Z-Shaped Building Materials

Abstract

A z-shaped building material includes a base defining a z-shape configuration and at least one break-line disposed on an exterior surface of the base such that a geometric pattern of the z-shaped building materials creates a three-dimensional visual appearance. A reveal is disposed around an outer periphery of the base for receiving mortar to join together adjacent building materials. The base is formed from a material selected from the group consisting of clay, clay and straw, clay-bearing soil, sand and lime, cement, concrete and mixtures thereof. The z-shaped building material may be a masonry brick having a dimension of about eight inches in a height direction and a dimension of about eight inches in a width direction. The z-shaped building material may be a face brick having a dimension of about eight inches in a height direction and a dimension of about eleven and five-eighths inches in a width direction.

Description

CROSS-REFERENCE To RELATED APPLICATION

This U.S. non-provisional patent application claims benefit of the priority of the filing date of U.S. provisional patent Application No. 63/031,072 filed on May 28, 2020.

FIELD OF THE INVENTION

This invention relates generally to building materials, such as construction and landscaping materials, and more particularly, to building materials that are z-shaped. In an advantageous exemplary embodiment, the invention is a masonry construction product having a z-shape.

BACKGROUND OF THE INVENTION

Bricks and pavers have long been used for construction and landscaping. Fired bricks, also known as artificial stone, have been around since at least about 4000 BC. Historically, bricks were composed of clay, or clay and straw. Contemporary bricks are made from clay-bearing soil, sand and lime, cement or concrete materials. The term “bricks” commonly refers to units of building materials that are joined together by mortar, adhesive or interlocking features.

Bricks are used as building materials to make walls, pavements and other masonry structures. For purposes of convenience in manufacturing and consistency in configuration, bricks are typically formed in cuboid blocks having an elongated rectangular shape. The rectangular shape allows bricks to be assembled in horizontal linear rows, generally referred to as courses. Courses of bricks are laid one upon the other to form a vertical wall of a structure. The courses may be staggered relative to adjacent courses in order to better distribute the force of vertical loads, as well as to produce an aesthetic visual appearance. Bricks of varying colors and textures may also be used to provide a further aesthetic appearance.

For centuries the rectangular shape of conventional bricks has served standard construction and landscaping well. However, laying courses of rectangular bricks is labor intensive and time consuming, particularly when the bricks are of a relatively small size. Furthermore, it is often desirable in contemporary building construction to create an aesthetic visual effect, such as an accent wall, by arranging the bricks in a geometric pattern other than horizontal rows. It is even more labor intensive and time consuming, and thus even more costly, to arrange rectangular bricks in a geometric pattern other than horizontal courses.

It is therefore apparent a need exists for a building material that overcomes the known deficiencies of rectangular bricks. A particular need exists for a building material that is less labor intensive and time consuming to use when constructing a vertical wall of a structure. The building material needs to provide at least the same, if not superior, capacity to distribute the force of vertical loads. The building material further needs to produce a desirable aesthetic appearance when the building material is arranged in a geometric pattern other than horizontal courses. It is desirable that the building material is in the form of bricks having a shape other than rectangular that is made from conventional material and in various colors and textures.

Certain aspects, objects, features and advantages of the present invention will be made apparent, or will be readily understood and appreciated by those skilled in the relevant art, as exemplary embodiments of the invention shown in the accompanying drawing figures are described in greater detail hereinafter. It is intended that all such aspects, objects, features and advantages of the invention envisioned by this disclosure of exemplary embodiments be encompassed by the scope of protection of the appended claims, given their broadest reasonable interpretation and construction in view of the prior art. These aspects, objects, features and advantages of the invention, as well as others not expressly disclosed, may be accomplished by any of the exemplary embodiments described herein and illustrated in the accompanying drawings. However, it should be appreciated that the drawing figures are for illustrative purposes only, and that many modifications, changes, revisions and substitutions may be made to any of the exemplary embodiments without departing from the general concepts of the invention as they may be broadly construed and interpreted.

