Abstract:
A wall system having high vertical and lateral stability as well as vertical loading capacity is disclosed. The wall system includes blocks formed from two opposing plates. The plates have a spacer holding the plates at a predetermined distance from one another. Each plate includes tongues and grooves for fitting together with adjacent blocks in the wall system when the blocks are stacked with one another. Once the blocks are stacked, the space between the opposing plates of the blocks is filled with an spray insulation to lock the blocks in place.

Description:
[0001]    A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 
       CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0002]    Not Applicable 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0003]    Not Applicable 
       REFERENCE TO SEQUENCE LISTING OR COMPUTER PROGRAM LISTING APPENDIX 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    Walls formed from traditional concrete blocks are inexpensive and can support heavy vertical loads. However, walls formed from traditional concrete blocks are very heavy, are difficult to insulate, are relatively thick, and have relatively low lateral support strength as compared to their vertical support strength and the lateral strength of poured concrete walls. Additionally, it is difficult to install wiring conduit and plumbing (especially drain lines) in concrete block walls. For example, placing an electrical outlet below a window is difficult because the inner walls of each individual block interfere with the steel conduit to the outlet required by code. 
         [0006]    Wood or steel stud framed walls covered in drywall, R-board, and/or oriented strand board (OSB) are inexpensive, can be easily insulated, and are very light. However, walls formed from wood and steel studs and drywall, R-board, and/or oriented strand board have relatively low vertical and lateral strength, and are time consuming to build and finish. Fiberglass bats are typically used to insulate these types of walls. Foam insulation seals air leaks and provides a much higher R value per volume, but foam insulation is difficult to use with traditional wood or metal stud walls because any foam on the face of the stud must be scraped off so that the drywall may be mounted flat to the face of the stud. It is impractical to mount the drywall, then fill the wall with foam insulation because holes must be placed in the double top plate of the framing or cut into the drywall every 16″ which would require an impractical amount of time and expense to repair. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    Aspects of the present invention provide a wall system with high vertical and lateral stability as well as vertical loading capacity. The wall system includes blocks formed from two opposing plates. A spacer holds the plates at a predetermined distance from one another. Each plate includes tongues and grooves for fitting together with adjacent blocks in the wall system when the blocks are stacked together. Once the blocks are stacked, the space between the opposing plates of the blocks is filled with an spray insulation to lock the blocks in place. 
         [0008]    In one aspect, a block performing a wall when stacked with a plurality of other blocks includes a first plate, a second plate, and a spacer. The first plate has an inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end. The top end of the first plate has a tongue or groove and the bottom end of the first plate has a tongue or groove substantially complementary to the tongue or group of the top end of the first plate. The second plate has an inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end. The top end of the second plate has a tongue or groove at the bottom end of the second plate has a tongue or groove substantially complementary to the tongue or groove of the top end of the second plate. The spacer is operable to attach to the inside face of the first plate and the inside face of the second plate and maintain the inside face of the first plate at a predetermined distance from the inside face of the second plate. 
         [0009]    In another aspect, a block performing a wall when stacked with a plurality of other blocks includes a first plate, a second plate, and a spacer. The first plate has an inside face, an outside face opposite the inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end. The outside face of the first plate at the first end of the first plate has a first indentation extending from the top end to the bottom end, and the outside face of the first plate at the second end of the first plate has a first protrusion substantially complementary to the first indentation. The second plate has an inside face, and outside face opposite the inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end. The outside face of the second plate at the first end of the second plate has a second indentation extending from the top end to the bottom end, and the outside face of the second plate at the second end of the second plate has a second protrusion substantially complementary to the second indentation. The spacer is operable to attach to the inside face of the first plate and the inside face of the second plate and maintain the inside face of the first plate at a predetermined distance from the inside face of the second plate. 
