Exterior polymer-based brick building material

Abstract

A simulated brick includes a polymeric core member and a laminate adhered to the core member. The core member and the laminate together define a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, and a rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion. The laminate covers the core member to define the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, and the core member is uncovered by the laminate on the base surface such that the core member defines the base surface.

We claim: 
     
         1 . A simulated brick comprising:
 a polymeric core member; and   a laminate adhered to the core member;   wherein the core member and the laminate together define a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion;   wherein the laminate covers the core member to define the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, and the core member is uncovered by the laminate on the base surface such that the core member defines the base surface.   
     
     
         2 . The simulated brick of  claim 1 , wherein the second thickness is between 5% and 70% of the first thickness. 
     
     
         3 . The simulated brick of  claim 1 , wherein the second thickness is between 35% and 60% of the first thickness. 
     
     
         4 . The simulated brick of  claim 1 , wherein the brick profile portion has an R-value of at least 2.0 h·° F.·ft 2 ·in/BTU. 
     
     
         5 . The simulated brick of  claim 1 , wherein the offset portion has an R-value of at least 1.0 h·° F.·ft 2 ·in/BTU. 
     
     
         6 . The simulated brick of  claim 1 , wherein the laminate has a thickness of approximately ⅛ inch. 
     
     
         7 . The simulated brick of  claim 1 , wherein the brick profile portion and the offset portion extend longitudinally between first and second longitudinal end surfaces, with the core member being uncovered by the laminate on the first and second longitudinal end surfaces such that the core member defines the first and second longitudinal end surfaces. 
     
     
         8 . The simulated brick of  claim 1 , wherein a junction between the outer surface of the offset portion and the first lateral surface of the brick profile portion comprises a radius surface. 
     
     
         9 . The simulated brick of  claim 1 , wherein the second lateral side of the brick profile portion comprises a planar surface extending from the base surface to the outer surface of the brick profile portion. 
     
     
         10 . The simulated brick of  claim 1 , wherein the lateral end surface of the offset portion comprises a planar surface extending from the base surface to the outer surface of the offset portion. 
     
     
         11 . The simulated brick of  claim 1 , wherein:
 the brick profile portion and the offset portion extend longitudinally between first and second longitudinal end surfaces, with the core member being uncovered by the laminate on the first and second longitudinal end surfaces such that the core member defines the first and second longitudinal end surfaces;   the second lateral side of the brick profile portion comprises a planar surface extending from the base surface to the outer surface of the brick profile portion; and   the lateral end surface of the offset portion comprises a planar surface extending from the base surface to the outer surface of the offset portion.   
     
     
         12 . The simulated brick of  claim 1 , wherein the second lateral side of the brick profile portion comprises a planar surface extending perpendicularly from the base surface to the outer surface of the brick profile portion. 
     
     
         13 . The simulated brick of  claim 1 , wherein the lateral end surface of the offset portion comprises a planar surface extending perpendicularly from the base surface to the outer surface of the offset portion. 
     
     
         14 . A simulated brick comprising:
 a polymeric core member; and   a laminate adhered to the core member;   wherein the core member and the laminate together define a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion, wherein the brick profile portion and the offset portion extend longitudinally between first and second longitudinal end surfaces;   wherein the laminate covers the core member to define the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, with the core member being uncovered by the laminate on the first and second longitudinal end surfaces such that the core member defines the first and second longitudinal end surfaces.   
     
     
         15 . The simulated brick of  claim 14 , wherein the second thickness is between 5% and 70% of the first thickness. 
     
     
         16 . The simulated brick of  claim 14 , wherein the second thickness is between 35% and 60% of the first thickness. 
     
     
         17 . The simulated brick of  claim 14 , wherein the brick profile portion has an R-value of at least 2.0 h·° F.·ft 2 ·in/BTU. 
     
     
         18 . The simulated brick of  claim 14 , wherein the offset portion has an R-value of at least 1.0 h·° F.·ft 2 ·in/BTU. 
     
     
         19 . The simulated brick of  claim 14 , wherein the laminate has a thickness of approximately ⅛ inch. 
     
     
         20 . The simulated brick of  claim 14 , wherein a junction between the outer surface of the offset portion and the first lateral surface of the brick profile portion comprises a radius surface. 
     
     
         21 . The simulated brick of  claim 14 , wherein the second lateral side of the brick profile portion comprises a planar surface extending from the base surface to the outer surface of the brick profile portion. 
     
     
         22 . The simulated brick of  claim 14 , wherein the lateral end surface of the offset portion comprises a planar surface extending from the base surface to the outer surface of the offset portion. 
     
     
         23 . A method of manufacturing a simulated brick, the method comprising:
 forming a polymeric core member including a brick profile portion having first and second lateral sides extending to a planar outer surface to define a first thickness, and an offset portion extending from the first lateral side of the brick profile portion to a lateral end surface and having an outer surface defining a second thickness smaller than the first thickness, the brick profile portion and the offset portion together defining a planar rectangular base surface extending from the second lateral side of the brick profile portion to the lateral end surface of the offset portion, wherein the brick profile portion and the offset portion extend longitudinally between first and second longitudinal end surfaces; and   applying a laminate to the core member, such that the laminate covers the core member to define the first and second lateral sides and the outer surface of the brick profile portion, and the lateral end surface and the outer surface of the offset portion, and the core member is uncovered by the laminate on the first and second longitudinal end surfaces such that the core member defines the first and second longitudinal end surfaces.