CA1149189A - Insulated construction block - Google Patents

Insulated construction block

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Publication number
CA1149189A
CA1149189A CA000397739A CA397739A CA1149189A CA 1149189 A CA1149189 A CA 1149189A CA 000397739 A CA000397739 A CA 000397739A CA 397739 A CA397739 A CA 397739A CA 1149189 A CA1149189 A CA 1149189A
Authority
CA
Canada
Prior art keywords
block
blocks
insulation
concrete
foamed
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000397739A
Other languages
French (fr)
Inventor
Garry B. Stevens
Martin Stuart
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to CA000397739A priority Critical patent/CA1149189A/en
Application granted granted Critical
Publication of CA1149189A publication Critical patent/CA1149189A/en
Expired legal-status Critical Current

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C1/00Building elements of block or other shape for the construction of parts of buildings
    • E04C1/40Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
    • E04C1/41Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts composed of insulating material and load-bearing concrete, stone or stone-like material
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2/42Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities
    • E04B2/44Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities using elements having specially-designed means for stabilising the position; Spacers for cavity walls
    • E04B2/46Walls having cavities between, as well as in, the elements; Walls of elements each consisting of two or more parts, kept in distance by means of spacers, at least one of the parts having cavities using elements having specially-designed means for stabilising the position; Spacers for cavity walls by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/02Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls built-up from layers of building elements
    • E04B2002/0256Special features of building elements
    • E04B2002/0289Building elements with holes filled with insulating material
    • E04B2002/0293Building elements with holes filled with insulating material solid material

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)

Abstract

ABSTRACT
An insulated construction block incorporates improved insulating features which minimize thermal conduction through the block itself and the mortar joints between adjacent blocks in a masonry wall. The block contains one or more moulded cavities extending the full length of the block into which insulation material is foamed in place to completely fill the space of the cavity or cavities and is designed to extend beyond the top and ends of the block to provide insulation through the mortar joints between the blocks.
Through the adhesive property of the insulation foam, the cementitious surfaces of the cavities are bonded to the foam and the block's structural characteristics, when compared to present day blocks, are greatly enhanced.

Description

INSULATED CONSTRUCTION BLOaK
BACKGROUND OF THE INVENTION
1. Field of Invention The invention relates to a building block for use in masonry- walls and~ more particularly, to an insulated concrete construction block provided with improved insulating features which minimize thermal conduction through the block itself and through mortar joints between adjacent blocks in a masonry wall.
2. Description of the Prior Art Conventional masonry construction of buildings employs pre-cast concrete blocks arranged end to end in rows and secured together by vextical mortar joints between adjacent blocks. Successive rows of blocks are secured to those below by horizontal mortar ~oints. ~enerally, the concrete blocks have a hollow interior to reduce the weight and facilitate 8~

