US20140083041A1

US20140083041A1 - Faux brick and faux brick system

Info

Publication number: US20140083041A1
Application number: US14/037,315
Authority: US
Inventors: Kyle Fairchild
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-09-26
Filing date: 2013-09-25
Publication date: 2014-03-27

Abstract

Faux brick and faux brick or masonry system are disclosed. An example system includes a plurality of low-density faux bricks (or blocks) and one or more couplings or faux joints configured to engage one or more of the plurality of faux bricks. To assemble a structure, a plurality of modular faux bricks and faux joints are provided, and the modular faux bricks are combined with faux joint to assemble a faux brick structure in which a plurality of faux joints are interspersed between the plurality of faux bricks.

Description

PRIORITY CLAIM

This application claims the benefit of U.S. Provisional Patent Application No. 61/705,763 filed Sep. 26, 2012 and titled “Faux Brick System” of Kyle Fairchild, hereby incorporated by reference in its entirety as though fully set forth herein.

BACKGROUND

Mud bricks have been used in construction dating back thousands of years. Typical materials used to manufacture modern bricks include stone, clay, concrete, and/or other aggregates. A mortar may be used to hold the bricks together.
Modern brick is expensive to manufacture, can have defects if not made properly (e.g., proper batching and baking), and is difficult to transport and use due to its weight. Many homeowners do not feel confident enough to install bricks and therefore rely on professional masons for brick construction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-F illustrate end, top, front, rowlock, sailor and soldier views of an example modular faux brick component.

FIG. 2 illustrates a perspective view of another example faux brick component.

FIG. 3 illustrates a variety of example faux brick components.

FIG. 4 illustrates a variety of example faux joint components.

FIG. 5 illustrates a variety of example faux brick structures formed from components of an example faux brick system.

FIG. 6 illustrates an example furnishing formed from components of an example faux brick system.

FIGS. 7A-C illustrate front, back and side views of another example furnishing formed from components of an example faux brick system.

