US20070277471A1

US20070277471A1 - Brick/block/paver unit and method of production therefor

Info

Publication number: US20070277471A1
Application number: US11/422,448
Authority: US
Inventors: Sidney T. GIBSON
Original assignee: Individual
Current assignee: Sidney Gibson Ltd
Priority date: 2006-06-06
Filing date: 2006-06-06
Publication date: 2007-12-06
Also published as: CA2591373A1; WO2007140586A1

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

The present invention is related to building units, particularly to brick, block and/or paver units.

BACKGROUND OF THE INVENTION

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 of surface appearance greatly limits the attractiveness, versatility and usefulness of such products.
U.S. Pat. Nos. 4,802,320, D297,464, D295,788, D311,444, D391,376, D461,567, D237,704 and 1,222,061 all illustrate blocks having a variety of shapes and having facing surfaces with vertical striations. None of these documents describe how the features of the facing surfaces were obtained.
U.S. Pat. Nos. 20,885, 1,872,522, 4,335,549, 1,534,353, 6,178,704, 6,029,943 and 5,622,456, Japanese patent publication 2004223796, Japanese patent 11262916 and Italian patent 1212006 all describe processes for splitting stone in which a fracture line is guided by spots, holes or grooves. None of these documents describe a correspondence between the arrangement of spots, holes or grooves and the detailed appearance of the facing surfaces of the resultant units. 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.
U.S. Pat. Nos. 6,918,715, 6,874,494, 6,886,551, 4,186,166, 6,827,073, 156,274 and 332,999 all describe processes and machines for splitting stone.
There remains a need in the art for a versatile and easy method of creating reproducible facing surfaces on brick, block and paver units to provide a greater variety of appearances to choose from while providing greater consistency of appearance of individual units within the same variety.

