US3546833A - Insulated building block construction - Google Patents

Insulated building block construction Download PDF

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US3546833A
US3546833A US3546833DA US3546833A US 3546833 A US3546833 A US 3546833A US 3546833D A US3546833D A US 3546833DA US 3546833 A US3546833 A US 3546833A
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block
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insulating
sections
blocks
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Arnold Perreton
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    • 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

Description

Dec. 15, 1970 A. PERRETON INSULATED BUILDING BLOCK CONSTRUCTION 3 Sheets-Sheet '1.

Filed Oct. 8, 1968 INVENTOR ARNOLD PERRE TON I) i TORNEYS Dec. 15, 1970 A. PERRETON INSULATED BUILDING BLOCK CONSTRUCTION 3 Sheets-Sheet 2 Filed 0G1;- 8, 1968 I INVENTOR ARNOLD PE RRE TON Dec. 15, 1370 A. PERRETON INSULATED BUILDING BLOCK CONSTRUCTION 3 Sheets-Sheet 3 Filed Oct. 8, 1968 I00 INVENTOR ARNOLD .PERRETON United States Patent 3,546,833 INSULATED BUILDING BLOCK CONSTRUCTION Arnold Perreton, 12 Centre St., Concord, N.H. 03301 Filed Oct. 8, 1968, Ser. No. 765,825 Int. Cl. E04b 2/20; E04c 1/08; B44f 9/04 U.S. Cl. 52314 10 Claims ABSTRACT OF THE DISCLOSURE An insulated building block in which the longitudinally extending side walls and intermediate wall are spaced and interconnected by longitudinally staggered webs thereby minimizing heat and moisture transmission transversely of the block. The webs between one of the side walls and the intermediate wall are recessed for receiving insulating inserts disposed between such side wall and the intermediate wall. The exterior face of one or more of the block walls is adapted to be formed of exposed aggregate, and the invention also includes the provision of specially-fitting blocks which greatly facilitate erection of the block wall.

BACKGROUND OF THE INVENTION This invention relates generally to building structures and more particularly as indicated to an insulated building block construction and method in which the block and associated insulating insert permit construction of a wall having uniform horizontal and vertical mortar joints and in which the resulting wall construction possesses superior heat and moisture control characteristics.

Numerous types of insulated building blocks have heretofore been proposed and utilized, including those forms disclosed and claimed in my US. Pat. No. 3,204,381, is sued Sept. 7, 1965. While the composite block and insulating inserts disclosed and claimed in my noted patent have performed well in use, in certain installation environments they have not been able to be used, for example, where it is required or desired to use 12" con crete blocks or their equivalent. Commercially available 12 blocks have not proven entirely satisfactory either, for several reasons. They are relatively unattractive, esthetically speaking, and are not designed with insulating and thermal conductivity considerations primarily in mind. Insulation must be provided either exteriorly or interiorally of the wall, with insulation in the latter instance normally being in the form of the pouring type which inherently presents moisture problems. If insulation is applied over the inside face of the block wall, this adds considerably to the material and labor expense, as well as presenting problems in terms of appearance.

SUMMARY OF THE INVENTION An object of the present invention is to provide a building *block specially designed to achieve maximum insulating properties while at the same time achieving a desired balance in the thermal conduction transversely of the block, without detracting from the load carrying properties of the block.

A further object of the present invention is to provide an insulated building block comprising a block of cement or similar materials and a separate insert of insulating material adapted to be positioned in the blocks as the erection of the wall proceeds.

A still further object of the invention is the provision of a composite insulated building block in which the building block and insulating insert are constructed and arranged so that vertical, longitudinal and transverse alignment of adjacent cement blocks is virtually assured thereby providing an attractive block wall having uniform mortar joints. The insulating inserts are tongue and grooved at their opposite ends so as to be automatically aligned with adjacent such inserts, thereby effecting the desired alignment of the cement blocks.

A further, more specific object of the present invention is to provide a 12." block of novel construction in which an intermediate longitudinal wall separates the block into two sections, one of which is adapted to receive the insulating insert and the other is adapted to function as a bearing and also an insulating section. The several transversely extending crosswebs interconnecting the longitudinal intermediate wall with the outside walls of the block are longitudinally staggered to reduce direct thermal and/ or moisture transmission through the wall to a desired minimum.

A still further object of the present invention is to provide an alternative block form in which at least one side wall thereof is provided with a plurality of transversely curved faces extending the entire height of the block so as to present a highly attractive wall surface, without, however, affecting the functional characteristics of the block.

Yet another object or aspect of the present invention is to provide a building block in which at least one exteriorly exposed face of the block uniquely exposes the gravel aggregate of which the block is made so as to provide an attractive yet durable block surface which requires no painting or other surface treatment. In accordance with the present invention, a retardant is applied to the face of the block to be exposed as the block is released from the block machine. Subsequently, after several hours curing, such face is scrubbed and cleaned with water or other suitable cleaning agents to remove the surface cement and thus leave exposed the gravel or chips embedded in the cement matrix of the 'block.

A still further object of the present invention is to provide a building block of the type described in which metal reinforcement members are placed between superimposed block members so as to reinforce the block walls. The reinforcing members are preferably constructed and arranged on the top surface of the block so that transverse bracing sections of the members over the web sections of the block thereby strengthen the same. The insulating inserts are formed with grooves or the like to receive such transversely extending sections of the reinforcing members, thus to avoid exposure of such sections to moisture or other atmospheric conditions which cause rusting which might lead to reinforcement failure or impairment.

Another object of the present invention is to provide a building block of the type described which can be suitably modified to facilitate construction of the wall. In accordance with the invention, specially constructed and fitting block members are provided; for example, corner, jamb, sill and head blocks, to expedite construction of the block wall while maintaining the above described attributes of the novel block construction.

