Patent Abstract:
A multi-component composite block includes a pair of opposed and parallel masonry face panels amalgamated with transverse non-masonry truss-webs or a truss-module including a plurality of joined non-masonry truss-webs. Truss-webs and/or truss-module are delivered within the mold assembly and aligned, retained, and held fast in place by mold apparatuses. Portions of truss-web and/or truss-module unite together with mold apparatuses to shape partitioned residual cavity spaces for the addition of concrete block forming material to form face panels. The truss-web members and/or truss-module have configured elements that integrate with the concrete mass of the face shells providing a permanent amalgamated bond. The assembled multi-component composite block is rigidly stable, durable, structural, lightweight, and thermally efficient.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The present application is based on and claims priority to U.S. Provisional Patent Application Ser. No. 61/617,156 filed Mar. 29 2012. 
     
    
     BACKGROUND 
       [0002]    The present disclosure generally relates to a multi-component masonry block. More specifically, the present disclosure relates to a masonry block that includes a pair of opposite facing panels that are joined with transverse non-masonry truss-web members or a truss module to form a composite block having enhanced energy saving properties. 
         [0003]    The United States Department of Energy has developed a national energy policy for the purpose of conserving energy, including buildings and housing, in order to preserve our natural energy resources and become. less reliant on foreign nations for energy sources. A majority of states have passed laws mandating that new building structures must comply with increased energy efficiency standards. Highly insulated thermal envelope systems are required in order to reduce the energy used to heat and cool the building&#39;s interior conditioned space. Many existing wall systems will not meet the new energy efficiency standards now mandated, and others will not meet newer energy efficiency standards planned for the future. 
         [0004]    Concrete block are extensively manufactured for use as a building material and are often used to construct single wythe masonry exterior walls for numerous building types and related structures. Conventional masonry blocks manufactured on modern block making machines have two parallel concrete face shells cast simultaneously with interconnecting, lateral, concrete cross-webs. These block units are individually laid to build single wythe masonry walls. 
         [0005]    However, a major drawback in typical single wythe concrete block construction is its inability to provide a well-insulated thermal envelope wall, because concrete blocks including concrete cross-webs exhibit high thermal conductivity and rapid heat loss through its composition. The insulation value of a typical single wythe concrete block wall may be marginally improved by filling the cores formed between the face shells and cross-webs with insulation. However, because the high thermally conductive concrete cross-webs penetrate the insulation, the cross-webs facilitate rapid heat loss through the wall by a process commonly referred to as thermal bridging. Thus, walls constructed with conventional single wythe concrete block can only provide a meager building thermal envelope, because they contain numerous concrete cross-webs in their framework. 
         [0006]    Adaptations to the typical block structure utilizing conventional manufacturing techniques have been developed, including: reducing the number of concrete cross-webs and/or reducing the cross sectional area of these webs. While these means reduce the overall thermal bridging effect of the cross-webs, they yet render an insufficient product for use in constructing high performance thermal envelopes that demand greater R-values to better conserve on the energy required to heat and cool a building&#39;s interior conditioned space. Other concrete block designs have been devised that completely separate the interior and exterior concrete face-shell segments with continuous interconnecting and/or adhered rigid insulation, thus eliminating the thermal bridging effect. These concrete blocks are formed with a middle rigid insulation material and outer concrete portions. The outer face-shells are cast on conventional block making machines and later factory assembled together with the mid-portion insulation component. 
         [0007]    These improvements provide an increase in thermal performance; however these block units have limitations associated with manufacturing, handling, and field installation. Further, methods for separating the block face shells by completely eliminating the concrete cross-webs and substituting them with plastic strut members are known. The concrete face shell segments are independently cast on conventional block making machines and later hand-assembled together with the synthetic cross members being joined utilizing various male-female connection schemes with the connections employing a resilient friction fit or adhesive bond to maintain engagement of the assorted components. These adaptations provide means to improving the thermal efficiency of concrete masonry units; however they lack connection strength, do not adequately provide vertical or lateral stability relative to face shell alignment, and require expensive, cumbersome, and time consuming assembly of the multiple component pieces. 