DETAILED DESCRIPTION

Faux brick and a faux brick system are disclosed herein. The term “faux” as used herein means “imitation.” For example, a faux brick may be manufactured of wood (or wood component(s) such as wood chips and/or saw dust) so that it has the appearance of a brick made of stone, clay, concrete, and/or other aggregate.
The faux brick is not limited to manufacture from wood. Other example materials of construction include but are not limited to any suitable material such as but not limited to, metal, plastic (or polymer) and/or synthetic material (e.g., carbon fiber, fiberglass).
In an example, the faux brick system includes components that are readily manufactured, easy to use and lightweight, making the components more desirable for the typical homeowner, other end-users who may be reluctant to install brick masonry, and/or those looking for an alternative to the traditional brick made of stone, clay, concrete, and/or other aggregates.
Before continuing, it is noted that as used herein, the terms “includes” and “including” mean, but is not limited to, “includes” or “including” and “includes at least” or “including at least.” The term “based on” means “based on” and “based at least in part on.”
FIGS. 1A-F illustrate a variety configurations of an example faux brick 100. Faux brick 100 may be sold individually and/or in combination with other faux brick(s) and/or other faux masonry components which may be included as part of a faux brick or faux masonry system. For example, the system may also include one or more faux joint (see, e.g., FIG. 4) configured to engage and couple faux bricks 100.
Faux brick 100 includes a front 110, top 120, rear 130, bottom 140, left end 160 and right end 180 surfaces. Of course, these directional terms are used only for the convenience of the reader and are not intended to be limiting to any particular orientation. For purposes of illustration, faux brick height is measured between top 120 and bottom 140 surfaces; faux brick width is measured between front 110 and rear 130 surfaces; and faux brick length is measured between left end 160 and right end 180 surfaces.
The faux bricks include at least one surface resembling a brick. Such a resemblance may be provided by any of a variety of means including application of one or more colorants, one or more laminates, textures, veneers, facades, and/or a combination of these or other techniques.
Faux brick 100 may be configured into any of a variety of configurations. Example configurations may include header, in which only left 160 or right 180 surfaces are visible and the width is oriented horizontally, as depicted by FIG. 1A. Another example configuration may include shiner, in which only top 120 and bottom 140 surfaces are visible and the width is oriented vertically, as depicted by FIG. 1B. Another example configuration may include stretcher, in which only front 110 or rear 130 surfaces are visible and the height is oriented vertically, as depicted by FIG. 1C. Another example configuration may include rowlock, in which only left 160 or right 180 ends are visible and the width is oriented vertically, as depicted by FIG. 1D. Another example configuration may include sailor, in which only top 120 or bottom 140 surfaces are visible as depicted by FIG. 1E and the length is oriented vertically and soldier in which only front 110 or rear 130 surfaces are visible and the length is oriented vertically as depicted by FIG. 1F. The system is not limited to use with these configurations, and may be used with fewer and/or other configurations now known or later developed.
Because the faux brick 100 is not manufactured of traditional brick materials (e.g., clay or stone), the faux brick 100 may be provided with a density that is substantially lower than typical ceramic, mud or stone bricks and, as such, may be considered a low-density block. In an example, a low density may be provided through selection of materials of construction, adjustment of porosity or buoyancy, hollowing an interior portion, and/or any of a variety of other techniques. The low-density block is easier to handle, yet still provides a sturdy building component.
In an example, to facilitate providing a faux masonry system including faux bricks of a variety of widths, lengths and heights, the faux bricks are constructed from a plurality of sub-blocks. For purposes of illustration, brick 100 includes sub-blocks 192, 194, 196, 198 coupled together. This coupling of sub-blocks may be accomplished by any of a variety of means including adhesion, nailing, pinning or interlocking. The faux bricks may also be assembled using glue or other adhesive, and/or by interlocking the faux bricks. In an example, the faux bricks may interlock by way of a keyway (e.g., interlocking similar to puzzle pieces wherein the faux brick includes male and female interlocks), tongue-and-groove, and/or other interlocking means. Alternatively, the sub-blocks may be formed together during manufacture so that the brick 100 is manufactured as a whole, but appears to be manufactured of multiple sub-blocks.
In an example, the sub-blocks 192, 194, 196, 198 shown in FIG. 1B have a length equal that of a full-sized, nominal brick 100 but have a width approximately 25% that of a full-sized, nominal brick. In other examples, sub-blocks may have a width equal to that of a full-sized, nominal brick but have a length approximately 25% that of a full-sized nominal brick or a height equal to that of a full-sized, nominal brick but a length of approximately 25% that of a full-sized nominal brick.
FIG. 2 illustrates a perspective view of another example faux brick 200. In this example, the faux brick 200 is a void brick including a plurality of bores, voids, cavities or other openings 210 aligned along its longitude. Openings 210 increase the porosity of brick 200, and may be used to reduce mass and/or provide a means for interconnecting bricks 200 (e.g., by inserting one or more rod there through). The voids may also be used to hold pens/pencils, e.g., as a deskplate and pencil holder. Likewise, the brick having voids may also be used to hold garden tools, or other items having handle portions that can be inserted through the voids 210.
FIG. 3 illustrates perspective views of other example faux brick. Faux bricks, 305, 310 and 315 also include one or more bores, voids, cavities or other openings (e.g., as described above for FIG. 2). Openings of bricks or blocks 310, 315, 345 and 355 are aligned along a longitude. Openings may take any of a variety of cross sections. Faux bricks 305 345, 355 and 365 include openings of rectangular cross section while faux bricks 310 and 315 include openings of circular cross section.
It is noted that the faux bricks may be provided with any number of openings in accordance with the desired level of brick porosity or mass. Faux bricks 345 and 365 include two openings and faux brick 355 exhibit three openings while faux bricks 320 and 310 include four and five openings, respectively.