SUMMARY OF THE INVENTION

There is provided a method of producing brick, block or paver units comprising: providing a cementitious or stone base block having a first side, an opposed second side and a plurality of perforations, each perforation extending 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 having a cross-section consisting of from 70-50% by area of perforated regions and from 30-50% by area of unperforated regions; and, providing a shock to the base block to split the base block along the splitting path.
There is further provided a cementitious or stone base block comprising a first side, an opposed second side and a plurality of perforations, each perforation extending 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 having a cross-section consisting of from 70-50% by area of perforated regions and from 30-50% by area of unperforated regions.
There is yet further provided a brick, block or paver unit comprising a striated facing surface produced by the method of the present invention. Products produced by the present method may find application in indoor, outdoor, residential, commercial and/or industrial environments. Some particular products that can be produced include, but are not limited to, veneer fascia blocks, retaining wall blocks, textured bricks (e.g. frog or 3-hole type bricks), skid resistant pavers, rumble strips, architectural elements (e.g. stacked columns, door surrounds, window surrounds, fireplace surrounds, chimney pots, architectural planters, etc.) fire resistant cladding, and a variety of industrial products.
Perforations in the base block may be created by any suitable method. For example, in a molding method, a molding material (e.g. a processed or reprocessed cementitious material) may be introduced into a suitably shaped mold in a fluid or semi-fluid state and elongated members, e.g. rods or comb-like structures, inserted into the mold before the molding material sets. The rods or comb-like structure may then be removed when the molding material is sufficiently set that the perforations will not fill in with the cementitious material. Masonry stone or calcite base blocks may be produced having a plurality of perforations creating a splitting path for future splitting of the base block into smaller units with textured faces.
Advantageously, the balance between perforated and unperforated regions maintains structural integrity of the base block during initial handling and curing, but permits splitting of the base block into smaller brick, block or paver units with a light shock, rather than requiring the use of heavy splitting equipment prevalent in the prior art.
Some techniques for splitting the base block include, for example, striking the block with a hammer, inserting wedges into the perforations and striking the wedges with a hammer, lightly pressing along the splitting path with a guillotine blade, lightly pressing along the splitting path with V-shaped fulcrums, applying a vibration to the base block, etc. Thus, the base blocks may be conveniently split into smaller brick, block or paver units on a production assembly line or during the curing process. The base blocks may even split under their own weight during transportation, or be split at a job site by a masonry contractor or a novice depending on the complexity of the splitting path.
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.
Further, the ease of splitting the base blocks allows for transportation of unsplit base blocks closer to an ultimate destination thereby eliminating handling of multiple smaller units. Transporting unsplit base blocks using existing skids and equipment, provides for more efficient stacking, nesting and storage thereby reducing the amount of space required to transport the same number of brick, block or paver units. Transporting unsplit base blocks also protects the facing surfaces of the units from damage thereby reducing wastage of the units from shipping and handling damage.
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.
In addition, the ability to consistently reproduce facing surfaces permits the formation of accurate bonding surfaces on the facing surfaces of block units intended for use as architectural elements and the like. Because the method produces consistent and reproducible facing surfaces, it is possible to create many modules having the same surface features so that when the architectural elements are stacked face-to-face, the surface features at the interface match up closely, thereby permitting the modules to be bonded at the interface, for example with adhesives.
By adjusting size, shape and spacing of the perforations, it is possible to create uniform, regular or random patterns, or combinations thereof, on a facing surface of a brick, block or paver unit. Any size and spacing of the perforations is possible provided the above-described relative ratio of perforated regions to unperforated regions in the splitting path is maintained. Perforations may be any shape, the shape being dictated by the desired appearance of the facing surface of the unit. For example, the perforations may have a circular, elliptical or polygonal cross-section, or a combination thereof. Polygonal cross-sections may be regular or irregular polygons. Some examples of regular polygons include squares, rectangles, hexagons, etc. Once the base block is split, units are created having a striated appearance on the facing surfaces. By planning the shape of the perforations in the base block, it is possible to create channels and/or ridges with a shaped profile which add specific detail and functional features to the faces, edges and corners of the finished units. For brick, block or paver units formed using this molding technique, the shape and size of each individual perforation may be controlled by the shape and size of individual elongated members inserted into the mold.
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.
Perforations may be arranged so that more than one splitting path is created in the base block. Having more than one splitting path permits the creation of corner units having two or more facing surfaces. Having more than one splitting path also permits the creation of more than two units from a single base block.
Set back features on the facing surface of a brick, block or paver unit may be created by providing a base block having a recess in one or more sides of the base block. In one embodiment, a perimetrical recess is provided around four sides of the base block and the perforations are arranged within the recess so that splitting the base block provides units having facing surfaces surrounded by set backs. Such set backs can provide for mortar joints in a structure. The size of the mortar joints can be controlled by controlling the size of the recess.
In a particular aspect of the present method, a recess with an undercut may be provided in the base block so that when the base block is split, the resulting set back has an undercut useful for tuck pointing of mortar in a mortar joint between adjacent units in a structure. Thus, the mortar joint is keyed in providing for a stronger joint.
Further features of the invention will be described or will become apparent in the course of the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more clearly understood, embodiments thereof will now be described in detail by way of example, with reference to the accompanying drawings, in which:

FIG. 1A is a plan view of a first embodiment of a perforated base block of the present invention;

FIG. 1B is a plan view of one block unit created by splitting the base block of FIG. 1A;

FIG. 1C is a perspective view of two block units created by splitting the base block of FIG. 1A;

FIG. 2A is a plan view of a second embodiment of a perforated base block of the present invention;

FIG. 2B is a plan view of one block unit created by splitting the base block of FIG. 2A;

FIG. 2C is a perspective view of two block units created by splitting the base block of FIG. 2A;

FIG. 3A is a plan view of a third embodiment of a perforated base block of the present invention;

FIG. 3B is a plan view of one block unit created by splitting the base block of FIG. 3A;

FIG. 3C is a perspective view of two block units created by splitting the base block of FIG. 3A;

FIG. 4A is a plan view of a fourth embodiment of a perforated base block of the present invention;

FIG. 4B is a plan view of one block unit created by splitting the base block of FIG. 1A;

FIG. 4C is a perspective view of two block units created by splitting the base block of FIG. 4A;

FIG. 5A is a plan view of a fifth embodiment of a perforated base block of the present invention;

FIG. 5B is a perspective view of two brick units created by splitting the base block of FIG. 5A;

FIG. 6A is a plan view of a sixth embodiment of a perforated base block of the present invention;