       SUMMARY 
       [0008]    The present disclosure is designed to address the above noted problems by introducing novel components, structure, and means of manufacturing a composite masonry unit quickly and efficiently without the need for post assembly of component parts. The disclosure also eliminates the need for manufacturing conventional block units having concrete cross-webs that cause thermal bridging. The disclosure makes use of any variety of synthetic non-masonry truss-webs and/or a truss-module comprising joined truss-web members and amalgamates these components with masonry facing panels to provide a composite block having increased unit structural stability and reduced thermal bridging. The device of the present disclosure utilizes an assortment of synthetic truss-webs and/or truss modules that are capable of being inserted into, and securely restrained within, a mold forming assembly. The disclosure provides a means for cement mixture during the molding process of concrete face shells to amalgamate with synthetic truss-webs and/or truss-module, which results in these components being permanently integrated and linked. The disclosure provides components and method for producing an intact composite: block comprising united concrete face shells with synthetic non-masonry truss-webs and/or truss-module, which provides a masonry block unit having superior resistance to vertical and lateral torque forces experienced during stripping, cubing, shipping, and handling, and provides structural integrity and strength between the interior and exterior face shell planes when the units are collectively assembled in a finished wall and subject to lateral, compressive, axial, and flexural loads. 
         [0009]    The present disclosure relates to composite masonry block units capable of being manufactured on conventional block making machines or other concrete forming machinery. A vertically oriented mold box assembly for forming concrete blocks is configured having internal walls of any arrangement of full or partially tapered or full or partially curved core bells, end core liners, and/or positioning spines, which configure interconnected conterminous cavity spaces. Portions of the cavity spaces are designed to receive truss-web members and/or a truss-module comprising joined truss-web members therein that combine with the internal walls of the mold box assembly and portions of the core bells and end liners to form distinct residual cavity spaces that are filled with cement block forming material therein. 
         [0010]    The truss-web members and/or truss-module are placed on top of a portable support plate, which is commonly referred to as a pallet. The pallet with truss-webs and/or truss-module thereon is delivered on conveyors and is positioned underneath the mold assembly. Alternatively, truss-web members and/or truss-module are placed on the pallet when the pallet is in a stationary position underneath the mold assembly. The pallet is lifted to abut the underside surface of the mold box assembly. During the lifting process, the truss-webs and/or truss-module are simultaneously inserted, aligned, and fitted into cavity portions of the mold assembly. The truss-webs members and/or truss-module comprise tapered or curved extended flanges that correspondingly mate to the profile of tapered or curved walls or partial tapered or curved segments thereof of core bells, end core liners, and/or positioning spines. The truss-web members and/or truss-module are held in vertical alignment by the lower supporting pallet and a top plate that can have a compression gasket, and are held and buttressed in a set horizontal position by the abutting core bells, end core liners, and/or positioning spines. 
         [0011]    When positioned within the mold assembly, portions of the truss-webs and/or truss-module combine with portions of the core bells and/or end core liners and walls of the mold assembly to create discrete residual cavities designated to receive cement material for the formation of concrete face shells that can have appendages. The abutting and mating contact of portions of the truss-webs and/or truss-module with portions of the core bells and/or end core liners creates a seal to prevent passage of cement mixture from flowing into other cavity spaces or voids within the mold assembly. Portions of the truss-webs and/or truss-module abut to and extend within the residual cavities designated to receive cement material and/or have hollows or voids thereof to be filled with the cement mixture. The truss-web members and/or truss-module are configured such that when plastic cement material is added to cavities designated to receive the cement material, it dispenses in, through, below, to the sides, above, and/or around portions of the truss members and/or truss-module integrating and connecting the two diverse material elements. 
