Abstract:
The invention provides an insulator for use in combination with a structural block having top and bottom surfaces that are connect by side surfaces. The side surfaces and the top and bottom surfaces define a continuous periphery that at least partially forms a mortar joint with adjacent blocks. The periphery has a generally vertical height bounded by the top and bottom surfaces, and a width bounded by the side surfaces. The insulator has a pre-formed portion of insulating material having top, bottom and side surfaces. The top and bottom surfaces define a height greater than the generally vertical height of the periphery of the block. The side surfaces define a width greater than the periphery of the block, so that the insulator extends into and insulates, on at least a portion of all surfaces forming the block periphery, the mortar joint between the block and adjacent blocks.

Description:
RELATED APPLICATIONS 
       [0001]    The present application claims the benefit of co-pending provisional patent application Ser. No. 60/904,085, filed Feb. 28, 2007 (attorney docket number 021448-9057-00), the subject matter of which is hereby incorporated by reference. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to concrete blocks. More specifically, the present invention relates to concrete blocks having a foam insulator. 
       SUMMARY 
       [0003]    In one embodiment, the invention provides an insulator for use in combination with a structural block having top and bottom surfaces that are connected by side surfaces. The side surfaces and the top and bottom surfaces define a continuous periphery that at least partially forms a mortar joint with adjacent blocks. The periphery has a generally vertical height bounded by the top and bottom surfaces, and a width bounded by the side surfaces. The insulator is a pre-formed portion of insulating material having top, bottom and side surfaces. The top and bottom surfaces define a height greater than the generally vertical height of the periphery of the block. The side surfaces define a width greater than the periphery of the block, so that the insulator extends into and insulates, on at least a portion of all surfaces forming the block periphery, the mortar joint between the block and adjacent blocks. 
         [0004]    In another embodiment, the invention provides a structural element having a structural block with top and bottom surfaces, and side surfaces that connect the top and bottom surfaces to define a continuous periphery that at least partially forms a mortar joint with adjacent blocks. The periphery has a height bounded by the top and bottom surfaces, and a width bounded by the side surfaces. An insulating portion has top, bottom and side surfaces. The top and bottom surfaces define a height greater than the height of the periphery of the block, and the side surfaces define a width greater than the width of the periphery of the block. The insulator extends into and insulates, on at least a portion of all surfaces forming the periphery of the block, the mortar joint formed between the block and adjacent blocks. 
         [0005]    In yet another embodiment the invention provides structure comprised of a plurality of structural elements operable to form a wall. The plurality of structural elements include at least first and second structural blocks. The blocks each have top and bottom surfaces, and side surfaces that connecting the top and bottom surfaces to define a continuous periphery that at least partially forms a first mortar joint between the adjacent side surfaces of the first and second blocks. The periphery has a height bounded by the top and bottom surfaces, and a width bounded by the side surfaces. At least first and second insulators each include top, bottom and side surfaces. The top and bottom surfaces define a height greater than the height of the periphery of the block, and the side surfaces defining a width greater than the width of the periphery of the block. The first and second insulators extend into and insulates, on at least a portion of all surfaces forming the periphery of the respective first and second blocks. 
         [0006]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is an end view of a block and an insulator according to one embodiment of the invention. 
           [0008]      FIG. 2  is a bottom view of the block and insulator of  FIG. 1 . 
           [0009]      FIG. 3  is a front view of the block and insulator of  FIGS. 1 and 2 . 
           [0010]      FIG. 4  is an exploded perspective view of the block and insulator of  FIGS. 1-3 . 
           [0011]      FIG. 5  is a perspective view of a plurality of blocks and insulators forming a wall of a structure. 
           [0012]      FIG. 6  is a perspective view of the blocks each having an additional foam insulator. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 
         [0014]      FIG. 1  shows a concrete block  10  and an insulator  15 . The concrete block  10  has an end profile that is generally in the shape of a rectangle, having top and bottom surfaces,  20 ,  25 , respectively and front and back surfaces,  30 ,  35 , respectively. The insulator  15  end profile is generally in the shape of a parallelogram, having top and bottom inclined surfaces,  40 ,  45 , respectively and front and back vertical surfaces,  50 ,  55 , respectively. The top and bottom surfaces  40 ,  45  of the insulator  15  define two inner edges  60  that are positioned within the end profile of the concrete block, while two outer edges  65  extend beyond the end profile of the concrete block  10 , in the illustrated embodiment. The insulator  15  is positioned between the front and back surfaces  30 ,  35  of the concrete block  10 . In the illustrated embodiment, at least a portion of the inclined surfaces  40 ,  45  extends beyond the top and bottom surfaces  20 ,  25  of the concrete block  10 . In some embodiments, slots  70  are included in a portion of the concrete block  10 , such that a lower portion of the block  10  may be removed to form a cutout  75 , as will be described in greater detail below. 