As mentioned above, in some examples, faux bricks may be constructed from a plurality of sub-blocks coupled together which may facilitate providing faux bricks of a variety of widths, lengths, and/or heights. For example, full-sized blocks may have a number of sub-blocks. A half modular faux brick may be comprised of half this number of sub-blocks. A three-quarter closure faux brick 320 may be comprised of three transverse sub-blocks to yield a length 75% of that of a full-sized brick having four transverse sub-blocks. A quarter closure faux brick 325 may be comprised of one transverse sub-block to yield a length 25% of that of a full-sized block having four transverse sub-blocks.
It is noted that faux brick 330 includes truncated vertical surfaces, yielding a removed edge and an additional surface or facet which may be disposed at any of a variety of angles relative to adjacent surfaces.
Queen closer bricks 335 have half the number of vertical sub-blocks of a full-sized faux brick, for example, in cases where a full-sized brick includes four vertical sub-blocks, a queen closer brick includes two vertical sub-blocks such that its width is 50% that of a full-sized block.
Split faux brick 340 may be comprised of two longitudinal sub-blocks so as to have a height 50% that of a full-sized block.
As with faux brick 100, faux brick 350 is “whole”, full-sized or nominal.
Faux brick 360 includes a width 50% that of a full-sized brick.
Bull nose bricks 370 include a rounded surface which may be provided by rounding off of an edge.
The surfaces of bricks 375, 380 and 385 include a notch or slot. A first faux “jamb” brick 375 includes a slot defining a vertical step while a second faux “jamb” brick 385 includes a slot defining a longitudinal step. Jamb bricks facilitate support of door or window frames when provided as part of any of a variety of larger faux masonry structures.
Brick 380 includes a slot or “frog” through a right surface.
Shims shown between layers of faux bricks 390 can be placed in the inside joints so that these can be leveled, and glue and/or putty and/or other material may be used to fill the joints and tooled. Still other examples are also contemplated, as shown for example in FIG. 4.
FIG. 4 illustrates a variety of example faux joints or coupling components. Faux joints may comprise two or more mating surfaces which cooperate or interact with adjacent faux bricks and a spanning surface. The spanning surface is typically viewable when a faux joint is engaged with one or more faux bricks in any of a variety of larger faux masonry structures.
Faux joint 465 may generally take the form of a bed joint or a head joint otherwise known as a “perpend.” Each faux bed joint generally has top mating surface 482, bottom mating surface (not visible), left surface 486, right surface 488, front spanning surface 481 and rear surface 483. Note, 445 references a head joint isolated from all bed joints. Faux bed joint height is measured between top 482 and bottom 484 surfaces; faux bed joint width is measured between front 481 and rear 483 surfaces; and faux bed joint length is measured between left end 486 and right end 488 surfaces.
A faux head joint 490 includes front 491, rear (not visible), left 492, right (not visible), bottom 496, and top 498 surfaces. Faux head joint height is measured between top 498 and bottom 496 surfaces; faux head joint width is measured between front 491 and rear surfaces; and faux head joint length is measured between left end 492 and right end surfaces.
For purposes of illustration, faux joint 405 is shown as it may include a concave spanning surface. Faux joints 415 and 430 include a spanning surface angled relative to the mating surfaces. Weathered joint 415 includes an overcut spanning surface while struck joint 430 includes an undercut spanning surface. A faux joint may include a spanning surface approximately perpendicular with the mating surfaces such as with raked joint 420. Faux joint 425 includes a spanning surface with a notch which may exhibit any of a variety of cross-sections, including but not limited to v-shaped. A faux joint may take the form of a grapevine joint 435. A faux joint 440 may include a spanning surface with a ridge/bead.
To resemble joint compound such as mortar, the coupling or faux bed joint may have a height significantly less than a height of the faux bricks and a width approximately equal to a width of the faux bricks such as with faux flush joint 470. Other examples (e.g., faux joint 420) may have a height that is significantly less than that of the bricks, and may have a width that is less than a width of the faux bricks.
As with faux bricks, materials for construction of faux joints may include but are not limited to any suitable material such as but not limited to, wood, metal, plastic (or polymer) or other synthetic material (e.g., carbon fiber, fiberglass). In another example, the joints may be made of a putty. Putty joints can be made into a mold or leveled wet and dried the same as a glue joint. Joint 450 illustrates a putty joint. Faux joint 460 includes glue head and bed joints.
Putty can also be used to make the bricks, such as the putty brick 455. In either case, the putty may be formed from combining sawdust, small wood particles, and/or other matter with glue and by applying pressure.
Of course, the faux brick system can have any type, number, and combination of components. For example, a faux brick system can be provided, to an end-user, as a kit with all of the components needed to construct a desired structure. In some examples, components may also be sold separately, to enable construction of structures not available as a kit, to supplement an existing kit (e.g., to make a larger structure, or replace a broken or missing component) or both of these.
Length, height, width and thickness of faux bricks and joints may be varied according to application or desire. In an example, nominal block height is eight (8) inches, and may therefore be referred to as an “8-inch block.” A block having a height of four (4) inches may be referred to as a “4-inch block” and so on. Joint thickness may be three-eighths (⅜) of an inch, but in other examples can be any suitable size, such as one-half (½) inch.
Before continuing, it should be noted that the examples described above are provided for purposes of illustration, and are not intended to be limiting. Other devices and/or device configurations may be utilized to carry out the operations described herein. For example, faux brick can also be burned, e.g., with a wood burner or laser engraver machine to provide designs, patterns, indicia, and/or a combination of these or other decorative elements.
