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CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Patent application Ser. No. 61/791,187 for “Insulated Block Wall System,” filed Mar. 15, 2013, which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This patent relates to concrete and other masonry blocks, walls and other structures and, more specifically, to such structures that contain insulation and utilize facing materials. 
       BACKGROUND OF THE INVENTION 
       [0003]    Masonry walls and similar structures have been made with a wide variety of construction materials and methods and therefore exhibit a large number of different characteristics. Among such walls, precast concrete block walls are well known. While precast concrete block or CMU (concrete masonry unit) walls are inexpensive and strong, conventional such walls provide relatively little resistance to heat transmission, may drain water poorly and are often unattractive. 
       SUMMARY 
       [0004]    The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim. 
         [0005]    This invention provides complementary components for the construction of clad, faced or other masonry walls and similar structures that are strong, inexpensive, avoid thermal bridges, resist transmission of heat, and are attractive and versatile because an enormous variety of decorative face members may be utilized. Moreover, embodiments of this invention effectively drain water while resisting penetration of the entire structure by water and provide structures that prevent facing materials from falling even if fire destroys insulating foam between the structural block and the facing. They may also present attractive systems in seismic properties and resistance to wind loading. 
         [0006]    The wall and other structures components and system of this invention include anchoring components that physically connect face materials to structural materials that are separated from the face materials by heat insulation and, generally, without undesirable thermal bridges. The components and system provide anchors that are coated with or imbedded in thermal insulation materials such as expanded polystyrene foams or a wide variety of other plastic or polymeric materials. Alternatively, the anchors may be fabricated from materials or combinations of materials (including, without limitation, materials coated with a thermal insulating coating) that themselves do not efficiently transmit heat and thereby avoid undesirable thermal bridges. Such materials may include, without limitation, basalt fibers, ceramic fibers, glass fibers or carbon fibers and other compatible and appropriate composite materials. 
         [0007]    The anchoring components of this invention may have a wide variety of shapes and structures for anchoring face materials to structural wall or other building materials across or through thermal insulation. Generally such anchors will maintain connections between building structure and face materials even if fire or other destructive seismic and other events damage or destroy insulation between the face materials and building structure so that such destructive events do not cause face materials to detach and fall. Generally such anchors have anchor ends that are captured in or otherwise attached to the face materials and structural materials. Such connections may include bulbous, spread, cap-like, plate-like, bent, threaded or other anchor ends that are captured in slots, grooves, threaded members or the like. Such receiving structures can include T-slots, dovetail slots or other anchor-engaging structures, and such slots or structures can open above and or below the assembled location of the anchor, such as one or two edges of the structural material or face material. “Key-hole” slots are also usable that have an opening large enough for the anchor end to be inserted in a space that communicates with space partially covered by a structure defining a narrower slot through which a smaller portion of the anchor can extend. Anchor-to-facing or anchor-to-structure connections can simply slide together, can have “insert and slide” structure, can have an “engage and turn” structure, and can include threaded components (including, without limitation, threaded male members like screws and bolts and threaded female members like nuts) among other alternatives. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    Illustrative embodiments of the present invention are described in detail below with reference to the following drawing figures: 
           [0009]      FIG. 1  is a perspective view of a first exemplary embodiment of assembled structural block, insulation and facing components of the concrete masonry system of this invention. 
           [0010]      FIG. 2  is a perspective view of an exemplary stretcher sub-assembly of this invention. 
           [0011]      FIG. 3  is a perspective view of an exemplary sash sub-assembly of this invention. 
           [0012]      FIG. 4  is a perspective view of an exemplary right half sash sub-assembly of this invention. 
           [0013]      FIG. 5  is a perspective view of an exemplary left half sash sub-assembly of this invention 
           [0014]      FIGS. 6 and 7  are perspective views of exemplary left corner sub-assemblies of this invention. 
           [0015]      FIGS. 8 and 9  are perspective views of exemplary right corner sub-assemblies of this invention. 
           [0016]      FIG. 10  is a perspective view of an exemplary facing sub-assembly of this invention usable for first course and lintel structures. 
           [0017]      FIG. 11  is an enlarged perspective view of the exemplary stretcher unit of this invention shown in  FIG. 2 . 
           [0018]      FIGS. 12 and 13  are top and right end views of the stretcher unit shown in  FIG. 11 . 
           [0019]      FIG. 14  is an exploded perspective view of the stretcher unit shown in  FIG. 11 . 
           [0020]      FIG. 15  is a perspective view of the top, left, end and back of the exemplary facing shown in  FIG. 14 . 
           [0021]      FIG. 16  is a top view of the facing of  FIG. 15 . 
           [0022]      FIG. 17  is a perspective view of the exemplary insulation insert shown in  FIG. 14 . 
           [0023]      FIG. 18  is a top view, and  FIG. 19  is an end view, of the insulation insert of  FIG. 17 . 
           [0024]      FIG. 20  is a perspective view of the exemplary anchor shown in  FIG. 14 . 
           [0025]      FIGS. 21 and 22  are top and side views, respectively, of the exemplary anchor of  FIGS. 14 and 20 . 
           [0026]      FIG. 23  is a perspective view of the exemplary stretcher unit shown in  FIG. 2  with a vertical section exposing one of the anchors. 
           [0027]      FIG. 24  is another perspective view of the exemplary stretcher unit shown in  FIG. 2  with a horizontal section taken just above the anchors or anchors to show their positions in the assembly. 
           [0028]      FIG. 25  is an enlarged fragmentary top view of the relative geometry of an exemplary sliding dovetail joint between the insulation and structural block of this invention. 
           [0029]      FIG. 26  is an end perspective view of a first course or bottom row of an exemplary embodiment of a wall of this invention. 
           [0030]      FIG. 27  is a side view of the exemplary installation of  FIG. 26 . 
           [0031]      FIG. 28  is a perspective view of a face block and a modified insulation block used in a first course or lintel installation such as those depicted in  FIGS. 26 ,  27 ,  29  and  30 . 
           [0032]      FIG. 29  is an end view of an exemplary embodiment of a lintel installation of this invention. 
           [0033]      FIG. 30  is a perspective view of the exemplary lintel installation of  FIG. 29 . 
           [0034]      FIG. 31  is an enlarged end view of exemplary gasket material between two insulation blocks of this invention. 
           [0035]      FIGS. 32 and 33  are right hand and left hand corner assemblies, respectively, of this invention. 
           [0036]      FIG. 34  is plan view of a corner reinforcement structure. 
           [0037]      FIG. 35  is a perspective view of an exemplary wall of this invention, the top course of which utilizes full sash blocks to accommodate movement. 
           [0038]      FIG. 36  is a view of an exemplary wall like that of  FIG. 35  showing a movement joint using sash half blocks. 
           [0039]      FIGS. 37 and 38  are end views of like stacked block sub-assemblies of this invention and gasket material with the thickness of grout in  FIG. 37  about twice that in  FIG. 38 . 
       
