System for providIng a textured wall structure

United States Patent Application 20020157340

A brick or other structural member is provided for use in building a wall or other similar structure which is to be provided with a cementitious surface coat application to one, typically exposed, face. The brick includes a relief pattern or profile on at least one face. This allows the installer to adequately affix an external cementitious surface coat to the outer surface of, a brick wall, while also providing a “depth gauge”, which can identify proper coating thickness during installation, which not only ensures proper application thickness but can preclude waste due to overapplication. The added brick texture (a.k.a. profile) increases the surface area of the brick to improve the bonding of the brick surface coating and to provide mechanical underpinning for the surface coating.

Kirby, Wayne H. (Suwanee, GA, US)
Samples, Paul A. (Alpharetta, GA, US)
Bedolla, Jorge S. (North Augusta, SC, US)

09/770777

10/31/2002

01/26/2001

Click for automatic bibliography generation

Boral Industries, Inc.

52/515

52/311.1, 52/415, 52/443, 52/561

B28B11/08; E04F13/04; (IPC1-7): E04B1/62

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GREEN, CHRISTY MARIE

ALSTON & BIRD LLP (CHARLOTTE, NC, US)

1. A method of providing a structure including bricks each having at least one surface, said method comprising the steps of: (a) extruding a brick column suitable for severing into separate bricks; (b) severing said brick column into individual bricks; (c) providing a relief profile to at least one side surface of each of said bricks; (d) constructing a brick wall with said profiled face surfaces being commonly oriented; and (e) applying a cementitious surface coat to said brick face sides in order to conceal said profile.

2. The method of claim 1, wherein step “b” is performed before step “c”.

3. The method of claim 1, wherein step “b” is performed after step “c”.

4. The method of claim 3, wherein step “c” includes the step of applying a profile to a brick surface comprised of a plurality of elongate imprints of about one-sixteenth of an inch which are configured to cause an applicator of a cementitous mixture to apply a coating sufficient to preclude recognition of said imprints.

5. The method of claim 2, wherein step “b” includes the step of applying a profile to a brick surface comprised of a plurality of elongate imprints of about one-sixteenth of an inch which are configured to cause an applicator of a cementitous mixture to apply a coating sufficient to preclude recognition of said imprints.

6. The method of claim 1, wherein step “b” includes the step of selecting a thickness said surface coat is to be applied in step “e”, and then selecting said profile such that said predetermined thickness of said cementitious surface coat must be applied in order to conceal said profile.

7. A method of providing a structure including bricks each having at least one surface, said method comprising the steps of: (a) extruding a brick column; (b) severing said brick column into individual bricks; (c) providing a relief profile to at least one side surface of each of said bricks, said relief profile having a recessed recognizable pattern; (d) constructing a brick wall with said profiled face surfaces being commonly oriented; and (e) applying a cementitious surface coat to said brick face sides in order to conceal said profile.

8. The method of claim 7, wherein step “b” is performed before step “c”.

9. The method of claim 7, wherein step “b” is performed after step “c”.

10. The method of claim 9, wherein step “c” includes the step of applying a profile to a brick surface comprised of a plurality of elongate imprints of about one-sixteenth of an inch which are configured to cause an applicator of a cementitous mixture to apply a coating sufficient to preclude recognition of said imprints.

11. The method of claim 8, wherein step “c” includes the step of applying a profile to a brick surface comprised of a plurality of elongate imprints of about one-sixteenth of an inch which are configured to cause an applicator of a cementitous mixture to apply a coating sufficient to preclude recognition of said imprints.

12. The method of claim 7, wherein step “c” includes the step of selecting a thickness said surface coat is to be applied in step “e”, and then selecting said profile such that said predetermined thickness of said cementitious surface coat must be applied in order to conceal said profile.

13. A method of providing a structure including bricks each having at least one surface, said method comprising the steps of: (a) extruding a brick column; (b) severing said brick column into individual bricks; (c) providing a relief profile to at least one side surface, said relief profile having a recognizable, repeating, pattern of each of said bricks; (d) constructing a brick wall with said profiled face surfaces being commonly oriented; and (e) applying a cementitious surface coat to said brick face sides in order to conceal said profile.