         [0012]    Consequently, block forming cement material is placed from above the mold assembly into the residual mold cavity spaces forming a pair of opposed and parallel rectangular masonry panels that can comprise appendages. The cement material is vibrated and compacted, which further facilitates the flow of the cement mixture to dispense around protrusions and/or penetrate into voids and/or indentations of the truss-webs members and/or truss-module forming a dense structural amalgamation of the diverse materials. Subsequently, the pallet is lowered from the block mold assembly, which simultaneously removes the synthetic non-masonry truss-webs members and/or truss-module and concrete masonry face shells united as a cohesive unit thereon. The composite masonry block unit is then cured Until such time as the cement block forming material sets to a hardened concrete mass. 
         [0013]    Accordingly, the present disclosure can provide a system of components, structure, and a method for producing a sturdy composite masonry block. 
         [0014]    The present disclosure provides a composite block that is cost-effective and is easily and economically mass produced on conventional block making machines or other concrete forming machines and eliminates the need for post-assembling of various pre-manufactured components. The concrete block is modular, lightweight, easy to grasp, lift, handle, and place, and is resistant to sound transmission, rot, decay, insects, mold, and moisture movement. The composite block exhibits particularly high thermal resistance properties with negligible thermal bridging heat transfer between the exterior and interior concrete face shell panels. The composite block may be used in single wythe masonry wall construction and provide attractive and durable exterior and interior finishes, structural load-bearing capabilities, and improved thermal envelop performance. 
         [0015]    The present disclosure can provide a pair of exterior exposed substantially rectangular formed concrete face shell panels amalgamated and integrally bound with synthetic non-masonry truss-web members and/or truss-module that serve to space apart and hold together in alignment the concrete panels. 
         [0016]    The present disclosure can provide synthetic non-masonry truss-web members and/or truss-module that extend across the space between two independent concrete face shell panels for securing the panels in opposing, parallel, and fixed space orientation and to accommodate and provide for compression and tensile restraint and shear transfer between the panels. 
         [0017]    The present disclosure can provide a method of delivering, inserting, aligning, and fitting, truss-web members and/or truss-module into block making molds used for forming concrete block, securing and holding fast the truss members and/or truss-module during the cement casting, vibration, and compaction of the concrete facing panels, and simultaneous removal of the truss members and/or truss-module together with the concrete face panels as an amalgamated, interconnected, composite unit from the block making molds. 
         [0018]    The present disclosure can provide truss-web members and/or truss-module having portions thereof acting in conjunction with other block mold apparatuses or portions thereof to form contiguous walls that create distinct cavities for receiving cement mixture. 
         [0019]    The present disclosure can provide truss-web members and/or truss-module having portions thereof acting in conjunction with other mold apparatuses or portions thereof to create containment seals to prevent semi-plastic cement mixture from flowing outside cavity spaces designated to receive the cement mixture and into other mold cavity spaces during the placement of the cement mixture into block forming molds. 
         [0020]    The present disclosure can provide truss-web members and/or truss-module having a portion thereof containing voids, holes, hollows, indents, cavities dimples openings, fissures, extensions, projections, flanges, lips, and/or nubs or other designs which accommodates the placement of a plastic cement mixture to flow and be distributed within, by, under, over, through, and/or around portions of the truss-web members and/or truss-module to form an integral homogenous bonding of the masonry panels to the truss-web members and/or truss-module. 
         [0021]    The present disclosure can provide truss-web members and/or truss-module having surface portions thereof containing indentations, serrations, holes, hollows, protrusions, bulges, a thickened mass or texture to provide a better grip of the composite block unit. 
         [0022]    A related device of the present disclosure is the truss-web members and/or truss-module can have surface portions thereof containing indentations, serrations, holes, hollows, protrusions, bulges, a thickened mass, or texture that provides the surface portion areas with uneven consistency to which concrete grout mixture can more readily bond to when masonry walls constructed with the present composite block are filled with the grout mixture to strengthen the walls. This improved bonding of the concrete grout to the truss-web members and/or truss-module, which are integrated to the face shell panels, provides increased flexural strength to the masonry walls. 