    
    
     DETAILED DESCRIPTION 
       [0040]    The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. 
         [0041]    A basic block wall assembly  10  of a first embodiment of the insulated block system of this invention is depicted in  FIG. 1 . It includes an insulated stretcher block sub-assembly  12  (also shown in  FIG. 2 ), together with other blocks, reinforcement and gasket material further described below. 
         [0042]    Each insulated block assembly is assembled from three components, a structural block, a facing block, and insulation block between these. The insulated stretcher block  12  depicted in  FIGS. 11 ,  12  and  13  incorporates an insulation block  18  containing anchors  20  and sandwiched between a structural stretcher block  14  and a facing block or facing  16 . 
         [0043]    As will be appreciated by review of the Figures, the exemplary components depicted in the Figures are consistent in size and relative proportions such as height as compared to length and depth. Components of different sizes than those depicted in the Figures and components with different proportions are easily designed and manufactured utilizing the information provided here. For instance, among many other possibilities, a system of this invention may be produced with structural, insulation and facing blocks nominally one-half as tall as the components illustrated in the Figures as compared to length and depth. Numerous other relative proportions are likewise easily utilized. 
         [0044]    Details of the structures of the exemplary components of exemplary stretcher block assembly  12  are well depicted in  FIGS. 14-22 . 
         [0045]    As is particularly well shown in  FIGS. 14 and 15 , each of structural stretcher block  14  and face block  16  have a vertical face penetrated by vertical slots or grooves. Block  14  face  22  includes two “dovetail” cross-section, through slots or grooves  26  and three dovetail cross-section stopped slots or grooves  24 . 
         [0046]    Face block  16  face  28  includes two dovetail cross section through slots or grooves  30  on face  28  and three dovetail cross-section stopped slots or grooves  32 . 
         [0047]    Through slots or grooves  26  on block  14  penetrate both the top  34  and bottom  36  of block  14 . Through slots or grooves  30  on facing  16  penetrate both of the top  38  and bottom  40  of facing block  16 . 
         [0048]    Stopped slots or grooves  30  on face blocks  16  open down (penetrating the bottom  40  of facing block  16 ), and stopped slots or grooves  24  on block  14  open up (penetrating the top  34  of block  14 ). 
         [0049]    Insulation block  18  may be a single piece of plastic foam or other appropriate material and could also be built up from components among other alternatives. As depicted in the drawings, block  18  is a generally rectangular slab with faces  42  and  44  configured to mate with blocks  14  and  16 . Portions of each block  18  may lap a portion of each block  18  beside which it is positioned end to end in order to limit transmission of heat through the wall front to back or back to front. For instance, among other alternatives such as half-lap joint, a tongue  48  on one end of each block  18  may be received in a groove  46  on the other end. Ridges  54  on the top  50  and bottom  52  compress gaskets  58  to limit heat transmission above and below insulation blocks  18 . 
         [0050]    As is apparent in several of the figures, the tongue  48  and groove  46  ends inter-fit to provide continuous insulation horizontally. 
         [0051]    Numerous alternative insulation block end structures are possible, including among others, ship-lapping, multiple tongues and grooves, scarfing and butting. 
         [0052]    Gasket strips  58  are captured between opposed tops  50  and bottoms  52  of insulation blocks  18  (and, more specifically between ridges  54  on the tops  50  and bottoms  52  of the insulation blocks  18 ), thereby providing continuous insulation vertically in the system  10 . The exemplary insulation blocks  18  shown in the figures have round regions  178  (marked in  FIG. 17 ) that result from the injection of foam during production of blocks  18  in one production method. Ridges  54  entirely encircle these regions  178  to insure a good and continuous seal between the top  50  of insulation blocks  18  and overlying gasket  58 . Such round regions are not necessary to the practice of this invention. Gasket  58  is seated between insulation blocks  18  to provide a continuous thermal barrier up and down the wall  10  of this invention. Additionally, it transmits water vertically and helps prevent mortar from blocking the ends of water management grooves  94  in the faces of insulation blocks  18 . Gasket  58  can be made in a number of different configurations and lengths, and usable gasket could be made with differences in each of the structural characteristic depicted in the Figures and described here. 
