional brick wall. THe process did not prove commercially satisfactory. Panels made in this fashion characteristically suffer from the flow of concrete around the bricks, into the recesses of the template, and onto the faces of the bricks, which spoils the appearance of the panel and therefore renders it practically unusable. This problem is aggravated by the necessity to tamp or vibrate the concrete prior to curing; the bricks tend to jump from the recesses. Furthermore, the rigidity of materials previously used in the templates and the necessity to size the recesses uniformly, coupled with the normal variation of bricks from nominal dimensions, prevents uniform engagement of the bricks in the recesses. Commercially produced bricks and tiles have a tolerance of at least ±1/8 inch from nominal dimensions.
It is the primary object of my invention to provide an improved brick-faced masonry panel and a method of manufacture thereof which greatly reduces the cost of these panels as compared with conventional methods of construction, yet produces a panel of high quality and strength with a uniformly attractive appearance and no concrete leakage onto the brick faces. Further objects and advantages of the invention will appear as the following description proceeds.
According to the present invention, I form a template from rubber or other elastomeric material. The template has undercut ridges surrounding and dividing the brick-receiving recesses. These recesses have openings slightly smaller in size than the nominal dimensions of the bricks to be used. The walls of opposed ridges in each recess are inclined away from one another from the opening toward the bottom of the recess, and preferably attain at least the nominal dimensions of the bricks at their bottoms. Consequently, any brick that falls within the normal tolerance limits will cause more or less compression of the ridges near the opening, and will consequently form a tight seal around the periphery of the brick. This holds the brick firmly in place when tamping or vibrating the concrete which is later poured, and prevents leakage onto the brick face at the bottom of the recess.
Having filled the recess of the template with bricks, and seated the template in a mold, I pour a panel of concrete or other casting material, which may be reinforced in a conventional manner by steel mesh or rods. After curing, the template and mold are removed and the brick-faced panel is ready for use. I have found that extremely large panels may be made in this way, up to at least 10 by 40 feet in size, and that these panels fully satisfy A.S.T.M. standards for outdoor construction use. The panels have a uniformly attractive appearance with no grout leaks on the exposed brick faces.
DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out the subject matter which I regard as my invention, it is believed that a clearer understanding may be gained from the following detailed description of a preferred embodiment and mode of practice thereof, referring to the accompanying drawings, in which:
FIG. 1 is a fragmentary sectional view in end elevation showing a template and parts of a mold used in its fabrication;
FIG. 2 is a fragmentary plan view of the template and mold of FIG. 1;
FIG. 3 is a fragmentary view in perspective showing the template;
FIG. 4 is a fragmentary sectional view in end elevation showing the use of the template in the casing of a masonry panel; and
FIG. 5 is a fragmentary perspective view of a completed masonry panel.
Referring to FIGS. 1 and 2, I first assemble a mold which includes a top plate 24 and a series of caps 16 and 17 which have frustoconical locating pins 18 and are preferably made of aluminum. These pins are received in recesses 27 formed in the top plate to position the caps in lateral and longitudinal rows, and in spaced-apart relation as shown. The caps have trapezoidal cross sections so that their longitudinal edges 20 are inclined toward one another from the base of each cap toward its upper portion. The lateral edges of the caps are similarly inclined.
A sandblasted steel backing plate 28 is inserted in a molding press (not shown) in spaced relation to the top plate 24 and the caps 16 and 17. Gum rubber or other uncured elastomeric material is then injected under pressure into the mold, which is then pressed and heated as required to cure and harden the rubber material to form a template 10.
The template is formed with a series of recesses 23, 25 which are separated by longitudinal ridges 14 and interconnecting lateral ridges 15, the latter being staggered like the grouting in courses of brick. These ridges are undercut as a result of the form of the caps 16 and 17, with the opposed peripheral walls 22 of each recess inclined away from one another toward the flat bottom surface of the recess. The dimensions of the bottom surface of the recess are preferably at least equal to the nominal face dimensions of the selected bricks, and may have the nominal dimensions plus the brick tolerance. The top opening 19 of each recess 23 is slightly smaller than the nominal dimensions. This insures that a brick of even the minimum size, when placed in the recess, will interfere with the ridges at the opening, so that the template will form a secure liquid seal completely around the edges of the brick. The openings 19 preferably have the nominal brick dimensions less the tolerance. For example, if brick 2 1/4 by 8 inches are used, having a tolerance of ±1/8 inch, the dimensions of the bottom of the recess may be 2 154 by 81/8 inches, while the opening 19 are 21/8 by 7 7/8 inches. The ridges may be 1/2-inch thick at the level of the openings 19, and 1/4-inch thick where they join the bottoms of the recesses.
