Patent Grant
10487504
The present invention relates to structural blocks such as those commonly referred to as “concrete blocks” used for constructing both load bearing and non-load bearing walls of buildings.
Structural blocks are usually formed with two or three vertical holes formed therein and are constructed of concrete comprised of at least one of cinders, sand, gravel, and other types of aggregates. Less commonly, the blocks may be constructed of fired brick or clay tile. The holes in the blocks provide a substantial decrease in weight and material without a commensurate decrease in structural strength. The holes also provide some insulating value as closed airspace in a completed wall.
There are projects for which a 24-inch concrete block is advisable. However, to date, 24-inch concrete blocks have not been considered for thermal characteristics. Accordingly, commercially available 24-inch blocks are not designed with insulating and thermal conductivity considerations in mind. Rather, insulation is provided for either exteriorly or interiorly of the wall, with insulation in the latter instance normally being in the form of the pouring type which inherently presents moisture problems. Additionally, if insulation is applied over the inside face of the block wall, this adds considerably to the material and labor expense, and presents problems in terms of appearance.
An object of the structural block assemblies disclosed herein is to provide a structural block especially designed to achieve maximum insulating properties while at the same time achieving a desired balance in the thermal conduction transverse to the block, without detracting from the load carrying properties of the block. Therefore, provided for herein is a structural block, and most preferably, a 24″×8″×12″ structural block, having a high-density insulation material having a density of about 1.3-1.8 lbs/ft3 installed on a forward member of the structural block, wherein, when installed as part of a wall of a building, the forward member is directed towards the outside facing wall of the building. The insulation material allows the structural block to meet maximum R-values (insulated units must exhibit a specified minimum insulation R-value, which relates to a measure of thermal resistance (i.e., resistance to heat flow) in a given thickness of material. Generally, the R-value is the ratio of the temperature difference across an insulator and the heat flux. The higher the R-value, the more effective the insulation is at resisting heat flow). Additionally, the structural block conforms to National Concrete Masonry Association (“NCMA”) standards. When the structural block is cut in half, the structural block is half-way insulated. Additionally, the structural block is designed to be open so that vertical steel and concrete grout can go through the structural block.
The structural block assembly includes a structural block that includes a body having oppositely situated forward and rearward members, oppositely situated proximal and distal members, and a chamber formed between the forward and rearward members and the proximal and distal members. A web, which is positioned within the chamber, centrally extends from the rearward member towards the forward member such that a gap is created between the web and the forward member. The web also has a slot formed therethough, wherein the slot assists in maximizing an R-value for the block.
The assembly further comprises an insulation insert that is disposed between the web and the forward member, thereby dividing the chamber into a proximal-oriented compartment and a distal-oriented compartment. When used for building purposes, the forward member is installed towards an outside-oriented wall.
These and various other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects obtained by its use, reference should be had to the accompanying drawings and descriptive matter, in which there is illustrated and described preferred embodiments of the invention.
For a better understanding of these and other objects of the present invention, reference will be made to the detailed description of the present invention which is to be read in association with the accompanying drawings, wherein:
For purposes of the description hereinafter, the terms “top,” “bottom,” “forward,” “rearward”, “proximal”, “distal,” “interior”, “exterior,” and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations, except where expressly specified to the contrary. It is also to be understood that the specific elements, members, and components, illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting unless expressly stated otherwise.
The present invention is directed to a structural block and assembly, as illustrated in various preferred and non-limiting embodiments in
In one preferred and non-limiting embodiment illustrated in
A top side 22 of forward face 14 is contiguously formed with top sides 26 and 28 of respective proximal and distal members 18 and 20 and is recessed relative thereto, while a top side 24 of rearward member 16 is contiguously formed with top sides 26 and 28 of respective proximal and distal members 18 and 20 and is raised relative thereto. Bottom sides 30, 32, 34, and 36 of respective forward member 14, rearward member 16, proximal member 18, and distal member 20 are coplanar with one another.
A longitudinally extending groove 38 is continuously formed through top side 24, an exterior side 40 of proximal member 18, and bottom side 34 of proximal member 18. Groove 38 preferably is a sash groove used as a sealing spacer for a rubber control joint gasket to seal windows and doors.