         [0053]    Gasket  58  may be made of any appropriate material. Compliant material that can compress to adjust for differences in the thickness of mortar between blocks, which mortar establishes the spacing between blocks, is desirable so that a good seal will be achieved notwithstanding such variations in mortar thickness and block spacing.  FIGS. 37 and 38  depict gasket  58  between upper and lower insulation blocks  18  with different spacing and differing amounts of compression of gasket  58 . Such gasket material may, for instance, accommodate mortar joints including and between approximately ¼ inch and ½ inch in thickness. 
         [0054]    Appropriate gasket materials will typically be somewhat flexible, preferably provides good insulation slowing transmission of heat and should be a resilient material that can be somewhat compressed between insulation blocks  18  to provide a seal between such blocks while resisting passage horizontally of air, water or heat. Usable materials may include expanded styrene, polystyrene, polypropylene and other foams, neoprene, natural and synthetic rubbers and other polymer materials and other suitable conventional and newly-developed gasket materials. Adhesive may be pre-applied to one or both of the top and bottom gasket surfaces, and such adhesive may be protected with a release paper or film that is removed before installation. 
         [0055]    The faces  42  and  44  of each insulation block  18  are the same but are rotated 180 degrees (or flipped) about a horizontal axis relative to each other. Each face  42  and  44  includes two vertically oriented dovetail “tails” or keys  60  essentially the full height of block  18  and three dovetail tails or keys  62  that are not full height. Keys  62  are topped by a sloping ramp surface  64  that dies into the face  42  or  44  of the block  18  as the case may be, and each of tails or keys  60  terminates in a shorter ramp  66  that does not extend all the way to face  42  or  44  as the case may be. Grooves  24  in block  14  and grooves  32  in face block  16  terminate in sloping regions or ramps  68  in the case of grooves  24 , and ramps  70  in the case of grooves  32 . 
         [0056]    As may be appreciated by reference to  FIG. 25 , the cross sectional shape of each groove may actually be more complex than the simple “dovetail” shapes used, for instance, in woodworking, where the “dovetail” shape is usually defined by only three planes, two of which are sloping relative to the face of the workpiece and the third of which is parallel to the face of the workpiece. The exemplary cross sectional shape of the slots or grooves of the embodiment of this invention depicted in the drawings may be defined by: (a) parallel entry walls  72  that face each other, (b) inner walls  74  that are likewise parallel and facing each other, (c) sloping walls  76  that join walls  72  and  74 , and a back wall  78  that joins the two inner walls  74 . This structure avoids inclusion of any “inside” or “outside” acute corners (i.e., corners less than 90°), which facilitates manufacture and the avoidance of damage because such acute corners are easily broken (in the case of outside corners) or jammed with debris (in the case of inside corners). 
         [0057]    As can also be seen on  FIG. 25 , the tail or key  60  is generally defined by parallel neck walls  80 , sloping walls  82  and exterior wall  84 , with the corner  86  formed by walls  82  and  84  rounded over. Significantly, a small vertical raised area or rub rib  88  on each sloping wall  82  provides an easier slip fit (by reducing the total contact area between grooves and tails), with firm sealing contact (between the groove walls  76  and the rub rib  88 ), and accommodates manufacturing mold wear resulting in changes in component dimensions. 
         [0058]    As can be appreciated by reference to  FIGS. 20-24 , anchors  20  are imbedded in insulation blocks  18  to prevent separation of facing  16  from structural blocks  14 . Such anchors  20  may insure the integrity of the wall in the event of fire, wind loading or earthquakes. As shown in  FIGS. 20 ,  21  and  22 , anchors  20  may be fabricated of sheet metal to provide two dovetail-shaped opposite ends  90  integrally formed with a neck or plate  92  between them. 
         [0059]    Anchors  20  are dimensioned so that they can be positioned within insulation block  18  entirely encapsulated by the material of the insulation block  18 , and with the dovetail-shaped ends  90  positioned within opposed grooves  24  and  32  of face block  16  and structural block  14 , respectively, when insulation blocks  18  are assembled with structural blocks  14  and face blocks  16 . If the insulating material of insulation block  18  burns, melts or otherwise loses its integrity, because, for instance, the structure  10  is loaded beyond the ability of insulation blocks  18  to secure face block  16  to stretcher block  14 , anchors  20  will prevent face blocks  16  from falling away from structural blocks  14  because the ends  90  are wider than the mouths of grooves  24  and  32 . As a result, vertical downward movement of face block  16  will drive the end  90  of anchors  20  up against ramp  70  in facing block  16  and down against ramp  68  in block  14 . This will typically prevent the face block  16  from falling off or otherwise away from the structure provided by blocks  14 . 