14. The method of claim 13, wherein step “b” is performed before step “c”.

15. The method of claim 13, wherein step “b” is performed after step “c”.

16. The method of claim 15, wherein step “c” includes the step of applying a profile to a brick surface comprised of a plurality of elongate imprints of about one-sixteenth of an inch which are configured to cause an applicator of a cementitous mixture to apply a coating sufficient to preclude recognition of said imprints.

17. The method of claim 14, wherein step “c” includes the step of applying a profile to a brick surface comprised of a plurality of elongate imprints of about one-sixteenth of an inch which are configured to cause an applicator of a cementitous mixture to apply a coating sufficient to preclude recognition of said imprints.

18. The method of claim 13, wherein step “c” includes the step of selecting a thickness said surface coat is to be applied in step “e”, and then selecting said profile such that said predetermined thickness of said cementitious surface coat must be applied in order to conceal said profile.

19. A brick structure, comprising: a) a plurality of bricks held together by mortar, said bricks each having a recognizable pattern thereon; and b) a cementitious finishing surface coat applied to said brick face sides in order to conceal said recognizable pattern of said relief profile.

20. The brick structure of claim 19, wherein said pattern is comprised of a plurality of elongate imprints of about one-sixteenth of an inch which are configured to cause an applicator of a cementitous mixture to apply a coating sufficient to preclude recognition of said imprints.

21. A brick structure, comprising: a) a plurality of bricks held together by mortar, said bricks each having a recognizable, repeating, pattern thereon; and b) a cementitious finishing surface coat applied to said brick face sides in order to conceal said recognizable, repeating, pattern of said relief profile.

22. The brick structure of claim 21, wherein said pattern is comprised of a plurality of elongate imprints of about one-sixteenth of an inch which are configured to cause an applicator of a cementitous mixture to apply a coating sufficient to preclude recognition of said imprints.

23. A brick having a profile on one side, said profile comprised with a recognizable recessed pattern which functions as “depth gauge”, in that it assists an applicator in identifying proper coating thickness during installation, thus not only ensuring proper application thickness but reducing waste due to overapplication.

24. The brick as claimed in claim 23, wherein said profile includes a plurality of imprints each having an approximately one-sixteenth inch depth.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims full priority to and incorporates by reference prior pending provisional application serial No. 60/847, filed Jan. 27, 2000, entitled “System for Providing a Textured Wall Structure”.

TECHNICAL FIELD

[0002] The present invention generally relates to wall structures, and particularly relates to a method, apparatus and system for providing a textured wall structure having a brick underlying structural portion.

BACKGROUND OF THE INVENTION

[0003] Brick walls and other similar structures are well known for use in residential or commercial settings.

[0004] It is common practice to provide bricks for the outer brick layer of the walls of a house or other structure, and then to provide the exterior or visible wall surface with a external surface coat of a mortar, cementitious or other covering for aesthetic purposes.

[0005] However, there are always needs for improvement, especially in the area of aesthetic appeal. However, it is desirable to provide such external surface coats with a consistent thickness; enough material should be used in order to provide adequate coating, but too much material should not be used in order to prevent waste or sagging.

[0006] Therefore it may be seen that there is a need in the art for an improved brick or concrete block structure having an external surface coats with a consistent and adequate thickness.

SUMMARY OF THE INVENTION

[0007] The present invention overcomes deficiencies in the art by providing a brick or other structural member for use in building a wall or other similar structure which is to be provided with an application of a known acceptable cementitious surface coating to one, typically exposed, face. The brick includes a relief pattern or profile on at least one face. This allows the brick and coating installer to adequately affix an external surface coat to the outer surface of a brick wall, while also providing a “depth gauge”, which can identify proper coating thickness during installation, which not only ensures proper application thickness but can preclude waste due to overapplication. In one embodiment, this external surface coat can be a mortar mix adapted such as known in the art for applying as an external surface coat.

[0008] Generally described, the present provides a relief pattern of profile on one face of bricks, which allows the installer to adequately affix an external surface coat to the outer surface of a brick wall, while also providing a “depth gauge”, which can identify proper coating thickness during installation.

