Simulated brick product

Abstract

A simulated product comprised of a piece of wood having upper and lower surfaces, the upper surface having a plurality of indentations formed therein, and a finishing coating on the upper surface, the finishing coating having a colour to resemble a brick material. A molding of a simulated concrete material may be placed intermediate adjacent brick products.

Description

FIELD OF THE INVENTION

The present invention relates to a construction product and particularly, relates to a simulated brick product and a method for forming such a simulated brick product.

BACKGROUND OF THE INVENTION

One of the basic construction materials is brick which is used both interiorly and exteriorly. In particular, brick is frequently used interiorly for walls and around fireplaces for its aesthetic effect. However, one of the disadvantages of brick is that it is a relatively dense material and thus, adequate support must be provided for a wall formed of bricks. Furthermore, the laying of bricks is a skill generally beyond the reach of most do-it-yourselfers and accordingly, the building of walls having a brick appearance can be fairly expensive when done by a skilled brick layer.

In order to overcome the above disadvantages, it has been suggested in the prior art that simulated brick products might be used. Generally, the prior art has attempted to take panels and treat them in a manner which produces the desired brick appearance. This is an approach taken in the teachings of U.S. Pat. Nos. 3,882,218 and 3,621,625. Generally, the materials which have been used are ceramic or plastic materials though cork has also been suggested as a possible base material.

One unique approach is that shown in U.S. Pat. No. 4,313,775. The patentee teaches the provision of a simulated brick decorative surface which is formed from specially shaped and cut sections of wood. In particular, the patentee teaches that the wood sections are cut across the grain preferably in an angle of 90° resulting in a rigid, yet flexible thin piece of wood which gives the appearance of being one edge of a brick.

While the above approaches can provide a product which simulates a brick wall, there is still the need for a product and a process for simulating bricks.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a simulated brick product and a method of producing the same.

It is a further object of the present invention to provide a simulated product which may be installed by an average do-it-yourselfer.

It is a still further object of the present invention to provide a simulated product and a method of producing the same wherein the product is light weight and easy to handle.

According to one aspect of the present invention, there is provided a simulated brick product comprising a piece of a wood material having upper and lower surfaces, the upper surface having a plurality of indentations formed therein, and a finishing coating on the upper surface, the finishing coating having a colour to resemble a brick material.

According to a further aspect of the present invention, there is provided a floor comprising a sub-floor, a plurality of simulated brick pieces, each of the brick pieces comprising a piece of a wood material having upper and lower surfaces, the upper surface having a plurality of indentations formed therein, and a finishing coating on the upper surface, the finishing coating being of a colour to simulate a brick product.

In a still further aspect of the present invention, there is provided a method of covering a surface to resemble a brick surface, the method comprising the steps of supplying a simulated brick product comprising a piece of wood material having upper and lower surfaces, the upper surface having a plurality of indentations formed therein, and a finish coating on the upper surface, the finish coating having a colour to resemble a brick material, adhering the simulated brick product in a plurality of rows to a substrate, and installing a molding intermediate the simulated brick product, the molding having an outer facing surface of simulated concrete.

The simulated brick product of the present invention may be formed of any suitable size and configuration. Thus, traditionally, a brick will generally have a side wall dimensions with a length of between 20 cm and 30 cm and a “height” of between 5 cm and 10 cm. In order to simulate the traditional brick product, the dimensions of the simulated product will preferably fall within these ranges though other dimensions could equally well be employed.

The wood material which is utilized is any one which is capable of having recesses formed on a surface thereof. Thus, the wood material may either be any suitable hard or soft wood or alternatively, may be selected from engineered wood products such as plywoods and/or composite wood materials.

As aforementioned, the simulated wood product has a plurality of recesses formed in the display side thereof. Preferably, these recesses are arranged to provide a random look and not the repeat look that characterizes many simulated products. This can be achieved by running the wood product between two rollers, one of which is designed to create the recesses therein. A random look can be achieved by proper sizing of the roller and location of the protruding portions forming the recesses. Thus, proper selection of the parameters will ensure that two bricks sequentially running through the apparatus will usually have at least a slightly different appearance.

The surface having the recesses formed therein is then preferably provided with a surface coating which will simulate the appearance of a brick. As bricks can vary enormously in appearance, many different types of coatings may be utilized and such coatings are known to those skilled in the art.

The simulated brick products may be provided with means for securing the same together such as a mortice or a tenon arrangement. Alternatively, a molding or a similar device may be utilized between the individual simulated brick products to help simulate the concrete usually utilized therein. The molding simulating the concrete may be formed of any suitable material and may be secured in place by any suitable means. Thus, in one embodiment, the molding may be secured by means of the mortice and tenon arrangement or alternatively, may be adhesively secured either to a substrate (to which the simulated brick product is also secured) or alternatively, the molding may be adhesively secured to the simulated brick product.

