Abstract:
Molding equipment comprising a mold having at least one cavity is disclosed. Each cavity allows the formation of a brick. A brick molding element is installed on top of each cavity to allow the formation of a mortise interlock element. The brick molding element is typically secured in place by mean of a securing mechanism. The molding equipment may be used for molding a variety of inter-engaging stackable brick element.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present patent application claims the benefits of priority of U.S. Patent Application No. 62/079,198, entitled “Wet Cast Brick Molding Equipment, Method of Using the Same and Brick made therewith”, and filed at the United Stated Patent and Trademark Office on Nov. 13, 2014, the content of which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to the field of stackable inter-engaging bricks, blocks, stones and the like for building mortarless walls. This invention relates more precisely to the process of manufacturing individual smooth or embossed face inter-engaging bricks, blocks, stones and the like. As used herein, the word “bricks” also refers to blocks, stones and the like. 
       BACKGROUND OF THE INVENTION 
       [0003]    Stackable inter-engaging bricks are used to build mortarless walls and this is known in the art. Wall building blocks which may be stacked and interlocked without being held together by a binding agent such as mortar are known. One such block has a top face which comprise a tongue element and a bottom face which comprise a mortise element. Both elements are configured in such a way that when two blocks are stacked, the bottom face of a block engages with the top face of a like block disposed below while the top face of the block engages with the bottom face of an above-disposed block. An example of such a block is shown in U.S. Pat. No. 6,108,995 (Bouchard et al.). 
         [0004]    In the process of manufacturing stackable inter-engaging bricks, multiple attached splittable bricks made of brick material such as concrete are first cast in a metal mold. The molded attached brick units are then extracted from the said mold and conveyed through the manufacturing plant on steel or wood plates. The molded attached brick units are then cured in kilns in order to cure the said brick material. Once cured, each of the attached bricks are detached in the middle in two individual split face bricks by the mean of a known splitting equipment. In this embodiment, every molded attached brick unit can produce two split face bricks. 
         [0005]    The reason for manufacturing two split face bricks from a single attached splittable brick unit is found in the fact that, prior the completion of the curing procedure, an uncured single brick would be too fragile to be conveyed in the manufacturing plant without being unacceptably damaged or deformed in the process. Conveying uncured individual prior art bricks would result in an increase of defective or rejected bricks. 
         [0006]    Also, the process of cutting attached brick units into individual bricks causes the bricks to have split faces, which may not be always desired. 
         [0007]    Other methods for making mortarless bricks such as wet cast fail to result in properly formed inter-engaging features as existing wet cast mold require the mold to be filed with an open top portion. 
         [0008]    There is thus a need to find a mean by which stackable bricks could be molded, conveyed and cured individually without being damaged or deformed unacceptably and in such a way that the resulting brick faces could be smooth, embossed or preferably have alternating design to represent a design as close as possible to a design obtain from the use of conventional bricks, stones and mortar materials. 
       SUMMARY OF THE INVENTION 
       [0009]    The shortcomings of the prior art are generally mitigated by providing a molding equipment having unmolding features integrated thereto and by providing a flexible mold cover having a protruding portion creating the inter-engaging stackable lip portion of the brick. 
         [0010]    According to one aspect of the present invention, a method to manufacture various form of individual smooth, embossed or predetermined textured face bricks is provided. Each of the bricks has a tongue interlock element and a mortise interlock element configured in such a way that the bricks are in a mutual engagement when bricks, blocks or stones or the like are stacked one of top of the other. 
         [0011]    Molding equipment in accordance with the present invention comprises a mold having at least one and preferably a plurality of cavities. Each cavity allows the formation of a brick. A brick molding element is installed on top of each cavity to allow the formation of a mortise interlock element. The brick molding element is typically secured in place by mean of a fastening device such as screws or bolts. 
         [0012]    The method generally comprises: a) selecting the individual molds in which individual texture of a face of the bricks are to be molded, b) placing the molding portion in the structural base portion c) adding some amount of wet cast concrete in the molded cavities, d) placing the cover portion on top of the molding portion by carefully inserting the cover insert in their respective position in the complementary portion of the molding cavities, e) locking the securing mechanism  186  of the cover portion  180  to respectively secure the cover portion on the molding portion, f) adding wet cast concrete to fill the molding cavities until the desired quantity of concrete has been added, g) if required, removing any excess concrete placed in the cavities and producing a plane surface, h) storing the molding equipment away for drying and/or curing. 
