BRICK WITH INTERNAL SUPPORT STRUCTURE

Abstract

Shown and described herein are various embodiments for a brick having one or more honeycomb assemblies encased within a concrete encasement, each of said honeycomb assemblies having a top plate, a bottom plate spaced apart from and parallel to the top plate, and a honeycomb layer positioned between the top plate and the bottom plate. The brick may also have a side rib extending outwardly from a first end of the brick and a side notch sized to accept the side rib and placed on an opposing second end of the brick. Some embodiments may also have a top rib extending upwardly from a top surface of the brick and a bottom notch sized to accept the top rib and placed on a bottom surface of the brick

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to co-pending U.S. Provisional Application No. 63/524,766 filed on Jul. 5, 2023, which is herein incorporated by reference in its entirety.

BACKGROUND

Bricks are commonly used to construct exterior and interior walls, retaining walls for landscaping, and enclosures. Bricks are also used as veneers on the outside of buildings which do not necessarily require structural support and heavy loads but are instead just for aesthetics. Generally speaking, known bricks are heavy, do not provide much thermal insulation, and require several steps to complete their installation, typically requiring mortar and other additives to install.

FIELD OF THE INVENTION

The embodiments herein provide an improved brick that can be used in the construction of various different structures to provide a number of new benefits.

BRIEF DESCRIPTION OF THE DRAWINGS

These drawings illustrate certain aspects of some of the embodiments of the present disclosure and should not be used to limit or define the systems, assemblies, and methods herein.

FIG. 1 is a front perspective view of an exemplary brick, according to one or more embodiments, and showing the location of section plane A-A;

FIG. 2 is a cross-sectional view of the embodiment of the brick shown in FIG. 1, taken along the section plane A-A;

FIG. 3 is a cross-sectional view of another embodiment of the brick, taken along the section plane A-A;

FIG. 4 is a front perspective view of a portion of a wall comprised of exemplary bricks, according to one or more embodiments, and showing the location of the section plane B-B;

FIG. 5 is a cross-sectional view of two bricks from the wall shown in FIG. 4, taken along the section plane B-B; and

FIG. 6 is a front perspective view of a portion of a wall comprised of exemplary bricks as well as a cap, according to one or more embodiments;

FIG. 7 is a front perspective view of an embodiment of the honeycomb assembly, according to one or more embodiments and showing the location of Detail A;

FIG. 8 is a detailed perspective view of Detail A shown in FIG. 7; and

FIG. 9 is a top perspective view of a portion of a wall comprised of exemplary bricks as well as a cap, according to one or more embodiments.

FIG. 10 is a top perspective view of a honeycomb layer, according to one or more embodiments.

DETAILED DESCRIPTION

The present disclosure provides a number of different embodiments of a brick having a hollow center that is filled with a honeycomb material. The bricks may contain corresponding features like ribs and notches which interlock to connect the bricks together. Some embodiments of the brick may contain a pipe slot placed within the notch or rib (or both) to allow a pipe to pass through the wall created by the bricks, in a direction that is parallel to the wall itself. Caps with corresponding grooves can be used to cap the top of a wall containing an embodiment of the bricks, where the caps can be assembled using a cap slot that joins with a rib that may be placed along the top surface of the brick.

• • 10 brick
  • 18 central axis of the brick
  • 15 top rib
  • 20 bottom notch
  • 30 concrete encasement
  • 48 honeycomb assembly
  • 55 side rib
  • 60 side notch
  • 100 top plate
  • 105 bottom plate
  • 110 honeycomb layer
  • 115 tubular cavity
  • 120 central axis of tube
  • 200 cap
  • 205 central axis of cap
  • 210 cap notch
  • 250 pipe slot
  • 260 pipe