These and other objects and advantages of the invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which:

3 BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded perspective view of a building block, an insulating insert and a metal reinforcing member constructed in accordance with the present invention;

FIG. 2 is a plan view of a section of a wall constructed with the components of FIG. 1;

FIG. 3 is a side elevational view of the wall of FIG. 2, with parts broken away to show more clearly the insulating inserts;

FIG. 4 is a perspective view of an alternative block form of the invention;

FIG. 5 is a top plan view, partially fragmented, of a typical wall section in which both regular and special fitting blocks are provided; and

'FIG. 6 is a vertical sectional View, partially fragmented, of a wall section containing other types of specially fitting blocks.

DETAILED DESCRIPTION Referring now in more detail to the drawings, where like parts are indicated by like reference numerals, and initially to FIGS. 13, a building block constructed in accordance with the present invention is generally indicated at 10 and comprises side walls 12 and 14 and an intermediate wall 16, all of which extend longitudinally of the block the full vertical dimension thereof. The side wall 14 and intermediate wall 16 are interconnected by end webs 18 and 20, which also extend fully vertically of the block, and an intermediate web 22, with the exposed exterior faces of the end webs 18 and 20 and the side wall 14 presenting a substantially flat contour in the usual manner.

The block further includes intermediate web sections 24 and 26 which extend between and interconnect the intermediate wall 16 and the side wall 12, with each Web 24 and 26 being formed with an opening commonly designated at 28 for a purpose to be presently described. The bottom of each opening 28 is defined by a web bottom wall 30 located approximately intermediate the top and bottom surfaces of the block.

It will be noted that the intermediate webs 24 and 26 are longitudinally staggered relative to the webs 18, 20 and 22. In this manner, direct thermal and moisture transmission through the block wall is greatly reduced. The total cross-sectional area of the webs 18-26 preferably comprises about 10% of the total cross-sectional area of a vertical plane through any of the walls 12, 14 and 16. It has been found that this percentage provides the desired balance between insulating qualities of the block and moisture transmission. It should be noted that the web area indicated as preferred approaches the minimum area consistent with providing some breathing of the block. By breathing is meant the ability to transmit directly heat and moisture transversely through the block. If some degree of moisture conductance is not provided, a moisture buildup inevitably results on the inside wall during periods of high humidity, which obviously presents problems where the inside wall is finished with materials not able to satisfactorily adsorb such moisture. The preferred web area is, however, sufliciently low so as to provide the block with self-insulating properties, through the void areas, to the maximum extent practical without impairing the strength of the block.

The webs 18, 20, and 22 extend the full height of the block and serve to partially define block cavities 32 and 34. By making the upper ends of the webs 18, 20 and 22 coextensive with the block walls 14 and 16, a substantially greater bearing surface is provided. It will also be noted that the building block is thickened in the region of the connection of each of the intermediate webs 24 and 26 with the longitudinal walls 12 and 16. Thus, thickened sections commonly designated at 36 interconnect each A web 24 and 26 with the adjacent wall section thereby providing greater bearing surface and thus bearing strength in the region of the web formation. The thickened sections also serve to minimize block breakage in the web sections during subsequent handling.

In accordance with a further aspect of the present invention, the exterior surface 40 of the side wall 12 is manufactured so as to provide exposed aggregate particles commonly designated at A. The exposure of such aggregate particles is not only attractive, but provides a durable block surface which obviates the need for painting or otherwise treating the surface of the block to preserve the same. The exposure of the aggregate A during manufacture of the block is accomplished by applying a suitable retardant to one or more faces of the block, as desired, as the building block is released from the block machine. Then after curing a suitable time to harden the remainder of the block, for example, overnight, the face or faces on which the retardant has been applied is scrubbed and washed with Water or other cleaning solutions to remove the surface cement thereby exposing the aggregate embedded in the cement matrix of the block. The type of aggregate selected can be varied to create the desired esthetic effect, with marble, quartz or granite chips being examples of aggregate particles frequently used and variously combined to achieve the desired appearance. In this regard, the aggregate can often be obtained inexpensively, from local rock formations, thereby permitting a desirable identification of the exposed aggregate When the blocks are used in the same general area. It will also be noted that the color of the aggregate exposed can be selected as desired to give a particular appearance.

Where it is desired to expose the aggregate on one or more faces of the block, the formulation of the block is of significance. In normal block formation, the aggregate component comprises about 2530% of the total formulation, with the remainder comprising cement (15-20%) and sand (50-60%). Where the block is going to be treated so as to expose one or more faces, it is desirable to significantly increase the proportions of cement and aggregate, with the percentage of cement being increased primarily to provide a stronger bond for the aggregate, which is particularly desired at the region of the exposed face. The stronger bond minimizes the breaking off or dislodging of the aggregate particles exposed.

The preferred formulation for the block constituents where aggregate is to be exposed at one or more faces comprises aggregate in the range of 45-65%, cement 2030% and sand 10-30%, with the most preferred formulation being 55% aggregate, 25% cement and 20% sand. As above indicated, the aggregate can be selected based on several factors, including size, color and weight. In regard to this last mentioned factor, lightweight aggregates are desirably used where the weight of the block is a significant factor. In addition, certain of the lightweight aggregates employed, for example, pumice, possess superior insulating properties thereby increasing the property of the block in this respect.

To even further add to the attractive appearance of the blocks, vertical score lines 42 are desirably formed in the outside face of the side wall 12 to provide a unique wall appearance. These can be spaced as desired, preferably unsymetrically, so as to be pleasingly dissimilar to normal wall joint formation.

The insulating insert 50 is generally indicated at 50 and is preferably formed of a relatively rigid insulating material such as polystyrene or the like. The insert 50 is slightly greater in length and height than the block 10, with such increased dimension being identical with the desired thickness of the mortar joints. The insert 50 is of a width to fairly closely fit within the openings 28 formed in the intermediate flanges 24 and 26.