FIG. 6B is a perspective view of two paver units created by splitting the base block of FIG. 6A;

FIG. 6C is a perspective view of two paver units created by splitting the base block of FIG. 6A and a third paver unit;

FIG. 7A is a plan view of a seventh embodiment of a perforated base block of the present invention;

FIG. 7B is a perspective view of two block units created by splitting the base block of FIG. 7A;

FIG. 8A is a plan view of an eighth embodiment of a perforated base block of the present invention;

FIG. 8B is a plan view of one block unit created by splitting the base block of FIG. 8A;

FIG. 8C is a perspective view of three block units created by splitting the base block of FIG. 8A;

FIG. 9A is a plan view of a ninth embodiment of a perforated base block of the present invention;

FIG. 9B is a plan view of one block unit created by splitting the base block of FIG. 9A;

FIG. 9C is a perspective view of two block units created by splitting the base block of FIG. 9A;

FIG. 10A is a plan view of a tenth embodiment of a perforated base block of the present invention;

FIG. 10B is a plan view of one block unit created by splitting the base block of FIG. 10A;

FIG. 10C is a perspective view of two block units created by splitting the base block of FIG. 10A;

FIG. 11A is a plan view of an eleventh embodiment of a perforated base block of the present invention;

FIG. 11B is a plan view of one block unit created by splitting the base block of FIG. 11A;

FIG. 11C is a perspective view of two block units created by splitting the base block of FIG. 11A;

FIG. 12A is a plan view of a twelfth embodiment of a perforated base block of the present invention;

FIG. 12B is a plan view of two types of block units created by splitting the base block of FIG. 12A;

FIG. 12C is a perspective view of the two types of block units of FIG. 12B;

FIG. 13A is a plan view of a thirteenth embodiment of a perforated base block of the present invention;

FIG. 13B is a plan view of two types of block units created by splitting the base block of FIG. 13A;

FIG. 13C is a perspective view of the two types of block units of FIG. 13B;

FIG. 14A is a plan view of a fourteenth embodiment of a perforated base block of the present invention;

FIG. 14B is a plan view of one block unit created by splitting the base block of FIG. 14A;

FIG. 14C is a perspective view of four block units created by splitting the base block of FIG. 14A;

FIG. 15A is a plan view of a fifteenth embodiment of a perforated base block of the present invention;

FIG. 15B is a plan view of one block unit created by splitting the base block of FIG. 15A;

FIG. 15C is a perspective view of four block units created by splitting the base block of FIG. 15A;

FIG. 16A is a plan view of a sixteenth embodiment of a perforated base block of the present invention;

FIG. 16B is a plan view of one block unit created by splitting the base block of FIG. 16A;

FIG. 16C is a perspective view of three block units created by splitting the base block of FIG. 16A;

FIG. 17A is a plan view of a seventeenth embodiment of a perforated base block of the present invention;

FIG. 17B is a plan view of two types of block units created by splitting the base block of FIG. 17A;

FIG. 17C is a perspective view of four block units created by splitting the base block of FIG. 17A;

FIG. 18A is a plan view of an eighteenth embodiment of a perforated base block of the present invention;

FIG. 18B is a plan view of one capitol component of an architectural element, the capitol component created by splitting the base block of FIG. 18A;

FIG. 18C is a perspective view of two capitol components created by splitting the base block of FIG. 18A;

FIG. 19A is a plan view of a nineteenth embodiment of a perforated base block of the present invention;

FIG. 19B is a plan view of one column component of an architectural element, the column component created by splitting the base block of FIG. 19A;

FIG. 19C is a perspective view of two column components created by splitting the base block of FIG. 19A;

FIG. 20A is a plan view of an architectural column assembled from the components of FIGS. 18C and 19C; and,