The faux brick and system described above may be used in an example method to construct various structure(s). FIGS. 5-7 illustrate a variety of example faux brick structures which may be formed by assembly from example components of a faux brick system. For example, a plurality of faux bricks and a plurality of joints may be interspersed between or otherwise combined with the plurality of faux bricks, and assembled so as to provide any of a wide variety of faux brick structures. In an example, the faux brick may also be assembled inside an edifice as a wall, pillar or arch, and even as steps, and/or flooring.
FIG. 5 illustrates example faux brick structures which may be constructed using faux brick systems. Generally, in the construction of walls, pillars or piers, bed joint top surfaces contact a first, superior faux brick, bed joint bottom surfaces contact a second, inferior faux brick and a head joint top as demonstrated by faux joint 465.
In an example method, faux brick or low-density block of the variety disclosed may be assembled using joints described above. Example joints may be a wood joint, putty joint, or glue joint. Nails, staples, screws or combinations of these may also be used. The faux bricks may also be combined by welding the wood which, for example, may indicate pieces of wood glued or otherwise fused together.
In some examples bed joints may include a width approximately equal to a width of the faux bricks with which they are assembled or to which they are coupled. In other examples, the bed joint includes a width less than a width of the faux bricks with which they are assembled or to which they are coupled as with a raked joint. In still other examples, the bed joint includes a width greater than a width of the faux bricks with which they are assembled or to which they are coupled such as with an extruded joint.
Head joints may include a height approximately equal to the height of the faux bricks with which they are assembled or to which they are coupled but may vary from this according to the intended finalized structure.
Faux bricks assembled into walls or pillars 520, 525, 530, 545, 550, 560 and 565 are shown arranged in a sequence of courses between which bed joints are interspersed. A first plurality of faux bricks are provided to yield a first course and a second plurality of faux bricks are provided to yield a second course supported by the first course and so on. Left and right surfaces of faux bricks comprising the second course are spaced from the left and right surfaces of faux bricks of the first course.
Structure 520 illustrates a mixed running and stack bond configuration and structure 530 demonstrates a faux brick pier configuration while structure 525 illustrates a faux brick cornel configuration. In a faux brick cornel configuration, a faux brick is assembled to extend out from a wall or pillar to any of a variety of distances. For example, the brick may extend three-quarters (¾) of an inch.
With Flemish bonds, when a third plurality of faux bricks is provided to yield a third course supported by the second course, the left and right surfaces of faux bricks comprising the third course are approximately aligned with the left and right surfaces of the faux bricks comprising the first course.
In some examples, end surfaces of faux brick components of adjacent courses are spaced by approximately half of the length of one of the faux bricks. This configuration is exhibited in common bond 545, American bond 560, Flemish bond 550 and running or stretcher bond 575.
In examples wherein the end surfaces are spaced by approximately half of the distance between left and right surfaces, the sum of two brick widths and one head or perpend thickness may be approximately equal to a brick length in accordance with a coordinating metric.
Faux bricks and faux joints may also be assembled to provide a faux brick floor. Structure 505 illustrates an hourglass configuration brickwork floor; structure 510 illustrates a herringbone configuration brickwork floor; and structure 515 illustrates a basket weave configuration brickwork floor. Structure 535 illustrates a faux brick circular configuration.
In an example, rather than arranging top surfaces of faux bricks of one course parallel to top surfaces of faux bricks of another course, top surfaces of faux bricks of one course may be angled relative to top surfaces of faux bricks of another course such as with “tiger tooth” configuration 555 and herringbone configuration 570. Configuration 570 includes a 45 degree orientation but this may be varied.
In an example, to provide for the construction of arches 540, the distance between a brick top surface and a brick bottom surface may be greater at the left surface than at the right surface such that the brick top surface is angled relative to the brick bottom surface.
In another example manner of providing for the construction of arches 540, the distance between a joint top surface and a joint bottom surface may be greater at the left surface than at the right surface such that the joint top surface is angled relative to the joint bottom surface.
Structure 565 illustrates a stack bond configuration.
According to a method of assembling the faux bricks, a plurality of modular faux bricks are provided; at least one faux joint is provided; and the modular faux bricks are combined with the at least one faux joint to assemble a faux brick structure. For example, to produce a Flemish body, a plurality of modular faux bricks are oriented as stretchers and are alternated with a plurality of modular faux bricks oriented as headers within a course. Alternating courses include a pair of modular faux bricks oriented as queen closers.
The operations shown and described herein are provided to illustrate example implementations. It is noted that the operations are not limited to the ordering shown. Still other operations may also be implemented.
Due to the unique nature of the faux brick and system described herein, the faux brick are not limited to traditional masonry construction. Indeed, the faux brick may even be used to make furniture. FIG. 6 illustrates an example furnishing in the form of a table 600 formed from components of an example faux brick system. Table 600 is configured to support a weight equal to or greater than an average adult.
Still other types of furniture (indoor and/or outdoor; household and/or industrial) may be constructed using the faux brick and system described herein. By way of further example, FIGS. 7A-C illustrate front, back and side views of another example furnishing in the form of a dresser 700 formed from components of an example faux brick system.
It is noted that the examples shown and described are provided for purposes of illustration and are not intended to be limiting. Still other examples are also contemplated. The components described herein are not limited in size, shape, or function. The components may also be used to construct any suitable structure. Other components, component configurations, and/or structures are also contemplated as being within the scope of the disclosure, as will become readily apparent to one of ordinary skill in the art after becoming familiar with the teachings herein.