         [0060]    Because anchor  20  is entirely encapsulated by the insulation material of block  18  (absent fire or other degradation of insulation  18 ), anchor  20  does not contact either of block  14  or face block  16  and thus does not provide a thermal bridge between face block  16  and structural block  14 . 
         [0061]    As depicted in the Figures illustrating an exemplary system of this invention, anchor  20  may be fabricated of sheet metal of any suitable type, including steel, stainless steel, aluminum and other metals and alloys. Many other materials and cross sectional and longitudinal shapes are possible. For instance, among other possibilities, anchor  20  could be forged, molded or cast of metal or another material (including, without limitation, polymers and polymer composites) with appropriate thermal and structural properties so that the anchor  20  will not melt or burn at the temperatures encountered in structure fires and have sufficient strength and an appropriate shape to keep the face block  16  coupled to the structural blocks  14  in the event of a fire or other circumstance that damages the material of insulation block  18 . 
         [0062]    Anchor  20  also may be made of wire, bar or rod bent or otherwise formed into a suitable shape. Selection of material and configuration of anchor  20  will be typically dictated by the size and composition of the other system components and the temperature (in a fire) and other extreme physical conditions it is desired that anchor  20  be able to withstand. For instance, stainless steel anchors  20  may be desirable in particularly corrosive environments. 
         [0063]    This masonry system may provide highly effective management of water. As an example, the components depicted in the figures provide drainage of water away from the interior of structural stretcher blocks  14  and, therefore, away from the interior of a building wall or other structure made of the components of this invention. 
         [0064]    First, full length grooves  26  in stretcher block  14  and grooves  30  in face blocks  16  permit any water within those grooves to drain down while remaining near the exterior of a structure made from these components. Water that enters grooves  24  in block  14  drains down and then away from the interior of block  14  when it encounters ramps  68 . The vertical spaces between the interlocking components illustrated in  FIG. 25  accommodate such vertical drainage. 
         [0065]    Second, vertical water management grooves  94  are incorporated in both the front and rear faces  42  and  44 , respectively, of insulation blocks  18  to permit water to flow down either the front or back of blocks  18 . 
         [0066]    Third, gasket  58  ( FIGS. 1 and 31 , among others) that is positioned horizontally between insulation blocks  18  is perforated by vertical holes  96  through which water can drain from grooves  94  in an insulation block  18  above the gasket  58  and into grooves  94  in an insulation block below that gasket  58 . Including relatively closely spaced vertical holes  96  in gasket  58  will insure that at least one such vertical hole  96  will be near each vertical groove  94  in insulation  18 . 
         [0067]    Fourth (and finally), an appropriate water path may be provided out the front of the wall at a foundation, at a lintel, or at another location where the downward extending wall stops. Such a “bottom row” detail at a floor or foundation is depicted in  FIGS. 26 and 27 . A metal, membrane or other flashing  100  is provided so that there is a path to the outside extending from a location above and behind the lowest course of structural blocks down and under the lowest course of insulation blocks  18  and facing blocks  16 . Because this configuration prevents any connection between the lowest (first course) insulation blocks  18  and the structural blocks, common concrete blocks  104  may be used for the first course, and the tails or keys  60  and  62  are removed (for example, by wire cutting) from the rear-facing side  44  of block  18  to result, for example, in a modified insulation block  106  depicted in  FIG. 28 . Cotton cords or other appropriate water conduits may be positioned on top of blocks  104 , over the flashing  100  and out to the front of facing  16 . 
         [0068]    Insulation block  106  shown in  FIG. 28  may be produced by omitting the anchors  20  and cutting off just the tails or keys  60  and  62  in an upper portion of the block, so that water management grooves  94  are intact, ensuring channels for water to travel down between the upper portion  108  of block  106 . If desired, water management grooves  94  may be enlarged. Adhesive may be positioned on the block  106  to bond to the flashing. More of block  106  may be removed in a lower portion  110  of block  106 . This defines a vertical slot or pocket  112  between the lower portion  110  of block  106  and flashing  100  (well depicted in  FIG. 27 ). Such a pocket or slot  112  helps to accommodate a lintel angle  114  used at a header location, as depicted in  FIGS. 29 and 30 , which show use of such a lintel angle  114  together with rebar  116  and bond beam concrete masonry units  118 . Although not depicted in  FIG. 29  to avoid confusion, gasket  58  may be positioned on top of flashing  100  and lintel angle  114  and under the insulation block  106 . 