FIG. 1 is a front perspective view of an exemplary brick 10 having an exterior concrete encasement 30 with a hollow center and a top rib 15 running horizontally along the top side of the brick 10 and here along the central axis (although not required). In this embodiment, a side rib 55 is also used which runs vertically along an end of the brick 10, here until connecting with the top rib 15. In some embodiments, the top rib 15 may extend to connect with the side rib 55 at a substantially right angle (approx. 90 degrees between the side rib 55 and the top rib 15). The top rib 15 may comprises a strip of the concrete encasement 30 which extends upwardly or vertically. The two components may join together so that they create a ridge that is extended away from the main body of the brick 10. Both ribs 15 and 55 may comprise a raised section of the brick 10 which is essentially rectangular in shape and should be shaped to be accepted into a side notch 60 (shown and described more below). The concrete encasement 30 preferably covers the entire exterior of the brick 10 so that each surface on the exterior of the brick may be comprised of concrete. Section plane A-A is shown cutting vertically down through the brick 10.

FIG. 2 is a cross-sectional view of the embodiment of the brick 10, showing one embodiment for filling the hollow center of the concrete encasement 30 with a honeycomb assembly 48. In this embodiment, there are two layers of honeycomb assemblies 48 used, but the number of layers of honeycomb assemblies 48 can vary. While here there are several layers of the honeycomb assembly 48 used but it should be noted that any number of layers of honeycomb assemblies 48 can be used with the embodiments herein.

In this embodiment, a bottom notch 20 may run horizontally along the bottom side of the brick 10 and aligned with the central axis of the brick 10, i.e. runs mostly down the middle of the bottom surface. Preferably, the bottom notch 20 has a rectangular shape and/or “U” shape which aligns with the same rectangular shape and/or “U” shape of the top rib 15. The honeycomb assembly 48 may comprise its own individual layers, including a mostly flat and planar bottom plate 105 separated from a mostly flat and planar top plate 100 with a honeycomb layer 110 placed in between these two plates 100/105. Preferably the two plates 100/105 are positioned horizontally.

FIG. 3 is a cross-sectional view of another embodiment of the brick 10, taken along the section plane A-A where in this embodiment the concrete encasement 30 has a mostly rectangular shape with no ribs or notches (here the brick 10 has a smooth exterior surface that is mostly flat and planar). Also note in this embodiment three layers of the honeycomb assembly 48 are used, each layer having the same individual layers as the previous embodiment, including a mostly flat and planar bottom plate 105 separated from a mostly flat and planar top plate 100 with a honeycomb layer 110 placed in between these two plates 100/105.

FIG. 4 is a front perspective view of a portion of a wall comprised of exemplary bricks 10, according to one or more embodiments, and showing the location of the section plane B-B cutting vertically down the center of two bricks 10. On the ends of each brick 10 may be either the side rib 55 or side notch 60, such that each brick 10 that is adjacent to each other can be joined at the side by interlocking the rib 55 within the notch 60. In other words, for this embodiment each brick 10 may have a first and second end with the first end having the side notch 60 and the opposing second end having a corresponding side rib 55. Both the side ribs 55 and the side notches 60 may be oriented vertically and may be directly in the center or near the central axis 18 of the brick 10.

FIG. 5 is a cross-sectional view of two bricks 10 from the wall shown in FIG. 4, where the interlocking between the top rib 15 and bottom notch 20 can be observed for this embodiment. The bottom notch 20 of the top brick 10 is preferable shaped to interlock with the top rib 15 of the bottom brick 10.

FIG. 6 is a front perspective view of a portion of a wall comprised of exemplary bricks 10 as well as a cap 200, according to one or more embodiments. The cap 200 may be elongate pieces of concrete having a rounded top surface and a bottom notch 210 running along the bottom surface. The bottom notch 210 of the cap 200 is similar to the bottom notch 20 of the brick 10, it should be shaped similar to the top rib 15 so that the top rib 15 can interlock with the bottom notch 210 of the cap 200.

FIG. 7 is a front perspective view of an embodiment of the honeycomb assembly 48 where the various individual layers are shown in detail. When aligned atop of one another, the top plate 100 of the bottom honeycomb assembly 48 layer would be adjacent to and in contact with the bottom plate 105 of the top honeycomb assembly 48 layer. Detail A is shown where further information on the honeycomb is provided below.