         [0010]    In another aspect, a system for forming a wall includes a plurality of blocks and spray insulation. The plurality of blocks forms the wall when stacked, and each block of the plurality of blocks includes a first plate, a second plate, and a spacer. The first plate has an inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end. The top end of the first plate has a tongue or groove and the bottom end of the first plate has a tongue or groove substantially complementary to the tongue or groove of the top end of the first plate. The second plate has an inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end. The top end of the second plate has a tongue or groove at the bottom end of the second plate has a tongue or groove substantially complementary to the tongue or groove of the top end of the second plate. The spacer is operable to attach to the inside face of the first plate and the inside face of the second plate and maintain the inside face of the first plate at a predetermined distance from the inside face of the second plate, forming a space between the inside face of the first plate and the inside face of the second plate. The spray insulation is operable to substantially fill the space formed between the inside face of the first plate and the inside face of the second plate of each block of the plurality of blocks. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0011]      FIG. 1  is an isometric cutaway view of a system of blocks and spray insulation forming a wall. 
           [0012]      FIG. 2  is an isometric view of a partially assembled block of a system of blocks and spray insulation for forming a wall. 
           [0013]      FIG. 3  is an overhead perspective view of stacked blocks of a system of blocks in spray insulation for forming a wall. 
       
    
    
       [0014]    Reference will now be made in detail to optional embodiments of the invention, examples of which are illustrated in accompanying drawings. Whenever possible, the same reference numbers are used in the drawing and in the description referring to the same or like parts. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0015]    While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not delimit the scope of the invention. 
         [0016]    To facilitate the understanding of the embodiments described herein, a number of terms are defined below. The terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity, but rather include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as set forth in the claims. 
         [0017]    As described herein, an upright position is considered to be the position of apparatus components while in proper operation or in a natural resting position as described herein. Vertical, horizontal, above, below, side, top, bottom and other orientation terms are described with respect to this upright position during operation unless otherwise specified. The term “when” is used to specify orientation for relative positions of components, not as a temporal limitation of the claims or apparatus described and claimed herein unless otherwise specified. 
         [0018]    The phrase “in one embodiment,” as used herein does not necessarily refer to the same embodiment, although it may. Conditional language used herein, such as, among others, “can,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. 
         [0019]    Referring to  FIGS. 1-3 , a system  100  for forming a wall includes a plurality of blocks  102  and spray insulation  104 . The plurality of blocks  102  forms the wall when stacked in an interlocking fashion. Each block  102  of the plurality of blocks includes a first plate  106 , a second plate  108 , and a spacer  120 . The first plate  106  has an inside face  110 , a top end  112 , a bottom end  114  opposite the top end  112 , a first end  116 , and a second end  118  opposite the first end  116 . The first plate  106  also has an outside face  162  opposite the inside face  110 . The top end  112  of the first plate  106  has a tongue or groove, and the bottom end  114  of the first plate  106  has a tongue or groove substantially complementary to the tongue or groove of the top end  112  of the first plate  106 . In one embodiment, as shown in  FIG. 1 , the top end  112  has a tongue, and the bottom end  114  has a substantially complementary groove. In one embodiment, the first plate  106  has an indentation  117  in the inside face  110  of the first plate  106 . In one embodiment, the indentation  117  is operable to receive a first end  122  of the spacer  120 . In one embodiment, the first plate  106  is formed from a mixture of cement and at least one of perlite or polypropylene fibers (e.g., polypropylene fiber bundles). 
         [0020]    In one embodiment, the second plate  108  is substantially similar to the first plate  106 , except that the orientation of the inside face and outside face are reversed with respect to the first end and second end to promote easier interlocking of the blocks  102  (see, for example,  FIG. 2 ). The second plate  108  has an inside face  124 , a top end  126 , a bottom end  130  opposite the top end  126 , a first end  128 , and a second end  132  opposite the first end  128 . In one embodiment, the second plate  108  has an outside face  160  opposite the inside face  124  of the second plate  108 . The top end  126  of the second plate  108  has a tongue or groove, and the bottom end  130  of the second plate  108  has a tongue or groove substantially complementary to the tongue or groove of the top end  126  of the second plate  108 . Because the top end  112  and a bottom end  114  of the first plate  106  and the top end  126  and bottom end  130  of the second plate  108  all have complementary tongues and grooves, when all of the blocks  102  are upright or upside down in stacked together, each time or groove interlocks with the tongue or groove of an adjacent block  102  (i.e., the block  102  above and/or below). 
