Thin brick and method for making

Abstract

A thin brick and method of forming a thin brick having a generally rectangular base portion with a plurality of laterally extending tabs extending therefrom is provided. An outer perimeter edge of each tab and a respective opposite side of the base portion has a precise dimension. A decorative upper portion is integrally formed with the base portion and has a generally rectangular shape, sized and shaped to substantially match the size and shape of the base portion. The upper portion extending from the base portion has a thickness that is at least equal to a thickness of the base portion.

1 . A thin brick, comprising:
 a generally rectangular base portion having a plurality of laterally extending tabs extending therefrom, with an outer perimeter edge of each tab and a respective opposite side of the base portion having a relatively precise dimension; and   a decorative upper portion integrally formed with said base portion having a generally rectangular shape, sized and shaped to substantially match the size and shape of the base portion, the upper portion extending from said base portion and having a thickness that is at least equal to a thickness of said base portion.   
     
     
         2 . The thin brick of  claim 1 , wherein the plurality of laterally extending tabs comprises at least one tab on a long side of said base portion and at least one tab on a short side of said base portion. 
     
     
         3 . The thin brick of  claim 2 , wherein the plurality of laterally extending tabs consists of a pair of tabs on one long side of said base portion and a single tab on one short side of said base portion. 
     
     
         4 . The thin brick of  claim 3 , wherein the plurality of tabs are spaced apart along the perimeter of the base portion with the single tab being generally centered on the short side and the pair of tabs being generally equally spaced from respective ends of the long side. 
     
     
         5 . The thin brick of  claim 1 , wherein the dimensions of the base portion have a dimensional tolerance of ±0.01 or less. 
     
     
         6 . A method of forming a thin brick, comprising:
 forming a base member having a generally rectangular perimeter with a plurality of laterally extending tabs extending therefrom, with an outer perimeter edge of each tab and a respective opposite side of the base member having a relatively precise dimension;   providing a thin brick having an outer decorative texture;   attaching a back side of the thin brick to the base member such that a perimeter of the back side is substantially aligned with the generally rectangular perimeter of the base member;   providing a mold material in a mold form;   inserting the thin brick and base member into the mold material until a back side of the base member is substantially flush with a top surface of the mold material;   allowing the mold material to cure;   removing the thin brick and base member from the mold to form a mold cavity;   inserting a cementitious material into the mold cavity;   allowing the cementitious material to cure into a thin brick; and   removing the thin brick from the mold, the thin brick having a base portion with a plurality of a laterally extending tabs extending therefrom, an outer perimeter edge of each tab and a respective opposite side of the base portion having a relatively precise dimension and an upper decorative portion integrally formed with the base portion that substantially matches the outer decorative texture.   
     
     
         7 . The method of  claim 6 , further comprising forming at least one tab on a long side of said base portion and at least one tab on a short side of said base portion. 
     
     
         8 . The method of  claim 7 , further comprising forming a pair of tabs on one long side of said base portion and a single tab on one short side of said base portion. 
     
     
         9 . The method of  claim 8 , further comprising forming the single tab to be generally centered on the short side and the pair of tabs to be generally equally spaced from respective ends of the long side. 
     
     
         10 . The method of  claim 6 , further comprising forming the base portion with a dimensional tolerance of ±0.01 or less. 
     
     
         11 . The method of  claim 6 , further comprising adhesively attaching the thin brick to the base member. 
     
     
         12 . The method of  claim 6 , further comprising forming a plurality of mold cavities in each mold. 
     
     
         13 . The method of  claim 12 , further comprising forming a plurality of mold cavities having different textures in each mold. 
     
     
         14 . A method of forming a thin brick wall, comprising:
 providing a plurality of thin bricks, each comprising:   a generally rectangular base portion having a plurality of laterally extending tabs extending therefrom, with an outer perimeter edge of each tab and a respective opposite side of the base portion having a relatively precise dimension; and a decorative upper portion integrally formed with said base portion having a generally rectangular shape, sized and shaped to substantially match the size and shape of the base portion, the upper portion extending from said base portion and having a thickness that is at least equal to a thickness of said base portion;   attaching the plurality of thin bricks to an existing structure such that the plurality of tabs of one thin brick abut against a side of an adjacent thin brick;   applying mortar between adjacent thin bricks over said plurality of tabs and to the structure.   
     
     
         15 . The method of  claim 14 , further comprising providing thin bricks having a pair of spaced apart tabs on a long side and a single tab generally centered on a short side and with no tabs on a sides of said brick opposite the tabs. 
     
     
         16 . The method of  claim 14 , wherein the sides opposite the tabs abut at least one tab of an adjacent brick.