The insulating block 50 is formed of longitudinally spaced notches 52 and 54 which extend transversely through the block. The notches 52 and 54 are of a depth and height to receive the bottom, solid sections of the webs 24 and 26, upwardly defined by the flat surfaces 30, when the insulating block is disposed and properly aligned with the block. Although the notches 52 and 54 could be received in the webs 24 and 26, respectively, of the same block, they are preferably received in the adjacent webs of adjacent masonry blocks as shown in FIGS. 1-3, so that each insulating block bridges adjacently layed masonry blocks. In this manner, each block is accurately keyed in with the suceeding block, and inserted so as to assure straightness. It will be noted that obtaining the desired straightness is further enhanced by the presence of the thickened sections 36 around each web the distance between opposite ones of which is only slightly greater than the width of the insulating block thereby to accurately position the same.

Each insulating block 50 is formed with means to assure the vertical, longitudinal and transverse alignment and spacing of adjacently disposed insulating blocks thereby assuring the laying of a truly straight block wall. In accordance with the invention, one end 56 of the insulating block is provided with an outwardly extending tongue portion 58, the upper portion 60 of which extends above the top surface of the block 10. An intermediate top projection 64 extends from the top surface of the block the same distance as the tongue portion 60, and a similar projection 66 is formed at the opposite end of the block. Such opposite end is also formed with a groove 68 which is coextensive in width, depth and height with the tongue 58 thereby providing a tongue and groove arrangement when adjacent insulating blocks 50 are disposed longitudinally in end to end relation, as shown in FIG. 2.

Each block 50 is formed with a series of bottom grooves 70 which are coextensive in size with the above described upwardly extending projections 60, 64 and 66. In this manner, these latter projections are adapted to extend into the bottom grooves 70 of a superimposed insulating block when the next row or course of building blocks are laid. It will thus be seen that by virtue of the longitudinal and transverse tongue and groove arrangements between adjacent and superimposed insulating blocks, the laying of a perfectly straight block wall is assured.

Metal reinforcing members commonly designated at 80, and best seen in FIG. 1, are adapted to be disposed in the horizontal mortar joints between courses of blocks to reinforce and rigidify the block wall. The reinforcement members 80 are provided with one or more transversely extending cross wires 82 which are spaced so as to be received in grooves 72 and 74 formed in the top surface of the insulating inserts 50. The longitudinal side walls of each metal reinforcing member 80 are disposed on the top surface of the walls 12 and of the concrete block to either side of the insulating insert 50. The reinforcing members 80 are embedded in the horizontal mortar joint during construction of the wall thereby providing the same with the desired reinforcement and eliminating moisture transmission to the reinforcing member. It will be noted that the cross wires 82 are in alignment with the webs 24 and 26 thereby improving the rigidity of the block wall in a transverse direction. The reinforcing members preferably come in 10' lengths, although it will be apparent that the length could be varied as desired without affecting the functional characteristics of the reinforcement.

Referring to FIG. 1, it will be noted that the front and rear faces of the cement block 10 are formed with vertically extending grooves commonly designated at 90 which extend the entire height of the groove. Such grooves function to provide additional joint volume in transversely spaced areas of the block thereby improving the mechanical locking between longitudinally adjacent blocks to thus provide a stronger wall.

A block wall constructed of the above described components is shown in plan and ele-vational views in FIGS. 2 and 3, respectively. The special relation of the cement blocks and insulating inserts will be particularly evident from these figures and the uniformity of the horizontal and vertical mortar joints will be evident.

It will be seen that the invention thus far described is unique in several important respects. The shape of the insulating block 50 and the arrangement thereof with the associated building block 10 assure both vertical, transverse and longitudinal alignment of the insert, and thus the blocks, as construction of the wall proceeds. In addition to this alignment feature, the blocks 50 provide the highly desirable insulating effect transversely of the concrete blocks. To reduce thermal and moisture transmission transversely through the block even further, the several intermediate connecting web sections in the block are longitudinally staggered, with the web sections 24 and 26 being disposed approximately intermediate the length of the cavities 32 and 34. The bearing strength of the block is maximized through the provision of flat top bearing surfaces which are increased in area in the region of the web sections 24 and 26 by providing the described thickened sections 36 interconnecting the webs 24 and 26 with the adjacent wall portions of the block. Finally, through a unique process during the final stages of block formation, an exposed aggregate face 40 is provided which is both highly attractive and durable.

There is shown in FIG. 4 a slightly modified block form, with the same reference numerals being applied, where applicable, as in FIGS. 1-3. In the FIG. 4 form, one exposed side wall is formed preferably by molding to provide a pair of vertically contoured block sections and 102, with the section 100 being interconnected to the intermediate wall 16 by integral web sections 104 and 166, respectively. Similarly, interconnecting web sections 108 and 110 interconnect the wall section 102 with the adjacently disposed region of the intermediate wall 16. The openings 32 and 34 in this region of the block are thus somewhat reduced in cross sectional area.

The FIG. 4 block form is otherwise of the same construction as previously described in connection with the FIG. 1 block form, and cooperates with the insulating insert and the reinforcing members in the same way. It will be visualized that a unique wall surface will be provided by a wall constructed partially or entirely of blocks of the FIG. 4 form. It will also be apparent that the contouring of the inside wall of the block of the FIG. 4 form in no way detracts from the functional advantages of the block as above described. The curved side wall sections 100 and 102 can be disposed so as to form the exterior or interior wall surface, as desired. In the case of the latter disposition, the exterior side wall could be formed of exposed aggregate as described above in connection with FIGS. 1-3.

In accordance with a still further aspect of the present invention, specially constructed and fitting concrete block forms are provided to expedite the laying of the block wall. These are shown in FIG. 5, which comprises a top plan view of a typical section of a 12" wall containing both regular and specially fitting block units, and in FIG. 6, which comprises a vertical sectional view of a typical wall section through a sash.

Referring to FIG. 5, the regular 12" block described above is designated by the same reference numeral 10, and disposed at the right thereof as viewed in this figure is a half jamb block generally indicated at and a corner block generally indicated at 122. Contiguous the corner block 122 at the opposite end thereof is a full jamb block generally indicated at 124.