         [0069]    Insulation blocks  18  may be formed of expanded polystyrene or other expanded, foamed, fused, bonded or other polymer materials or a wide variety of other suitable materials providing the structural and thermal blocking properties appropriate for this member and any other desirable properties that may include strength, flame retardation, smoke suppression and water impermeability. 
         [0070]    The insulation block  18  may be made of conventional expandable polystyrene foam and of modified polystyrene foam such as BASF Neopor® foams, which are expandable polystyrene foams formulated with graphite in the cell structure, creating a grey-hued material that, according to the manufacturer, provides better thermal performance than traditional expandable polystyrene foam. Other foams and other insulating materials may also be used, such as polyurethane or isoprene foams, among others. The insulation blocks  18  may be formed in suitably shaped molds that may include magnetic or other clips or hold-downs that hold the anchors in place within the mold while the expandable foam is introduced into the mold cavity and the insulation block  18  is formed. Essentially any front to back thickness of insulation block  18  is usable that is thick enough (i.e., on the order of at least about 1″ thick) to form the desired structure and provide heat insulation. Thicknesses between approximately 1″ and approximately 10″ will typically be appropriate, but thinner and thicker insulation blocks  18  are also possible. The thickness of the insulation block  18  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 of this invention is to be used. 
         [0071]    As is indicated in  FIGS. 14 ,  23  and  24 , anchors  20  are positioned within the mold so that one will be located with one of its ends in each of the opposing stopped keys  62  located near the ends of the insulation block  18  and approximately centered top to bottom within the insulation block  18 . Thus, in the examples depicted in the drawings, two anchors  20  attach each facing block  16  to each structural block  14 , and there is no anchor  20  in the centrally located stopped keys  62 . 
         [0072]    Other numbers of grooves and tails or keys in blocks  14 ,  16  and  18  may be used than the number depicted in the drawings and described above, and different numbers of anchors  20  can be utilized than the number depicted in the drawings and described above. 
         [0073]    Although not depicted in the drawings or described above, a single facing block  16  may overlap and adhere or otherwise attach to a plurality of insulation blocks  18  containing one or more anchors  20 , and a single insulation block  18  containing one or more anchors  20  may overlap and adhere or otherwise attach to a plurality of structural blocks  14 . Thus, a single facing block  16  may overlap with a plurality of structural blocks  14 , and a single insulation block  18  containing one or more anchors  20  may overlap with a plurality of facing blocks  16 , structural blocks  14 , or both. 
         [0074]    One of the advantages of the block system of this invention is that there are three mortar locations within the thickness of a wall rather than the two typical in a conventional concrete block wall. Specifically (with reference to  FIG. 2 ), there are mortar locations (1) along the front top  120  and adjacent ends of block  14 , (2) along the rear top  122  and adjacent ends of block  14  (as in a typical concrete block wall), and (3) there are also mortar locations along the top, bottom and end of facing block  16 . This additional mortar line between facing blocks  16  provides additional sealing and integrity in the walls and other structures of this system. 
         [0075]      FIGS. 32 and 33  depict construction of successive courses of a wall of this invention at a corner, illustrating an approach for achieving a strong, attractive corner incorporating the insulation and other benefits of this disclosure. Numerous other components consistent with this invention may be used in order to form corners. The approach illustrated here is but one example. 
         [0076]    In this example,  FIG. 32  depicts a standard or stretcher unit  12  incorporating a stretcher block  14 , a facing block  16  and an insulation block  18  together with a “right hand corner” assembly  126 . Similarly,  FIG. 33  depicts a second course including a standard or stretcher unit  12  incorporating a stretcher block  14 , a facing block  16  and an insulation block  18  together with a “left hand corner” assembly  128 . 
         [0077]    Right hand corner assembly  126  depicted in  FIG. 32  may include right L-corner sub-assembly  146  shown in  FIG. 8  and a right lapping corner sub-assembly  148  shown in  FIG. 9 . Left hand corner assembly  128  depicted in  FIG. 33  may include left L-corner sub-assembly  130  shown in  FIG. 6  and a left lapping corner sub-assembly  132  shown in  FIG. 7 . These assemblies can be used at structure corners and returns. Each sub-assembly in  FIGS. 7 and 9  has a structural block, a facing block and an insulating block, as set forth in this table: 
         [0000]    
       