FIG. 8 is a detailed perspective view of the embodiment of the honeycomb assembly 48 shown in FIG. 7 is shown in further detail. In this embodiment, the honeycomb layer 110 comprises a series of tubular cavities 115, each having a central axis 120 that is aligned with each of the other axes 115 of the other cavities 115. Stated differently, each of the central axes 115 should be substantially vertical and they may each be parallel with one another. In some embodiments, the central axis 120 may be plus or minus 5-10 degrees from being perfectly vertical due to constraints with manufacturing and materials some tolerances could be more difficult. Each cavity 115 preferably has the same cross-sectional shape, but no specific shape is required. In the example provided in FIG. 8, the cavities 115 have a hexagonal cross-section but other shapes can be used such as ovals, squares, circles, trapezoids, parallelograms, rectangles, and similar. Each cavity 115 may share at least one vertical wall with the adjacent cavity 115. The honeycomb layer 110 can be comprised of many different materials including but not limited to: cardboard, plastics, metal, composites, paper, cellulose, and any combination of these. It has been discovered that materials like cardboard, paper, and cellulose products can be used effectively in the honeycomb layer 110 when they are completely encased by the concrete encasement 30, as shown in the embodiments herein.

FIG. 9 is a top perspective view of a portion of a wall comprised of exemplary bricks 10 as well as a cap 200 having a triangular shape with a pointed top surface, or in other words two slanted surfaces that meet at a ridge which travels horizontally along the central axis 205 of the cap 200. The central axes 18 for each of the bricks 10 are shown here to see how they align vertically atop each other and are substantially parallel to one another. Each of the central axis 18 is also preferably aligned with the bottom notches 20 and top ribs 15. In this embodiment, an additional pipe slot 250 has been placed down the center of the top rib 15 of the some of the bricks 10. The pipe slot 250 is preferably sized to accept a cylinder or pipe 260 that can have a circular or oval cross-sectional shape. The pipe slot 250 is preferably a strip of concrete that is removed from the top rib 15 (if used) or removed from the concrete encasement 30 on the top surface of a brick 10. The pipe slot 250 may be aligned with the central axis 18 such that the two are substantially parallel to one another.

Any type of cement could be used to produce the concrete encasement 30, using any ratio of different components, either traditional masonry components or otherwise. Once assembled, the wall of bricks 10 may produce a smooth wall on each side with an aesthetically pleasing surface such that further finishing like drywall, spackle, plaster, painting, etc. may not be required.

FIG. 10 is a top view of a honeycomb layer 110. As illustrated, the honeycomb layer 110 comprises a series of tubular cavities 115 that are interconnected with one another. In the illustrated embodiment, the tubular cavities 115 have a hexagonal cross-section but other shapes can be used such as ovals, squares, circles, trapezoids, parallelograms, rectangles, and similar. The tubular cavities 115 may each have dimensions suitable for a particular application, including a side length (Ls), a side-to-side height (Hs), a vertex-to-vertex width (Wv). These dimensions may vary, for example, from about 1 mm to about 150 mm. In some embodiments, the side length (Ls) may range from about 1 mm to about 150 mm, about 25 mm to about 150 mm, about 40 mm to about 80 mm, or about 40 mm to about 60 mm. In some embodiments, the side-to-side height (Hs) may range from about 1 mm to about 150 mm, about 50 mm to about 150 mm, about 75 mm to about 125 mm, or about 90 mm to about 110 mm. In some embodiments, the vertex-to-vertex width (Wv) may range from about 1 mm to about 150 mm, about 50 mm to about 150 mm, about 75 mm to about 150 mm, or about 100 mm to about 130 mm.

Walls that are constructed using embodiments of the bricks 10 shown and described herein can be much lighter than traditional brick walls, making the materials easier to transport, easier to install, and they do not strain a foundation, basement, or other substructure that may be required underneath a brick wall. Additionally, it has been found that the embodiments of the bricks 10 can have increased thermal resistivity, making them more insulating than a traditional brick. Further, it has been found that they have increased sound absorbing abilities, making the bricks 10 better for isolating sound between two adjacent rooms or adjacent properties. Additionally, the use of the notches/ridges allows the bricks 10 to be assembled into a wall without requiring mortar in most situations, which makes the walls much easier, faster, and less expensive to install than traditional brick walls. The reduction in overall concrete by using a concrete encasement 30 with a hollow center also substantially reduces the carbon footprint to produce the bricks 10 when compared to a traditional brick since the concrete production process typically produces a large amount of carbon, and this has been substantially reduced.