handling of the blocks by workmen. One widely used construction block includes a central web extending transversely across the hollow interior of the block to connect the side walls of the block and preserve its streng-th.
Generally, such conventional construction blocks have relatively poor insulative value. The concrete material of the block allows appreciable thermal conduction, particularly at the end walls and central web where straight conductive paths are provided which allow direct heat conduction between the inner and outer side walls of the block. In addition, when such conventional blocks are assembled in a masonry wall, the vertical mortar joints between adjacent blocks and the horizontal mortar joints between successi~e rows of blocks are poorly insulated. Typically, air spaces in the mortar joints between the blocks allow sufficient air circulation to result in loss of heat by convection.
Similarly, air is able to circulate through the hollow interior of the blocks resulting in additional loss of heat.
Thus, such a masonry wall has usually been insula~ed by installation of a separate insulative barrier, e.g., conventional studs or furring strips with fiberglass or other insulation, on the inner face of the wall.
Although it has been proposed to utilize insulation inserts in the hollow interior spaces of conventional masonry blocks, such arrangements have not provided satisfactory insulative characteristics because of the loss of heat by conduction through the central web and end walls of the block. Further, no provision has been made to prevent loss of heat through the mortar joints between adjacent blocks
- 3 -In addition, various proposals have been made in the prior art to provide alternate forms of insulated masonry blocks by eliminating the centrally located transverse web of the conventional block and providing other interior configurations to achieve one or more hollow insulating spaces for receiving insulating material within the block. However, such proposals have generally sacrificed the overall strength of the conventional block without appreciably improving its insulative characteristics. Moreover, the complex internal configuration of such insulated blocks has made the blocks difficult and expensive to manufacture and install.
Consequently, such insulated masonry bloc]cs have not received widespread acceptance in the construction industry.
Nevertheless, because of the presently-increasing concern about dwindling sources of conventional fossil fuels and the ' need to adequately insulate building walls, there is definitely a need for an insulated construction block which is simple and effective in design and capable of manufacture and installation at reasonable cost. ~ primary consideration in the design of a satisfactory insula'ed construction blocks is to maximize the insulative properties without sacrificing the strength of the block. To limit heat loss through the concrete material of the block itself, it is necessary to achieve a concrete block structure which eliminates direct paths for thermal conduction through the block. Furthermore, it is important~that the construction block achieve adequate insulation in the mortar joints between adjacent blocks in the same row and between successive rows of blocks.
- 4 -9~9 SUMMARY OF THE INVENTION
An object of the invention is to provide an insulated building block with enhanced insulation characteristics due to a minimum of thermal conduction through the block.
Another object of the invention is to provide an insulated building block which effectively achieves insulating the mortar joints between adjacent blocks and between successive rows of blocks in A masonry wall to the same value as the block itself.
A further object of the invention is to produce a block very similar in shape and form to present day blocks so that workers installing these blocks will handle familiar sizes and shapes.
It is also an object of this invention to provide an insulated building block whose structural integrity, strength and resistance to shock, is enhanced because of the adhesive and resilient qualities of the foamed in place insulation. Insulation inserts do not have these qualities.
An additional advantage provided by the foamed in place insulation material is the fact that the dense surface skin of the insulation foam locks in the low conductivity gas created during the foaming process. This retains the high initial "R" ratings of the insulation foam because the surface skin prevents the loss of this valuable gas.
When insulation inserts cut from board stock are used, the gases will slowly escape an~ therefore lose some of its insulation value. The dense surface skin of the insulation foam also acts as a barrier to water thus preventing loss of insulation value because of moisture ~9~
- 5 penetration.
The invention is embodied in a building block haviny one or more cavities to be filled with foamed in place insulation material extending the full length of the block from one end to the other and from top to bottom of the block~ The insulation cavities can be located on one side, two sides or the centre of the block or any combi-nation thereof. The block also contains hollow spaces or voids similar to regular, presently used building blocks, which can remain hollow spaces or voids or be filled with reinforced concrete or other material dependiny on design requirementsO Further, this block can have a self positioning, interlocking feature~ In one case, the insula-tion projection that insulates through the mortar joints projects higher than the mortar joint and fits into a depression in the bottom of the block above in the foam cavity and rests in its proper location when the top of this insula-tion projection comes in contact with the bottom of the insulation of the block above. This feature can be used with mortar joints, or dry stacked full course high blocks that are surface bonded or epoxy bonded in p-lace of the mortar. If a fire barrier is required, aluminum, or other noncombustible material strips can be placed between courses as a fire barrier and can be installed during the manufacture of the block or at the time of erection.