         
               
               
             
               
               
               
               
             
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                   
                 Sub-assembly element 
               
             
          
           
               
                 Sub-assembly 
                 Structural block 
                 Facing block 
                 Insulation block 
               
               
                   
               
             
          
           
               
                 Left L-corner 
                 134 
                 136 
                 138 
               
               
                 130 
                   
                   
                   
               
               
                 Left lapping corner 
                 140 
                 142 
                 144 
               
               
                 132 
                   
                   
                   
               
               
                 Right L-corner 
                 150 
                 152 
                 154 
               
               
                 146 
                   
                   
                   
               
               
                 Right lapping corner 
                 156 
                 158 
                 160 
               
               
                 148 
               
               
                   
               
             
          
         
       
     
         [0078]    As is apparent in the figures, the four sub-assemblies  130 ,  132 ,  146  and  148  may be made using only two special structural blocks. More specifically, blocks  134  and  156  may be identical, and blocks  140  and  150  may be identical. 
         [0079]    Special purpose blocks and sub-assemblies in accordance with this disclosure can incorporate a wide variety of interlocking and anchoring configurations. In the exemplary configurations shown in the figures where blocks  134  and  156  are the same and blocks  132  and  150  are the same and the blocks have a “standard” size cavity  174  and a smaller cavity  176  (marked in  FIGS. 6 and 7 ). Additionally, each of the blocks may have a dovetail groove in one end near the standard size cavity  174  and adjacent to one block longer face, together with three such grooves on the adjacent longer face. The other blocks are the mirror image. Among other things, this configuration permits structure corners to be built with corner blocks  134 / 156  and  132 / 150  having vertically aligned standard size cavities in the corner of the structure. Rebar and grout or concrete can be placed in those vertically aligned cavities to strengthen the structure. This configuration also accommodates the insulation block  18  structure depicted in the figures and described above. A full length block  18  with the appropriate two of its dovetail keys removed (making insulation blocks  144  and  160 ) is used with structural blocks  156  and  140 . An L-shaped insulation block  138  or  154  is fabricated by appropriately cutting and joining (with adhesive or other means) mitered portions of insulation blocks  18 . Using the positioning of anchors  20  within insulation block  18  described above and depicted in the figures, one anchor will remain in insulation blocks  144  and  160 , and two anchors will remain in insulation blocks  138  and  154 . Other numbers and configurations of anchors and keys in insulation blocks are possible. 
         [0080]    Corner reinforcement tie wire inserts  162  (see  FIG. 34 ) may be used as shown in  FIG. 33  where additional corner strength is desired. Similarly, mortar or grout can be placed in any or all of the block  14  cavities. The cavities align vertically so that, rebar can be inserted in vertically aligned block  14  cavities together with mortar to provide further strength, particularly, for instance at corners of structures of this invention. 
         [0081]    Accommodation for wall movement because of temperature changes or other factors without creation of an air or water-admitting penetration through the entire wall can be accomplished with (full size) sash blocks  164  as depicted in  FIG. 35  and with half sash blocks  166  as depicted in  FIG. 36 , together with a gasket or barrier  168  having an X-shaped cross-section that is received in opposed grooves  170  in the sash blocks  164  or half sash blocks  166 . Sash blocks  164  and half sash blocks  166  are shown individually in  FIGS. 3 ,  4  and  5 . 
         [0082]    The exemplary structural blocks  14  and other structural blocks of this invention may be made using conventional, typically inexpensive, concrete materials or from a variety of other cementitious materials and other compositions providing sufficient strength, density and other qualities appropriate for the particular application. The blocks  14  shown in the drawings have flat top webs. Such blocks can also be produced with webs with V-shaped tops. Such blocks with V-shaped web tops may provide benefits relative to water drainage, aesthetics and other things. 
         [0083]    Face blocks  16  and other such blocks can be made of concrete and virtually any other desired material that will provide adequate strength and weather resistance and, importantly, other desired aesthetic qualities. For instance, face blocks may be made of marble or another natural stone, a wide variety of castable or moldable materials, metals (including aluminum), wood and other machineable or formable materials. 
         [0084]    Insulation blocks  18  may be married to blocks  14  and  16  using adhesives or other means, and adhesives can act as lubricants to facilitate assembly of the face insulation and structural blocks. Among other alternatives, when adhesive is used, 3M brand Polystyrene Foam  78  Adhesive may be used. Other adhesives may also be used provided that they do not damage the insulation blocks  18  and otherwise provide appropriate application and performance properties. 
         [0085]    Insulation blocks  18  are designed to make use of adhesives unnecessary. The blocks of this invention may be joined simply by sliding the tails or keys  60  and  62  of insulation blocks  18  into the grooves or slots  24  and  26  of blocks  14  and the grooves or slots  30  and  32  of face blocks  16 . Sloping ramps  64  and  68  may facilitate introduction of the tails or keys  60  and  62  into the grooves or slots of blocks  14  and  16 . Whether adhesive is used or not, a hydraulic or other press may be used to facilitate this assembly: (a) by pressing the top  50  of insulation block  18  and bottom  36  of block  14  until the tails  60  and  62  are seated in the grooves  24  and  26  of block  14 , and (b) by pressing the top of  38  of facing block  16  and bottom of insulation block  18  until the tails  60  and  62  of block  18  are seated in the grooves  30  and  32  of facing block  16 . This assembly may be done in any desired order of steps, including simultaneously. 