         [0023]    The present disclosure can provide truss-web members and/or truss-module being solid, or portions thereof containing vertical and/or horizontal cavities and/or other configurations to allow for the passage of insulation material to flow and be distributed through and within portions of the truss-web members and/or truss-module. 
         [0024]    The present disclosure can provide truss-web members and/or truss-module having portions thereof containing vertical cavities and/or horizontal voids with the horizontal void openings sized from ⅛″ to 1″ diameter to prevent the passage of plastic cement out to pass through portions of truss-web members and/or truss-module, but allow for the passage of insulation material to flow and be distributed through and within portions of the truss-web members and/or truss-module. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]      FIG. 1  is a perspective view of a composite masonry block constructed according to the disclosure. 
           [0026]      FIG. 2  is a perspective view of a truss-web member. 
           [0027]      FIG. 3  is a perspective view of an alternate embodiment of a truss-web member. 
           [0028]      FIG. 4  is a perspective view of an alternate embodiment of a truss-web member. 
           [0029]      FIG. 5  is a. fractional perspective view of a block forming mold assembly constructed according to the present disclosure and shows relative movement between a pallet, having truss-web members supported thereon. and the mold assembly. 
           [0030]      FIG. 6  is a fractional perspective view similar to  FIG. 5  showing a pallet raised to abut a mold assembly, with truss-web members inserted into, aligned with, braced, and held fast by mold assembly apparatuses, with the truss-webs and the apparatuses establishing residual cavities for receiving block funning cement material. 
           [0031]      FIG. 7  is a perspective view of an alternative configuration having multiple truss-web members united together with connecting components forming a truss-module. 
           [0032]      FIG. 8  is a fractional perspective view of an alternate block forming mold assembly constructed according to the present disclosure showing a pallet having a truss-module supported thereon beneath the mold assembly. 
           [0033]      FIG. 9  is a fractional perspective view similar to  FIG. 8  and shows relative movement between a pallet having a truss-module supported thereon and a mold assembly. 
           [0034]      FIG. 10  is a view similar to  FIG. 9  showing pallet raised to abut mold assembly, with a truss-module inserted into, aligned with, braced, and held fast by mold assembly apparatuses, with the apparatuses and the truss-module establishing residual cavities for receiving block forming cement material. 
           [0035]      FIG. 11  is a view similar to  FIG. 10  showing a block forming mold assembly having truss-module and block forming cement material therein. 
           [0036]      FIG. 12  is a view similar to  FIG. 11  showing pallet lowered from mold assembly and supporting thereon a composite masonry block having parallel, longitudinal, concrete face shells amalgamated with a synthetic truss-module. 
           [0037]      FIG. 13  is a perspective view of an alternative truss-module configuration according to the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0038]    Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of components, structure, means of manufacture and other aspects set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” “consisting,” “containing,” “being,” or “having” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “integrated,⇄ “connected,” “supported,” “joined.” “united,” “incorporated,” fastened,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. 
         [0039]    With reference to  FIG. 1 , a composite block unit composed preferably of concrete masonry connected together with rigid non-masonry synthetic material such as plastic or rubber and made according to the present disclosure is generally designated by reference numeral  10 . The composite block unit  10  includes two generally planer masonry facing panels  12  contiguous with and integrally joined to coupling truss-web members  20 . 
         [0040]    The rectangular masonry facing panels  12  are molded to the same height and length dimensions as each other and each have an outer surface  1  and an inner surface  16 . 
         [0041]    Extending perpendicular from inner surface  16  of masonry facing panels  12  are two formed thickset appendages  14 , which are equal in height to the panels  12 . The appendages  14  are fashioned in a spaced relation to each other along the longitudinal length of the panels  12  such that when multiple block units  10  are laid in a wall using a traditional masonry running bond pattern, the appendages  14  are in direct vertical alignment with those above and below each other. 