FIG. 20B is a perspective view of the architectural column of FIG. 20A.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIGS. 1A to 1C, base block 10 has a series of regularly-spaced identical perforations 11 (only one labeled) extending entirely through the base block from one side to the opposed side. The perforations have circular cross-sections. The series of perforations is arranged in a straight line A-A, along which the base block may be split by a light shock. On splitting the base block, two virtually identical standard building blocks 16,17 are produced, having textured faces 18,19, respectively. The textured faces have a consistent and reproducible uniform striated appearance as a result of the arrangement of regularly-spaced identical perforations in the base block.
Referring to FIGS. 2A to 2C, base block 20 has a series of two types of regularly-spaced perforations 21,22 (only one of each type labeled) extending entirely through the base block from one side to the opposed side. Both types of perforations have circular cross-sections, although perforations 21 have a smaller diameter than perforations 22. The series of perforations is arranged in a straight line, along which the base block may be split by a light shock. On splitting the base block, two virtually identical standard building blocks 26,27 are produced, having textured faces 28,29, respectively. The textured faces have a consistent and reproducible regular striated appearance as a result of the arrangement of regularly-spaced perforations in the base block. The textured faces have alternating shallow and deep sections as a result of the difference in diameter of the two types of perforations.
Referring to FIGS. 3A to 3C, base block 30 has a series of irregularly-spaced perforations 31 (only one labeled) of widely differing cross-sectional shapes extending entirely through the base block from one side to the opposed side. The series of perforations is arranged in a straight line, along which the base block may be split by a light shock. On splitting the base block, two virtually identical standard building blocks 36,37 are produced, having textured faces 38,39, respectively. The textured faces have a consistent and reproducible, but random, striated appearance as a result of the arrangement of irregularly-spaced perforations in the base block. Although the textured faces have a random appearance, each block has the same appearance and the appearance can be consistently reproduced in other building blocks.
Referring to FIGS. 4A to 4C, base block 40 has a series of two types of regularly-spaced perforations 41,42 (only one of each type labeled) extending entirely through the base block from one side to the opposed side. One type of perforation 41 has circular cross-sections, and the other type 42 has a rounded rectangular cross-sections. The series of perforations is arranged in a straight line, along which the base block may be split by a light shock. On splitting the base block, two virtually identical standard building blocks 46,47 are produced, having textured faces 48,49, respectively. The textured faces have a consistent and reproducible regular striated appearance as a result of the arrangement of regularly-spaced perforations in the base block. The textured faces have narrow sections as a result of perforations 41 and wide sections as a result of perforations 42.
Referring to FIGS. 5A and 5B, base block 50 has a series of regularly-spaced identical perforations 51 (only one labeled) extending entirely through the base block from one side to the opposed side. The perforations have circular cross-sections and are arranged in a manner similar to FIG. 1A. Thus, the series of perforations is arranged in a straight line, along which the base block may be split by a light shock. One half of the base block is designed to be a 3-hole brick and the other half a recess (frog) brick. On splitting the base block, 3-hole brick 56 and frog brick 57 are formed having identical textured faces 58,59 respectively. The textured faces have a consistent and reproducible uniform striated appearance as a result of the arrangement of regularly-spaced identical perforations in the base block.
Referring to FIGS. 6A to 6C, base block 60 has a series of regularly-spaced identical perforations 61 (only one labeled) extending entirely through the base block from one side to the opposed side. The perforations have circular cross-sections with a diameter of 0.25 inches. The series of perforations is arranged in a straight line along which the base block may be split by a light shock. On splitting the base block, two virtually identical skid resistant paving stones 66,67 are produced, having textured faces 68,69, respectively. The textured faces have a consistent and reproducible uniform striated appearance as a result of the arrangement of regularly-spaced identical perforations in the base block. FIG. 6C illustrates paving stones 66,67 in place together with a third paving stone 65 produced in a similar manner.
Referring to FIGS. 7A and 7B, base block 70 has a series of two types of regularly-spaced perforations 71,72 (only one of each type labeled) extending entirely through the base block from one side to the opposed side. Both types of perforations have circular cross-sections, although perforations 71 have a smaller diameter than perforations 72. The series of perforations is arranged in an arc B-B, along which the base block may be split by a light shock. On splitting the base block, two building blocks 76,77 are produced, having textured faces 78,79, respectively. The textured faces have consistent and reproducible regular striated appearances as a result of the arrangement of regularly-spaced perforations in the base block. The textured faces have alternating shallow and deep sections as a result of the difference in diameter of the two types of perforations. Textured face 78 is convex while textured face 79 is concave. When laid side-by-side as illustrated in FIG. 7B, the textured faces of blocks 76,77 create an undulating appearance. Since many such blocks may be reproduced consistently, a course of such blocks can provide a block wall having a consistent undulating appearance.