         [0086]    The desired relative positions of the blocks will be maintained under normal circumstances as a result of friction between rub ribs  88  (visible in  FIG. 25  and that protrude from and extend up and down the sloping walls  82  of the tails or keys) and the sloping walls  76  of the groove or slot in the structural block  14  or face block  16  as the case may be. As noted above, adhesive may be used to facilitate assembly and secure the assembled block components to each other. Other numbers, shapes, sizes, and locations of rub ribs than those depicted in the drawings may be used. For example, rub ribs could comprise one or more bumps protruding anywhere from the tails or keys  60  and  62 . 
         [0087]    The use of sloping ramps  70  on face block  16 , sloping ramps  64  on insulation block  18  and sloping ramps  68  on structural block  14  provide the capacity to align insulation block  18  relative to the face block  16  in structural block  14  more accurately than might be the case using other stopping structures. This is because the opposing faces will “lock up” within a small range of relative positions rather than providing a hard stop as might be the case if stop structures square to the block faces were used. These sloping surfaces also provide better encouragement (than would square ledges) for water to drain down within the wall structure. 
         [0088]    Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and subcombinations are useful and may be employed without reference to other features and subcombinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications can be made without departing from the scope of the claims below. 
         [0089]    For instance, anchors  20  can be configured in numerous other shapes and of different materials, including various different cross sectional sheet metal and wire shapes and sizes. Alternatives to anchors  20  with round end structures having a diameter just less than the width of the tails or keys  62  at the location where the end structures will be imbedded in the tails  62  may be well-suited for their purpose because, among other reasons, they can be rotated along their longitudinal axis during positioning and molding of insulation blocks  18 , making them easy to position and use. Other alternative anchor shapes may also be used, including, for instance, anchors having vertically oriented, plate-shaped square or rectangular ends of appropriate width, which ends may be joined by a sheet or web of metal or another material. Similarly, an anchor may be made of cast metal with a central, rectangular web and flaring, dovetail-shaped ends embedded in the tails or keys  62  similar in shape to the anchors  20  depicted in the drawings. Among other wires usable for anchors are 0.15″ diameter round galvanized steel wire. Various other wire-making materials can also be used, including, for instance, stainless steel in particularly corrosive environments. 
         [0090]    As is indicated in  FIGS. 14 ,  23  and  24 , anchors  20  are positioned within the insulation block  18  mold so that one will be located within with one of its ends in each of the opposing the stopped tails or keys  62  near the ends of insulation blocks  18  and centered top to bottom within the insulation block  18 . Thus, in the examples of standard stretcher assemblies  12  depicted in the drawings, two anchors  20  attach each facing block  16  to one structural block  14 . 
         [0091]    Other numbers of grooves and tails in blocks  14 ,  16  and  18  can be used than the number depicted in the drawings and described above, and different numbers of anchors  20  can be utilized than the number depicted in the drawings and described above. 
         [0092]    Appropriate adjustments and configurations may also be desirable in producing the special-purpose sub-assemblies of this invention. For instance, insulation block  172  used with the half-sash units illustrated in  FIGS. 4 and 5  may be produced by wire cutting out a central region of the insulation block  18  of appropriate width. The two insulation block ends can then be adhesively bonded together to result in a half-sash insulation block  172  containing the two anchors  20  that were in insulation block  18  and the same length as the half sash structural blocks  166 . 
         [0093]    One aspect of this disclosure includes four main components: a facing block, a structural block, anchors that prevent the facing from separating from the structural block and insulation between the facing block and the structural block. Most of the detailed description and figures contemplate structures in which anchors are embedded in the insulation blocks and are normally thermally insulated from the face and structural blocks so that the anchors do not form a thermal bridge. Other alternatives are possible. For instance the anchors may be separate components from the insulation that are assembled on site or are preassembled with one or more of the insulation, facing or structural components before those components or subassemblies of those components are assembled on site. Furthermore, anchors, facing blocks and structural blocks could be preassembled or assembled on site so that there is a cavity between the facing and structural blocks into which insulation can be installed in solid form or inserted as a liquid that may foam, and in any event solidifies, in situ. Such alternative anchors may be mounted in either or both of the facing and structural blocks and engaged with the other of these blocks during assembly of the components. In another alternative, an anchor component may be attached to each of the facing and structural blocks and then coupled during component assembly. 
         [0094]    Block assemblies may be manufactured with a structural block with a vertical side penetrated by at least one groove, a facing block with a vertical side penetrated by at least one groove, an insulation block With front and back vertical sides, With the front side comprising at least one upward facing tail or key and the back side comprising at least one downward facing tail or key, by performing the following steps, in no particular order: sliding the structural block and insulation blocks relative to each other so that the downward facing tails or keys are received in the structural block grooves, and sliding the facing block and insulation block relative to each other so that the upward facing tails or keys are received in the facing block grooves. The blocks may be pressed together with a press. 
         [0095]    Insulation blocks may be manufactured by:
       a. providing a mold containing a cavity in the shape of the desired insulation block,   b. providing at least a first anchor,   c. positioning the first anchor within the mold at a location corresponding to a desired anchor location in the insulation block,   d. charging the mold with insulation-forming material,   e. permitting the insulation-forming material to cure, and   f. removing the cured insulation block containing the anchor from the mold.
 