The top plate 24 is provided with a network of grooves 26 running between the caps 16, 17 so that the top surface of each ridge 14, 15 will have a convexly rounded form as shown, for the purpose of simulating grouting grooves between bricks.
At the lateral edges of the template, a ridge 12 is formed which has the form of half of a ridge 14 divided on a vertical plane of symmetry. A suitable mold part (not shown) forms the vertical edge. The longitudinal ends of the template are provided with similar half ridges 13, but only at the ends of those alternate recesses 23 which are the size of a complete brick. To conform to the staggered pattern in which bricks are conventionally laid, half-recesses 25 are formed in alternate courses of the template by suitably abbreviated caps 17. The bottom surfaces of these recesses intersect the longitudinal ends. This variation provides for joints between separately cast masonry panels which will form a smooth transition, not revealing the presence of the joint to casual observation.
The longitudinal and lateral edges of the template are molded with a depending apron 30. The plate 28 is bonded to the rear face of the template 10 in the curing process, and the apron 30 encloses and seals the edges of this plate.
After curing is completed, the plate 24 and the caps 16, 17 are stripped from the template. The finished template is shown in FIG. 3, one corner being stripped away from the backing plate 28 to more clearly illustrate the construction.
One or more of the templates 10 are secured to a flat bed (not shown), whose edges and ends are enclosed by a suitable framework of steel channels 38 having a depth sufficient for casting a masonary panel 40 of any desired thickness. A series of bricks, tiles, stone slabs or other selected blocks are then inserted in the recesses 23, 25, as shown in FIGS. 3 and 4. Ordinarily, it is desired to cast relatively large panels, typically on the order 10 by 40 feet, and a number of the templates 10 are butted together. The half-recesses 25 are aligned longitudinally with mating-half recesses in an adjacent template, for receiving bricks of standard size in overlapping relation to the abutting templates. The half-ridges 12 and 13 abut mating half-ridges in adjoining templates to form a full ridge of the standard thickness, except at the edges of the entire panel which is to be cast. After the complete series of templates has been butted and leveled properly, the bricks 34 are inserted in place by hand, or with the help of jigs or placing machines.
Commercially produced bricks have a tolerance of at least ±1/8 inch. A brick of the minimum size within the tolerance range will be slightly smaller than the width or length of the bottoms of the recesses 23, 25, but will nevertheless fit tightly into the openings at the tops of the ridges, since the dimensions of the openings are made equal to the nominal size minus the maximum tolerance. A brick which is oversized will fit tightly at the bottom as well as the top of the recess, compressing the adjacent ridges 14 to some extent.
It is preferred, in making panels of substantial size, to provide steel-reinforcing rods or mesh 36, and this is next laid within the frame 38. Finally, the concrete or other casting material 40 is poured, tamped or vibrated and cured for a suitable time.
After curing, the panel 40 with the bricks 34 bonded thereto is removed from the frame 38 and the template 10. The completed panel is shown in FIG. 5. Because of the rounded form of the top surfaces of the ridges 12, 13, 14, and 15, concave grooves 42 and 44 appear between the bricks, simulating the grouting grooves which appear in conventional brick construction. At the longitudinal and lateral edges of the panel, half-grooves 43 and 45 appear, the latter occurring only at the ends of alternate, full bricks. Upon assembling the panel with other panels to form a building wall, these half-grooves mate with similar half-grooves of the abutting panels to conceal the joints. Half-bricks 35 are used in alternate courses only at the ends of the panel, to mate with adjoining half-bricks of an adjacent panel.
The primary advantage of my improved panel and method of construction is that the faces of the bricks are uniformly clean and free of cement, which is prevented from leaking onto the faces by the compression fit between the bricks and the undersized recesses. The elastomeric template also makes it practical to use bricks which vary considerably in size from nominal dimensions, such as are commercially available at minimum cost. While I have illustrated and described a preferred embodiment and mode of practice of my invention, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the true spirit and scope of the invention, which I intend to define in the appended claims without limitation to the details of the foregoing embodiment and mode of practice.