In certain preferred embodiments, the bloc~s may be provided with various optional features such as a thin concrete bridye ~nder the insulation cavities which provides an effective fire barrier. Penetxation of a fire throush the exterior concrete wall covering the foam , 93~
- 6 -would be limited to one course of blocks and only to limited areas of that course since the insulation burns in a vertical direction and thus would encounter the next barrier being the bottom of the block on the next course.
This feature reduces the production of toxic gases due to fire, that are the main cause of fire deaths.
In one embodiment, the insulation projections at the top of the bLock that insulates the mortar joint, act as support screeds to precisely position the block being erected the required distance above the row of blocks below. This feature greatly assists the ease with which this block is erected.
Notwithstanding the preferred embodiment of the block consisting of moulded concrete, the material forming the block can be of any other type suitable for forming or moulding and the block can be dimensioned in any desired Iength, width, height, colour, texture or pattern on its surface to make the block more architecturally attractive.
It is also envisaged that half blocks, end blocks, corner blocks and bond beam blocks can be constructed with the same insulation properties as the above described blocks but are not described herein.
This invention will now be described with respect to certain embodiments and illustrations wherein: -IN THE DRAWINGS
Figure 1 is a perspective view of a construction block in three parts showing the insulation cavities in accordance with the principles of the invention.
Figure 2 is a perspective view of a construction block moulded in one piece showing the insulAtion cavities with concrete fire barriers along the bottom of -the cavities in accordance with the principles of the invention.
Figure 3 is a perspec~ive view of a construction block as described in Figures 1 and 2 with the foamed in place insulation that bonds the concrete walls together showing the insulation projections beyond the top and ends of the concrete part of the block for insulating the mortar joints ln accordance with the principles of the inver.tion;
Figure 4 is a partial section through a wall showiny the relation between the concrete blocks, the insulation foam and the mortar joints;
Figure 5 is an end view of figure 1;
Figure 6 is a plan view of figure 1;
Figure 7 is an end view of figure 2;
Figure 8 is a plan view of figure 2;
Figure 9 is a plan vlew;of figure 3 showing the insulation projections at both ends;
Figure 10 is a plan view of figure 3 showing the insulation projections at one end only;
Figure 11 is an end view of figure 3 with foamed in place insulation projecting above the top of the bloc]c;
Figure 12 is a side view of all blocks with three concrete webs or ties showing the insulation projections and indicating the location of the fire barrier and thermal bridges;
Figure 13 is a perspective view of a construction block moulded in one piece showing the insulation cavities with the concrete fire barrier along the bot-tom of the g~89 cavities as shown in figure 2 only this design has only two.webs and end cavities fo.r hand holds;
Figure 14 is a perspective view of a construction block as described in figure 13 with the foamed in place insulation that bonds the concrete walls together showing the insulation projections beyond the top and ends of the concrete part of the block for insulating the mortar joints in accordance with the principles of the inventlon;
Figure 15 is an end view of figure 13;
F.igure 16 is an end view of figure 14;
Figure 17 is a plan view of figure 13i Figure 18 is a plan view of figure 1~ showing the foam projections beyond both ends of the bloc]c;
Figure 19 is a plan.view.of figure 14 showing the foam projections beyond one end only of the block;
Figure 20 is a side view of figure 14 indicating the location of the fire barrier and thermal bridges;
Figure 21 is a partial plan view of a wall erected with blocks as shown in figure 18;
Fig~lre 22 is a partial plan view o~ a wall erected with blocks as shown in figure l9i Figure 23 is a perspective view of a construction block in two parts showing the insulati.on cavity on one side in accordance with the principles of the invention;
Figure 24 is a perspective view of a construction block moulded in one piece showing the insulation cavity on one side with the concrete fire barrier along the bottom of the cavity in accordance with ~he principles of the invention.
Figure 25 is a plan view of figure 23 Figure 26 is a plan view of figure 24;
- Figure 27 is an end view of figure 23;
Figure 28 is an end view of figure 23 with foamed in .
place insulation projecting above the top of the block;
Figure 29 is an end view of figure 24;
Figure 30 is an end view of figure 24 with foamed in place insulation projecting above the top of the block;
Figure 31 is a plan view of figures 28 and 30 showing the insulation projection at both ends;
Figure 32 is a plan view of figures 28 and 30 showing the insulation projection at one end only;
Figure 33 is a perspective view of a construction block in two parts showing the insulation cavity in the centre in accordance with the principles of this invention;
Figure 34 is a perspective view of a construction block moulded in one piece showing the insulation cavity in the centre of the block with the concrete fire barrier along the bottom of this cavity in accordance with the principles of the invention;
Figure 35 is a plan view of figure 33 Figure 36 i5 a plan view of figure 34 Figure 37 is an end view of figure 33 Figure 38 is an end view of figure 33 with foamed in place insulation projecting above the top of the block;
Figure 39 is an end view of figure 34;
Figure 40 is an end view of figure 34 with foamed in place insulation projecting above the top of the block;
Figure 41 is a plan view of figures 38, 40 and 44 showing the insulation projection at both ends;