[0009] Therefore it is an object of the present invention to provide an improved brick structure.

[0010] It is a further object of the present invention to provide a brick structure which includes an improved external surface coat, in one instance being an external surface coat mortar mix known in the art.

[0011] It is a further object of the present invention to provide a brick structure which includes an improved external surface coat which is easy to apply.

[0012] It is a further object of the present invention to provide a brick structure which includes an improved external surface coat which can be applied evenly and reliably.

[0013] It is a further object of the present invention to provide a brick structure which includes an improved external surface coat which can be applied efficiently.

[0014] Therefore it is an object of the present invention to provide an improved brick for use within an improved brick wall.

[0015] It is a further object of the present invention to provide a brick member which allows for an improved external surface coat to be applied thereto.

[0016] It is a further object of the present invention to provide a brick member which allows for easy application of an external surface coat thereto.

[0017] It is a further object of the present invention to provide a brick member which allows for even and reliable application of an external surface coat thereto.

[0018] It is a further object of the present invention to provide a brick member which allows for efficient application of an external surface coat thereto.

[0019] It is a further object of the present invention to provide an improved method and apparatus for providing an improved brick structure.

[0020] It is a further object of the present invention to provide an improved method and apparatus for providing an improved brick structure which includes an improved external surface coat.

[0021] It is a further object of the present invention to provide an improved method and apparatus for providing an improved brick structure which includes an improved external surface coat which is easy to apply.

[0022] It is a further object of the present invention to provide an improved method and apparatus for providing an improved brick structure which includes an improved external surface coat which can be applied evenly and reliably.

[0023] It is a further object of the present invention to provide an improved method and apparatus for providing an improved brick structure which includes an improved external surface coat which can be applied efficiently.

[0024] Other objects, features, and advantages of the present invention will become apparent upon reading the following detailed description of the preferred embodiment of the invention when taken in conjunction with the drawing and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is an overall pictorial view of the system 10 according to the present invention, illustrating a human applicator 60 applying a surface coat to the face of a wall 20 of bricks 100 (a.k.a. “brick structure”). In one embodiment this surface coat can be a mix mortar specially adapted as known in the art for use on vertical surfaces.

[0026] FIG. 2 is an illustrative view of a method used to provide one brick face with a relief profile. This method (and the apparatus which provides it) includes the extrusion of a column 99 of clay or other suitable material, the subsequent provision of a profile, by means such as a roller or other suitable device (see client for alternate devices), and the subsequent separation of the column into individual bricks having the profile on one side face. However, it should be understood that more than one side could be provided with the profiling.

[0027] FIG. 3 is a detailed view of a first version of the brick profile considered under the present invention, illustrating a portion of a brick 100, showing the brick with an unfinished brick face portion 100U having exposed relief marks, and a finished brick face 100F portion which has the relief marks covered by the surface coat.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0028] Generally described, the present invention is directed towards the provision of a relief profile on one face of bricks, which allows the installer to adequately affix an external surface coat to the outer surface of a brick wall, while also providing a “depth gauge”, which can identify proper coating thickness during installation.

[0029] The Application Method

[0030] Reference is made to FIG. 1, which shows an overall pictorial view of the system 10 according to the present invention, illustrating a human applicator 60 applying the surface coat to the face of a brick wall structure 20 with a trowel 50.

[0031] The brick wall structure 20 is comprised of bricks 100 held together by conventional mortar between the bricks.

[0032] The portion of the wall face which does not yet include the surface coating is designated as an unfinished wall face 22.

[0033] The portion of the wall face which does include the surface coating thereon is designated as a finished wall face 24. As may be seen, there are some unfinished areas within the finished wall face region which have the profile still showing, which provides guidance for the applicator to recognize that more surface coating is needed.

[0034] As my be understood, the provision of the recessed markings on the face of the brick structure provide in effect a “depth gauge”, which tends to assist the applicator in making sure that the surface coating is not only applied, but is applied to a sufficient depth. If the applicator does not apply enough surface coating, the recessed relief markings will show through. The relief also provide additional surface area which encourages better adhesion of the coating.

