Method and apparatus for manufacturing brick strips, the manufactured brick strip, and a mesh form layer of material provided with such brick strip

Abstract

 The invention relates to a method and an apparatus (1) for manufacturing brick strips (2) from a curable mortar (3). According to the method said mortar is cast onto a carrier (7) and a visual surface of the said cast mortar is structured, whereby said mortar is cast in at least one form formed by said carrier (7) and a separate brick stencil (9), and said brick stencil (9) is removed before said mortar cures.
Preferably a mesh form layer of material (8) is placed on said carrier (7), and/or sheet form material, if desired thermically insulating material, is used as carrier.
The apparatus (1) comprises a dosing unit (10) for arranging a curable mortar (3) onto a carrier (7), structuring means (11) located in the manufacturing apparatus (1) downstream of said dosing unit (10), transporting means for moving said carrier (7) relative to said dosing unit (10) and structuring means (11), and whereby a brick stencil (9) is placed on said carrier (7) and forms a form therewith.
Preferably a template (9) is in the form of an endless belt.
In a preferred embodiment a mesh-form layer of material (8) is arranged upstream of said dosing unit between said carrier (7) and said brick stencil (9), preferably said carrier consists of sheet form material, if desired thermically insulating material.

Description

[0001] The current invention relates to a method for manufacturing brick strips from a cured mortar, whereby the mortar is cast onto a carrier and a visual surface of the cast mortar is structured.

[0002] Such a method is known and is described for example in the German Gebrauchsmuster 82.20346. According to this known method, mortar cast onto a carrier is cut with the aid of cutting means into brick strips, which are subsequently cured. The use of cutting elements results in a brick strip with straight, smooth and therefore regular sides. The invention has for its object to improve the known method in that the manufactured brick strips acquire rather the appearance of a part of a so-called hand-moulded brick, the sides of which follow an irregular course.

[0003] This is achieved according to the invention because the mortar is cast into at least one form shaped by the carrier and a separate brick stencil is removed before the mortar is cured. It has been found surprisingly that, namely through the removal of the brick stencil, the brick strip greenlings acquire the appearance of a hand-moulded brick.

[0004] In order to increase speed of manufacture, it is recommended that a template provided with a number of brick stencils is used.

[0005] In order to give the visual surface as well as the sides of the manufactured brick strip the appearance of a hand-moulded brick, it is recommended that the degree of filling of the form is greater than 100%, whereby the brick stencil or the template is preferably covered with a layer of mortar, so that the surface of the brick strip greenling can be structured without the stencil or template thereby impending.

[0006] If the manufactured brick strip has to have a flamed aspect, it is recommended that, after the mortar has been introduced into the form, mortar of a divergent colour is added to it, whereby the latter comes to lie substantially on the visual surface, so that a small quantity thereof is sufficient to obtain an optimal effect.

[0007] For an application of the manufactured brick strip where large surfaces must be provided with the brick strips, it is recommended that a mesh form layer of material is laid onto the carrier. Suprisingly it has been found namely that the mortar cast into the form penetrates into this mesh form layer of material and completely embeds this layer in the mortar mass, so that after curing of the brick strops a good attachment of the mesh form layer of material on the brick strips is obtained, so that the brick strips, now mutually situated at a fixed distance, can be applied to a relatively large surface in one operation. The surface that has to be covered with brick strips is provided with an adhesive layer, which, when the mesh form layer of material provided with brick strips is arranged, penetrates through the mesh form material between the brick strips, thereby directly filling the joints between adjacent brick strips. In this way an additional pointing operation can on the one hand be omitted and on the other hand there is the important resulting advantage that no seam occurs between layers of material provided with brick strips that are to be arranged adjacent to one another. If use is made of a brick strip mortar which first cures after coming into contact with the adhesive layer, the layer of material and brick strip are sufficiently flexibel that they can be arranged on shaped or round corners, while use of separate corner elements can be dispensed with.

[0008] The use of the template, which only in fact needs to be cleaned after each casting operation on the parts that have been in contact with the mortar, and the speed of manufacture can be further automated if a template in the form of an endless belt is used.

[0009] As carrier, a disposable or multiple use plastic foil can be used or for other architectural applications a sheet form material such as chipboard or a thermically insulating sheet form material such as polystyrene sheet.