BRIEF DESCRIPTION OF THE DRAWINGS

The aforementioned aspects, objects, features and advantages of the present invention will be more fully understood and appreciated when considered in conjunction with the accompanying drawing figures, in which like reference characters designate the same or similar parts throughout the several views.

FIG. 1 is a front elevation view showing a typical layout of conventional bricks according to the prior art.

FIG. 2 is a front elevation view showing a typical layout of z-shaped building materials according to the present invention.

FIG. 3 is a front elevation view of a typical z-shaped building material according to a first exemplary embodiment of the present invention.

FIG. 4 is a front elevation view of a typical z-shaped building material according to a second exemplary embodiment of the present invention.

FIG. 5 shows various views of the z-shaped building material shown in FIG. 4.

FIG. 6 is a front elevation view of a building constructed with conventional bricks and z-shaped building materials according to the present invention illustrating an aesthetic visual appearance produced by the geometric pattern of the z-shaped building materials.

FIG. 7 is a front elevation view of a monument constructed with conventional bricks and z-shaped building materials according to the present invention illustrating an aesthetic visual appearance produced by the geometric pattern of the z-shaped building materials.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The following is a detailed description of one or more exemplary embodiments of z-shaped building materials formed in accordance with the present invention. Each exemplary embodiment is described more fully hereinafter with reference to the accompanying drawing figures. In each exemplary embodiment shown and described herein, the z-shaped building material is useful for construction and landscaping. In particular, z-shaped building materials according to the invention are useful for replacing conventional bricks and pavers in construction and landscaping projects.

The z-shaped building materials may be made of any suitable material that is formable into the desired “z” shape, while retaining sufficient strength and stiffness for use in the construction of a vertical wall of a structure. Preferably, but not necessarily, the z-shaped building material is made of the same or similar materials as conventional bricks and pavers. By way of example and not limitation, the z-shaped building material may be made of clay, clay and straw, clay-bearing soil, sand and lime, cement or concrete materials, or mixtures thereof. The z-shaped building material may also be made in any suitable color or texture to produce a desirable aesthetic effect.

In a particularly advantageous embodiment, the z-shaped building material is a masonry construction product. In the exemplary embodiments described herein and illustrated by the accompanying drawing figures, the z-shaped building material is a brick useable for construction in the same manner as a conventional brick or useable for landscaping in the same manner as a conventional brick or paver. The z-shaped brick may be in the form of solid masonry wherein the brick supports the building structure. Alternatively, the z-shaped brick may be in the form of brick veneer wherein the building structure, for example an underlying wood or metal frame, or concrete wall, supports the brick veneer. The primary difference between the z-shaped brick, also referred to herein as “masonry brick,” and the z-shaped brick veneer, also referred to herein as “face brick,” is the greater thickness in the depth direction of the masonry brick relative to the face brick.

FIG. 1 is a front elevation view showing a typical layout of conventional bricks 10 historically used in construction and landscaping. The generally rectangular bricks 10 are arranged in a pattern of horizontal rows, generally referred to as courses 12. The courses 12 of bricks 10 may be staggered relative to adjacent courses 12 in order to provide greater strength and stability by better distributing the force of vertical loads. The staggered courses 12 of bricks 10 also serve to produce a more aesthetic visual appearance to a vertical wall of a structure. The bricks 10 may also be of varying colors or textures to provide a further aesthetic appearance. The bricks 10 may be of any desired height, width and depth (thickness) dimensions suitable for a particular construction or landscaping application.