         [0042]    Shown in  FIGS. 1 and 2  are coupling, truss-web members  20 , which unite with and join masonry facing panels  12 . Truss-web members  20  have vertical sides  21 , vertical ends  22 , and vertical cavities  23  formed therein that extend from the top to the bottom. It is understood that the configured cavities may be vertical and/or horizontal holes, may be more than one, and formed in various circumference profiles. Cavities  23  make truss members  20  significantly void in order to decrease their thermal conductivity, reduce material costs, and allow the truss members  20  to be filled with insulation material While yet maintaining portions of connecting perpendicular, longitudinal, and diagonal facets to provide lateral and vertical connective and rigid strength between the masonry members. 
         [0043]    Truss-web members  20  comprise extended end flanges  24  and extended connector tongues  26 . The connector tongues  26  vertically encompass only a partial height of the flanges  24 . 
         [0044]    Truss-web members  20  interface with thickset appendages  14  and masonry facing panels  12 . Truss ends  22  and extended flanges  24  border the three exterior edges of the appendages  14  and the flanges  24  also abut the interior surface  16  of the panels  12 . The junction between these components constrains both inward and longitudinal relative movement between the two panels  12  and provides torsional resistance to composite block unit  10 . 
         [0045]    Connector tongues  26  are opposite facing and internally penetrate into the mass of thickset appendages  14  creating a fastening of truss-webs  20  with masonry facing panels  12 . The tongues  26  are shorter than the height of the appendages  14  allowing the concrete mass of the appendages  14  to be formed around, above, and below the tongues  26  thereby establishing a secure connection that constrains outward and vertical relative movement between the two panels  12  and further provides torsional stiffness to composite block unit  10 . 
         [0046]    Truss-web members  20  comprise tapered extended flanges  28  with thicker mass. trending downward formed on vertical sides  21 . Variations of the tapered flanges  28  can include having one, two (shown), three, or more tapered flanges of any variety of widths, or a continuously formed tapered flange along entire the vertical sides  21 . The truss-webs  20  also comprise tapered segments  29  with thicker mass trending downward formed on the interior faces of wall segments that define cavities  23 . Variations of the taper on the flanges  28  and the wall segments  29  can include an arc, curve, obtuse angle segments, and other such configurations that provide a contour with thicker mass trending downward. The tapered flanges  28  and the tapered wall segments  29  are purposed for aligning, positioning, bracing, and holding fast the truss-web members  20  during the production of composite block unit  10 . 
         [0047]      FIG. 3  shows an alternate embodiment of a truss-web member according to the present disclosure, which incorporates and combines features of truss-web member  20 . Truss-web members can have horizontal cavities  31  formed therein extending thorough vertical sides  21 . Truss-web members can have a partial indented hollow  32  formed on extended flanges  24  extending vertically over only a partial height of the flanges  24 . The indented hollow  32  can alternately be a cavity (not shown) formed continuously through the flanges  24 . 
         [0048]      FIG. 4  shows an alternate embodiment of a truss-web member according to the present disclosure, which incorporates and combines features of truss-web member  20 . Truss-web members can he constructed without extended side flanges  24 . Truss ends  22  may be formed having one, two, three (shown), or more contiguous anchors  35  which are configured having a massed segment thereof larger in size than a segment thereof in closer proximity to the truss ends  22 . The truss-web members can he constructed with one, two, or more of various shaped indentations  36  and/or with one, two or more various shaped protrusions  37  on vertical sides  21 , which are imposed for improved grip during handling of block unit assembly  10 . Vertical sides  21  can also be imprinted with any of a variety of textures (not shown) to improve grip during handling. 
         [0049]      FIG. 5  illustrates a block forming mold assembly generally designated by reference numeral  40 . The mold assembly  40  includes a mold box  41  (partially shown), which configures a vertically oriented cavity that is open on its top and bottom. The mold assembly  40  also includes a series of end core liners  42  and center core bell  43  placed within the mold assembly. The end core liners  42  and center core. hell  43  are purposed for forming cores and/or hollows in a block, which is known in the art of block making. 