[0035] Thus it may be seen that an important feature of the invention is recognition of the effectiveness of providing a profile which includes a recognizable pattern and has a sufficient depth, so that applications are “forced” to apply a sufficient amount of coating. The depth of the profile can be varied depending on the type of covering needed; if a thicker coating is needed, a deeper and/or wider profile groove may be used. The “recognizable pattern” concept has been determined to assist applicators beyond that which might be provided by a more random profile such as discussed later with respect to Texture Two.

[0036] Manufacture of the Bricks

[0037] Reference is now made to FIG. 2, which shows an exemplary manufacturing method. This method (and the apparatus which provides it) includes the extrusion of a column of clay or other suitable material, the subsequent provision of a profile (by means such as a roller 50 or other suitable profiling device), and the subsequent separation of the column into individual bricks having the profile on one side face.

[0038] However, it should be understood that the separation could be done before the profiling step, and the profiling could be applied by roller, stamp, or other suitable means.

[0039] Texture One

[0040] FIG. 3 is a detailed view of a first version of the recessed brick profile considered under the present invention, illustrating a portion of a brick, showing the brick with an unfinished brick portion having exposed relief marks 101, and a finished brick portion which has the relief marks (a.k.a. “markings”) covered by the surface coating.

[0041] As may be understood, this recognizable, repeating, pattern appearance, which may be referenced as a “diamond shaped pattern”, can be imprinted into the extruded brick column via a roller such as described above. Pressure of the roller may be controlled to achieve a consistent depth of imprint of about one-sixteenth of an inch.

[0042] The diamond-shaped patterns can be variously sized, and can be in the range of ¼ to {fraction (5/16)} to ⅜ inches, “tip-to-tip”.

[0043] It should be understood that other recognizable patterns could be used. A single insignia (such as a trademark) on each brick would be a recognizable but not repeating pattern. The use of repeating rectangles, circles, triangles, or other geometric designs which “repeat” on the same brick (the repeating is shown in FIG. 3 for example) could also be used in the preferred embodiment.

[0044] Texture Two

[0045] Texture Two may be provided with fine vertical scoring achieved by scratching the surface with fine stiff wire during the extrusion process, with the scratch direction being along the extrusion axis. This is not a recognizable repeating, pattern, but it is a relief profile.

[0046] It may be understood that in Texture Two the cut which separates the bricks from an extruded brick column is made substantially perpendicular or transverse to the scratch direction. In other words, the scratch marks are perpendicular to the bed face. The spacing of the wire scratches can be approximately one-sixteenth inches apart, and the depth again can be one-sixteenth inches.

[0047] Alternative Embodiments

[0048] It should be understood that FIG. 2 only shows application of the profile to the top side of the brick column. However, in practice the applicant contemplates the provision of relief to at least one side of the column, and possibly to at least two other sides of the column.

[0049] It should also be understood that concrete or other blocks or members could also be used for providing a wall surface to be covered, with a suitable profiling step used therefor.

[0050] It should also be understood that other profile depths could be used with the blocks or bricks, but an important feature of the invention remains in that the profiling is selected with a desired application thickness in mind.

[0051] Incorporation of Other Applications

[0052] U.S. patent application No. 08/997,658, claiming priority in respect of Australian patent application P04466, filed Jan. 6, 1997, and all of their related applications such as continuations, divisionals, or continuations-in-part are hereby incorporated by reference.

[0053] It may be understood that the present invention may be used in conjunction with or independently of the disclosure illustrated in these incorporated applications.

[0054] Conclusion

[0055] Therefore it may be seen that the present invention overcomes deficiencies in the prior art by providing a brick or other structural member for use in building a wall or other similar structure which is to be provided with a surface coating application to one, typically exposed, face. The brick includes a relief pattern or profile on at least one face. This allows the installer to adequately affix an external surface coat to the outer surface of a brick wall, while also providing a “depth gauge”, which can identify proper coating thickness during installation, which not only ensures proper application thickness but can reduce waste due to overapplication.