Masonry unit

A masonry unit comprising a block, a first insulation member, and a second insulation member. The block comprises a web transversely formed and connected to an anterior face shell and a posterior face shell. The web has formed on each of oppositely situated abutment side walls thereof a groove. The first insulation member comprises a pair of thumb grips formed on a forward wall thereof, and a pair of plugs formed on an oppositely situated rearward wall thereof. A channel extends from each of the thumb grips to a terminal end of the forward wall. The second insulation member comprises a rearward wall comprising a pair of grooves formed therein, wherein each groove formed in the rearward wall receives one of the plugs. The second insulation member further comprises a pair of flanges, wherein one of the flanges is received within one of the grooves formed on the web.

BACKGROUND TO THE INVENTION

1. Field of the Invention

The present disclosure relates to masonry, and more particularly to insulating building blocks used in the masonry field.

2. Background of the Invention

The present invention is aimed at improving upon the insulated building block disclosed in U.S. Pat. No. 4,856,249 to Nickerson (“'249”). '249 discloses a two web concrete block having an insulation insert placed within the core of the block to provide thermal insulation over the face of the block except where the cross-ties or webs are located. The insulation insert disclosed in '249 comprises two parts held together by plugs on one part and corresponding holes on the other part. Such a design allows the plug-bearing part to be pushed down against the hole-bearing part thereby causing the plugs to shear off and allowing the former plug-bearing part to slide down to ship lap an insulating insert located in a block located directly below.

The insulated building block disclosed in '249 has several design flaws. For example, the plug and hole design of the insulation insert prevents reuse of the insulation insert once the plugs are shorn off. That is, once the plugs are shorn off, the insulation insert is effectively a two-piece structure which is difficult to work with if there becomes a need to reinstall the insulation insert in a block while a wall is being constructed.

Additionally, the design of the block in '249 has the length of the block extended to protect the vertical edges of the insulation insert that were extended to interlock with the adjacent insulation insert. During packaging of the masonry units in large cubes of blocks, the extended pieces of the block are easily damaged, thereby causing the blocks to be rejected. Additionally, the insulation insert extends above the block at a top side thereof which causes the insulation insert to become crushed or broken.

Also, when water is forced against the face of a masonry wall built from masonry units disclosed in '249, the water can migrate through the outside face shell of the block. Once the water reaches the insulation insert, there is no direct path for the water to run out of the face shell, and the water, therefore, continues to build up in the block's face shell. This water build-up causes damage and negatively affects the physical appearance of the wall.

The physical design of the insulation insert disclosed in '249, in addition to the thickness of the face shell of the block, makes the masonry unit difficult to handle. Typically, a mason picks up a block by grabbing the web or face shell of the block. However, the location of the insulation insert relative to the block, as disclosed in '249, prevents the mason from extending his grip wide enough to safely handle the block.

Also, steel reinforced block walls oftentimes have vertical reinforcing rods or rebars placed in the core of the blocks. These rebars become part of the wall when concrete grout is poured around the rebars to bond them to the wall in a specific location. However, the height of the web of the block makes it difficult to control the flow of the grout. Currently, there is to no method of preventing the grout from flowing over the top of the web into a core that is not to be grouted.

SUMMARY OF THE INVENTION

The above mentioned disadvantages and draw-backs of the prior art are alleviated or greatly overcome by a masonry unit comprising a block and an insulation insert. The block comprises a web transversely formed and centrally connected to an anterior face shell and a posterior face shell. The anterior face shell comprises a top side which slopes downwardly towards and is contiguously formed with an exterior directed side of the anterior face shell such that the exterior directed side has a lower height compared to an oppositely situated interior directed side of the anterior face shell. The web has formed on each of oppositely situated abutment side walls thereof a vertically extending groove.

The insulation insert comprises a first insulation member and a second insulation member. The first insulation member comprises a forward wall oppositely situated to a rearward wall, a proximal lateral wall oppositely situated to a distal lateral wall, and a top side oppositely situated to a bottom side. The top side comprises a substantially planar portion contiguously formed with the rearward wall, and a sloped portion that slopes downwardly towards and is contiguously formed with the forward wall. The substantially planar portion of the top side comprises a recessed portion centrally formed therein. An opening, which is aligned with the recessed portion of the top side, is centrally formed through the forward wall and the rearward wall and extends from the bottom side towards the top side where it terminates at an abutment wall. A pair of thumb grips is formed on the forward wall, while a pair of engagement members, such as, e.g., plugs, wherein the pair of engagement members is formed on the rearward wall. Each of the thumb grips has a weep hole formed therein. A respective channel extends from the weep holes formed in the thumb grips to a terminal end of the forward wall of the first insulation member.