Referring back to the half jamb block 120, the same is formed with a relatively flat end face formed with a vertically extending notch 132 for receiving jamb memher 133. The block 120 further includes exterior and interior side walls 134 and 136, respectively, and an intermediate wall 138 which defines with the interior wall 136 a cavity 140. A connecting Web 142 similar to the above identified webs 24 and 26 interconnects the walls 134 and 138 and is similarly recessed to receive insulating insert 144. The block 120 is additionally formed with an outwardly extending opening 146 which is adjacent the end opening 148 formed in the block 18 when the jamb block is positioned as shown in FIG. 5. In such position, the web 142 and adjacent web 26 are spaced so as to receive the bottom notches in the insulating insert 144 in the manner above described.

The corner block 122 comprises longitudinally extending walls 150 and 152 and transversely extending spaced webs 154, 156 and 158, with the latter web being vertically coextensive with the height of the block and presenting a fiat exterior face coplanar with the exterior face of the adjacent block 10. The web 154 is recessed in the same manner as the webs 24 and 26 described above to receive the notched insulating insert 160. The longitudinal side walls of the block and the connecting web sections define cavities 162 and 164 which receive insulating insert sections as shown.

The corner block 122 further includes a laterally inwardly directed corner section 166 which is adapted to extend between the adjacent sections of the blocks 10 and 124 thereby to provide the full 12 transverse dimension of the block wall throughout the corner section.

The full jamb block 124 is similar in most respects to the regular block 10 except that the end face 170 is entirely closed and slotted as shown in 172 for receiving jamb member 174. The block 124 further includes side walls 176 and 178, intermediate wall 180 and transverse connecting webs 182, 184 and 186 which are longitudinally staggered in the manner above described to reduce the heat and moisture transmission transversely through the wall. Similar to block 10, the connecting webs 182 and 186 are recessed to receive the notches of the insulating insert members disposed in such region of the block.

Referring to FIG. 6, sill and head blocks 126 and 128 are generally similar to the half jamb block 120 previously described, with one exception. The blocks 126 and 128 are not provided with connecting web portions between the exterior and intermediate longitudinal walls commonly designated at 208 and 202, respectively. Each block 126 and 128 further includes exterior side walls 204 and essentially closed bottom and top walls designated at 206 and 207, respectively with each wall being formed with a groove 208 adapted to receive the adjacent sash structure.

Although not shown in the FIG. plan view, it will be understood that the reinforcing members 80 previously described may, if desired, be provided, and that the insulating inserts may be formed with transverse grooves to receive the cross sections of such reinforcing members, as above described. It will further be apparent that insulating insert 50 may require some modification when employed with the specially fitting blocks shown in FIGS. 5 and 6. This is normally accomplished simply by on the spot cutting as required to fit in the particular shaped cavity of the specially fitting block. Thus, abbreviated insert sections are formed and disposed in the cavity 164 of the block 122.

Although not visible in FIGS. 5 and 6, it will be understood that the exterior faces of all the several block forms illustrated may be formed with the exposed aggregate surface 40 as above described with reference to the block illustrated in FIG. 1. It will also be understood that, if desired, the specially fitting blocks just described can be formed with contoured exterior surfaces as shown in FIG. 4.

It will thus be seen that the several objects of the in vention have been accomplished. A composite building block has been provided which is of unique construction and adapted to receive insulating insert members shaped to automatically longitudinally, vertically and transversely align adjacently disposed insert members and thus the blocks associated therewith. In this manner the plane of the block wall can be maintained perfectly straight as the wall is erected. The construction of the blocks themselves and the insulating inserts collectively serve to minimize the heat and moisture transmission between the opposite longitudinal walls of the block, with the several interconnecting webs between the longitudinal sections of the block being longitudinally staggered and generally intermediate a block cavity. In this manner, heat and moisture transmission transversely directly through the block is controlled and minimized. In addition to these advantageous insulating properties, the block is structurally rugged with the main load carrying section of the block being relatively thickened as described to provide maximum load bearing characteristics. The block in a single unit thus provides functional advantages not heretofore obtained in blocks of this type and size.

In addition to the above noted functional advantages, the block is at the same time highly attractive. The exposed aggregate face provides a unique appearance which has the additional advantage of reducing maintenance of the block wall substantially.

What is claimed is:

1. An insulated building wall having uniform mortar joints comprising a plurality of building blocks each having longitudinally extending and transversely spaced side walls and a longitudinally extending intermediate wall generally coextensive in length with and spaced transversely from said side walls, a plurality of transversely extending web sections interconnecting said side walls respectively with said intermediate wall, said web sections including two end webs and an intermediate web coextensive with and extending uninterrupted between one of said side walls and said intermediate wall and defining therewith a pair of longitudinally spaced cavities, said end and intermediate webs and said one side wall and said intermediate Wall forming the major load-bearing portion of said block, the remainder of said web sections comprising a pair of webs extending between said intermediate wall and the other of said side walls and serving asv the sole connection therebetween, said last mentioned pair of webs being longitudinally staggered relative to said end webs and said intermediate webs and interconnected to said intermediate wall substantially midway of said cavities, the longitudinal staggering of said plurality of webs serving to minimize heat and moisture transmission transversely of said block, insulating insert means associated with each block, said insulating insert means being constructed and arranged relative to its associated block so as to extend beyond the leading edge and top surface of said block an amount equal to the desired thickness of the vertical and horizontal mortar joint, each insulating insert means being formed With alignment means for precisely aligning the superimposed and longitudinally adjacent insulating inserts, thereby serving to align the blocks associated therewith and thus provide uniform vertical and horizontal mortar joints.

2. The combination of claim 1 further including reinforcing means disposed between vertically spaced blocks and adapted to be embedded in said horizontal mortar joint thereby reinforcing said wall.