Referring to FIGS. 8A to 8C, base block 80 has four series of two types of regularly-spaced perforations 81,82 (only one of each type labeled) extending entirely through the base block from one side to the opposed side. Both types of perforations have circular cross-sections, although perforations 81 have a smaller diameter than perforations 82. Each of the four series of perforations is arranged in an arc, along which the base block may be split by a light shock. On splitting the base block, three building blocks 85,86,87 and six scrap pieces 84 are produced. Each building block is double-sided having a concave textured face 88 (only one labeled) and an opposed convex textured face 89 (only one labeled). The textured faces have consistent and reproducible regular striated appearances as a result of the arrangement of regularly-spaced perforations in the base block. The textured faces have alternating shallow and deep sections as a result of the difference in diameter of the two types of perforations. A plurality of such building blocks laid side-by-side can provide a curved block wall having a consistent appearance.
Referring to FIGS. 9A to 9C, base block 90 has two series of regularly-spaced perforations 91 (only two labeled) extending entirely through the base block from one side to the opposed side. One series of perforations starts at a first edge of the base block and is arranged in a straight line about halfway to an opposed edge of the base block. The other series of perforations starts at the opposed edge of the base block and is arranged in a straight line about halfway to the first edge. The two series of perforations are parallel to each other but are set apart by a distance. Spanning the distance between the two series of perforations is a single rectangular perforation 92 with rounded ends that is oriented perpendicular to the two series of perforations. Thus, a Z-shaped splitting path is created in the base block. On splitting the base block, two identical step blocks 96,97 are produced, each step block having two uniformly textured surfaces 98,99. As illustrated in FIG. 9C, when laid side-by-side with a third step block 95 produced in a similar manner, the step blocks provide skid-resistant stairs. Each step block is formed with cavities 94 to reduce the weight of the step blocks.
Referring to FIGS. 10A to 10C, base block 100 has a series of regularly-spaced identical perforations 101 (only one labeled) extending entirely through the base block from one side to the opposed side. The perforations have circular cross-sections. The series of perforations is arranged in a straight line along which the base block may be split by a light shock. The series of perforations is located within recess 102. On splitting the base block, two virtually identical standard building blocks 106,107 are produced, having textured faces 108,109, respectively, with joint set backs 104,105 respectively. The textured faces have a consistent and reproducible uniform striated appearance as a result of the arrangement of regularly-spaced identical perforations in the base block. The textured faces have joint set backs as a result of the recess in the base block.
Referring to FIGS. 11A to 11C, base block 110 has a series of irregularly-spaced perforations 111 (only one labeled) of widely differing cross-sectional shapes extending entirely through the base block from one side to the opposed side. The series of perforations is arranged in a straight line along which the base block may be split by a light shock. The series of perforations is located within recess 112. On splitting the base block, two virtually identical light shell blocks 116,117 are produced, having textured faces 118,119, respectively, with joint set backs 114,115 respectively. The textured faces have a consistent and reproducible, but random, striated appearance as a result of the arrangement of irregularly-spaced perforations in the base block. The textured faces have joint set backs as a result of the recess in the base block.
Referring to FIGS. 12A to 12C, base block 120 has five series of regularly-spaced identical perforations 121 (only one labeled) extending entirely through the base block from one side to the opposed side. The perforations have circular cross-sections. Each of the five series of perforations is arranged in a straight line, along which the base block may be split by a light shock. The five series of perforations are parallel to each and spaced apart equidistantly. On splitting the base block, four virtually identical double-sided standard building blocks 126 (only one shown) and two virtually identical single-sided standard building blocks 127 (only one shown) are produced. Textured faces 128,129 of the double-sided block and textured face 125 of the single-sided block are virtually identical in appearance. The textured faces have a consistent and reproducible uniform striated appearance as a result of the arrangement of regularly-spaced identical perforations in the base block. Any number of double-sided blocks may be created from a single base block by having more or fewer series of perforations.
Referring to FIGS. 13A to 13C, base block 130 has five parallel series of two types of regularly-spaced perforations 131,132 (only one of each type labeled) and one series of two types of regularly-spaced perforations 131,132 (only one of each type labeled) perpendicular to and bisecting the five parallel series. All perforations extend entirely through the base block from one side to the opposed side. One type of perforation 131 has circular cross-sections, and the other type 132 has a rounded rectangular cross-sections. Each of the six series of perforations is arranged in a straight line, along which the base block may be split by a light shock. On splitting the base block, eight virtually identical triple-sided standard building blocks 136 (only one shown) and four virtually identical double-sided standard building blocks 137 (only one shown) are produced. Textured faces 138,139 of the double-sided block are perpendicular to each other, one being a long face and the other a short face. The triple-sided block has two long textured faces 133,134 and one short textured face 135. The textured faces have a consistent and reproducible regular striated appearance as a result of the arrangement of regularly-spaced perforations in the base block. The textured faces have narrow sections as a result of perforations 131 and wide sections as a result of perforations 132.