         [0013]    According to one aspect of the present invention, the wet cast brick molding equipment typically permits for the molding of a plurality of brick elements in a simultaneous manner. Consequently, depending on the embodiment of the invention, the brick molding may have 1, 2, 3, or as many as 10 brick elements simultaneously molded. The quantity of brick molded therein will vary according to the number of molding cavities. 
         [0014]    According to one aspect of the present invention, the wet cast brick mold is configured to be stackable as to allow easy storage of the molded brick element during the drying period. 
         [0015]    According to one aspect of the present invention, the molding equipment may, depending on the embodiment, be used for molding various types of inter-engaging stackable bricks such as main brick element, finishing top plate and corners. 
         [0016]    According to one aspect of the present invention, it is disclosed a wet cast molding equipment for molding individual stackable inter-engaging bricks without being damaged or deformed during molding, the molding equipment comprising:
       a main body comprising a molding module having a molding cavity adapted to cast an appropriate material to produce the brick, the molding module defining a first brick longitudinal side and a second brick longitudinal side; and   a cover releasably secured to the main body, the cover comprising a cover insert having a lip forming element for creating an inter-engaging lip portion on the brick, the cover at least partially covering the molding cavity.       
 
         [0019]    According to one aspect of the present invention, the molding equipment may have a main body further comprising a structural base portion comprising first and second side elevation elements. 
         [0020]    According to one aspect of the present invention, the first and second side elevation elements of the molding equipment may have a molding opening and a releasing opening, wherein the molding opening supports a first elongated member inserted in the main body, about the first longitudinal side. 
         [0021]    According to one aspect of the present invention, the molding equipment may have a first elongated member kept in the molding opening of the first and second side elevation elements during molding of the brick and in placed in the releasing opening for supporting the first elongated member during the unmolding of the brick. 
         [0022]    According to one aspect of the present invention, the molding equipment may comprise side elevation members having securing openings for securing the cover to the main body. 
         [0023]    According to one aspect of the present invention, the side elevation members of the molding equipment may comprise suitable securing mechanisms for retaining the cover on top of the molding cavity during molding. 
         [0024]    According to one aspect of the present invention, the main body of the molding equipment may have a first elongated member and a second elongated member longitudinally inserted thereto. 
         [0025]    According to one aspect of the present invention, the molding equipment may further have a cover plate comprising longitudinally elevated sides for increasing the cover longitudinal and torsional strength. 
         [0026]    According to one aspect of the present invention, the cover plate may be secured to the cover insert using glue, and/or any suitable fasteners. 
         [0027]    According to one aspect of the present invention, the cover insert may be made from a suitably flexible material as used for the molding cavity to promote easy unmolding of the brick. 
         [0028]    According to one aspect of the present invention, the main body of the molding equipment may comprise three distinct molding cavities and three corresponding cover inserts. 
         [0029]    According to one aspect of the present invention, the side of the cover insert opposite to a side forming the lip forming element may be at an angle with a vertical plane formed by a lower face of the brick to promote easy removal of the cover insert and the brick upon completion of molding processes. 
         [0030]    According to one aspect of the present invention, the molding equipment may further comprise an unmolding aid formed from an arc plate integrated to the structural base portion for easy removal of the brick, from the molding cavity. 
         [0031]    According to one aspect of the present invention, the molding equipment may comprise an arc plate member mounted on the structural base portion and engaging with both side elevation members through apertures located thereto. 
         [0032]    According to one aspect of the present invention, the structural base portion of the molding equipment may have weight reducing openings located under the arc plate to reduce the weight of the structure as long. 
         [0033]    According to one aspect of the present invention, it is disclosed a brick made using the wet cast molding equipment of the present invention. 
         [0034]    According to one aspect of the present invention, it is disclosed a method of making wetcast brick using a molding equipment having a molding module and a cover, the method generally comprising the steps of:
       adding some amount of wet cast concrete in a molding cavity of the molding module,   placing the cover on top of the molding cavity by carefully inserting a cover insert in its respective position in a complementary portion of the molding cavity, and   releasably securing the cover on the molding module to at least partially cover the molding cavity.       
 
         [0038]    According to one aspect of the present invention, the method of making wetcast brick may further comprising the steps of:
       placing the molding module in a structural base portion; and   inserting a first elongated member in a molding opening of both side elevation members.       