FIG. 2 is a front elevation view showing a typical layout of z-shaped building materials 20 according to the present invention. The z-shaped building materials 20 depicted in FIG. 2 may, for example, be in the form of masonry brick or face brick. Regardless, the z-shaped building materials 20 are arranged in a pattern 22 that produces an aesthetic visual appearance. In particular, the pattern 22 produces a perception that a vertical wall of a structure is three-dimensional when viewed by a person from a sufficient distance. Thus, z-shaped building materials 20 produce a three-dimensional illusion or effect on the vertical wall of the structure that provides an aesthetic visual appearance. At the same time, the z-shaped building materials 20 provide at least the same or superior distribution of the force of vertical loads on the vertical wall of the structure, as will be explained in greater detail hereinafter. If desired, the z-shaped building materials 20 may also be of varying colors or textures to provide a further aesthetic appearance.

FIG. 3 is a front elevation view of a typical z-shaped building material 30 according to a first exemplary embodiment of the present invention. The z-shaped building material 30 is in the form of a masonry construction product (e.g. masonry brick or face brick) or a landscaping paver. For purposes of illustration only, the exemplary embodiment depicted in FIG. 3 is a z-shaped masonry brick 30. The z-shaped masonry brick 30 may have any dimensions suitable for a particular building construction or landscaping application. As shown herein in a particularly advantageous example, the z-shaped masonry brick 30 has a dimension of about eight inches (8″) in a height direction H, and an overall dimension of about eight inches (8″) in a width direction W. However, the masonry brick 30 may have a dimension between about eight inches (8″) and about twelve inches (12″) in the height direction H. The masonry brick 30 generally has a dimension of between about two inches (2″) and about four inches (4″) in a depth or thickness direction T (see FIG. 5). Regardless, the dimensions of the masonry brick 30 allow it to be used seamlessly in conjunction with standard rectangular bricks 10 to provide a further unique aesthetic visual appearance. The z-shape of the masonry brick 30 provides more resting points on a vertical wall of a structure, and consequently, results in a stronger vertical rise than bricks 10.

As shown herein, the masonry brick 30 has a beveled edge, also referred to herein as a reveal 32, around its entire outer periphery for receiving mortar to join adjacent masonry bricks 30. The reveal 32 extends inwardly in the thickness direction T from the exterior surface of the masonry brick 30 along the outer periphery of the masonry brick 30. Reveal 32 may have any suitable dimension, or extent, in the corresponding height direction H or the corresponding width direction W, as applicable. In a particular example, however, the extent of the reveal 32 is about one-half inch (½″). Regardless, the reveal 32 creates an aesthetic deeper rolled appearance on the exterior surface of the masonry brick 30. As shown herein, the masonry brick 30 is further provided with an indented break-line 34 having an extent of about one-quarter inch (¼″) to about one-half inch (½″). The break-line 34 on the exterior surface of the masonry brick 30 creates a subtle three-dimensional illusion or effect when viewed by a person from a suitable distance. In addition, the break-line 34 leaves a clean and even break when a portion of the masonry brick 30 is broken off to conform to the geometry of the construction or landscaping application.

FIG. 4 is a front elevation view of a typical z-shaped building material 40 according to a second exemplary embodiment of the present invention. The z-shaped building material 40 is likewise in the form of a masonry construction product or landscaping paver. However, the exemplary embodiment depicted in FIG. 4 in contrast is a z-shaped face brick 40. The z-shaped face brick 40 may have any dimensions suitable for building construction or landscaping. As shown herein in a particularly advantageous example, the z-shaped face brick 40 has a dimension of about eight inches (8″) in a height direction H, and an overall dimension of about eleven and five-eighths inches (11⅝″) in a width direction W. However, the face brick 40 may have a dimension between about eight inches (8″) and about twelve inches (12″) in the height direction H. The face brick 40 generally has a dimension of between about one-half inch (½″) and about two inches (2″) in a thickness direction T (see FIG. 5). Regardless, the dimensions of the face brick 40 allow it to be used seamlessly in conjunction with standard rectangular bricks 10 to provide a further unique aesthetic visual appearance. The z-shape of the face brick 40 provides more resting points on a vertical wall of a structure, and consequently, results in a stronger vertical rise than bricks 10.

