Brick/block/paver unit and method of production therefor

Abstract

In a method of splitting a base block to form brick, block or paver units, a cementitious or stone base block having a first side, an opposed second side and a plurality of perforations is provided. Each perforation extends through the base block from the first side to the opposed second side, the plurality of perforations creating a splitting path in the base block. The splitting path has a cross-section consisting of from 70-50% by area of perforated regions and from 30-50% by area of unperforated regions. The base block may be split along the splitting path by a light shock to produce the brick, block or paver units. A wide variety of consistent and reproducible facing surfaces on brick, block and paver units may be produced that integrate texture, pattern, configuration and shape.

1 . Method of producing brick, block or paver units comprising:
 providing a cementitious or stone base block having a first side, an opposed second side and a plurality of perforations, each perforation extending through the base block from the first side to the opposed second side, the plurality of perforations creating a splitting path in the base block, the splitting path having a cross-section consisting of from 70-50% by area of perforated regions and from 30-50% by area of unperforated regions; and,   providing a shock to the base block to split the base block along the splitting path.   
   
   
       2 . Method of  claim 1 , wherein the base block is produced by molding a molding material in a mold. 
   
   
       3 . Method of  claim 2 , wherein the plurality of perforations is produced by inserting elongated members into the mold before the molding material sets. 
   
   
       4 . Method of  claim 1 , wherein the perforations have circular, elliptical or polygonal cross-sections or a combination thereof. 
   
   
       5 . Method of  claim 1 , wherein the perforations are arranged in a straight line or a curve. 
   
   
       6 . Method of  claim 1 , wherein the base block comprises more than one splitting path. 
   
   
       7 . Method of  claim 1 , wherein the perforations are arranged within a recess in the base block. 
   
   
       8 . Method of  claim 7 , wherein the recess has an undercut. 
   
   
       9 . Brick, block or paver unit comprising a striated facing surface produced by the method of  claim 1 . 
   
   
       10 . Cementitious or stone base block comprising a first side, an opposed second side and a plurality of perforations, each perforation extending through the base block from the first side to the opposed second side, the plurality of perforations creating a splitting path in the base block, the splitting path having a cross-section consisting of from 70-50% by area of perforated regions and from 30-50% by area of unperforated regions. 
   
   
       11 . Base block of  claim 10  produced by molding a molding material in a mold. 
   
   
       12 . Base block of  claim 11 , wherein the plurality of perforations is produced by inserting elongated members into the mold before the molding material sets. 
   
   
       13 . Method of providing a bonding surface on a cementitious or stone module for an architectural element comprising:
 providing a cementitious or stone base block having a first side, an opposed second side and a plurality of perforations, each perforation extending through the base block from the first side to the opposed second side, the plurality of perforations creating a splitting path in the base block, the splitting path having a cross-section consisting of from 70-50% by area of perforated regions and from 30-50% by area of unperforated regions; and,   providing a shock to the base block to split the base block along the splitting path to produce a first module having a facing surface with a bonding surface that corresponds to a bonding surface on a second module.   
   
   
       14 . Method of constructing an architectural element comprising: providing first and second cementitious or stone modules having corresponding bonding surfaces produced by the method of  claim 13 ; bringing the first and second modules together to form an interface between the bonding surfaces of the first and second modules; and bonding the first module to the second module at the interface to form the architectural element. 
   
   
       15 . Method of  claim 14 , wherein the first and second modules are bound together with an adhesive. 
   
   
       16 . Architectural element produced by the method of  claim 14 .