Process for making brick-faced construction material and brick-faced block made by this process

Abstract

This invention aims to provide a novel process for making brick-faced block. Colored brick material 11 is laid into a plurality of individual molds 8 of a molding unit 7 to mold at once a plurality of bricks 5 arranged with a predetermined space between each pair of adjacent bricks 5. Then a base block 1 made of foamed resin and coated with a brick adhesive layer 4 is placed and pressed against the molding unit 7 to bond at once these bricks 5 to the brick adhesive layer 4. Thereupon the brick adhesive layer 4 is partially exposed to form joints 6 in accordance with the predetermined space between each pair of adjacent bricks 5. Thereafter, steps of stripping and aging are carried out to form a brick-faced block A.

What is claimed is:  
     
         1 . Process for making brick-faced construction material comprising steps of: 
 molding a plurality of bricks with a predetermined space between each pair of adjacent bricks at once by laying colored brick material such as colored mortar or a mixture of inorganic material and binder into a plurality of individual molds distributed on a molding unit;    placing and pressing a base coated on its surface with still uncured adhesive layer formed by suitable adhesive such as mortar- or resin-based adhesive against said plurality of bricks arranged with said predetermined space between each of adjacent bricks so that said base may be bonded to said plurality of bricks at once and at the same time joints are formed by said still uncured adhesive layer in accordance with said predetermined space between each pair of adjacent bricks;    stripping said bricks bonded to the base by means of said adhesive layer from said molding unit at once; and    aging said bricks and adhesive layer and thereby curing them.    
     
     
         2 . Process for making brick-faced construction material as defined by    claim 1   , further comprising, immediately before said step of molding the bricks, a step of coating said individual molds with inorganic pigment having a tone differing from the tone of said colored brick material by applying or spraying said inorganic pigment.  
     
     
         3 . Process for making brick-faced construction material as defined by    claim 1    or    2   , wherein said step of molding the bricks is carried out placing a jig on the molding unit so that its mortar permeable zones defined by through-holes, meshes, stripes or parallel lines lie over the individual molds and its masking zones cover ribs defining peripheries of the individual molds arranged with said predetermined space between each pair of adjacent bricks, laying the colored brick material on said jig and smoothing said colored brick material with a smoothing tool so that said colored brick material may be evenly laid into the plurality of individual molds.  
     
     
         4 . Process for making brick-faced construction material defined by any one of claims  1 - 3 , wherein said step of placing and pressing the base against the bricks includes a step of vibrating the molding unit after placement of said base or during pressing said base.  
     
     
         5 . Process for making brick-faced construction material defined by any one of claims  1 - 4 , wherein said base comprises a block or a panel made of organic or inorganic material.  
     
     
         6 . Brick-faced block comprising: 
 a base block made of foamed resin;    an adhesive layer formed by adhesive such as mortar- or resin-based adhesive; and    a plurality of bricks molded from colored brick material such as colored mortar or a mixture of inorganic material and binder and bonded to said base block by means of said adhesive layer with a predetermined space between each pair of bricks so that said adhesive layer may be partially exposed to form joints in accordance with said predetermined space between each pair of adjacent bricks.    
     
     
         7 . Brick-faced block as defined by    claim 6   , wherein said plurality of bricks of said colored brick material arranged with said predetermined space between each pair of adjacent bricks are molded at once utilizing the molding unit including the individual molds arranged in accordance with positions at which said bricks being still uncured will be bonded at once to said adhesive layer being also still uncured.