 
         [0041]    According to one aspect of the present invention, the method of making wetcast brick may further comprising the steps of:
       removing any excess concrete placed in the cavities and producing a plane surface; and   storing the molding equipment away for drying and/or curing.       
 
         [0044]    According to one aspect of the present invention, the method of making wetcast brick may further comprising the steps of:
       removing a first elongated member from the molding opening and removing the molding portion from the structural base portion;   inserting the first elongated member in the unmolding opening of both side elevation members; and   applying a downward pressure to a second elongated member located on the opposite side of the molding module in relation to the first elongated member to force the extraction of the brick and cover insert from the molding cavities, and remove the brick from the molding module.       
 
         [0048]    Other and further aspects and advantages of the present invention will be obvious upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0049]    The above and other aspects, features and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawings in which: 
           [0050]      FIG. 1  is a perspective view of the wet cast brick molding equipment for a brick element. 
           [0051]      FIG. 2  is a top plan view of the wet cast brick molding equipment of  FIG. 1 . 
           [0052]      FIG. 3  is a rear elevation view of the wet cast brick molding equipment of  FIG. 1 . 
           [0053]      FIG. 4  is a right elevation view of the wet cast brick molding equipment of  FIG. 1 . 
           [0054]      FIG. 5  is a top plan view of the molding element of the wet cast brick molding equipment of  FIG. 1 . 
           [0055]      FIG. 6  is a front elevation view of the molding element of  FIG. 5 . 
           [0056]      FIG. 7  is a cross-sectional view along A-A axis of the molding element of  FIG. 6 . 
           [0057]      FIG. 8  is a right elevation view of the wet cast brick molding equipment of  FIG. 1 . 
           [0058]      FIG. 9  is a perspective view of the molding portion of the wet cast brick molding equipment of  FIG. 1  having brick element molded therein. 
           [0059]      FIG. 10  is a front elevation view of the molding element of  FIG. 10 . 
           [0060]      FIG. 11  is a cross-sectional view along A-A axis of the molding element of  FIG. 10 . 
           [0061]      FIG. 12  is a perspective view of the structural base portion of the molding portion of the wet cast brick molding equipment of  FIG. 1   
           [0062]      FIG. 13  is a lateral elevation view of the side elevation members of the wet cast brick molding equipment of  FIG. 1   
           [0063]      FIG. 14  is a top plan view of the cover portion of the wet cast brick molding equipment of  FIG. 1   
           [0064]      FIG. 15  is a front view of the cover portion of  FIG. 14 . 
           [0065]      FIG. 16  is a right elevation view of the cover portion of  FIG. 14 . 
           [0066]      FIG. 17  is a perspective view of the cover portion of  FIG. 14 . 
           [0067]      FIG. 18  is a top plan view of the structural base portion of the wet cast brick molding equipment of  FIG. 1 . 
           [0068]      FIG. 19  is a rear elevation view of the structural base portion of  FIG. 18 . 
           [0069]      FIG. 20  is a bottom plan view of the structural base portion of  FIG. 18 . 
           [0070]      FIG. 21  is a cross-sectional view along A-A axis of the structural base portion of  FIG. 18 . 
           [0071]      FIG. 22  is a perspective view of a plurality of the wet cast brick molding equipment of  FIG. 1  stacked one onto the other. 
           [0072]      FIG. 23  is an exploded view of the wet cast brick molding equipment of  FIG. 1  in and unmolding position. 
           [0073]      FIG. 24  is a perspective view of the structural base portion and molding portion of the wet cast brick molding equipment of  FIG. 1  in and unmolding position. 
           [0074]      FIG. 25  is a cross-sectional view along A-A axis of the structural base portion of  FIG. 24 . 
           [0075]      FIG. 26  is an exploded cross sectional view of the wet cast brick molding equipment of  FIG. 24 . 
           [0076]      FIG. 27  is a cross-sectional view along A-A axis of the wet cast brick molding equipment of  FIG. 24  having a brick element molded therein. 
           [0077]      FIGS. 28-34  are perspective, left, right, top, bottom, front and rear views of a brick molded using a molding equipment of the present invention. 
           [0078]      FIGS. 35-41  are perspective, left, right, top, bottom, front and rear views of a second brick element molded using a molding equipment of the present invention. 