[0010] The invention relates further to an apparatus for performing the method in accordance with the invention, said apparatus comprising a dosing unit for depositing a curable mortar onto a carrier, structuring means located downstream from the dosing unit in the manufacturing apparatus, and transporting means for moving the carrier relative to the dosing unit and structuring means, and is characterized by a brick stencil to be placed on the carrier and shaping a form therewith. In order to be able to structure the visual surface of each brick greenling in a simple manner, it is recommended that in each form the brick greenling has a so-called head of mortar material. This can be achieved if the height of the dosing opening constituted by a wall of the dosing unit and by the carrier is greater than or equal to the height of the form.

[0011] In order to restrict the part of the template and/or brick stencil coming into contact with the mortar, it is recommended that there are lateral walls arranged upstream of and connecting onto the structuring means and arranged above them at a mutual distance that is smaller than the width of the brick stencil. It is to be recommended here that the transporting means act on a stencil edge located between the lateral walls and a respective stencil side, so that the transporting means act upon a portion of the side of the stencil which remains substantially clean, so that friction and possible technical faults as well as wearing of the stencil material is in large measure decreased. The application of the brick strips manufactured according to the invention can be advanced further if a mesh form layer of material can be arranged upstream of the dosing unit between the carrier and the brick stencil, and/or the brick stencils are arranged in a mutual brick bond in the template.

[0012] The exterior of the brick strip greenlings can be further adapted to the appearance of hand-moulded brick forms by applying an irregular wave structure in the direction of movement. This is achieved because the structuring means comprise a doctor arranged reciprocating in relation to the brick stencil, and/or the structuring means comprise a structuring roller which possesses a rolling part with a different, preferably smaller, diameter located above the form.

[0013] If desired the apparatus can be provided with a sand applying unit located downstream from the structuring means.

[0014] Another aspect of the invention relates to a brick strip with a hand-moulded appearance manufactured according to the invention, and a mesh form layer of material provided with at least one brick strip, in which a part of the mesh form layer of material is embedded and anchored.

[0015] If the mesh form material is formed of fibres, glass fibres for example, the brick strips are usually still a little flexible and can be applied in an easy manner onto undulating surfaces or around corners of building elements, whereby no obstruction is caused by the possibly rigid layer of material which holds the brick strips at a determined mutual distance.

[0016] Mentioned and other characteristics will be explained on the basis of a number of embodiments of the method and apparatus according to the invention, without the invention being restricted thereto. Reference is made to the appended drawing in which:

Fig. 1 is a perspective view of an apparatus according to the invention for manufacturing brick strips embedded in mesh form material and arranged in a mutual brick bond;

Fig. 2 is a partly broken away view along the arrow II form fig. 1, on a larger scale;

Fig. 3 is a perspective view on another scale of the product of brick strips embedded in mesh form material manufactured with the apparatus shown in fig. 1;

Fig. 4 is detail IV from fig. 3 on a very much larger scale:

Fig. 5 shows a method corresponding in principle with fig. 1 for manufacturing separate brick strips laid onto a carrier sheet, using a separate template;

Fig. 6 shows a product manufactured using the apparatus shown in fig. 1, whereby a sheet form material is used as carrier;

Fig. 7 shows a variant of detail VII from fig. 2 ; and

Fig. 8 shows another type of structuring means for manufacturing brick strips according to the invention, having a substantially hand-moulded appearance.

[0017] Fig. 1 shows an apparatus 1 for manufacturing brick strips 2 from a curable mortar 3. The brick strips 2 generally indicated with the reference number 2 can be further sub-divided into brick strip greenlings to be cured 2a and cured brick strips 2b (fig. 6). Apparatus 1 comprises a conveyor belt 5, the upper part 6 of which conveys in the direction of arrow 4. Onto upper part 6 are successively laid a carrier track 7 and a mesh form layer of material 8 which, with the aid of a template 9 in the form of an endless belt, are guided without a mutual relative displacement under dosing unit 10, after which a structure is applied on the dosed mortar using structuring means 11, following which template 9 is removed at the point of the position 12 before the curing of the mortar. Sand 14 is subsequently applied to the resulting brick strip greenlings from a sand application unit 13, after which mesh form layer of material 8 is cut along lines 15 using cutting means 114, as shown in fig. 3.

[0018] Dosing unit 10 is filled with mortar 3 form a mixing vessel 16 via a funnel 17 and a screen 18. The layer 19 of mortar 3 applied can be adjusted. The dosing tank 21 is rigidly attached to two arms 19 and 20 (not shown). Both arms are pressed against the stops 23 and 24 with the aid of the cylinder 22. Stop 23 is an end of a bolt 28 provided with a screw-thread, which is guided into a fixed yoke 25. The space between stop 23 and yoke 25 is adjustable using the crank 26. With the aid of a toothed wheel 29 attached firmly to bolt 28, a chain 30 and another toothed wheel 31, the stop 24 of a bolt 27, against which arm 20 is pressed, can be adjusted at the same time and in the same measure. A dosing opening 32 which in principle is formed by a wall 33 and a carrier 7 can be adjusted by turning crank 26. The adjustment of dosing opening 32 is dependent on the amount of material which is dammed up against stucturing roll 34 comprised in structuring means 11. Draining away of the dammed mortar material is prevented with the aid of lateral walls 35 and 36 arranged upstream of this structuring roll 34 and located above template 9.