         [0050]    As can best be seen in  FIGS. 5 and 6 , a lower plate commonly referred to as a pallet  50  is raised to seal the bottom of the mold assembly  40 . The mold box  41 , end core liners  42 , center core bell  43 , and raised pallet  50 , cooperate to form a conterminous cavity comprising interconnected cavity spaces  52  and  57 , which are closed at the bottom and opened on the top. In the art of conventional block making, the cavities  52  and  57  are simultaneously and collectively tilled with cement mixture, which forms concrete face panels interconnected with concrete cross webs. 
         [0051]    Referring to  FIG. 5 , according to the present disclosure, end core liners  42  and center core bell  43 , are configured comprising extended flanges  45  having tapered ends  46  with thicker mass trending upward. Variations of the tapered end  46  on the flanges  45  can include an arc, curve, obtuse angle segments, and other such configurations that provide a contour with thicker mass trending upward. The upward slant of the tapered flange ends  46  are formed in opposing orientation to and in mating alignment with the downward slant of tapered surfaces  28  of truss-web members  20 . The extended flanges  45  having tapered ends  46  located on a mutual side of end core liners  42  and center core bell  43  can be two (shown), three, or more. The end core liners  42  and center core bell  43  can also be formed with constant planer tapered sides  82  and  83  with thicker mass trending upward (as shown in  FIG. 8 ). 
         [0052]    According to the present disclosure, mold assembly  40  can be configured comprising vertically oriented spine members  47  having tapered ends  46  with thicker mass trending upward. Variations of the tapered ends  48  can include an arc, curve, obtuse angle segments, and other such configurations that provide a contour with thicker mass trending upward. The upward slant of the tapered ends  48  are formed in opposing orientation to and in mating alignment with the downward slant of tapered segments  29  of truss-web members  20 . The spine members  47  are configured smaller in width and breadth than cavity spaces  23  of the truss-webs  20  and are equal or less than the height of the truss-webs  20 . 
         [0053]    As best shown in  FIGS. 5 and 6 , the mold assembly  40  can further be configured including a continuous horizontal top plate  44  (partially shown). The top plate  44  covers end core liners  42 , center core bell  43 , and cavity spaces  57  formed between the end core liners and the center core bell in order to prevent cement mixture from entering into and filling the end core liners  42 , center core  43 , and cavity spaces  57 . 
         [0054]    Top plate  44  can have compression gaskets  49  comprised of rubber or other material affixed to the bottom of the top plate  44  at the truss-web members  20  juncture locations, which serves to lessen impact and prevent the truss-webs  20  from crushing or cracking when inserted into the mold assembly  40  due to the rapid, upward, robust force applied when pallet  50  is mechanically lifted. 
         [0055]    According to the method of the present disclosure, and seen in  FIGS. 5 and 6 , truss-web members  20  are placed on pallet  50  prior to the pallet being delivered beneath the mold assembly  40 , or the truss-webs  20  are placed on the pallet  50  when the pallet  50  is in a stationary fixed position immediately underneath the mold assembly  40  and the pallet  50  is set to be lifted. Once positioned immediately below the mold assembly  40 , the pallet  50  is raised, which lifts the truss-web members  20  thereon. During the upward conveyance, the truss-web members  20  become aligned into specific position by their tapered surfaces  28  engaging contact with the tapered ends  46  of flanges  45  and their tapered segments  29  engaging contact with tapered surfaces  48  of spine members  47 . 
         [0056]    Referring to  FIG. 6 , when block forming assembly is in position as shown with pallet  50  raised and abutting mold assembly  40 . truss web members  20  are installed in fixed location within mold box  41  being tightly aligned to, firmly braced, and held fast from relative movement by the tapered ends  46  of flanges  45 , tapered surfaces  48  of spine members  47 , bottom pallet  50 , and top plate  44  which can have gaskets  49 . 