           [0079]      FIGS. 42-48  are perspective, left, right, top, bottom, front and rear views of a third brick element molded using a molding equipment of the present invention. 
           [0080]      FIGS. 49-55  are perspective, left, right, top, bottom, front and rear views of a fourth brick element molded using a molding equipment of the present invention. 
           [0081]      FIG. 56  is a perspective view of a second embodiment of a wet cast brick molding equipment. 
           [0082]      FIG. 57  is a perspective view the cover insert of the wet cast brick molding equipment of  FIG. 56 . 
           [0083]      FIG. 58  is a perspective view the cover insert of the wet cast brick molding equipment of  FIG. 56 . 
           [0084]      FIG. 59  is a perspective view the molding element of the wet cast brick molding equipment of  FIG. 56 . 
           [0085]      FIG. 60  is a perspective view the wet cast brick molding equipment of  FIG. 56 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0086]    A novel wet cast brick molding equipment, method to manufacture the same and brick made therewith will be described hereinafter. Although the invention is described in terms of specific illustrative embodiments, it is to be understood that the embodiments described herein are by way of example only and that the scope of the invention is not intended to be limited thereby. 
         [0087]    The expressions “lip”, “lip portion” as used therein, for example in the expression “lip forming element” should be understood as a round shaped lip, but also cover a triangular lip element or any other suitable form to fulfill the present invention. As such, lip should be understood as any shape that allows the brick element to be retained on top of one another to form individual stackable inter-engaging bricks as disclosed herein. 
         [0088]    Now referring to  FIGS. 1-11 , in the present embodiment, the wet cast brick molding equipment  100  generally comprises a structural base portion  110 , a molding portion  150  and a cover portion  180 . The structural base portion  110  typically holds the molding portion  150  during molding of the wet cast concrete while the cover portion  180  is typically used to retain an important protrusion portion, also referred as a lip forming element  184  for creating the inter-engaging lip portion  186  of the brick element  300  molded therein. 
         [0089]    Now referring to  FIGS. 12-13 , in the present embodiment, the structural base portion  110  generally comprises a base plate  120 , right and left side elevation member  122   a ,  122   b  generally mounted thereto and a stopper plate  126  also mounted thereto, preferably engaging with both side elevation members  122   a ,  122   b . Additionally, according to the present embodiment, the structural base portion  110  preferably comprises an arc plate member  128  mounted on the base plate  120  and engaging with both side elevation members  122   a ,  122   b  through apertures located thereto. According to another embodiment, the arc plate  128  could be secured using fasteners or any other suitable means provided the arc plate is solidly fixated to the base plate  120  and/or to both side elevation members  122   a ,  122   b . The base plate  120 , preferably has opening located under the arc plate  128  to reduce the weight of the structure as long as sufficient strength is retained from the base plate  120  and overall structural base portion  110 . 
         [0090]    Now referring to  FIGS. 1-13 , in the present embodiment, the side elevation member  122  typically comprises a molding opening  130  and a releasing opening  132 . The molding opening  130  is configured to support a first elongated member  170  inserted in the preferably malleable portion  154  of molding element  150 . As such, the first elongated member  170  is kept in the molding opening  130  on both sides of the structural base portion  110  during molding of the brick element  300  whereas the releasing opening  132  is configured to support the first elongated member  170  during unmolding of the brick element  300 . Furthermore, the side elevation members  122   a ,  122   b  generally have openings for securing the cover portion  180  thereto. Understandably, although openings are preferred, the side elevations  122  could comprise any suitable securing mechanisms for retaining the cover portion  180  on top molding portion  150  after pouring of a portion of the wet cast concrete the molding of the brick element  300 . 
         [0091]    Now referring to  FIGS. 5-11 , in the present embodiment, the molding portion  150  generally comprises a molding element having molding cavities for molding of the individual brick element. In addition, the molding element preferably has a first  170  and second  160  elongated member longitudinally inserted thereto. The at least one, preferably a plurality of molding cavities  152  for molding brick elements  300  may varies in design depending on the specific brick element  300  to be molded. The first  170  and second  160  elongated members partly integrated to the molding element  154  are preferably of cylindrical shapes as to promote easy insertion in the molding opening  130  and a releasing opening  132  of the elevated side members  122   a ,  122   b.    
