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[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”.
[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.
[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.
[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.
[0025]
[0026]
[0027]
[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
[0031] The brick wall structure
[0032] The portion of the wall face which does not yet include the surface coating is designated as an unfinished wall face
[0033] The portion of the wall face which does include the surface coating thereon is designated as a finished wall face
[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
[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]
[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
[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
[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.