Brick/block/paver unit and method of production therefor

Abstract

In a method of splitting a base block to form brick, block or paver units, a cementitious or stone base block having a first side, an opposed second side and a plurality of perforations is provided. Each perforation extends through the base block from the first side to the opposed second side, the plurality of perforations creating a splitting path in the base block. The splitting path has a cross-section consisting of from 70-50% by area of perforated regions and from 30-50% by area of unperforated regions. The base block may be split along the splitting path by a light shock to produce the brick, block or paver units. A wide variety of consistent and reproducible facing surfaces on brick, block and paver units may be produced that integrate texture, pattern, configuration and shape.

Description

FIELD OF THE INVENTION[0001]The present invention is related to building units, particularly to brick, block and / or paver units.BACKGROUND OF THE INVENTION[0002]Brick, block and paver units are typically made by various known methods from stone, cement or other stone-like materials. Such units are useful in the construction of various structures, for example, walls, driveways, etc., and may be molded from processed or reprocessed materials or cut from natural stone. Since the available supply of good grade natural stone is diminishing, there is considerable interest in the art for producing high quality, natural looking products from molded materials. However, the ones presently available on the market have a rough unfinished appearance resembling broken stone or concrete due to the detailing processes. Detailing processes generally involve splitting and pitching of the unit to produce faces having unpredictable and uneven surfaces. The lack of reproducibility and unpredictability o...

AI Technical Summary

Benefits of technology

[0013]Advantageously, the method of the present invention reduces molding cycle time per unit and eliminates the need for splitting and pitching machinery presently used in existing manufacturing. Through the use of a one step molding process, a more efficient manufacturing operation is achieved at less cost per unit.

[0015]Advantageously, the method of the present invention provides for a wide variety of consistent and reproducible facing surfaces on brick, block and paver units that integrate texture, pattern, configuration and shape and the ability to create multiple units from a single part. With the present method, a wide variety of different types of facing surfaces may be produced, while permitting each type of facing surface to be produced in a consistent and reproducible manner. Such a combination of versatility and consistency makes the present method particularly advantageous in the art. In addition, imprints, for example names, logos, etc., may also be included in the brick, block or paver units.

[0018]Any arrangement of perforations is permissible provided the perforations create a splitting path through the base block. For example, by arranging the perforations in lines or curves, it is possible to create straight or curved facing surfaces, respectively, on the unit. Complicated facing surfaces may be reproducibly created by having complicated arrangements of perforations.

Problems solved by technology

However, the ones presently available on the market have a rough unfinished appearance resembling broken stone or concrete due to the detailing processes.

Detailing processes generally involve splitting and pitching of the unit to produce faces having unpredictable and uneven surfaces.

The lack of reproducibility and unpredictability of surface appearance greatly limits the attractiveness, versatility and usefulness of such products.

Further, none of these documents describe the creation of a splitting path having a cross-section with an advantageous balance between perforated and unperforated regions for ease of splitting the block with a light shock.

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