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1. WO2021035311 - INTER-ENGAGING BRICKS AND METHOD OF MANUFACTURE

Note: Text based on automatic Optical Character Recognition processes. Please use the PDF version for legal matters

[ EN ]

Claims

1. A method of forming a clay brick comprising the steps of:

providing a die;

extruding a clay material through the die to form a column; and cutting the column to form one or more bricks, each brick having an elongate shape defining a top bedding surface, a bottom bedding surface, a face, a back, a first side and a second side, wherein the method further comprises:

forming a first side interlock in the first side, and forming a second side interlock in the second side, wherein the interlocks are formed so that the first side interlock is complementary to the second side interlock and so that when two such bricks are placed side-by-side, respective interlocks engage,

wherein substantially the entire top bedding surface and the entire bottom bedding surface are planar.

2. The method according to claim 1 wherein, during use of the brick, the top and bottom bedding surfaces of adjacent bricks in adjacent courses are bonded to one another, the face is a visible surface of the brick, the back is a surface opposed to the face and the first and second sides engage between adjacent bricks in the same course.

3. The method according to claim 1 or claim 2 comprising the step of grinding the top and bottom bedding surfaces so that they are substantially entirely planar. The grinding step may occur after the extruding step. The grinding step may occur after a step of firing the brick.

4. The method according to any of claims 1 to 3 further comprising forming one or more rebates in the brick.

5. The method according to claim 4 wherein a first rebate is formed in the face.

6. The method according to claim 5 wherein the first rebate is formed at an edge between the face and the bottom.

7. The method according to any of claims 4 to 6 wherein a second rebate is formed at an edge between the face and the second side.

8. The method according to any of claims 4 to 7 comprising forming one or more of the rebates by cutting, grinding or by use of a shaper cap.

9. The method according to claim 7 or claim 8 wherein the second rebate is formed by a shaper cap.

10. The method according to any of claims 4 to 9 further comprising treating the one or more rebates with one or more of: filling with grout or mortar, smooth or wire cut texture; rendering; painting; or painting with textured paint.

11. The method according to any preceding claim further comprising forming the first side interlock and the second side interlock with a shaper cap.

12. The method according to claim 11 wherein the first side interlock and the second side interlock comprise complimentary tongues and grooves.

13. The method according to claim 12 wherein one or more tongues have a height of between 1 mm and 9 mm.

14. The method according to claim 12 or claim 13 wherein one or more grooves have a depth of between 1.5 mm and 10 mm.

15. A fired clay face brick for use in construction having an elongate shape defining a top bedding surface, a bottom bedding surface, a face, a back, a first side and a second side, wherein the first side is formed with a first side interlock, and the second side is formed with a second side interlock, and wherein the interlocks are formed so that the first side interlock is complementary to the second side interlock and so that when two such bricks are placed side-by-side, respective interlocks engage wherein substantially the entire top bedding surface and the bottom bedding surface are planar.

16. The brick according to claim 15 wherein the first side interlock and the second side interlock comprise complimentary tongues and grooves.

17. The brick according to claim 16 wherein one or more tongue has a height of between 1 mm and 9 mm.

18. The brick according to claim 16 or claim 17 wherein one or more groove has a depth of between 1.5 mm and 10 mm.

19. The brick according to any of claims 15 to 18 further comprising one or more rebates.

20. The brick according to claim 19 wherein one or more rebates are formed in the face.

21. The brick according to claim 19 or claim 20 wherein one or more rebates are formed by grinding.

22. The brick according to any of claims 19 to 20 wherein a first rebate is formed at an edge between the face and the top.

23. The brick according to any of claims 19 to 22 wherein a second rebate is formed at an edge between the face and the second side.

24. The brick according to any of claims 19 to 23 wherein the one or more rebates are one or more of: filling with grout or mortar, smooth or wire cut textured; rendered; painted; or painted with textured paint.

25. The brick according to any of claims 15 to 24 comprising a length of multiples of 240 mm.

26. The brick according to any of claims 15 to 25 having a height of less than 172 mm.

27. The brick according to any of claims 15 to 26 having one of the following sets of dimensions (length x width x height):

230 x 110 x 76 mm,

290 x 90 x 50 mm,

203 x 92 x 57 mm,

194 x 92 x 57 mm,

215 x 102.5 x 65 mm,

240 x 115 x 71 mm,

208 x 107 x 69 mm,

240 x 115 x 63 mm,

228 x 108 x 54 mm,

222 x 106 x 73 mm,

250 x 120 x 65 mm,

250 x 120 x 62 mm.

28. The brick according to any of claims 15 to 27 wherein the interlocks are formed by a shaper cap.

29. A system for forming a construction comprising:

a plurality of bricks according to any of claims 15 to 28 arranged in a course with one or a first or second side interlock of a brick within the course engaging with an interlock of at least one adjacent brick.

30. The system according to claim 29 comprising a plurality of courses arranged vertically with the top bedding surfaces of bricks of a lower course adjacent the bottom bedding surfaces of bricks of an upper course.

31. The system according to claim 30 wherein the top bedding surface of a brick is adhered to the bottom bedding surface of a brick of an adjacent course with adhesive. The adhesive may have a height of less than 1 mm.

The adhesive may be an adhesive other than mortar.

32. The system according to any of claims 29 to 31 comprising at least one alignment bar to align one or more courses of bricks.

33. The system according to claim 32 wherein the alignment bar forms part of an alignment frame, the alignment frame further comprising one or more vertical bars.

34. The system according to claim 18 further comprising brackets for joining the alignment bars to the frame.

35. The system according to claim 34 wherein the brackets comprise a quick release mechanism.

36. The system according to any of claims 29 to 35 further comprising a brick tie for joining one or more bricks to a support structure, the brick tie comprising a shank with a helical profile for screwing into at least one of said plurality of bricks and into the support structure.

37. The system according to any of claims 29 to 36 further comprising a sill, the sill comprising a plurality of said bricks bonded together.

38. The system according to any of claims 29 to 37 further comprising filling a rebate between adjacent courses with mortar wherein the mortar is moulded.

39. A method of forming a construction comprising:

providing a plurality of bricks according to any of claims 15 to 28; arranging the bricks in a course with side interlocks of a brick within the course engaging with at least one respective interlocks of an adjacent brick.

40. The method according to claim 39 comprising arranging a plurality of courses vertically with the top bedding surfaces of bricks of a lower course adjacent the bottom bedding surfaces of bricks of an upper course.

41. The method according to claim 40 wherein the top bedding surface of a brick is adhered to the bottom bedding surface of a brick of an adjacent course with adhesive.

42. The method according to any of claims 39 to 41 comprising using at least one alignment bar to align one or more courses of bricks.

43. The method according to claim 42 wherein the alignment bar forms part of an alignment frame, the alignment frame further comprising one or more vertical bars.

44. The method according to any of claims 39 to 43 further comprising providing a brick tie for joining one or more bricks to a support structure, the brick tie comprising a shank with a helical profile and screwing the tie into at least one of said plurality of bricks and into the support structure.

45. The method according to any of claims 39 to 44 further comprising providing a sill, the sill comprising a plurality of bricks bonded together.

46. The method according to any of claims 39 to 45 further comprising filling a rebate between adjacent courses with mortar, and moulding the mortar.