~ ~9~8~

Figure 42 is a plan view of figures 38, ~0 and 44 showing the insulation projection at one end only;
Figure 43 is a perspective view of a self positioning, interlocking construction block as described in figure 33 with the foamed in place insulation that bonds the c~ncrete walls togethe.r, showing the insulation projection beyond the top and ends of the concrete plus the inter-locking slot at the bottom of the insulation cavity all in accordance with the principles of the invention;
Figure 44 is an end view of figure 43;
Figure 45 is a partial section through a wall showing the relation between the concrete, the insulation foam and the mortar joints of the self positioning, interlocki.ng blocks;
Figure 46 is a partial section through a wall showing : the relation between the concrete and insulation foam :Eordry stacking full course high blocks ready to be surface bonded or bonded by epoxy in the joints of these self positioning interlocking blocks;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
More particularly in the drawings, Figure 1, a prefer-red embodiment of the insulated: construction block cons-ists of three concrete parts. I'he middle part 1 contains two interior hollow spaces or voids 2, two side walls 3, two end walls S and one central bridge 6 extending trans-versely and connecting the two side walls 3. The side walls 3, form one side of the insulation cavity 4 and the other side of the insulation cavity is formed by the wall of part 7. Part 7 forms the interior and exterior face of ~9~8~

the block. This face can be any architectural figure, f colour, texture or thickness but must be a minimum thickness required to meet the fire regula-tion section of the building codes for protection of foam insulation against open flame. Illustrated is the threa parts in their approximate positions as a full block without foam insulation to hold the parts together.
Where more insulation is desired to give a higher insulated block, the insulation cavity 4 is widened and this extra width reduces the width of the middle part 1. The sizes especially suitable for these blocks are the same widths as regular concrete blocks, namely eight inch, ten inch and twelve inch or twenty centimetre, twenty-five centimetre and thirty centimetre blocks. The heights and lengths should also be the same as regular blocks.
- Other sizes of regular, concrete blocks are possible as well as blocks of special widths, lengths and heights.
Figure 2 has the same parts as Figure 1 except the walls 7, are connected to the middle part 1 by a thin concrete bridge 8, which acts as a fire barrier along the bottom portion of the block.
Figure 3 shows the foamed in place insulation 9 filling the cavities ~ as shown in Figure 1 or Figure 2 completely and extending over the top and beyond the ends of the block. This projected insulation foam will provide insulation in the mortar joints between successive rows of blocks as well as in the vertical mortar joints between adjacent blocks.

-~g~8~

Figure 4 is a section through a wall and shows the relation of the walls 3 and 7 and the foamed in place insulation 9 to each other. Figure 4 also shows the projection of the insulation 10, into the mortar ~oint of a successive row of blocks above. Mortar 11, fills the joint completely and thereby bonds tpe blocks together, allow load bearing to carry from one block to the block below and prevents exposure of the insulation foam to detrimental influences of the environment. The top projection is moulded to a precise height from the bottom of the block and acts as a support screed to accurately position the block and assure the required mortar joint between courses of blocks and therefore assists in the ease of laying the block.
Figure 5 is an end view of Figure 1.
Figure 6 is a plan view of Figure 1 and is as explained in Figure 1.
Figure 7 is an end view of Figure 2.
Figure 8 is a plan view of Figure 2 and is as explained in Figure 2.
Figure 9 shows the foamed in place insulation 9 wi-th projections 12 projecting an equal distance beyond both end walls of the block. This distance is equal to one~
half of the thickness of the mortar joints between blocks. -Figure 10 shows the foamed in place insulation 9 that is flush with one end of the block and with projections 13 projecting beyond the other end of the block. This distance is equal to the full thickness of the mortar joints between blocks.