The second insulation member comprises a rearward wall oppositely situated to a forward wall, a top wall oppositely situated to a bottom wall, and a proximal lateral wall oppositely situated to a distal lateral wall. An opening is centrally formed through the forward wall and the rearward wall and extends from the bottom wall towards the top wall where it terminates at an underside of an abutment portion. The rearward wall comprises a pair of engagement members, such as, e.g., substantially vertically extending grooves formed therein, wherein engagement members are separated from one another by the opening of the second insulation member. In an exemplary embodiment, the pair of engagement members comprises a pair of grooves, wherein each of the grooves is formed in the rearward wall, extends to the bottom wall, and is further formed therein.

The second insulation member may further comprise a pair of flanges. Each of the flanges, which are oppositely situated from one another, may extend from the forward wall and towards and into the opening. The second insulation member may further comprise a pair of plates, wherein each plate may be positioned on opposite sides of the opening of the second insulation member and which may perpendicularly extend from the top wall and from the rearward wall of the second insulation member.

The masonry unit may be composed by engaging the engaging members on the rearward wall of the first insulation member with the engaging members on the rearward wall of the second insulation member such that the openings of the two members are aligned, and such that the top wall of the second insulation member is directed towards the top side of the first insulation member.

The resulting insulation insert may then be positioned on the block so that the flanges of the second insulation member are engaged with the grooves formed on the web of the block, the respective undersides of the abutment wall and the abutment portion of the insulation insert abut a top wall of the web, and the lateral sides of the insulation insert extend past the lateral side of the anterior face shell of the block. When used, the plates of the second insulation member flank the top side of the web.

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.

DETAILED DESCRIPTION OF THE INVENTION

Referring toFIGS. 1-3, an exemplary insulation insert10comprises a first insulation member12and a second insulation member70. Referring toFIGS. 1-5, first insulation member12comprises a forward wall14oppositely situated to a rearward wall16, a lateral wall18oppositely situated to a lateral wall20, and a top side22oppositely situated to a bottom side24. An opening26is centrally formed through forward wall14and rearward wall16. Opening26extends from an underside25of an abutment wall28to bottom side24to create a substantially U-shaped structure through first insulation member12. Opening26essentially divides insulation insert10into a portion30and a portion32.

Top side22comprises a horizontally extending planar portion38and a horizontally extending sloped portion40, wherein each of portions38and40are coterminously formed with lateral walls18and20. Horizontally extending planar portion38is coterminously formed with horizontally extending sloped portion40on one side thereof and is further coterminous with rearward wall16on an opposite side thereof. Horizontally extending sloped portion40slopes downwardly from horizontally planar portion38towards bottom side24and is coterminous on an opposite side thereof with forward wall14.

A recessed notch42is centrally and continuously formed through horizontally extending planar portion38of top side22and a segment of horizontally extending sloped portion40of top side22, such that recessed notch42is approximately aligned with opening26and approximately extends a horizontal length of opening26. A recessed notch44is formed through sloped portion40and extends from recessed notch42towards underside25of abutment wall28, wherein recessed notch42is centrally aligned with recessed notch44, and further wherein recessed notch42comprises a horizontal length greater than that of recessed notch44such that recessed notch44is flanked on both sides thereof by recessed notch42.

Bottom side24comprises a horizontally extending planar portion46and a horizontally extending planar portion46′, wherein portions46and46′ are separated from one another by opening26. Horizontally extending planar portion46is coterminous with rearward wall16and lateral wall20; while horizontally extending planar portion46′ is coterminous with rearward wall16and lateral wall18.