[0019] Via an unshown wheel connecting with the lower part of conveyor belt 5 and a transmission 35, structuring roll 34 is driven in the same direction and at the same speed as upper part 6 of conveyor belt 5.

[0020] The visual surface 38 can be further structured with the aid of the disc 36 located downstream from structuring roll 34 Disc 37 is arranged eccentrially around a driven shaft 39, so that disc 37 performs a fairly random movement while it is in contact with the mortar 3 persent in template 9.

[0021] From the position 12 template 9 is turned over in upward direction, thereby supported by rollers 39 and 40. Template 9 subsequently passes two pairs of cleaning knives 41 and 42 arranged on either side of template 9. The removed mortar is collected in a container 43. A comparable cleaning again takes place with pairs of cleaning knives 44 and 45 at the point of dosing unit 10. The removed mortar falls directly into dosing unit 10. Template 9 is guided from the first two pairs 41 and 42 in a longitudinal guide 46 and 47 which guide template 9 to immediately in front of dosing unit 10.

[0022] Because both lateral side walls 35 keep a longitudinal edge 48 and 49 free of mortar, these substantial clean longitudinal edges 48 and 49 can be used for guiding as well as for driving template 9.

[0023] Driving of template 9 is effected with the aid of rollers 52 and 53, 54 and 55 (not shown) which are arranged for free rotation round the shafts 50 and 51 respectively. With the aid of shafts 50 and 51 and with enclosure of template 9, mesh form layer of material 8, carrier track 7 and upper part 6, rollers 52-55 are pressed against a resilient, rotatable counter roll. Because upper part 6 is driven by unshown means, template 9, mesh form layer of material 8 and carrier track 7 are also driven. Using this relatively simple construction, relative displacement between template 9, mesh form layer of material 9 and carrier track 7 can be prevented between the point of dosing unit 10 and the position 12.

[0024] The form 57 which is shaped by the stencil 58 arranged in template 9 and carrier track 7 is provided with mesh form material. After traversing apparatus 1, it has been found, surprisingly, that, as fig. 4 shows in more detail, the mesh form material 8 is embedded in brick strip 2a, so that both are anchored to one another. Because each form 57 is completely covered with mortar 3 the degree of filling thereof is greater than 100%. The so-called head on the form 57 provides the advantage that by using structuring means 11 a structure can be applied to it in a quite simple manner, this structured surface eventually forming the visual surface of the brick strip 2.

[0025] If desired it is possible to apply mortar 59 with a colour different form mortar 3 from the pressurised tank 58 onto mortar 3 already present via a gun 60 upstream or downstream of structuring roll 43, so that the formed brick strips acquire a flamed visual surface.

[0026] Fig. 3 and 4 attempt to reproduce the hand moulded brick character of the manufactured brick strips 2. It can be seen clearly that sides 61 and 62 are irregular in height, whereby the various edges 63 are irregular and random from strip to strip. This effect results because the template is removed prior to curing of the formed brick strip greenlings therein. The mesh form material parts 64 and 65 which are each provided with brick strip greenling 2a anchored in them are dried in an unshown drying chamber after cutting.

[0027] Fig. 5 shows another template 66. It will be apparent to a person skilled in the art that such templates 66 can be used in a comparable manner in place of an endless template 9, whereby such a template 66 must be placed continuously beneath dosing unit 10 using manpower of suitable means. In this case there is between upper part 6 of the conveyor belt and template 66 a foil strip 67 which serves as carrier material and from which the cured brick strips are simple to remove. The longitudinal strips 68 and 69 serve to cover the respective ends 70 and 71 of foil strip 67 and allow some measure of tolerance for the position and moment at which foil strip 67 has to be arranged beneath template 66.

[0028] Fig. 6 shows another product according to the invention, whereby sheet form material such as composition board or a polystyrene sheet is used as carrier mateial 72. Such sheets in an already adapted form can in principle be used in place of carrier track 7 in the apparatus shown in fig. 1.