         [0092]    Now referring to  FIGS. 14-23 , in the present embodiment, the cover portion  180  generally comprises a cover plate  182 , a cover insert  184  also referred as a protruding portion and a securing mechanism  186  for securing the cover to the a structural base portion  110 . The cover plate also preferably comprises longitudinally elevated sides for increasing the cover portion  180  longitudinal and torsional strength. Understandably, the longer the cover portion  180  is, according to the higher number of molding cavities, the more the need for increased longitudinal and/or lateral reinforcement elements such as longitudinally elevated sides. For instance, one could have a cover portion  180  with transverse longitudinal or lateral reinforcement along the top side of the cover portion  180 . 
         [0093]    Now referring to  FIGS. 22-27  in the present embodiment, the cover plate  182  is generally secured to the cover insert  184  using glue, and/or any suitable fasteners. Another embodiment could as well have a reversibly secured cover insert to increase versatility of the molding equipment. As such, the user could use the same molding equipment for various typed of inter-engaging stackable mortarless bricks or blocks. The cover insert  184  is typically made from a suitably flexible material as used for the molding portion to promote easy unmolding of the brick element. Although less preferable, hardened material such as steel, hardened or low flexibility thermoset polymers, could also be used as cover insert  184 . 
         [0094]    Now referring to  FIGS. 23-24 , in the present embodiment, the molding portion  150  comprises three distinct molding cavities  152  and three corresponding cover inserts  184 . Understandably, another embodiment could have a different number of molding cavities  152  and cover insert  184  for insertion on top thereof. The higher quantity of molding cavities  152 , the stronger will the other components have to be. For instance, for a wider i.e. more than three molding cavities  152 , the elongated members  160 ,  170  and structural base portion  110  will require adequate reinforcements. The molding cavities will vary depending in the type of brick element  300  to be molded therein. Bricks element  300  such as regular brick (typical building block having a brick plate having an individual smooth, embossed or predetermined textured face decorative portion and a securing portion for securing to the wall of substantially vertical section with the aid of fasteners), plate (double size for completing a top layer and to provide adjustment for the last top layer), corner (angled edges to allow for compatible with complementary edges from other brick elements) and cap portion (a brick element comprising the brick face with an longitudinal prism shaped plate cover for finishing a top layer or for decoration a window opening) may all be moulded using various embodiment of the present molding equipment as long as a cover portion is secured to allow the creation of the lip element in the brick element molded therein. 
         [0095]    According to one embodiment of the present invention, now referring to  FIG. 27 , the cover insert  184  side  190  opposite to the lip forming side  188  is preferably at an angle with regards to a vertical axis formed by the lower face  192  of the brick element  300  to promote easy removal of the cover insert  184  and molded brick element  300  upon completion of the molding process. 
         [0096]    Now referring to  FIGS. 24-27 , the wet cast molding equipment  100  according to one embodiment preferably has an unmolding aid feature formed from the arc plate  128  of the structural base portion  110  for easy removal of the cured or partly cured brick elements  300 , from the molding cavities  152 . The unmolding aid is an arced portion  128  in the structural base portion  110  typically hidden during molding operation by the complementary void  162  of the molding element  154 . Upon unmolding, once the brick element  300  is substantially hardened to withstand the unmolding procedure, the molding portion is removed from the molding position, that is from the insertion of the first elongated member  170  in the molding opening  130  of both elevated side members  122 , and further placed in the aiding unmolded position. The aided unmolded position typically required insertion of the first elongated member  170  in the unmolding opening  132  of both elevated side members  122 . Upon insertion of the first elongated member  170  in the corresponding unmolding opening  132  of both elevated side members  122 , a downward gradual pressure is generally applied to the second elongated member  160  located on opposite side of the molding element  154  than the first elongated member  170  to force the extraction of the brick element  300  and cover insert  184  from the molding cavities  154 , thus completing the removal of the brick element  300  from the molding equipment  100 . 
         [0097]    The method for molding a brick element  300  using the molding equipment  100  of the present embodiment comprises:
       placing the molding portion  150  in the structural base portion  110 ;   adding some amount of wet cast concrete in the molded cavities  154 ;   placing the cover portion  180  on top of the molding portion  150  by carefully inserting the cover insert  184  in their respective position in the complementary portion of the molding cavities  154 ;   locking the securing mechanism  186  of the cover portion  180  to respectively secure the cover portion  180  on the molding portion  150 ;   adding wet cast concrete to fill the molding cavities  154  until enough concrete has been added;   if required, removing any excess concrete placed in the cavities and producing a plane surface;   storing the molding equipment away for drying and/or curing;   preferably stacking the molding equipment  100  one on top of the other.       