3. A building block comprising a pair of spaced side walls and a longitudinally extending intermediate wall generally coextensive in length with and spaced transversely from each of said side walls, a plurality of transversely extending web sections interconnecting said side walls respectively with said intermediate wall, said web sections including two end webs and an intermediate web coextensive with and extending uninterrupted between one of said side walls and said intermediate wall and defining therewith a pair of longitudinally spaced cavities, said end and intermediate webs and said one side wall and said inter-= mediate wall forming the :major load-bearing portion of said block, the remainder of said web sections comprising a pair of webs extending between said intermediate wall and the other of said side walls and serving as the sole connection therebetween, said last mentioned pair of Webs being longitudinally staggered relative to said end webs and said intermediate web and interconnected to said intermediate wall substantially midway of said cavities, each of said last mentioned pair of connecting webs being formed with an upwardly opening recess extending downwardly a substatnial distance from the top of said webs, insulating insert means disposed between said intermediate wall and said other side wall in said recesses, said insulating insert means being provided with alignment means to insure longitudinal and transverse alignment with longitudinally adjacent and superimposed similar such insert means thereby insuring erection of a straight block wall, said transverse alignment means comprising a tongue formed on the leading end of said insert means and a groove for receiving said tongue formed on the trailing edge of said insert means thereby to transversely align succeeding insert means and thus the blocks associated therewith, each of said insulating inserts being further formed with upwardly extending projections on the top surface thereof and complemental recesses in the bottom wall thereof, said projections being received in the complemental recesses of a superimposed insert thereby serving to augment the transverse alignment of said inserts and thus said blocks, the top surface of each of said inserts being formed with a plurality of transversely extending grooves, and metallic reinforcement means having longitudinal side sections adapted to overlie said intermediate wall and said other wall, and transverse sections extending between and interconnecting said side sections, said transverse sections being disposed in said transversely extending grooves so as not to interfere with the vertical alignment and interconnections of superimposed insulating inserts, said grooves and said transverse sections of said reinforcing member being in the plane of said pair of said connecting webs thereby to rigidify the block in such area upon erection of the block wall.

4. The building block of claim 3 wherein the exterior face of at least one of said side walls is formed of exposed aggregate.

5. The block of claim 3 wherein said block is formed of 20-30% cement, -30% sand, and 45-65% aggregate.

6. The 'block of claim 3 wherein said block is formed of 25% cement, sand and 55% aggregate.

7. The building block of claim 3 wherein said one side wall comprises a plurality of longitudinally spaced curved wall sections, the plane of curvature of each of said curved wall sections being perpendicular to the longitudinal axis of said block.

8. The building block of claim 3 wherein said intermediate wall and said other side wall are transversely enlarged in the regions thereof adjacent said last mentioned pair of webs thereby to provide a substantially greater top bearing surface on said block.

9. A building block comprising a pair of spaced side walls and a longitudinally extending intermediate wall generally coextensive in length with and spaced transversely from each of said side walls, a plurality of transversely extending Web sections interconnecting said side walls respectively with said intermediate wall, said web sections including two end webs and an intermediate web coextensive with and extending uninterrupted between one of said side walls and said intermediate wall and defining therewith a pair of longitudinally spaced cavities, said end and intermediate webs and said one side wall and said intermediate wall forming the major load-bearing portion of said block, the remainder of said web sections comprising a pair of webs extending between said intermediate wall and the other of said side walls and serving as the sole connection therebetween, said last mentioned pair of webs being longitudinally staggered relative to said end webs and said intermediate web and interconnected to said intermediate wall substantially midway of said cavities, each of said last mentioned pair of connecting webs being formed with an upwardly opening recess extending down wardly a substantial distance from the top of said webs, insulating insert means disposed between said intermediate wall and said other side wall, said insert means being formed with a pair of notches for receiving said webs, the spacing of said recessed webs and said notches being such as to permit positioning of said insert means either substantially entirely within said block or in a longitudinally staggered position bridging adjacently disposed blocks, said insulating insert means being further provided with alignment means to insure longitudinal and transverse alignment with longitudinally adjacent and superimposed similar such insert lmeans thereby insuring erec tion of a straight block wall, said transverse alignment means comprising a tongue formed on the leading end of said insert means and a groove for receiving said tongue formed on the trailing edge of said insert means thereby to transversely align succeeding insert means and thus the blocks associated therewith, each of said insulating inserts being further formed with upwardly extending projections on the top surface thereof and complemental recesses in the bottom wall thereof, said projections being received in the complemental recesses of a superimposed insert thereby serving to augment the transverse alignment of said inserts and thus said blocks, the top surface of each of said inserts being formed with a plurality of transversely extending grooves, and metallic reinforcement means having longitudinal side sections adapted to overlie said intermediate wall and said other wall and transverse sections extending between and interconnecting said side sections, said transverse sections being adapted to be disposed in said transversely extending grooves so as not to interfere with the vertical alignment of superimposed insulating inserts, said grooves and said transverse sections of said reinforcing member being in the vertical plane of said recessed connecting webs.

10. A building block comprising a pair of spaced side walls and a longitudinally extending intermediate wall generally coextensive in length with and spaced transversely from each of said side walls, a plurality of transversely extending web sections interconnecting said side walls respectively with said intermediate wall, said web sections including two end webs and an intermediate web coextensive with and extending uninterrupted between one of said side walls and said intermediate wall and defining therewith a pair of longitudinally spaced cavities, said end and intermediate webs and said one side wall and said intermediate wall forming the major load-bearing portion of said block, the remainder of said web sections comprising a pair of webs extending between said intermediate Wall and the other of said side walls and serving as the sole connection therebetween, said last mentioned pair of webs being longitudinally staggered relative to said end webs and said intermediate web and interconnected to said intermediate Wall substantially midway of said cavities, each of said last mentioned pair of connecting webs being formed with an upwardly opening recess extending downwardly a substantial distance from the top of said webs, insulating insert means disposed between said intermediate wall and said other side wall, said insert means being formed with a pair of notches for receiving said webs, the spacing of said recessed webs and said notches being such as to permit positioning of said insert means either substantially entirely within said block or in a longitudinally staggered posiiton bridging adjacently disposed blocks, said insulating insert means being further provided with alignment means to insure longitudinal and transverse alignment with longitudinally adjacent and superimposed similar such insert means thereby insuring erection of a straight block wall, the top surface of each of said inserts being formed with a plurality of transversely extending 11 grooves, and metallic reinforcement means having longi tudinal side sections adapted to overlie said intermediate Wall and said other Wall and transverse sections extending between and interconnecting said side sections, said transverse sections being adapted to be disposed in said transversely extending grooves so as not to interfere'with the vertical alignment of superimposed insulating inserts, said grooves and said transverse sections of said reinforcing member being in the vertical plane of said recessed connecting webs.