Claims

1. A faux brick system, comprising:

a plurality of low-density faux bricks; and

at least one coupling configured to engage one or more of the plurality of blocks.

2. The faux brick system of claim 1, wherein the low-density faux bricks further comprise a plurality of sub-blocks coupled together.

3. The faux brick system of claim 1, wherein the sub-blocks have a length equal to a length of the blocks.

4. The faux brick system of claim 1, wherein at least one of the low-density faux bricks further comprise at least one cavity formed therein.

5. The faux brick system of claim 1, wherein the low-density faux bricks further comprise a variety of lengths, heights and widths.

6. The faux brick system of claim 1, wherein the at least one coupling has a thickness significantly less than a height of the low-density faux bricks.

7. The faux brick system of claim 1, wherein the low-density faux bricks have at least one surface resembling a stone brick.

8. The faux brick system of claim 1, wherein the low-density faux bricks further comprise full-sized blocks having a number of sub-blocks and queen closer blocks having half the number of sub-blocks.

9. The faux brick system of claim 1, wherein a brick top surface is angled relative to a brick bottom surface.

10. The faux brick system of claim 1, wherein a joint top surface is angled relative to a joint bottom surface.

11. A faux brick system, comprising:

a plurality of head joints, each having top, bottom, left, right, front and rear surfaces;

a plurality of bed joints, each having top, bottom, left, right, front and rear surfaces; and

a plurality of faux bricks each having top, bottom, left, right, front and rear surfaces;

wherein the plurality of joints are assembled by interspersing between the plurality of faux bricks.

12. The faux brick system of claim 11, wherein a bed joint top contacts a first faux brick and a bed joint bottom contacts a second faux brick and a head joint top.

13. The faux brick of claim 11, wherein the head joint includes a height approximately equal to the height of a faux brick.

14. The faux brick system of claim 11, wherein a first plurality of faux bricks comprise a first course and a second plurality of faux bricks comprise a second course supported by the first course; and wherein left and right surfaces of faux bricks comprising the second course are spaced from the left and right surfaces of faux bricks of the first course.

15. The faux brick system of claim 11, wherein a top surface of one of the plurality of faux bricks is angled relative to a top surface of another of the plurality of faux bricks.

16. The faux brick system of claim 11, wherein the sum of two brick widths and one head joint thickness is approximately equal to a brick length.

17. A method of assembling faux bricks, comprising:

providing a plurality of modular faux bricks;

providing at least one faux joint; and

combining the modular faux bricks with the at least one faux joint to assemble a faux brick structure.

18. The method of claim 17, further comprising orienting a plurality of the modular faux bricks as stretchers.

19. The method of claim 17, further comprising orienting a plurality of the modular faux bricks as headers.

20. The method of claim 17, further comprising orienting a plurality of the modular faux bricks as queen closers.