Bottom side24further comprises a sloped portion48and a sloped portion48′ contiguously formed with forward wall14, wherein sloped portion48is separated from sloped portion48′ by opening26. Sloped portion48is coterminous with planar portion46, forward wall14, and lateral wall20; while sloped portion48′ is coterminous with planar portion46′, forward wall14, and lateral wall18. Each of sloped portions48and48′ slopes downwardly from forward wall14towards respective planar portions46and46′.

First insulation member12further comprises a thumb grip50and a thumb grip50′ to respectively formed on portion30and portion32. Thumb grips50and50′ are dimensioned and configured to allow a user to insert a portion of the user's thumb into respective grips50and/or50′ to thereby assist in the mobilization of insulation insert10and/or the masonry unit. To that end, in an exemplary embodiment, each of thumb grips50and50′ comprises a respective arcuate-shaped groove51and51′ which is formed on horizontally extending sloped portion40of top side22and on forward wall14, and which extends from portion40to above a horizontal midsection X of forward wall14. Weep holes53and53′ are respectively formed at a base of grooves51and51′. Vertically extending, arcuate-shaped channels52and52′ are formed within forward wall14and extend from respective weep holes53and53′ to respective sloped portions48and48′. Channels52and52′ provide an outlet for fluid, such as, e.g., water, which has entered thumb grips50and50′, thereby, preventing the undesirable accumulation of water which would otherwise damage insulation insert10and/or the masonry unit.

Referring toFIG. 5, rearward wall16of first insulation member12comprises an essentially planar surface. A plug54and a plug54′ are respectively formed on rearward wall16of portion30and on rearward wall16of portion32. Each of plugs54and54′ has a respective substantially rounded body56and56′ which terminates at a respective base58and58′ and at an oppositely situated respective cap60and60′. Caps60and60′ of respective plugs54and54′ are situated approximately below horizontal midsection X of rearward wall16, and bases58and58′ are level with horizontally extending planar portions46and46′.

Referring toFIGS. 6 and 7, second insulation member70comprises a body71having a forward wall72oppositely situated to a rearward wall74, a top wall76oppositely situated to a bottom wall78, and a lateral wall80oppositely situated to a lateral wall82. Top wall76comprises an anterior leading edge84oppositely formed to a posterior leading edge86. Anterior leading edge84is contiguously formed with lateral wall80, lateral wall82, and forward wall72, while posterior leading edge86is contiguously formed with lateral wall80, lateral wall82, and rearward wall74.

Bottom wall78comprises a planar portion79which is substantially parallel to top wall76and which is contiguously formed with rearward wall74. Bottom wall78further comprises a sloped portion81which is contiguously formed with planar portion79and with forward wall72, wherein sloped portion81slopes downwardly from forward wall72to planar portion79.

Bottom wall78is offset from lateral wall80to form a channel88which extends from forward wall72to rearward wall74, and which is defined, at least in part, by an upper abutment wall92which is transversely positioned to a lateral abutment wall90. Similarly, bottom wall78is offset from lateral wall82to form a channel94which extends from forward wall72to rearward wall74, and which is defined, at least in part, by an upper abutment wall98which is transversely positioned to a lateral abutment wall96.

An opening100is centrally formed through bottom wall78and through forward wall72and rearward wall74and extends towards top wall76where it terminates at an underside102of an abutment portion104of body71, wherein abutment portion104is located approximately above a horizontal mid-section X of body71. Opening100confers a substantially U-shaped configuration to body71, and essentially divides second insulation member70into a portion106and a portion108, wherein abutment portion104is contiguously formed with and joins portion106to portion108.

Referring toFIG. 6, rearward wall74of abutment portion104is recessed relative to rearward walls74of portion106and portion108, thereby creating a lateral wall110and a lateral wall112, wherein lateral wall110is contiguously formed with rearward wall74of portion106, lateral wall112is contiguously formed with rearward wall74of portion108, and each of lateral walls110and112is parallel to lateral walls80and82. Where lateral wall110meets posterior leading edge86of top wall76, posterior leading edge86turns perpendicularly towards anterior leading edge84, then turns perpendicularly towards lateral wall112, and then turns perpendicularly towards rearward wall74to join to lateral wall112to effectively form a notched portion114on an area of top wall76, wherein notched portion114has underside102as its lowermost boundary.

Second insulation member70further comprises flanges116and118. Flanges116and118respectively extend from rearward wall74and from planar portion79of bottom wall78of portions106and108towards and into opening100where they respectively terminate at top walls120and122.