         [0057]    When truss web members  20  are in fixed position within mold assembly  40 , discrete residual cavities  52  are formed with each cavity  52  being defined by the generally vertical walls of mold box  41 , walls of end core liners  42 , wall of core bell  43 , truss ends  22 , and truss flanges  24 . Connector tongues  26  extend into the cavities  52 . The cavities  52  are open on the top and closed on the bottom by bottom pallet  50 . 
         [0058]    The abutting and mating contact of tapered surfaces  28  of truss-web members  20  to tapered ends  46  of flanges  45  creates a seal between the truss-web members  20  and end core liners  42  and the truss-web members  20  and center core bell  43  which prevents passage of cement mixture from flowing into cavity spaces  57  between the end core liners  42  and the core bell  43 . 
         [0059]    Cement mixture  55 , preferably a low slump mixture consisting generally of a combination of cement, cement substitutes, sand, aggregate, and water, is placed from above into formed cavities  52 , which is known in the art of block making. When placed into formed cavities  52 , the cement mixture  55  collectively flows around, above and below the extending tongues  26  of truss-web members  20  and forms thickset appendages  14  and facing panels  12  (as shown in  FIG. 1 ). Truss ends  22  and flanges  24  surround, and the truss tongues  26  embed into, a portion of the collective mass of the cement mixture  55 , which integrates and bonds the truss-web members  20  to the masonry facing panels  12 . 
         [0060]    Mold assembly  40  is mechanically vibrated and cement mixture  55  is mechanically compacted with compression shoes (not shown) that are configured to match the horizontal profile of cavities  52 , which is known in the art of block making. The truss-web members  20  are firmly confined from movement relative to the mold assembly  40 , horizontally by flange tapered ends  46  and spike tapered end  48  and vertically by pallet  50  and top plate  44  that can have gaskets  49  and results in the truss-web members  20  to utterly communicate with the vigorous movement of the mold assembly  40  during the vibration and compaction process. without independent wiggle and provides for the cement mixture  55  to become tightly formed around truss tongues  26  and completely filled within the space between extended end flanges  24  without consequential gaps forming between the mentioned components. 
         [0061]    Cement mixture  55  is allowed to set for approximately five (5) seconds, and then downward mechanical force is applied by the compression shoes to the cement mixture  55  while pallet  50  is simultaneously lowered down from mold assembly  40 , which is known. The stiffened—from vibration and compaction—cement mixture  55  is contiguous and integrally fastened with cross-web members  20  and together these amalgamated components are concurrently lowered and released from the mold assembly  40  producing a finished composite block unit  10  (as shown in  FIG. 1 ). The pallet  50  with block unit  10  thereon is then delivered to a kiln where the cement mixture  55  is cured and hardened in accordance with known practices. 
         [0062]      FIG. 7  illustrates an alternate embodiment of the disclosure. A truss-module generally designated by reference numeral  60  is shown, which incorporates two truss-web members and features thereof as disclosed above including, but not limited to, truss ends  22 , cavities  23 , flanges  24 , truss tongues  26 , and extended tapered flanges  28 . 
         [0063]    Truss-module  60  is made of rigid non-masonry synthetic material such as plastic and includes two truss-web components  71  joined together with generally planer panels  61  that serve to connect and space apart the truss-web components  71 . The truss-web components  71  incorporated with the panels  61  configure an inner vertical cavity  70 . 
         [0064]    Panels  61  have inner surfaces  62  and outer surfaces  63 . The panels  61  include formed ribs  64  on the inner surfaces  62 , which can extend less than or equal to the full height of the panels  61 . The panel ribs  64  comprise planer tapered ends  65  with thicker mass trending downward. Variations of the taper on the ends  65  can include an arc, curve, obtuse angle segments, and other such configurations that provide a contour with thicker mass trending downward. The panel ribs  64  can be one, two, three (shown), or more of any variety of widths being solid or portions thereof comprising hollows and placed at various locations along the inner surfaces  62  or can be a continuously formed tapered surface formed along entire the inner surfaces  62  being solid or portions thereof comprising hollows. The ribs  64  with tapered ends  65  are purposed for alignment and positioning during placement of truss-module  60  into mold assembly  80  (as shown in  FIG. 8 ) and bracing and holding fast the truss-module  60 . 