Referring to FIGS. 14A to 14C, base block 140 is cross-shaped and has four series of irregularly-spaced perforations 141 (only one labeled) of widely differing cross-sectional shapes extending entirely through the base block from one side to the opposed side and meeting at a single large perforation 142 in the center of the base block. Each of the four series of perforations is arranged in a straight line, along which the base block may be split by a light shock. On splitting the base block, four virtually identical corner blocks 144,145,146,147 are produced, each having two textured faces, a long face 148 (only one labeled) and a short face 149 (only one labeled). The textured faces have a consistent and reproducible, but random, striated appearance as a result of the arrangement of irregularly-spaced perforations in the base block. Although the textured faces have a random appearance, each block has the same appearance and the appearance can be consistently reproduced in other building blocks. The two textured faces 148,149 are perpendicular to each other, suitable for a corner block in block wall construction.
Referring to FIGS. 15A to 15C, base block 150 is cross-shaped and has four series of irregularly-spaced perforations 151 (only one labeled) of widely differing cross-sectional shapes extending entirely through the base block from one side to the opposed side. Each of the four series of perforations is arranged in a straight line, along which the base block may be split by a light shock. Each of the four series of perforations is within recess 152 of the base block. On splitting the base block, four virtually identical light shell corner blocks 154,155,156,157 are produced, each having two textured faces, a long face 158 (only one labeled) and a short face 159 (only one labeled), and joint set back 153 (only one labeled). The textured faces have a consistent and reproducible, but random, striated appearance as a result of the arrangement of irregularly-spaced perforations in the base block. The textured faces have joint set backs as a result of the recess in the base block. Although the textured faces have a random appearance, each block has the same appearance and the appearance can be consistently reproduced in other building blocks. The two textured faces 158,159 are perpendicular to each other, suitable for a corner block in block wall construction.
Referring to FIGS. 16A to 16C, base block 160 has three series of regularly-spaced identical perforation 161 (only one labeled) extending entirely through the base block from one side to the opposed side. Each of the three series of perforations is arranged in a straight line, along which the base block may be split by a light shock. The three series meet at the center of the block at an angle of 120-degrees between each of the series. On splitting the base block, three virtually identical 120-degree corner blocks 165,166,167 and three scrap pieces 164 are produced. Each of the three corner blocks has textured faces 168,169 (only one of each labeled). The textured faces have a consistent and reproducible uniform striated appearance as a result of the arrangement of regularly-spaced identical perforations in the base block.
Referring to FIGS. 17A to 17C, base block 170 has three series of regularly-spaced identical perforation 171 (only one labeled) extending entirely through the base block from one side to the opposed side. Each of the three series of perforations is arranged in a bent line, along which the base block may be split by a light shock. The angle of the bend in each of the three series is 120-degrees. On splitting the base block, two virtually identical 120-degree double-sided corner blocks 176,177, one 120-degree single-sided concave corner block 175, one 120-degree single-sided convex corner block 174, and six scrap pieces 173 are produced. The textured faces on all of the corner blocks have a consistent and reproducible uniform striated appearance as a result of the arrangement of regularly-spaced identical perforations in the base block.
Referring to FIGS. 18A to 18C, base/capitol architectural components having bonding surfaces for construction of an architectural element may be created by splitting base block 180 along splitting path C-C comprising a series of regularly-spaced identical perforations 181 (only one labeled) extending entirely through the base block from one side to the opposed side. The perforations have circular cross-sections. The series of perforations is arranged in a straight line C-C, along which the base block may be split by a light shock. On splitting the base block, two virtually identical base/capitol architectural components 186,187 are produced, having virtually identical bonding surfaces 188,189, respectively. The textured faces have a consistent and reproducible uniform striated appearance as a result of the arrangement of regularly-spaced identical perforations in the base block.
Referring to FIGS. 19A to 19C, columnar architectural components having bonding surfaces for construction of an architectural element may be created by splitting base block 190 along three splitting paths D-D comprising three series of regularly-spaced identical perforations 191 (only one labeled) extending entirely through the base block from one side to the opposed side. The perforations have circular cross-sections. The three series of perforations are arranged in straight lines D-D, along which the base block may be split by a light shock. On splitting the base block, two virtually identical columnar architectural components 196,197 and two scrap pieces 195 (only one shown) are produced, each columnar component having two virtually identical bonding surfaces 198,199, respectively. The textured faces have a consistent and reproducible uniform striated appearance as a result of the arrangement of regularly-spaced identical perforations in the base block.
Referring to FIGS. 20A and 20B, architectural element 200 is assembled from the two columnar components 196,197 of FIG. 19C and the two base/ capitol components 186,187 of FIG. 18C.
The consistent and reproducible appearance of the textured surfaces permits matching bonding surfaces of the base/capitol components to the bonding surfaces of columnar components at interfaces 202, and matching the bonding surfaces of the two columnar surfaces at interface 203. The components are bonded together at the interfaces with an epoxy adhesive.
Other advantages which are inherent to the structure are obvious to one skilled in the art. The embodiments are described herein illustratively and are not meant to limit the scope of the invention as claimed. Variations of the foregoing embodiments will be evident to a person of ordinary skill and are intended by the inventor to be encompassed by the following claims.