Referring toFIGS. 1-3, first insulation member12is attached to second insulation member70by engaging plug54within grooves138and140and by engaging plug54′ within grooves134and139such that openings26and100are aligned. Once so engaged, first insulation member12is offset relative to second insulation member70such that lateral wall20of first insulation member12extends past lateral wall82of second insulation member70, lateral wall80of second insulation member70extends past lateral wall18of first insulation member12, and planar portion38of top side22extends past top wall76.

Insulation insert10may be positioned within an exemplary block201as shown inFIGS. 8-10to form an exemplary masonry unit200. Here, block201comprises a web202centrally disposed between and connected to an anterior face shell204and an oppositely situated posterior face shell206.

Each of face shells204and206comprises a respective top side208and210oppositely situated to a respective bottom side212and214, a respective interior-directed side216and218oppositely directed to a respective exterior-directed side220and222, and a respective lateral side224and226oppositely directed to a respective lateral side228and230. Top side208tapers downwardly towards and is contiguous with exterior-directed side220of anterior face shell204such that a vertical height of anterior face shell204is lower at exterior-directed side220by about ⅛ of an inch compared to a vertical height of interior-directed side216. Such a difference in height protects insulation insert10from being compressed by the weight of a masonry unit(s) that lie(s) above masonry unit200during cubing, prevents water from flowing into the mortar joint as the water flows down anterior face shell204, and allows compaction of mortar at interior-directed side216when a mortar joint is tooled as less space is created at interior-directed side216.

Web202comprises a top side232directed towards top sides208and210and oppositely situated to a bottom side233. Top side232comprises a horizontal length that extends from interior-directed sides216and218of respective face shells204and206. Top side232further comprises a recessed portion234that extends along the horizontal length of top side232. Recessed portion234is flanked on a side thereof by a sloped lateral wall236which slopes away from recessed portion234downwardly towards an abutment side wall238, and is flanked on an opposite thereof by a sloped lateral wall240which slopes away from recessed portion234downwardly towards an abutment side wall242. Abutment side walls238and242are contiguously formed with bottom side233. Furthermore, each of abutment side walls238and242comprises a respective groove (not shown) formed therein, wherein the groove is transversely formed relative to bottom side233.

When insulation insert10is assembled on block201, flange116engages with the groove formed in abutment side wall238and flange118engages with the groove formed in abutment side wall242to thereby secure insulation insert10in a vertical position and to thereby prevent insulation insert10from slipping out of position. Underside25of abutment wall28and underside102of abutment portion104abut top side232of web202and are guided thereon by sloped lateral walls236and240. Top side208extends above top side22and top wall76, and sloped portion40of top side22of first insulation member12abuts interior-directed side216of anterior face shell204. Additionally, lateral walls20and82of insulation insert10extend past lateral side228of anterior face shell204, and lateral side224of anterior face shell204extends past lateral walls18and80of insulation insert10.

FIGS. 11-13respectively depict other exemplary masonry units300,400, and500. Each of masonry units300,400, and500comprises insulation insert10in association with respective blocks301,401, and501. Similar to block201, blocks301,401, and501respectively comprises tapered top sides302,402, and502, which slope downwardly towards and are coterminous with respective exterior-directed sides304,404, and504of respective anterior face shells306,406, and506. Blocks301,401, and501, further respectively comprise a web308,408, and508having respective proximal abutment side walls and oppositely situated distal abutment side walls. Each of proximal and distal abutment side walls310,410,510,312,412, and512has a groove formed therein, wherein the grooves receive flanges116and118of second insulation member70.

FIGS. 14 and 15depict an exemplary second insulation member600. Second insulation member600is essentially identical to second insulation member70except that second insulation member600further comprises a grout shut-off saddle602positioned on rearward wall74thereof. Saddle602comprises a plate604and a plate606which is disposed on rearward wall74and extends outwardly therefrom on opposite sides of abutment portion104such that plates604and606are transversely positioned relative to rearward wall74and are parallel to one another to thereby form an opening607between plates604and606. Each of plates604and606extends below horizontal axis X which defines a midline of body71of second insulation member600and creates a respective space614and616between a respective bottom side610and612of plates604and606and between bottom wall78of body71.