[0029] Fig. 7 shows a variant of a structuring roll 73 which is provided at the point of forms 74 with a neck portion 75 having a smaller diameter, so that downstream of this structuring roll 73 ribs 76 result, whereby another type of brick strip similar to hand-moulded brick can be manufactured.

[0030] Finally, fig. 8 shows a doctor 77 which via arrow 78 is reciprocally movable relative to mortar layer 3, so that a longitudinal wave shape 78 can be formed. An irregular lower edge 79 further advances the attainment of a hand-moulded brick appearance. This doctor can be applied in combination with or without structuring roll 34 or 73.

[0031] The mesh form material can be constructed of for example glass fibres of E-glass, which, if the material is to come into contact with alkali during use, can be impregnated against it. If a carrier foil is used, any suitable flexible plastic foil can be applied.

[0032] The use of an endless template has a number of exceptional advantages: firstly, the template remains moist during use, so that the stencils arranged in it can be filled and emptied easily, secondly, only those parts of the template which are soiled by mortar are cleaned, and the parts of the template not coming into contact with mortar remain substantially free of mortar and can be used for the guiding and driving thereof. The template can in principle be manufactured of any plastic in which the stencils can be fitted easily, and which, in the case of an endless belt, lend themselves to use in a curved form.

[0033] Further adaption can be obtained by giving the form walls an irregular, rustic or erratic shape.

Claims

1. Method for manufacturing brick strips from a curable mortar, whereby said mortar is cast onto a carrier and a visual surface of the said cast mortar is structured, characterized in that said mortar is cast in at least one form formed by said carrier and a separate brick stencil, and that said brick stencil is removed before said mortar cures.

2. Method as claimed in claim 1, characterized in that a template provided with a number of brick stencils is used.

3. Method as claimed in claim 1 or 2, characterized in that the degree of filling of said form exceeds 100%.

4. Method as claimed in claims 2 and 3, characterized in that said brick stencil or template is covered with a layer of mortar.

5. Method as claimed in any of the foregoing claims, characterized in that after placing said mortar in said form, mortar of a divergent colour is added thereto.

6. Method as claimed in any of the foregoing claims, characterized in that a mesh form layer of material is placed on said carrier.

7. Method as claimed in claims 2-6, characterized in that a template in hte form of an endless belt is used.

8. Method as claimed in claims 1-7, characterized in that sheet form material, if desired thermically insulating material, is used as carrier.

9. Apparatus for performing the method as claimed in claims 1-8, comprising a dosing unit for arranging a curable mortar onto a carrier, structuring means located in the manufacturing apparatus downstream of said dosing unit, and transporting means for moving said carrier relative to said dosing unit and structuring means, characterized by a brick stencil to be placed on said carrier and forming a form therewith.

10. Apparatus as claimed in claim 9, characterized in that a number of brick stencils are accomodated in a template.

ll. Apparatus as claimed in claim 10, characterized in that said template is in the form of an endless belt.

12. Apparatus as claimed in claim 11, characterized in that the height of a dosing opening formed by a wall of the dosing unit and the carrier is greater than or equal to the height of said form.

13. Apparatus as claimed in claim 12, characterized by lateral walls arranged upstream of and connecting to said structuring means, and mounted above them at a mutual distance which is smaller than the width of the brick stencil.

14. Apparatus as claimed in claim 13, characterized in that the transporting means act upon a brick stencil edge located between said lateral walls and a respective stencil side.

15. Apparatus as claimed in claims 9-14, characterized in that a mesh-form layer of material can be arranged upstream of said dosing unit between said carrier and said brick stencil.

16. Apparatus as claimed in any of the claims 10-15, characterized in that said brick stencils are arranged in said template in a mutual brick bond.

17. Apparatus as claimed in claims 9_-16, characterized in that said structuring means comprise a doctor arranged reciprocally relative to said stencil.

18. Apparatus as claimed in claims 9-17, characterized in that said structuring means comprise a structuring roll, wich possesses a roll portion located above the form having a different, preferably smaller, diameter.

19. Apparatus as claimed in claims 9-18, characterized by a sand application unit situated downstream of said structuring means.

20. Brick strip with a hand-moulded brick appearance manufactured according to any of the foregoing claims.

21. Brick strip as claimed in claim 20 arranged on a sheet form carrier material, if desired thermically insulating material.

22. Mesh form layer of material provided with at least one brick strip manufactured as claimed in claims 15-19, in which a part of said mesh form layer of material is embedded and anchored.

23. Layer of material as claimed in claim 22, provided with brick strips arranged in a mutual brick bond.

24. Layer of material as claimed in claim 22 or 23, characterized in that said mesh form material is formed of fibres for example glass fibres.

Drawing