References Cited UNITED STATES PATENTS Re. 12,310 1/1905 Miracle et a1 52442 1,637,321 7/1927 Johnson 264139 2,294,051 8/1942 Sjobring 52410 1 2 2,601,532 6/1952 Knighton' j SQ-612x 2,852,934 9/1958 Amundson 52-405 2,929,238 3/ 1960 Kaye 52442X 3,204,381 9/1965 Perreton 52504X 5 FOREIGN PATENTS 175,367 7/1953 Austria 52-437 985,377 3/1951 France 52314 1,181,369 1/1959 France 52405 10 ALFRED c. PERHAM, Primary Examiner US. Cl. X.R.

US3546833D 1968-10-08 1968-10-08 Insulated building block construction Expired - Lifetime US3546833A (en)

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Cited By (55)

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FR2188016A1 (en) * 1972-06-02 1974-01-18 Schaeffer Ets S Ccesseur
US3936987A (en) * 1975-01-13 1976-02-10 Edward L Calvin Interlocking brick or building block and walls constructed therefrom
US3982369A (en) * 1975-04-18 1976-09-28 Keleske Henry P Insulated building block
US4002002A (en) * 1976-04-19 1977-01-11 Barnhardt Jr Jacob C Insulating building block
US4004385A (en) * 1973-04-17 1977-01-25 Momotoshi Kosuge Building structure using concrete blocks
US4016693A (en) * 1975-08-22 1977-04-12 Warren Insulated Bloc, Inc. Insulated masonry block
US4034529A (en) * 1976-06-03 1977-07-12 Lampus Donald L Rebar bolster for solid grouted walls
US4058948A (en) * 1975-08-22 1977-11-22 Warren Insulated Bloc, Inc. Insulated masonry block
US4073111A (en) * 1976-01-16 1978-02-14 Warren Insulated Bloc, Inc. Insulated masonry block
US4107895A (en) * 1975-11-20 1978-08-22 Legrady Carl F Reinforcing bar locating means
US4130973A (en) * 1977-09-07 1978-12-26 Curt Holger Ingestrom Building block
US4134241A (en) * 1977-07-07 1979-01-16 Energy Block Ltd. Insulated building block
US4190995A (en) * 1978-07-26 1980-03-04 Armistead John A Composite building unit, method of producing same
US4193241A (en) * 1977-12-05 1980-03-18 Cooper Ralph F Masonry block insulating device
US4229922A (en) * 1979-06-04 1980-10-28 Clark Jr John E Wall assembly
US4269013A (en) * 1979-04-26 1981-05-26 West Earl L Insulated building block wall construction
US4337755A (en) * 1980-04-23 1982-07-06 Pitha Jay R Solar collector block
US4344263A (en) * 1980-07-28 1982-08-17 Farmont Johann H Building log with high thermal insulation characteristics
US4348845A (en) * 1980-06-02 1982-09-14 Iannarelli Anthony N Thermally insulated masonry block
US4485546A (en) * 1980-06-23 1984-12-04 Farila Lattblock Ab Method and apparatus for packing insulation material in hollow blocks
US4498266A (en) * 1982-06-22 1985-02-12 Arnold Perreton Concrete block and hollow insulating insert therefor
US4527373A (en) * 1980-04-17 1985-07-09 Cruise Thomas E Insulated concrete masonry unit with low density heat bridges
US4557094A (en) * 1984-02-10 1985-12-10 Epsm Inc. Insulated block building
US4557093A (en) * 1984-02-10 1985-12-10 Epsm Inc. Insulated building block
EP0209993A2 (en) * 1985-07-10 1987-01-28 Jacov Snitovski A thermally insulating masonry block, a method for manufacturing such a block, and a method of building a wall of such blocks
US4748782A (en) * 1984-06-14 1988-06-07 Johnson Stanley D Self-aligned and leveled insulated, drystack block structures and means and methods therefor
US4819396A (en) * 1982-07-07 1989-04-11 Cruise Thomas E Insulated concrete masonry unit with low density heat bridges
US5062244A (en) * 1991-03-04 1991-11-05 Ducharme Edgar R Insulating insert for the cores of building blocks
US5072556A (en) * 1989-12-20 1991-12-17 Egenhoefer George G Wall assembly construction
US5349798A (en) * 1992-09-17 1994-09-27 Fabricating Packaging Materials, Inc. Insulating insert for concrete blocks
US5649391A (en) * 1996-02-23 1997-07-22 Layne; Harry R. Embeddable mounting device and method
US5881524A (en) * 1990-10-26 1999-03-16 Ellison, Jr.; Russell P. Composite building system and method of manufacturing same and components therefore
US6111197A (en) * 1998-09-04 2000-08-29 Layne; Harry R. Embeddable mounting device
US6148576A (en) * 1998-08-19 2000-11-21 Janopaul, Jr.; Peter Energy conserving wall unit and method of forming same
US6629393B2 (en) 2001-08-13 2003-10-07 James J. Pignataro Masonry reinforcing tie
US20050081470A1 (en) * 2003-10-15 2005-04-21 Morito Utsunomiya Block and block connector
US20080202051A1 (en) * 2007-02-28 2008-08-28 Roehrig Robert C Concrete block system
US20080236081A1 (en) * 2007-03-28 2008-10-02 Francis Kennedy Insulated building block
US20080250736A1 (en) * 2005-09-22 2008-10-16 Laurentiu Dumitru Breaz Modular Elements, Network, Supporting Structure, Construct
US20090064991A1 (en) * 2007-09-06 2009-03-12 Keting Zheng Solar Energy Capturing Building Construction Materials, Systems and Methods
US20100018146A1 (en) * 2007-02-02 2010-01-28 Les Matériaux De Construction Oldcastle Canada, In Wall with decorative facing
US20110000161A1 (en) * 2007-02-02 2011-01-06 Les Materiaux De Construction Oldcastle Canada, Inc. Wall with decorative facing
US20120079783A1 (en) * 2006-09-19 2012-04-05 Michael Edward Nylin Simplified non-polystyrene permanent insulating concrete form building system
US20120186172A1 (en) * 2009-02-06 2012-07-26 Bouchard Andre Construction system for buildings
US20130014462A1 (en) * 2011-06-21 2013-01-17 Nv Bekaert Sa Method of reducing the width of cracks in masonry
US8635826B2 (en) * 2012-04-10 2014-01-28 Reward Wall Systems, Inc. Insulation insert panel for use with insulating concrete form (ICF) systems
US20140196397A1 (en) * 2013-01-17 2014-07-17 Tom Sourlis Insulated building block and wall structure
USD713975S1 (en) 2012-07-30 2014-09-23 Airlite Plastics Co. Insulative insert for insulated concrete form
US8919067B2 (en) 2011-10-31 2014-12-30 Airlite Plastics Co. Apparatus and method for construction of structures utilizing insulated concrete forms
US8992131B2 (en) 2010-09-28 2015-03-31 Les Matériaux De Construction Oldcastle Canada, Inc. Retaining wall
US9441342B2 (en) 2010-09-28 2016-09-13 Les Materiaux De Construction Oldcastle Canada, In Retaining wall
US20170145687A1 (en) * 2014-07-04 2017-05-25 Iida Group Holdings Co., Ltd. Construction block and wall face structure using same
US9670640B2 (en) 2010-09-28 2017-06-06 Les Materiaux De Construction Oldcastle Canada, Inc. Retaining wall
US9714510B2 (en) 2013-02-25 2017-07-25 Les Materiaux De Construction Oldcastle Canada Inc. Wall assembly
US9739058B1 (en) * 2013-06-24 2017-08-22 Johnson Concrete Company Modular construction block