         [0021]    In one embodiment, the second plate  108  has an indentation  134  in the inside face  124  of the second plate  108 . The indentation  134  is configured to receive a second end  136  of the spacer  120  opposite the first end  122  of the spacer  120 . In one embodiment, the indentation  117  in the inside face  110  of the first plate  106  corresponds to the indentation  134  in the inside face  124  of the second plate  108 . 
         [0022]    In one embodiment, the first end  116  of the first plate  106  has a tongue or groove, and the second end  118  of the first plate  106  has a tongue or groove substantially complementary to the tongue or groove of the first end  116  of the first plate  106 . The first end  128  of the second plate  108  has a tongue or groove, and the second end  132  of the second plate  108  has a tongue or groove substantially complementary to the tongue or groove of the first end  128  of the second plate  108 . Because the first and second ends of the first and second plates have complementary tongues and grooves, when all of the blocks  102  are stacked together in the same orientation (i.e., first end facing the same direction), each tongue or groove interlocks with the tongue or groove of an adjacent block  102  (i.e., the block  102  to the left or right). 
         [0023]    In one embodiment, the first and second plates  106 ,  108  are each approximately 1.5″ thick (i.e., between the outside face and inside face). In one embodiment, the top end and the first end include the tongues, and the tongues are rounded. The grooves in the bottom end and the second end have a radius of curvature and depth generally corresponding to the radius of curvature and height of the tongue in the top end and first end. In another embodiment, the top end and the first end include the tongues, and the tongues are V shaped. The grooves in the bottom end and the second end have a depth and width corresponding to the width and height of the tongues. 
         [0024]    The spacer  120  is operable to attach to the inside face  110  of the first plate  106  and the inside face  124  of the second plate  108  and maintain the inside face  110  of the first plate  106  at a predetermined distance from the inside face  124  of the second plate  108 . The spacer  120  may mount flush to the surface of the inside faces, or maybe affixed to indentations within the inside faces. In one embodiment, the spacer is formed from at least one of wood (e.g., a section of 2×2), PVC pipe, metal pipe, metal strapping, plastic strapping, welded metal wire, metal lathe, or brick ties. In one embodiment, the spacer  120  has a length from the first end  122  to the second end  136  of approximately 4 to 6 inches. 
         [0025]    Referring to  FIG. 3 , in one embodiment, the outside face  162  of the first plate  106  at the first end  116  of the first plate  106  has a first indentation  170  extending from the top end  112  to the bottom end  114  of the first plate  106 . The outside face  160  of the second plate  108  at the first end  128  has a second indentation  172  extending from the top end  126  to the bottom end  130  of the second plate  108 . The outside face  162  of the first plate  106  has a first protrusion  180  substantially complementary to the first indentation  170 . The outside face  160  of the second plate  108  has a second protrusion  182  substantially complementary to the second indentation  172 . Thus, when the blocks  102  are stacked end to end with the first ends oriented in the same direction, the first end of the block  102  nests inside a second end of an adjacent block  102 . 
         [0026]    Once the blocks  102  are assembled (e.g., stacked on top of one another and end to end such that the tongues, grooves, protrusions and/or indentations are interlocking), the space in the wall form between the opposing inside faces of the first and second plates of the blocks  102  is filled with the spray insulation  104 . The spray insulation  104  may be an expanding open or closed cell polyurethane foam or some other type of spray in insulation. In one embodiment, the spray insulation acts to fill the space and adhere or affix the plurality of stacked blocks  102  to one another, increasing the lateral strength of the wall formed by the stacked blocks  102  and spray insulation  104 . 
         [0027]    This written description uses examples to disclose the invention and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 
         [0028]    It will be understood that the particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention may be employed in various embodiments without departing from the scope of the invention. Those of ordinary skill in the art will recognize numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims. 
         [0029]    All of the compositions and/or methods disclosed and claimed herein may be made and/or executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of the embodiments included herein, it will be apparent to those of ordinary skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit, and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope, and concept of the invention as defined by the appended claims. 
         [0030]    Thus, although there have been described particular embodiments of the present invention of a new and useful BLOCK AND FOAM WALL SYSTEM it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.