         [0015]    The insulator  15  may be formed of any suitable insulating material. In one form, the insulator  15  is formed from extruded polystyrene foam having a density of at least 1.6 pounds per cubic foot. The insulator has a compressive strength within the range of 15-35 pounds per square inch, a more preferred compressive strength in a range of 20-30 pounds per square inch, and a density of 25 pounds per square inch. In another form, the insulator  15  has a density of about 1.3 pounds per cubit foot and a compressive strength of about 15 pounds per square inch. In a third form, the insulator  15  has a density of about 1.8 pounds per cubic foot and a compressive strength of about 40 pounds per square inch. In a fourth form, the insulator  15  has a density of about 2.2 pounds per cubic foot and a compressive strength of about 60 pounds per square inch. In yet another form, the insulator  15  has a density of about 3 pounds per cubic foot and a compressive strength of about 100 pounds per square inch. While the preceding examples have been given, it is to be understood that intermediate densities and compressive strength values are included within the scope of the invention. Further, densities and compressive strength values that are not within the range of examples can be attained by changing the material used to form the insulator  15 . 
         [0016]      FIG. 2  shows the concrete block  10  and the foam insulator  15  showing the bottom surfaces  25 ,  45 , respectively. The illustrated concrete block  10  includes two side surfaces  80  that are parallel to each other. The concrete block  10  includes outer wall members  85  that form the front and back surfaces  30 ,  35 . In the illustrated embodiment, the outer wall members  85  are connected by two inner cross-wall members  90  to form the concrete block  10 . The cross-wall members  90  define a middle aperture  95  and first and second side apertures  100  between the front and back surfaces  30 ,  35  of the block  10 . The middle aperture  95  is enclosed on four sides by the cross-wall members  90  and outer wall members  85 , while the first and second side apertures  100  are partially enclosed by one of the cross-wall members  90  and the outer wall members  85 . 
         [0017]      FIG. 3  shows the relationship between the concrete block  10  and the insulator  15  looking toward the front surfaces  30 ,  50 , respectively. The illustrated insulator  15  extends beyond the concrete block  10  along the top, bottom and side surfaces,  20 ,  25 ,  80 . Each insulator  15  includes means for forming a barrier between adjacent insulators  15  to reduce air flow and heat transfer through the structure. In the illustrated embodiment, the top and bottom surfaces  40 ,  45  of the foam insulator  15  are inclined, to form angled planes having inner and outer edges  60 ,  65 , respectively. 
         [0018]    As discussed in more detail below, the angled surfaces  40 ,  45  abut with the angled surfaces  40 ,  45  of the adjacent insulators  15  to reduce air flow and heat transfer through the structure formed with the concrete blocks  10 . Other surface configurations e.g. complementary and mating convolutions such as surfaces that have projections and complementary apertures that reduce air flow and heat transfer through the structure. In still other surface configurations, the concrete blocks  10  have combinations of interface surfaces, such as having a first column of concrete blocks  10  having a first interfacing surfaces and a second column of concrete blocks  10  having a second interfacing surfaces, e.g. the first column has planar angled surfaces that incline upward in the inward direction while the second column has planar angled surfaces that incline upward in the outward direction with respect to the inward and outward portions of the surface. 
         [0019]    The inner edges  60  are positioned generally between the top and bottom surfaces  20 ,  25  of the concrete block  10 , while the outer edges  65  are positioned beyond the top and bottom surfaces  20 ,  25 . In the illustrated embodiment, the top surface  40  of the insulator  15  has two notches  105  adjacent to the cross-wall members  90 , so that the insulator  15  is inserted into the concrete block  10  without interference between the cross-wall members  90  and the insulator  15 . The side surfaces  108  of the insulator  15  extend beyond and are generally parallel to the side surfaces  80  of the concrete block  10 . 
         [0020]      FIG. 4  shows the insulator  15  having notches  105  and being exploded off of the concrete block  10  having cutouts  75  on the cross-wall members  90  that receive the notches  105 . The illustrated insulator  15  is shaped generally like the letter “E” such that the insulator  15  includes a middle projection  110  and first and second side projections  115 . The concrete block  10  receives the middle projection  110  into the middle aperture  95 , and the first and second side projections  115  into the first and second side apertures  100 . Dotted lines  120  are included on the illustrated insulator  15  to define horizontal, to demonstrate that the top and bottom surfaces  40 ,  45  of the insulator  15  are inclined with respect to horizontal. The slots  70  are also shown on the cross-wall members  90 . 