Figure 11 sho~s the foamed in place insulation 9 with projections 10 projecting a distance above -the block to a height equal to the full thickness of the mortar joints between the block courses.
Figure 12 shows a side view of Figure 2 indicating the extent of thermal bridges 14 in this configuration due to the fire barrier 8 at the bottom of the block.
These bridges amount to less than 3% of the total block area. The possible heat loss through these areas is more than balanced by the greater pro-tection against the spread of fire through the insulation foam. Also shown is the insulation projections beyond the concrete portion of the block in order to insulate the mortar joints. The height of the block "h" is the designed height of the block including the foamed in place insulation. This dimension is always the same for a particular block regardless of variations in the height of the concrete portion of the blocks due to imperfect moulding. The insulation projections take up these variances to fully project the proper distance to the designed height of the block. The concrete variances are automatically adjusted by the mortar joints at the time of erection.
Figure 13 indicates an alternative one piece moulded construction embodiment of a two cavity, two web block having half cavity ends 15 as hand holds and a centre cavity 16, wi-th notches 17 moulded into this centre cavity allowing the splitting of a full block into -two half blocks in the field. The -two concrete webs 13 are precisely positioned to make the webs universal so that one web will always be positioned over the web below whether the blocks are stacked or staggered to the half point. This allows mortar in the joints over the webs more area for bearing and stabilizing the block to the block or blocks below. Further, a straight vertical void without obstructions is provided for reinforcing bars and concrete or grout where structural requirements specify reinforcing the~-wall.i~This:b1ock has a ~ire barrier 8 at the bottom of the insulation slots as shown in figure 2. Like in man~ blocks using mortar joints, figure 13 shows mortar keys 19 in the end face of the exterior cover walls 7. The centre or middle portion of the block consists of walls 20 connected by two webs 18 extending transversely across the hollow interior of the block to connect the,waLls of the block to give it strength.
Figure 14 shows the foamed in place insulation 9 in the block shown in figure 13 with the insulation proj-ections above the top and beyond the ends of concrete in order to insulate the mortar jointv Figures 15 and 17 are end and plan views respectively of figure 13.
Figures 16, 1~ and 19 are the end and two plan views respectively of figure 14 showing the foamed in place insulation projecting into the.mortar joints as described for figure 9 and 10.
Figure 20 shows a side view of a two web, two cavity block shown in figures 13 and 14 and indicates the location of the thin fire barrier ~ at the bottom of the insulation slot and also shows the maximum direct thermal bridges 14. This figure also shows the insulation ~.5 -~9~ 39 projection 10 above -the block to insulate the mortar joint between block courses and the one-half rnor-tar joint thickness of projections 12 beyond the end of the concre-te block butting up against the one-half mortar joint-thick-ness of the insulation projections 12 o~ the adjacent blocks which when combined, insulate a full vertical mortar joint equal to the insulation value of the block itself.
This is illustrated clearly in figure 21 where a partial plan view of three adjacent blocks in a wall are shown.
Figure 22 is a partial plan view of a wall showing the insulation projections 13 of the block shown in figure 19 projecting beyond one end o~ the block the distance of a full mortar joint 21 to butt against the insulation flush with the end of the adjacent block.
Figures 23 and 24 shows a block wi-th the same preferred embodiments as described for figures 1 and 2 respectively with the exception that there is only one insulation slot 4 on one side of the block containing the same principles as descrlbed in the embodiments of the invention.
Figures 25 and 27 are the plan and end views respectively of the block shown in figure 23.
Figures 26 and 29 are the plan and end views respecively of the block shown in figure 24.
Figures 28 and 30 are the end views of figures 23 and 24 respectively with insulation 9 in place projecting above the block lOo Figures 31 and 32 are plan views of the blocks shown in figures 23 and 24 respectively and show the insulation 9 projecting beyond both ends of the block 12 and beyond one end of the block 13 all as previously described in .. ..