The method of the present invention, as previously set forth, includes the step of forming the recesses in the wood product. Though this can be provided by many means such as stamping and the like; in a preferred embodiment the wood product passes along such that a roller having projections thereon leaves an impression or recesses on one surface of the wood. The projections are preferably irregularly spaced on the roller and also may have varying depths including a variation in the depth formed from a single projection.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus generally described the present invention, reference will be made to the accompanying drawings illustrating an embodiment thereof, in which:

FIG. 1 is a top plan view of a plurality of simulated bricks;

FIG. 2 is a perspective view of a plurality of simulated bricks;

FIG. 3 is an enlarged view of two simulated brick products in an abutting relationship;

FIG. 4 is a perspective view of the rear portion of one embodiment of a simulated brick product;

FIG. 5a is a side elevational view of the simulated brick products of FIG. 3;

FIG. 5b is a side elevational view of the simulated brick products of FIG. 3 utilizing a molding therebetween;

FIG. 6 is a side elevational view of a simulated brick product;

FIG. 7 is a side elevational view illustrating placement of simulated brick products on a substrate; and

FIG. 8 is a perspective view of an apparatus for producing simulated brick products.

DETAILED DESCRIPTIONS OF THE DRAWINGS

Referring to the drawings in greater detail and by reference characters thereto, there is illustrated a simulated brock product which is generally designated by reference numeral 10.

Simulated brick product 10 is an overall rectangular configuration having opposed sides 12, 14 and opposed ends 16, 18. Naturally, it will be understood that other configurations may be employed as is done in the case of conventional brick products or another similar products. Thus, the simulated brick product 10 could have a rectangular configuration, oval configuration, circular configuration, etc.

Simulated brick product 10 has an upper surface 20 wherein a plurality of irregularly shaped recesses 22 are formed. Recesses 22 are irregular in configuration and although they are repeated, they are sufficiently irregular that identification of a particular pattern is difficult.

In one embodiment, and similar to the conventional wood floor, there may be provided a tenon 24 on side 12 and a mortise 26 on side 14. Even further if desired, a similar tenon and mortise arrangement may be used on ends 16, 18.

In one embodiment, a lower surface of simulated brick product 10 is provided with a pressure sensitive adhesive 28 covered by a release paper backing 30. Thus, the product may easily be applied to a substrate by the end user merely by removing the paper backing 30.

In an exterior application, the simulated brick product 10 may be applied to a wall 32. As is known in the art, an adhesive 34 may be applied to wall 32 by means of an applicator 36.

As shown in FIG. 5b, a molding 41 may be placed between adjacent simulated brick products 10. In the embodiment as shown, molding 41 has a tenon and mortise arrangement tied in with those of the adjacent products. Alternatively, in an embodiment such as in FIG. 5a, a strip of molding may be adhesively secured in the portion between the side walls of brick products 10.

As shown in FIG. 8, there may be provided an apparatus generally designated by reference numeral 40 for use in manufacturing of simulated brick product 10. Apparatus 40 includes a base 42 having a plurality of shafts 44 mounted thereon. A pair of blocks 46 extend between a pair of shafts 44 while an upper member 48 is mounted on the top of shafts 44.

Mounted between blocks 46 and rotatably journalled therein is a roller 50 having a drive shaft 52 connected thereto. Drive shaft 52 is suitably driven by a motor (not shown). An upper wheel 54 is mounted to a shaft 56 which is screw threadably engaged with upper member 48. A block 58 is secured to blocks 46 to raise or lower the same. Roller 50 is provided with outwardly extending protrusions to form the desired pattern on a wood product passing therethrough.

It will be understood that the above described embodiment is for purposes of illustration only and that changes and modifications may be made thereto without departing from the spirit and scope of the invention.

Claims

1. A simulated brick product comprising:

a piece of a wood material having upper and lower surfaces;

said upper surface having a plurality of indentations formed therein; and

a finishing coating on said upper surface, said finishing coating having a colour to resemble a brick material.

2. The simulated brick product of claim 1 wherein said piece of a wood material is rectangular in configuration.

3. The simulated brick product of claim 2 wherein said piece of a wood material has a thickness of between 30 mm and 120 mm.

4. The simulated brick product of claim 1 wherein said wood material is a natural hard wood.

5. The simulated brick product of claim 1 wherein said piece of wood material has a length of between 20 cm and 30 cm.

6. The simulated brick product of claim 5 wherein said piece of wood material has a height of between 5 cm and 10 cm.

7. The simulated brick product of claim 3 further including an adhesive coating on said lower surface, said adhesive coating being covered by a release paper.

8. A floor comprising:

a sub-floor, a plurality of simulated brick pieces, each of said brick pieces comprising a piece of a wood material having upper and lower surfaces, said upper surface having a plurality of indentations formed therein, and a finishing coating on said upper surface, said finishing coating being of a colour to simulate a brick product.

9. The floor of claim 1 further including a molding intermediate at least some of said brick pieces, said molding having a simulated concrete surface.

10. A method of covering a surface to resemble a brick surface, the method comprising the steps of supplying a simulated brick product comprising a piece of wood material having upper and lower surfaces, said upper surface having a plurality of indentations formed therein, and a finish coating on said upper surface, said finish coating having a colour to resemble a brick material;

adhering said simulated brick product in a plurality of rows to a substrate; and

installing a molding intermediate said simulated brick product, said molding having an outer facing surface of simulated concrete.