Structural block assembly

A structural block assembly for providing insulation to a structure comprising a structural block and an insulation insert. The structural block 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, wherein a gap is formed between the web and the forward member. The insulation insert is disposed between the web and the forward member, thereby dividing the chamber into a proximal-oriented compartment and a distal-oriented compartment. The web also has a slot formed therethough, wherein the slot assists in maximizing an R-value for the completed wall constructed with the block.

BACKGROUND TO THE INVENTION

1. Field of the Invention

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.

2. Background of the Invention

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.

SUMMARY OF THE INVENTION

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/ft3installed 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.

DETAILED DESCRIPTION OF THE INVENTION

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 inFIGS. 1-7. As discussed hereinafter, the structural blocks and assemblies can be used in connection with and embody a variety of structural units, but has particular application in connection with concrete masonry units (CMUs). Accordingly, while discussed hereinafter primarily in connection with such CMUs, the structural blocks and assemblies described herein equally can be useful in connection with other types of structural or modular units for use in constructing and installing buildings, foundations, walls, load-bearing structures, and the like.In general, the structural block assembly comprises a structural block having a generally rectangular shaped body having a forward member oppositely situated to a rearward member, and a proximal member oppositely situated to a distal member. The structural block further comprises a web having a generally rectangular shaped body comprising a top side oppositely situated to a bottom side, wherein the top and bottom sides of the web are centrally and contiguously formed with and extend from the rearward member, and wherein the body of the web terminates at a forward leading wall that is contiguously formed with the top and bottom sides of the web and that is oriented and extends towards the forward member. A chamber is surrounded by the forward member, the rearward member, the proximal member, and the web. The structural block assembly further comprises an insulation insert. In a preferred embodiment, the insulation insert has a density of about 1.3 pounds per cubic foot to about 1.8 pounds per cubic foot. The insulation insert may be disposed within the chamber such that the insulation insert physically abuts the forward member, the proximal member, the distal member, and the forward leading wall of the web such that a discrete proximal chamber is wholly formed between the insulation insert, the rearward member, the proximal member and the web and a discrete distal chamber is wholly formed between the insulation insert, the rearward member, the distal member, and the web.

In one preferred and non-limiting embodiment illustrated inFIGS. 1-3, provided is a structural block10. In this embodiment, structural block10includes a generally rectangular shaped body12having a forward member14oppositely situated to a rearward member16, and a proximal member18oppositely situated to a distal member20, wherein forward, rearward, proximal and distal members14,16,18, and20surround a chamber21. In a preferred embodiment, forward and rearward members14and16have a length X of about 24 inches, and a maximum height Z of about 12 inches, and proximal and distal members18and20have a length Y of about 12 inches. The block configuration of 12-inches wide, 8-inches high, and 24-inches long is ideal because it allows the mason to construct a wall faster with fewer individual blocks, and to compete with the pre-fabricated construction materials which are installed presently.

A top side22of forward face14is contiguously formed with top sides26and28of respective proximal and distal members18and20and is recessed relative thereto, while a top side24of rearward member16is contiguously formed with top sides26and28of respective proximal and distal members18and20and is raised relative thereto. Bottom sides30,32,34, and36of respective forward member14, rearward member16, proximal member18, and distal member20are coplanar with one another.

A longitudinally extending groove38is continuously formed through top side24, an exterior side40of proximal member18, and bottom side34of proximal member18. Groove38preferably is a sash groove used as a sealing spacer for a rubber control joint gasket to seal windows and doors.

Structural block10further comprises a web42which is centrally and contiguously formed with an interior side44of rearward member16and longitudinally extends into chamber21and towards an interior side46of forward member14wherein a gap51is created between a forward leading wall54of web42and interior side46of forward member14. A top side48of web42is recessed relative to top side24of rearward member16, while a bottom side50of web42is coplanar with bottom side32of rearward member16.

A longitudinally extending opening52is formed through web42. Opening52continuously extends from top side48to bottom side50of web42and through forward leading wall54of web42, thereby essentially dividing web42into two equal subparts. Opening52is in fluid communication with chamber21.

An interior side56of distal member20of structural block10is divided into a rearward directed interior wall58and a forward directed interior wall60, wherein rearward directed interior wall58is contiguously formed with interior side44of rearward member16and forward directed interior wall60is contiguously formed with interior side46of forward member14. Forward directed interior wall60is recessed relative to rearward directed interior wall58, thereby exposing a buttress wall66which longitudinally extends from top side28to bottom side36of distal member20and which divides forward directed region60from rearward directed region58.

An interior side62of proximal member18comprises a longitudinally extending substantially convex shaped wall64that is contiguously formed with and continuously extends from top side26and bottom side34of proximal member18, and which overlies groove38. Convex shaped wall64has a rearward directed edge68and a forward directed to edge70, wherein forward directed edge70is non-planar with rearward directed edge68. Rearward directed edge68, buttress wall66of distal member20, and forward leading wall54of web42are coplanar with one another.

Forward directed edge70turns inwardly to form a longitudinally extending generally concave-shaped wall72which is contiguously formed with top and bottom sides26and34of proximal member18and with top and bottom sides22and30of forward member14.

Referring toFIGS. 4 and 5, an exemplary assembly100comprises structural block10and an insulation insert102. Referring toFIG. 6, insulation insert102comprises a top side104oppositely situated to a bottom side106, a forward face108oppositely situated to a rearward face110, and a proximal side112oppositely situated to a distal side114. Proximal side112has a generally concave-shaped longitudinally extending wall118which is contiguously formed with top and bottom sides104and106and with rearward face110, and which is further immediately adjacent to and contiguously formed with a generally convex-shaped longitudinally extending wall116, wherein wall116overhangs wall118and is contiguously formed with top and bottom sides104and106and with forward face108.

Insulation insert102may 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 insert102may be formed of additional or alternative foams, including, for example, polyurethane foam, isoprene foam, and the like.

Insulation layer102may 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 insert102can 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 insert102comprises a high-density insulation material having a density of about 1.3-1.8 lbs/ft3.

Another exemplary structural block is shown inFIG. 7. Here, a structural block200is essentially identical to structural block100except that block200has a web202in lieu of web42. Web202comprises a generally columnar shaped body204. Body204comprises a top wall206oppositely situated to a bottom wall (not shown), and a rearward directed wall210oppositely situated to a forward directed wall212. Rearward directed wall210is contiguously formed with interior side44of rearward member and extends therefrom such that forward directed wall212is directed towards interior side46of forward member14, wherein a gap214is created between forward directed wall212and interior side46. A continuously extending slot216is formed through rearward directed wall210and through top and bottom walls206and208and falls short of extending through forward directed wall212such that slot216is not in fluid communication with chamber21.

Although not shown, insulation insert102may be fitted within structural block200in an identical fashion as described above with references toFIGS. 4 and 5.

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.