For the sake of brevity, only certain ranges are explicitly disclosed herein. However, ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

Therefore, the present embodiments are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Although individual embodiments are discussed, all combinations of each embodiment are contemplated and covered by the disclosure. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure.

Claims

1. A brick comprising:

one or more honeycomb assemblies encased within a concrete encasement, each of said honeycomb assemblies comprising a top plate, a bottom plate spaced apart from and parallel to the top plate, and a honeycomb layer positioned between the top plate and the bottom plate.

2. The brick of claim 1 wherein:

the honeycomb layer comprises a plurality of cavities where each cavity has a central axis which is oriented vertically.

3. The brick of claim 1 wherein:

the honeycomb layer comprises a plurality of cavities where each cavity has a central axis and the central axis of each cavity is parallel to one another.

4. The brick of claim 1 wherein:

the honeycomb layer comprises a plurality of cavities where each cavity has at least one vertical wall, where each cavity shares a vertical wall with an adjacent cavity.

5. The brick of claim 1 further comprising:

a side rib extending outwardly from a first end of the brick; and

a side notch sized to accept the side rib and placed on an opposing second end of the brick.

6. The brick of claim 1 further comprising:

a top rib extending upwardly from a top surface of the brick; and

a bottom notch sized to accept the top rib and placed on a bottom surface of the brick.

7. The brick of claim 6 further comprising:

a pipe slot placed within the top rib.

8. A brick comprising:

a hollow center;

a first honeycomb assembly placed within the hollow center;

a second honeycomb assembly placed within the hollow center and positioned directly atop the first honeycomb assembly.

9. The brick of claim 8 wherein:

the first and second honeycomb assemblies each comprise a top plate, a bottom plate spaced apart from and parallel to the top plate, and a honeycomb layer positioned between the top plate and the bottom plate.

10. The brick of claim 9 wherein:

the top plate of the first honeycomb assembly is in contact with the bottom plate of the second honeycomb assembly.

11. The brick of claim 9 wherein:

the top plate and bottom plate of both the first and second honeycomb assemblies are each oriented horizontally.

12. The brick of claim 9 wherein:

the honeycomb layer for both the first and second honeycomb assemblies comprises a plurality of hexagonal tubes, each tube having a central axis which is oriented vertically.

13. The brick of claim 12 further comprising:

a side rib running vertically along on first end of the brick; and

a side notch sized to accept the side rib and running vertically along a second end of the brick.

14. The brick of claim 13 wherein:

the axes of the hexagonal tubes are each parallel to the side rib.

15. The brick of claim 13 further comprising:

a top rib which extends along a top surface of the brick to join with the side rib at a right angle.

16. A brick comprising:

a first honeycomb assembly comprising a first top plate, a first bottom plate spaced apart from and parallel to the first top plate, and a first honeycomb layer positioned between the first top plate and the first bottom plate;

a second honeycomb assembly comprising a second top plate, a second bottom plate spaced apart from and parallel to the second top plate, and a second honeycomb layer positioned between the second top plate and the second bottom plate; and

a concrete encasement layer which completely surrounds the first and second honeycomb assemblies; and

wherein the first and second honeycomb assemblies are placed atop one another such that the first top plate is in contact with the second bottom plate.

17. The brick of claim 16 further comprising:

a side rib extending outwardly from a first end of the brick;

a side notch sized to accept the side rib and placed on an opposing second end of the brick;

a top rib running horizontally along a top surface of the brick; and

a bottom notch sized to accept the top rib and placed on a bottom surface of the brick.

18. The brick of claim 17 wherein:

the side rib and side notch each have a rectangular shape.

19. The brick of claim 17 wherein:

the top rib comprises a strip of the concrete encasement layer which extends upwardly.

20. The brick of claim 17 further comprising:

a pipe slot placed within the top rib.