As shown herein, the face brick 40 has a beveled edge, also referred to herein as a reveal 42, around its entire outer periphery for receiving mortar to join adjacent face bricks 40. The reveal 42 extends inwardly in the thickness direction T from the exterior surface of the face brick 40 along the outer periphery of the face brick 40. The reveal 42 may have any suitable dimension, or extent, in the corresponding height direction H or the corresponding width direction W, as applicable. In a particular example, however, the extent of the reveal 42 is about one-half inch (½″). Regardless, the reveal 42 creates an aesthetic deeper rolled appearance on the exterior surface of the face brick 40. As shown herein, the face brick 40 is further provided with an indented break-line 44 having an extent of from about one-quarter inch (¼″) to about one-half inch (½″). The break-line 44 on the exterior surface of the face brick 40 creates a subtle three-dimensional illusion or effect when viewed by a person from a suitable distance. In addition, the break-line 44 leaves a clean and even break when a portion of the face brick 40 is broken off to conform to the geometry of the construction or landscaping application.

FIG. 5 shows various views of the z-shaped face brick 40 shown in FIG. 4. The various views include a front elevation view, a left-hand side elevation view, a right-hand side elevation view, and a top plan view that illustrate additional details of a typical face brick 40. In the illustrated embodiment, the face brick 40 optionally includes mechanical retention grooves 46 formed on the interior surface of the rear of the face brick 40. The retention grooves 46 ensure that the relatively thin face bricks 40 remain firmly adhered to a vertical wall of a structure. The optional retention grooves 46 preferably have an extent of between about one-half inch (½″) and about one inch (1″) in the thickness direction T.

FIG. 6 is a front elevation view of a building 50 constructed with z-shaped building materials 20 according to the present invention. FIG. 7 is a front elevation view of a monument structure 60 constructed with z-shaped building materials 20 according to the present invention. The elevation of the building 50 and the monument structure 60 each illustrate an aesthetic visual appearance produced by the geometric pattern of the z-shaped building materials 20. If desired, the building 50 or the monument structure 60 may be constructed using the z-shaped building materials 20 in conjunction with conventional bricks 10 to further the unique aesthetic appearance of the building 50 or monument structure 60. The conventional bricks 10 may be modular and of a standard size suitable for construction with the z-shaped building materials 20.

In view of the foregoing detailed description and the accompanying drawing figures, it will be apparent to those skilled in the art that the z-shaped building materials 20 of the present invention provide a novel and non-obvious masonry construction and landscaping product. The z-shaped building materials 20 and indented break-lines 34, 44 create an aesthetic visual appearance, and in particular, a three-dimensional illusion or effect when a vertical wall of a structure is viewed by a person from a sufficient distance. The structural integrity and strength of the z-shaped building materials 20 equals or exceeds that of conventional bricks 10 and traditional construction methods. Specifically, z-shaped building materials 20 according to the invention provide more resting points for a stronger vertical rise, while reducing material waste. The unique interlocking design of the z-shaped building materials 20 along with strategically-placed mechanical retention grooves 46 ensures that a vertical wall of a structure remains firmly adhered to the structure.

The z-shaped building materials 20 of the present invention provide a versatile product that has any number of construction and landscaping uses. In addition to masonry wall construction for residential and commercial buildings and other structures, the z-shaped building materials 20 may be used as pavers to create herringbone design interior floors, pavements, walkways, driveways and patios. The z-shaped building materials 20 may also be used to create hardscape areas around pools and spas, as well as landscape retaining walls and features, such as vertical waterfall structures. Finally, z-shaped building materials 20 according to the present invention can be manufactured from the same materials, in the same colors and textures, and in the same manner as conventional bricks 10 using a specialized mold configured to produce the unique z-shape of the modular z-shaped building materials 20.