         [0021]      FIG. 5  shows a portion of a wall  125  being formed by concrete blocks  10  and insulators  15 . The front surfaces  30  of the blocks  10  form a front wall surface  130 . The first and second side apertures  100  in the concrete blocks  10  are enclosed on four sides when the concrete blocks  10  are positioned adjacent one another. A portion of mortar  135  is positioned on the adjoining portions of the top, bottom and side surfaces,  20 ,  25 ,  80 , respectively, thereby forming a mortar joint  140 . The mortar joint  140  affixes the concrete blocks  10  with respect to one another. The concrete block  10  receives the insulator  15  in an interlocking relationship, such that the insulator  15  is generally affixed to the concrete block  10  when positioned adjacent to other concrete blocks  10  and insulators  15 . Movement of the insulator  15  with respect to the concrete block  10  is inhibited because of the relationship between the cutouts  75  and notches  105  and also because of the insulators  15  in adjacent concrete blocks  10 . 
         [0022]    A first concrete block  10   a  and a first insulator  15   a  are positioned adjacent a second concrete block  10   b  and a second insulator  15   b,  such that the side surfaces  80  of the first and second concrete blocks,  10   a,    10   b,  respectively form a first mortar joint  140   a.  The illustrated first mortar joint  140   a  is generally vertical. The first and second insulators  15   a,    15   b,  respectively extend into the space between the first and second concrete blocks  10   a,    10   b,  respectively, that is defined by the first mortar joint  140   a.  In some embodiments, the first and second insulators  15   a,    15   b,  are in contact with each other. In the illustrated embodiment, a third concrete block  10   c  and insulator  15   c  are placed on top of the second concrete block  10   b  and insulator  15   b  to form a second mortar joint  140   b  therebetween. The top and bottom surfaces  40 ,  45 , of the insulators  15   b,    15   c,  are inclined to form inner and outer edges  60 ,  65 . The outer edges  65  extend beyond the top and bottom surfaces  30 ,  35  of the concrete blocks  10   b    10   c,  while the inner edges  60  of the illustrated embodiment do not extend beyond the top and bottom surfaces  20 ,  25  of the concrete blocks,  10   b,    10   c.  In some embodiments, the inclined surfaces  40 ,  45  of the insulators  15   b,    15   c  are in contact with one another. 
         [0023]    The remaining slots  70  are included in the concrete block  10  such that another cutout  75  can be made in each of the concrete block cross-wall members  90  to receive a second insulator  15 ′, as is illustrated in  FIG. 6 . Two insulators  15 ,  15 ′ are inserted into each concrete block  10  in the embodiment shown in  FIG. 6 . The top and bottom surfaces  40 ,  45  of the insulators  15 ,  15 ′ are inclined with respect to the top and bottom surfaces  20 ,  25  of the concrete blocks  10  to form the interlocking relationship with the concrete block  10  and the adjacent insulators  15 ,  15 ′ as was described for a single insulator  15 , above. Although two cross-wall members  90  and two mating cutouts  75  are illustrated, it is envisioned that more cross-wall members  90 , and thus, more mating cutouts  75  could be included for larger concrete blocks  10  to increase the stability and strength of the concrete blocks  10 . 
         [0024]    The wall  125  may have a variety of thermal resistance values, depending on the thickness of the insulator  15 , the number of insulators  15  per block  10 , the density of the insulator  15 , and the relative dimensions of the block  10  and insulator  15 . One example includes a first wall having one 2″ wide insulator per block. The first wall has a thermal resistance within the range of 4-17 (hr sq.ft ° F./Btu inch). A second example includes a second wall having two 2″ wide insulators per block. The second wall has a thermal resistance within the range of 6-30 (hr sq.ft ° F./Btu inch). A third example includes a third wall having one 1″ wide insulator per block. The third wall has a thermal resistance within the range of 3-12 (hr sq.ft ° F./Btu inch). The block  10  used in these examples has dimensions of 15.69″×11.64″×3.72″, although this dimensions are not critical and the block  10  could be nearly any size or shape. The insulator(s)  15  used in these examples has length of about 16″ and a width of about 12″. Thus, the insulator dimensions are slightly larger than the block  10 . In some embodiments, the insulator  15  can be as much as ⅜″ greater in length and height than the block  10 . In some embodiments, the insulator  15  is more than ⅜″ wider and taller than the block  10 . The width of the insulator  15  has been shown in examples to range from 1-2 inches, but can range from as narrow at ¾″ to as wide as 4″. 
         [0025]    Various features and advantages of the invention are set forth in the following claims.