Claims

1. Method of producing brick, block or paver units comprising:

providing a cementitious or stone base block having a first side, an opposed second side and a plurality of perforations, each perforation extending 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 having a cross-section consisting of from 70-50% by area of perforated regions and from 30-50% by area of unperforated regions; and,

providing a shock to the base block to split the base block along the splitting path.

2. Method of claim 1, wherein the base block is produced by molding a molding material in a mold.

3. Method of claim 2, wherein the plurality of perforations is produced by inserting elongated members into the mold before the molding material sets.

4. Method of claim 1, wherein the perforations have circular, elliptical or polygonal cross-sections or a combination thereof.

5. Method of claim 1, wherein the perforations are arranged in a straight line or a curve.

6. Method of claim 1, wherein the base block comprises more than one splitting path.

7. Method of claim 1, wherein the perforations are arranged within a recess in the base block.

8. Method of claim 7, wherein the recess has an undercut.

9. Brick, block or paver unit comprising a striated facing surface produced by the method of claim 1.

10. Cementitious or stone base block comprising a first side, an opposed second side and a plurality of perforations, each perforation extending 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 having a cross-section consisting of from 70-50% by area of perforated regions and from 30-50% by area of unperforated regions.

11. Base block of claim 10 produced by molding a molding material in a mold.

12. Base block of claim 11, wherein the plurality of perforations is produced by inserting elongated members into the mold before the molding material sets.

13. Method of providing a bonding surface on a cementitious or stone module for an architectural element comprising:

providing a shock to the base block to split the base block along the splitting path to produce a first module having a facing surface with a bonding surface that corresponds to a bonding surface on a second module.

14. Method of constructing an architectural element comprising: providing first and second cementitious or stone modules having corresponding bonding surfaces produced by the method of claim 13; bringing the first and second modules together to form an interface between the bonding surfaces of the first and second modules; and bonding the first module to the second module at the interface to form the architectural element.

15. Method of claim 14, wherein the first and second modules are bound together with an adhesive.

16. Architectural element produced by the method of claim 14.