Regardless of the foregoing detailed description of exemplary embodiments of the invention, the optimum configuration of the article of manufacture, apparatus, device or system, and the manner of use, operation and steps of the associated methods, as well as reasonable equivalents thereof, are deemed to be readily apparent and understood by those skilled in the art. Accordingly, equivalent relationships to those shown in the accompanying drawing figures and described in the written description are intended to be encompassed by the present invention given the broadest reasonable interpretation and construction of the appended claims, the foregoing being considered as illustrative only of the general concept and principles of the invention(s). Furthermore, as numerous modifications and changes will readily occur to those skilled in the art, the exemplary embodiments are not intended to limit the invention to the specific configuration, construction, materials, manner of use and operation shown and described herein. Instead, all reasonably predictable and suitable equivalents and obvious modifications to the invention should be construed as falling within the scope of the invention as defined by the appended claims given their broadest reasonable interpretation and construction as would be understood by those skilled in the art in light of the foregoing written description and accompanying drawing figures in view of the relevant prior art.

Claims

1. A z-shaped building material, comprising:

a base defining a z-shape configuration; and

at least one break-line disposed on an exterior surface of the base;

wherein a geometric pattern formed by a plurality of the z-shaped building materials creates an aesthetic three-dimensional visual appearance.

2. The z-shaped building material according to claim 1, further comprising a reveal disposed around at least a portion of an outer periphery of the base.

3. The z-shaped building according to claim 1, wherein the base is formed from a material selected from the group consisting of clay, clay and straw, clay-bearing soil, sand and lime, cement, concrete and mixtures thereof.

4. The z-shaped building material according to claim 1, wherein the z-shaped building material is a masonry brick having a dimension of about eight inches (8″) in a height direction and a dimension of about eight inches (8″) in a width direction.

5. The z-shaped building material according to claim 1, wherein the z-shaped building material is a face brick having a dimension of about eight inches (8″) in a height direction and a dimension of about eleven and five-eighths inches (11⅝″) in a width direction.

6. The z-shaped building material according to claim 1, wherein the z-shaped building material has a dimension of between about eight inches (8″) and about twelve inches (12″) in a height direction, and/or wherein the z-shaped building material has a dimension of between about eight inches (8″) and about eleven and five-eighths inches (11⅝″) in a width direction.

7. A z-shaped building material for construction and landscaping, comprising:

a base defining a z-shape configuration having an overall dimension of about eight inches (8″) in a height direction and a dimension of between about eight inches (8″) and about twelve inches (12″) in a width direction;

at least one break-line disposed on an exterior surface of the base; and

a reveal extending around at least a portion of an outer periphery of the base.

8. The z-shaped building material according to claim 7, wherein a geometric pattern formed by a plurality of the z-shaped building materials creates a three-dimensional visual appearance.

9. The z-shaped building material according to claim 7, wherein the base is formed from a material selected from the group consisting of clay, clay and straw, clay-bearing soil, sand and lime, cement, concrete and mixtures thereof.

10. The z-shaped building material according to claim 7, wherein the z-shaped building material is a masonry brick.

11. The z-shaped building material according to claim 7, wherein the z-shaped building material is a face brick.

12. The z-shaped building material according to claim 7, wherein an extent of the at least one break-line is from about one-quarter inch (¼″) to about one-half inch (½″).

13. The z-shaped building material according to claim 7, wherein an extent of the reveal is about one-half inch (½″).

14. The z-shaped building material according to claim 7, further comprising at least one retention groove formed on an interior surface of the rear of the base.

15. The z-shaped building material according to claim 14, wherein an extent of the at least one retention groove is between about one-half inch (½″) and about one inch (1″).

16. The z-shaped building material according to claim 8, wherein the geometric pattern creates a three-dimensional visual appearance on a building.

17. The z-shaped building material according to claim 8, wherein the geometric pattern creates a three-dimensional visual appearance on a monument structure.