Referring toFIGS. 16 and 17, a masonry unit700comprises an insulation insert701engaged with block200. Insulation insert701comprises second insulation member600and first insulation member12. As shown inFIGS. 16 and 17, web202fits within opening607, and plates604and606of saddle602extend over top side232of web202and further extend to and physically abut interior-directed side218of posterior face shell206. In this arrangement, liquid grout is prevented from flowing into adjacent block cores.

It is noted that, in another exemplary embodiment, saddle602may be replaced by a separately molded U-shaped insert that may be placed over the top of the web on those cores where no grout is required.

FIGS. 18-20show an exemplary method of cubing a plurality of masonry units200. Referring toFIG. 18, an exemplary method comprises providing a first layer of masonry units200on a foundation704. Here, a row702comprising a plurality of masonry units200is positioned on foundation704such that adjacent masonry units200are positioned back to back to one another, e.g., exterior-directed side222of posterior face shell206of one of masonry units200from row702physically abuts exterior-directed side220of anterior face shell204of an immediately adjacent masonry unit200from row702.

A row706comprising a plurality of masonry units200is placed immediately adjacent to row702such that masonry units200of row706are oppositely situated to masonry units200of row702, and further such that forward walls14of first insulation members12of masonry units200of row702physically abut immediately adjacent interior-directed sides218of posterior face shells206of masonry units200of row706and vice versa. Each subsequent row comprising a plurality of masonry units200may be laid in this alternating fashion.

Referring toFIGS. 19 and 20, masonry units200may be stacked on top of the first layer of masonry units200by transversely positioning a second layer710of masonry units directly on and over the immediately underlying first layer. Similar to the positioning of the masonry units of the first layer, the masonry units of second layer710are positioned such that masonry units200forming a first row of second layer710are aligned, e.g., front to back; and masonry units200of a second row from second layer are aligned, e.g., back to front. Subsequent layers may be stacked in a manner as shown inFIGS. 19 and 20.

As would be obvious from a reading of the above-disclosure in light of the figures and claims included herein, the masonry unit described above has several advantages over the prior art. For example, the newly designed plug and groove feature provided on the respective first and second insulation members allows the insulation insert to be removed easily from a broken block, and further allows the first and second insulation members to be engaged with one another for use in another block.

The slope added to the top side of the first insulation member, along with the weep hole provided at the bottom of the thumb grips, provide a drainage path for water to drain out of the weeps located at the bottom side of the first insulation insert member. Additionally, the slope provided at the bottom side of the first insulation member provides a path for water to flow away from the masonry unit.

The thumb grips provided in the forward wall of the first insulation member allow the mason to grip the face shells of the block more readily.

Additionally, placement of the insulation insert onto the block and the hold of the insulation insert once positioned on the block have been enhanced. The depression formed on the top side of the web of the block assists in guiding the insulation insert into a vertical position. Additionally, by providing the second insulation member with a first and second flange, and by providing the web with a first and second groove respectively formed on opposite abutment side walls of the web, wherein the first flange is received within the first groove and the second flange is received within the second groove, the insulation insert is vertically held in place on the block.

Furthermore, the use of plates on the second insulation member which flank the abutment side walls of the web of the block prevents liquid grout from flowing into adjacent block cores.

A slope has been formed at the top side of the anterior face shell of the block so that a vertical height of the exterior-directed side of the anterior face shell is lower than a vertical height of the interior-directed side of the anterior face shell. Such slope protects the insulation insert from being compressed by the weight of the masonry units located above the insulation insert during cubing. The slope also prevents water from working its way into the mortar joint as the water runs down the anterior face wall. The slope also prevents compaction of mortar at the interior-directed side of the anterior face wall compared to the exterior-directed side of the anterior face wall when the mortar joint is tooled.

A method of cubing the masonry blocks is further provided, wherein such method is used in lieu of extending the length of the block, thereby, protecting the insulation inserts from breakage.

The foregoing description of the preferred embodiment of the invention is to be considered as illustrative and not as limiting. Various other changes and modifications will occur to those skilled in the art for performing substantially the same function, in substantially the same way, to achieve substantially the same result without departing from the true scope of the invention as defined in the appended claims.