~ ~9~39 the embodiments ~f the invention.
- In figure 33, an alternate embodiment of the insulated construction block consists of two concrete parts 1 with the two hollow spaces or voids 2. These concrete parts l provide the walls of the insulation slot 4 from end to end and top to bottom of the block. These parts have two outside walls 3 connected by two end walls 5 and a central web 6 extending transversely across the hollow interior of the block to connect the side walls of the block and to give it s-trength. The exterior of the block itself can be any architectural or artistic design, colour, texture or thic]cness. The overall widths of blocks especially suitable for these blocks are the same widths as regular concrete blocks namely eight inch, ten inch and twelve inch or twenty centimetre, twenty-five centimetre and thirty centimetre blocks. The hollow - voids or spaces 2 can be filled with reinforced concrete should the structural strength of reinforcing be specified~
Figure 3~ is a one piece block similar to the block shown in figure 33 but has a thin concrete fire barrier 8 along the bottom portion of the insulation slot or cavity 4. All other preferred embodiments a e in accordance with the principles of the invention as out-lined in the detailed description of figure 2 and the descriptions of the foamed in place insulation.
Figures 35 and 37 are plan and end views respectively of the two piece block shown in figure 33.
Figures 36 and 39 are plan and end views respectively of the one piece block with a fire barrier 8 along the ~L~9 bottom of the insulation cavity ~ as shown in figure 34.
Figures 38 and 40 are end views of blocks shown in figures 33 and 34 respectively including the insulation 9 and insulation projection 10.
Figures 41 and 42 are plan views~of the blocks shown in figures 33 and 34 respectively. Figure 41 shows the insulation projections 12 projecting beyond both ends of the block. Figure 42 shows the insulation projections 13 projecting beyond one end of the b]ock and flush with the other end of the block.
Figure 43 shows the ~oamed in place insulation bonding both parts 1 together as described earlier in accordance with the preferred embodiments and principles of the invention. In this figure however, the top insulation projection 22 projects further beyond the thickness of the mortar joint to fit and lock into the insulation slot 23 at the bottom of the block above as a tongue and groove joint. A11 other-detailed preferred embodiments are in accordance with the principles of the invention as explained in figure l, 2 and 3 herein.
Figure 44 is an end view of figure 43 showing the insulation projection 22 for insulating the mortar joints.
The insulation slot 23 at the bottom of the insulation cavity will receive projection 22 of the block below, positioning and interlocking the block being erected to the previously erected block. This view also shows the relation between the two concrete parts l and the relation to the foamed in place insulation 9.
Figure ~5 is a partial view of a wall section showing the relation between the concrete parts l, the insulation 9~L~9 - lq -foam 9 enclosed by the two outer parts 1, the mortar joints 24 between the block courses and how the insulation projections 22 fit into the self positioning inter-locking slot 23 in the bottom of each bloc]c.
Figure 46 is a partial view of a wall section showing the relation between the full course high concrete parts ; 25 without a mortar joint and the foamed in place insulation 9. This figure shows insulation projection 26 fitting into the self positioning, interlocking slot 23 in the bottom of the block above similar to a tongue and groove joint, all in accordance with the preferred embodiments and principles of the invention. This design is for the purpose of dry stacking the interlocking blocks in a wall and then either bonding the blocks together by a thin layer of bonding material trowelled onto the inside and outside surface of the blocks like plaster , or fused together at the joints with epoxy bonding material placed between the joints of adjacent blocks.
The present invention is not limited to the specific details shown and described, and modifications may be made in the various embodiments of the insulated construction block without departing from the principles of the invention.

I ~

Claims (10)