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US2294051A (en) * 1939-06-24 1942-08-25 Nils P Sjobring Wall construction
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US2601532A (en) * 1949-08-19 1952-06-24 James A Knighton Method of making faced building blocks and the like
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US2852934A (en) * 1952-08-08 1958-09-23 Thermoflector Corp Insulated hollow building blocks
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Cited By (73)

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FR2188016A1 (en) * 1972-06-02 1974-01-18 Schaeffer Ets S Ccesseur
US4004385A (en) * 1973-04-17 1977-01-25 Momotoshi Kosuge Building structure using concrete blocks
US3936987A (en) * 1975-01-13 1976-02-10 Edward L Calvin Interlocking brick or building block and walls constructed therefrom
US3982369A (en) * 1975-04-18 1976-09-28 Keleske Henry P Insulated building block
US4058948A (en) * 1975-08-22 1977-11-22 Warren Insulated Bloc, Inc. Insulated masonry block
US4016693A (en) * 1975-08-22 1977-04-12 Warren Insulated Bloc, Inc. Insulated masonry block
US4107895A (en) * 1975-11-20 1978-08-22 Legrady Carl F Reinforcing bar locating means
US4073111A (en) * 1976-01-16 1978-02-14 Warren Insulated Bloc, Inc. Insulated masonry block
US4002002A (en) * 1976-04-19 1977-01-11 Barnhardt Jr Jacob C Insulating building block
US4034529A (en) * 1976-06-03 1977-07-12 Lampus Donald L Rebar bolster for solid grouted walls
US4134241A (en) * 1977-07-07 1979-01-16 Energy Block Ltd. Insulated building block
US4130973A (en) * 1977-09-07 1978-12-26 Curt Holger Ingestrom Building block
US4193241A (en) * 1977-12-05 1980-03-18 Cooper Ralph F Masonry block insulating device
US4190995A (en) * 1978-07-26 1980-03-04 Armistead John A Composite building unit, method of producing same
US4269013A (en) * 1979-04-26 1981-05-26 West Earl L Insulated building block wall construction
US4229922A (en) * 1979-06-04 1980-10-28 Clark Jr John E Wall assembly
US4527373A (en) * 1980-04-17 1985-07-09 Cruise Thomas E Insulated concrete masonry unit with low density heat bridges
US4337755A (en) * 1980-04-23 1982-07-06 Pitha Jay R Solar collector block
US4348845A (en) * 1980-06-02 1982-09-14 Iannarelli Anthony N Thermally insulated masonry block
US4485546A (en) * 1980-06-23 1984-12-04 Farila Lattblock Ab Method and apparatus for packing insulation material in hollow blocks
US4344263A (en) * 1980-07-28 1982-08-17 Farmont Johann H Building log with high thermal insulation characteristics
US4498266A (en) * 1982-06-22 1985-02-12 Arnold Perreton Concrete block and hollow insulating insert therefor
US4819396A (en) * 1982-07-07 1989-04-11 Cruise Thomas E Insulated concrete masonry unit with low density heat bridges
US4557094A (en) * 1984-02-10 1985-12-10 Epsm Inc. Insulated block building
US4557093A (en) * 1984-02-10 1985-12-10 Epsm Inc. Insulated building block
US4769964A (en) * 1984-06-14 1988-09-13 Johnson Stanley D Self-aligned and leveled, insulated, drystack block
US4748782A (en) * 1984-06-14 1988-06-07 Johnson Stanley D Self-aligned and leveled insulated, drystack block structures and means and methods therefor
EP0209993A3 (en) * 1985-07-10 1987-12-23 Jacov Snitovski A thermally insulating masonry block, a method for manufacturing such a block, and a method of building a wall of such blocks
EP0209993A2 (en) * 1985-07-10 1987-01-28 Jacov Snitovski A thermally insulating masonry block, a method for manufacturing such a block, and a method of building a wall of such blocks
US5072556A (en) * 1989-12-20 1991-12-17 Egenhoefer George G Wall assembly construction
US5881524A (en) * 1990-10-26 1999-03-16 Ellison, Jr.; Russell P. Composite building system and method of manufacturing same and components therefore
US5062244A (en) * 1991-03-04 1991-11-05 Ducharme Edgar R Insulating insert for the cores of building blocks
US5349798A (en) * 1992-09-17 1994-09-27 Fabricating Packaging Materials, Inc. Insulating insert for concrete blocks
USRE37981E1 (en) * 1996-02-23 2003-02-11 Steel Block, Inc. Embeddable mounting device and method
US5649391A (en) * 1996-02-23 1997-07-22 Layne; Harry R. Embeddable mounting device and method