 
         [0106]    Notably, depending on the precise shape and configuration of the molding cavities  154 , the method for molding a brick element  300  may require the molding steps be completed using a vibrating table, conveyor or other device. 
         [0107]    After the required drying and/or curing time has lapsed, the brick elements  300  are unmolded. The unmolding may be achieved by manually deforming the preferably malleable molding element  154  and removing the cover portion  180  and brick element  300  from the molding cavity. 
         [0108]    Alternatively while using an embodiment having an unmolding aid, the unmolding may be achieved by moving the molding portion from a first position wherein the first elongated member  170  is inserted in the molding openings  130   a ,  130   b  to a second position to a second position wherein the first elongated member  170  is inserted in the unmolding openings  132   a ,  132   b  and applying downward pressure on the second elongated member  160  as to press the underside of the molding element  154  against the unmolding aid, the arced plate  128  until sufficient deformation of the molding element  154  allows easy removal of the cover insert  184  and cover portion  180  entirely. After removal of the cover portion  180 , further downward pressure is applied to the second elongated member  160  until easy removal of the brick element. 
         [0109]    Now referring to  FIGS. 28-34 , according to one embodiment of the present invention, the molding equipment may be used to mold brick element  300  having a brick face portion  302  and a support section  304  typically used for securing the brick element  300  on the wall to be covered with the brick elements  300 . The support sections  304  generally have an inter-engaging stacking configuration. The support section typically has a bevelled lower portion  306  connected or integrated to the brick face portion  302 . The support section  304  of the brick element also preferably has left  308  and right  312  sides at a slight angle whereas the brick face portion  302  has sides a substantially right angle. During installation, one generally begin by installing any suitable starter element wherein the lip brick element  314  typically sits on. The support section  304  is generally further secured to the wall to be covered with the brick element  300 . 
         [0110]    Now referring to  FIGS. 35-41 , according to one embodiment of the present invention, the molding equipment may be used to mold brick element  310  having one or both sides  316 ,  318  at an angle. This brick element  310  is generally used to cover corners of building walls. Understandably, the angle could vary according to the configuration of the wall to be covered. According to this configuration, both the support section  304  and the brick face portion  302  are at substantially the same angle. 
         [0111]    Now referring to  FIGS. 42-48 , according to one embodiment of the present invention, the molding equipment  100  may be used to mold brick element  320  having a brick face portion  302  and support section  304 . The support section  304 , according to this embodiment, only has a lip element  314  for stacking on top of a previous brick layer. Accordingly, this plate brick element  320  does not have superior lip engaging feature  322  thus preventing further stacking of additional brick element on top thereof. As such, the present brick element  320  is generally used for the upper most layer of brick elements  320 . Furthermore, the brick face portion  302  of the present brick element  320  substantially overlaps the support section  304  connected or integrated therewith. 
         [0112]    Now referring to  FIGS. 49-55 , according to one embodiment of the present invention, the molding equipment may be used to mold brick element  330  also having a brick face portion  302 , a support section  304  and a cover element  324 . Understandably, the cover element  324  could vary from one embodiment to the other. In this embodiment, the brick element  330  does not have superior lip engaging feature  322  thus preventing further stacking of additional brick element  300 ,  310 ,  320 ,  330  on top thereof. As such, the present brick element  330  is generally used for the upper most layer of brick elements  330 . It could however, also be user under wall openings, such as windows or doors. Furthermore, the brick face portion  302  of the present brick element  330  substantially overlaps the support section  304  connected to or integrated therewith. 
         [0113]    Now referring to  FIGS. 56-60 , according to one embodiment, the brick molding equipment  800  could have two molding cavities  854 . According to this embodiment, the brick molding equipment  800  comprise a cover portion  880  having hinges  882 ,  884  to promote cover portion  880  removal during unmolding. As such, following the drying and/or curing period, the cover portion  880  is preferably sequentially pulled using a specifically designed tool  890  allowing removal of the cover insert  892  from the side  894  opposite the lip forming element  896  to the lip forming side  896  thus minimising the strain applied to the lip element  898 . 
         [0114]    While illustrative and presently preferred embodiments of the invention have been described in detail hereinabove, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.