The embodiments of the invention in which an exclusive property or priviledge is claimed are defined as follows:-
1. Building blocks for walls or like structures, each of said blocks being a complete integral composite unit of a sandwich type construction consisting of one or more formed or moulded concrete members with one or more insulation cavities filled with "foamed in place insulation material "occupying the cavities provided by the concrete members, and where the insulation foam can be of the same dimensions, be shorter or project beyond the cavities provided by the concrete parts of the block and where the foamed in place insulation material bonds all parts together and provides a continuous insulation, and where the insulation cavities can be located to one side, two sides or the centre of the block or any combination thereof, and where the arrangement is such that any straight or bent vector heat flow striking the structure will always meet at least one barrier of insulation regardless of what point on the structure the vector seeks to go through in a straight line or otherwise, and where the individual blocks in one case are stacked together to form a wall by dry stacking and surface bonding the wall with a plaster like layer of bonding material, and where the blocks are bonded together using an epoxy bonding material between blocks and the most common use of using mortar in the joints between blocks forming a wall, with covers and openings requiring half blocks and bond beam blocks to support the blocks above opening.
2. Building blocks according to claim 1 consisting of a pair of spaced concrete side walls, one central concrete section consisting of two longitudinal walls, two end walls and a central web across the two longitudinal walls dividing the hollow interior region within the walls.
3. Building blocks according to claim 1 where the concrete parts are tied together by a thin concrete bridge providing an effective fire barrier against the burning of the foamed in place insulation material from one block course in a wall to the course above.
4. Building blocks according to claim 2 and 3 where the two longitudinal concrete walls of the central section are connected by two webs across, thus creating one enclosed hollow space and two spaces enclosed by three sides and open at the ends of the block, the webs dimensioned so that the webs line up over those below whether the blocks are staggered or not, allowing reinforcing and concrete to make these holes like reinforced internal columns.
5. Building blocks according to claim 1, 2 and 3 in which the foamed in place insulation material projects above and beyond the top and ends of the concrete parts of the block to provide insulation in the horizontal and vertical mortar joints between adjacent blocks.
6. Building blocks according to claim 1 and 2 in which the foamed in place insulation material is flush with the upper edge of the concrete parts but projects beyond one or both ends of the block and a premoulded insulation strip equal to the thickness of the mortar joints between block courses is placed to insulate the mortar joints between adjacent blocks during erection of the blocks.
7. Building blocks according to claim 1, 2 and 3 in which the foamed in place insulation material projects above the top of the concrete parts of the block to a pre-determined precise distance and acts as support screeds for the positioning of the block being erected on top.
8. Building blocks according to claim 1 and 2 in which the foamed in place insulation material is recessed at the bottom of the insulation cavities between the concrete parts of the block to an equal distance as the insulation material projecting above the top of the block when dry stacking blocks to make a wall, and to an equal distance plus the thickness of a mortar joint where mortar is used between blocks that make up a wall to achieve an interlocking and self positioning feature.
9. Building blocks according to claim 1 where a reflective fireproof sheet such as aluminum foil is placed between the foamed in place insulation during erection of the wall between courses to act as an effective fire barrier against the burning of the foamed in place insulation material from one block course in a wall to the course above and effectively closes off the central air cavities increasing the insulation value of the block.
10. Building blocks according to claim 1 designed to act as half blocks, corner blocks and bond beam blocks having the same insulation values as full blocks.
CA000397739A 1982-03-05 1982-03-05 Insulated construction block Expired CA1149189A (en)

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CA000397739A CA1149189A (en) 1982-03-05 1982-03-05 Insulated construction block

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CA000397739A CA1149189A (en) 1982-03-05 1982-03-05 Insulated construction block

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0171818A1 (en) * 1984-08-17 1986-02-19 Garry B. Stevens Method and apparatus for insulated building block
ES2267349A1 (en) * 2004-06-15 2007-03-01 Universidad De Cantabria Ceramic tiling element with sound and/or thermal insulation, has two external ceramic layers sandwiching insulating material layer in-between
EP2123839A2 (en) * 2008-05-23 2009-11-25 S.A.C.M.E. SpA Structural element for the building trade, machine and method to make it

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0171818A1 (en) * 1984-08-17 1986-02-19 Garry B. Stevens Method and apparatus for insulated building block
ES2267349A1 (en) * 2004-06-15 2007-03-01 Universidad De Cantabria Ceramic tiling element with sound and/or thermal insulation, has two external ceramic layers sandwiching insulating material layer in-between
EP2123839A2 (en) * 2008-05-23 2009-11-25 S.A.C.M.E. SpA Structural element for the building trade, machine and method to make it
EP2123839A3 (en) * 2008-05-23 2010-04-21 S.A.C.M.E. SpA Structural element for the building trade, machine and method to make it
US8549808B2 (en) 2008-05-23 2013-10-08 S.A.C.M.E. Spa Structural element for the building trade
US9561605B2 (en) 2008-05-23 2017-02-07 S.A.C.M.E. Srl Structural element for the building trade, machine and method to make it

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