US6148576A (en) * 1998-08-19 2000-11-21 Janopaul, Jr.; Peter Energy conserving wall unit and method of forming same
US6111197A (en) * 1998-09-04 2000-08-29 Layne; Harry R. Embeddable mounting device
US6271468B1 (en) * 1998-09-04 2001-08-07 Steel Block, Inc. Embeddable mounting device with faceplate
US6388192B1 (en) * 1998-09-04 2002-05-14 Steel Block, Inc. Embeddable mounting device
US6265657B1 (en) * 1998-09-04 2001-07-24 Steel Block, Inc. Embeddable mounting device
US6629393B2 (en) 2001-08-13 2003-10-07 James J. Pignataro Masonry reinforcing tie
US20050081470A1 (en) * 2003-10-15 2005-04-21 Morito Utsunomiya Block and block connector
US7802410B2 (en) * 2005-09-22 2010-09-28 Laurentiu Dumitru Breaz Modular elements, network, supporting structure, construct
US20080250736A1 (en) * 2005-09-22 2008-10-16 Laurentiu Dumitru Breaz Modular Elements, Network, Supporting Structure, Construct
US20120079783A1 (en) * 2006-09-19 2012-04-05 Michael Edward Nylin Simplified non-polystyrene permanent insulating concrete form building system
US9206599B2 (en) 2007-02-02 2015-12-08 Les Materiaux De Construction Oldcastle Canada, Inc. Wall with decorative facing
US20100018146A1 (en) * 2007-02-02 2010-01-28 Les Matériaux De Construction Oldcastle Canada, In Wall with decorative facing
US9803359B2 (en) 2007-02-02 2017-10-31 Les Materiaux De Construction Oldcastle Canada, Inc. Wall with decorative facing
US9464431B2 (en) 2007-02-02 2016-10-11 Les Materiaux De Construction Oldcastle Canada Inc Wall with decorative facing
US20110000161A1 (en) * 2007-02-02 2011-01-06 Les Materiaux De Construction Oldcastle Canada, Inc. Wall with decorative facing
US10472821B2 (en) 2007-02-02 2019-11-12 Les Materiaux De Construction Oldcastle Canada, Inc Wall with decorative facing
US20080202051A1 (en) * 2007-02-28 2008-08-28 Roehrig Robert C Concrete block system
US20080236081A1 (en) * 2007-03-28 2008-10-02 Francis Kennedy Insulated building block
US7739845B2 (en) * 2007-03-28 2010-06-22 Francis Kennedy Insulated building block
US20090064991A1 (en) * 2007-09-06 2009-03-12 Keting Zheng Solar Energy Capturing Building Construction Materials, Systems and Methods
US20120186172A1 (en) * 2009-02-06 2012-07-26 Bouchard Andre Construction system for buildings
US9890512B2 (en) 2010-09-28 2018-02-13 Les Materiaux De Construction Oldcastle Canada, Inc. Retaining wall
US8992131B2 (en) 2010-09-28 2015-03-31 Les Matériaux De Construction Oldcastle Canada, Inc. Retaining wall
US10273647B2 (en) 2010-09-28 2019-04-30 Les Materiaux De Construction Oldcastle Canada, Inc. Retaining wall
US9441342B2 (en) 2010-09-28 2016-09-13 Les Materiaux De Construction Oldcastle Canada, In Retaining wall
US9670640B2 (en) 2010-09-28 2017-06-06 Les Materiaux De Construction Oldcastle Canada, Inc. Retaining wall
US20130014462A1 (en) * 2011-06-21 2013-01-17 Nv Bekaert Sa Method of reducing the width of cracks in masonry
US8919067B2 (en) 2011-10-31 2014-12-30 Airlite Plastics Co. Apparatus and method for construction of structures utilizing insulated concrete forms
US8635826B2 (en) * 2012-04-10 2014-01-28 Reward Wall Systems, Inc. Insulation insert panel for use with insulating concrete form (ICF) systems
USD713975S1 (en) 2012-07-30 2014-09-23 Airlite Plastics Co. Insulative insert for insulated concrete form
US20140196397A1 (en) * 2013-01-17 2014-07-17 Tom Sourlis Insulated building block and wall structure
US10619348B2 (en) 2013-02-25 2020-04-14 Les Materiaux De Construction Oldcastle Canada Inc. Wall assembly
US9714510B2 (en) 2013-02-25 2017-07-25 Les Materiaux De Construction Oldcastle Canada Inc. Wall assembly
US10145102B2 (en) 2013-02-25 2018-12-04 Les Matériaux De Construction Oldcastle Canada Inc. Wall assembly
US10000927B1 (en) 2013-06-24 2018-06-19 Johnson Concrete Company Modular construction block
US9739058B1 (en) * 2013-06-24 2017-08-22 Johnson Concrete Company Modular construction block
US20170145687A1 (en) * 2014-07-04 2017-05-25 Iida Group Holdings Co., Ltd. Construction block and wall face structure using same
US9828766B2 (en) * 2014-07-04 2017-11-28 Iida Group Holdings Co., Ltd. Construction block and wall face structure using same

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