The mold may include at least one magnet or other structure, and may include multiple magnets or other structures, for holding one or more anchors inn position during the manufacturing process.
       
 
         [0102]    A structural block for use at an end, corner or the like in a block wall including structural blocks, insulation blocks and face blocks, each of which face blocks has at least one elongated groove, and each of which insulation blocks has at least one elongated tail or key, may comprise: a concrete masonry unit having a front vertical wall, a back vertical wall and two vertical end walls between the front vertical and back vertical walls, the front and one of the end the walls further comprising at least one vertically extending groove adapted to receive the at least one elongated tail or key. 
         [0103]    A facing block for use at a corner, end or the like in a block structure comprising structural blocks, insulation blocks and face blocks, each of which structural blocks has at least one elongated groove, and each of which insulation blocks has at least two elongated tails or keys, may comprise:
       a. an L-shaped decorative material comprising:
           i. a front face,   ii. an end face,   iii. a back face and   iv. an end inside face, and   
           b. each of the back face and the end inside face further comprising at least one vertically extending groove or slot adapted to receive one of the insulation block tails or keys.       
 
         [0110]    A thermally insulated wall structure may include structure blocks, face blocks, anchors for joining the face blocks to the structure blocks, and insulation for interposition between the structure blocks and the face blocks. The anchors may be configured to avoid providing thermal bridges.

Summary:
A insulated masonry wall system having insulation blocks between structural and face blocks to provide structures that are strong, inexpensive, avoid thermal bridges, and resist transmission of heat. The walls are attractive and versatile, and an enormous variety of decorative face members may be utilized. The face blocks are attached to the structural blocks to prevent facing materials from falling even if fire destroys the insulation blocks between the structural blocks and the facing. The system resists water penetration and effectively drains water that does penetrate any portion of the system.