Structural block 10 further comprises a web 42 which is centrally and contiguously formed with an interior side 44 of rearward member 16 and longitudinally extends into chamber 21 and towards an interior side 46 of forward member 14 wherein a gap 51 is created between a forward leading wall 54 of web 42 and interior side 46 of forward member 14. A top side 48 of web 42 is recessed relative to top side 24 of rearward member 16, while a bottom side 50 of web 42 is coplanar with bottom side 32 of rearward member 16.
A longitudinally extending opening 52 is formed through web 42. Opening 52 continuously extends from top side 48 to bottom side 50 of web 42 and through forward leading wall 54 of web 42, thereby essentially dividing web 42 into two equal subparts. Opening 52 is in fluid communication with chamber 21.
An interior side 56 of distal member 20 of structural block 10 is divided into a rearward directed interior wall 58 and a forward directed interior wall 60, wherein rearward directed interior wall 58 is contiguously formed with interior side 44 of rearward member 16 and forward directed interior wall 60 is contiguously formed with interior side 46 of forward member 14. Forward directed interior wall 60 is recessed relative to rearward directed interior wall 58, thereby exposing a buttress wall 66 which longitudinally extends from top side 28 to bottom side 36 of distal member 20 and which divides forward directed region 60 from rearward directed region 58.
An interior side 62 of proximal member 18 comprises a longitudinally extending substantially convex shaped wall 64 that is contiguously formed with and continuously extends from top side 26 and bottom side 34 of proximal member 18, and which overlies groove 38. Convex shaped wall 64 has a rearward directed edge 68 and a forward directed to edge 70, wherein forward directed edge 70 is non-planar with rearward directed edge 68. Rearward directed edge 68, buttress wall 66 of distal member 20, and forward leading wall 54 of web 42 are coplanar with one another.
Forward directed edge 70 turns inwardly to form a longitudinally extending generally concave-shaped wall 72 which is contiguously formed with top and bottom sides 26 and 34 of proximal member 18 and with top and bottom sides 22 and 30 of forward member 14.
Referring to
Insulation insert 102 may be made of conventional expandable polystyrene foam and of modified polystyrene foam such as NOVA or BASF Neopor@ foams, which are expandable polystyrene foams which may be formulated with graphite in the cell structure. Insulation insert 102 may be formed of additional or alternative foams, including, for example, polyurethane foam, isoprene foam, and the like.
Insulation layer 102 may have a forward to rearward thickness that is dependent upon the size of the block and upon the degree of desired heat insulation, wherein a thickness of up to at least about 1 inch is preferred. Additionally, the thickness of insulation insert 102 can be adjusted to achieve a desired R value for a particular foam material or to match desired dimensions of the structure within which the block system is to be used. In an especially preferred embodiment, insulation insert 102 comprises a high-density insulation material having a density of about 1.3-1.8 lbs/ft3.
As shown in
Another exemplary structural block is shown in
Although not shown, insulation insert 102 may be fitted within structural block 200 in an identical fashion as described above with references to
As appreciated by one of ordinary skill in the art, the structural blocks and assemblies disclosed herein provide an effective insulation layer for structures built using CMUs. The concrete blocks and the assemblies disclosed herein provide an effective means for meeting NCMA standards while also allowing the assemblies to meet maximum R-values.
The inventive block has less web as compared to conventionally used blocks, which allows the insert to take the place of the web in the block. The insert increases the R value of the wall and meets code requirements for strength. The insert supports the long side of the block so that it is less likely to fracture. The insert makes the block more sturdy and less likely to break and creates an R value of insulation for the wall. The 24-inch block is likely to fracture because the length is unsupported and fragile. With the insert, it is supported. A steel core, if required, may still be installed through the block alongside the insulation insert in the proximal or distal oriented compartments. The inventive block renders the wall more thermally efficient, meets code requirements, and allows masons laying block to compete with pre-fabricated construction since the blocks are longer, and the mason can complete the wall in less time. The insulation insert allows the block to meet or exceed ASTM code requirements.
CMUs having dimensions of 12-inches wide×8-inches high×24-inches long, 8-inches wide×8-inches high×24-inches long, or 6-inches wide×8-inches high×24-inches long are becoming more common in the construction industry, since the mason in the field has been using 16-inch blocks and the mason can lay a longer block and compete with pre-cast concrete as well as “tilt-up” or steel stud construction. This assists the mason to compete in the field with pre-fabricated materials.
Although the invention has been described in detail for the purpose of illustration based on what are currently considered to be practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope hereof. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.
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|---|---|---|---|
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| Number | Date | Country | |
|---|---|---|---|
| 62469568 | Mar 2017 | US |