         [0065]      FIG. 7  illustrates an embodiment of connector stud members  66  formed on, integrally attached to, and extending away from the outer surfaces  63  of panels  61 , which serve to further amalgamate the truss-module  60  with cement mixture. The studs  66  are formed less than the height of the panels  61  and are offset from both the top and bottom of the panels  61 . The studs  66  are “T” shaped as viewed in horizontal cross-section but may assume a variety of other shapes configured having a massed segment thereof larger in size than a segment thereof in closer proximity to the outer surface  63 . 
         [0066]    It is understood that the studs  66  may be one, two, three (shown), or more, may be formed in various configurations such as being hollow, perforated, offset, or planer or slanted protrusions, and may be positioned at various locations on or in the outer surface  63  of panels  61 . The intent of the studs  66  or other formed configurations is such that when plastic cement material is added to the molds, it dispenses in, through, below, to the sides. above, and/or around portions of the stud members or other configurations and integrates and bonds together truss-module  60  with formed masonry face panels  12  (as shown in  FIG. 12 ), which further resists lateral and vertical movement relative to the facing panels  12  and provides torsional stiffness to the composite block unit  90  (as shown in  FIG. 12 ). 
         [0067]    The truss-web portions  71  of truss-module  60  have inner surfaces  72  and outer surfaces  73 . The truss-webs  71  contain formed ribs  74  on the inner surfaces  72 , which extend less than or equal to the full height of the truss-webs  71 . The panel ribs  74  comprise planer tapered ends  75  with thicker mass trending downward. Variations of the taper on the tapered ends  75  can include an arc, curve, obtuse angle segments, and other such configurations that provide a contour with thicker mass trending downward. The truss-web ribs  74  may be one, two (shown), or more of any variety of widths being solid or portions thereof comprising hollows and placed at various locations along the inner surfaces  72  or may be a continuously formed tapered surface formed along entire the inner surfaces  72  being solid or portions thereof comprising hollows. The ribs  74  having the tapered ends  75  are purposed to align, and position during placement of the truss-module  60  into mold assembly  80  (as shown in  FIG. 8 ) and brace and provide fixed positioning to the truss-module  60  during further production. 
         [0068]      FIG. 8  illustrates an alternate embodiment of a block forming mold assembly fabricated according to the present disclosure is generally designated by reference numeral  80 , which incorporates and combines features of mold assembly  40  as disclosed above including, but limited to, mold box  41  (partially shown), top plate  54  having modifications(partially shown) that can have continuous gasket  79  encompassing the horizontal profile of truss-module  60  (partially shown). end core liners  42  (one shown) having modifications, and center core bell  43  having modifications. 
         [0069]    The end core liners  42  can be hollow or solid and comprise generally vertical planer sides  81  and tapered planer side  82  with thicker mass trending upward. Variations of the tapered side  82  can include an arc, curve, obtuse angle segments, and other such configurations that provide a contour with thicker mass trending upward. The upward slant of the tapered sides  82  are formed in opposing orientation to and in mating alignment with the downward slant of tapered extended flanges  28 . In lieu of the tapered sides  82 , end core liners  42  can be formed with extended flanges  45  having tapered ends  46  with thicker mass trending upward (as shown in  FIG. 5 ). 
         [0070]    The center core bell  43  can be hollow or solid and fashioned comprising planer tapered sides  83  and sides  84  having thicker mass trending upward. Variations of the tapered sides  83  and  84  can include an arc, curve, obtuse angle segments, and other such configurations that provide a contour with thicker mass trending upward. The upward slant of the tapered sides  83  are formed in opposing orientation to and in mating alignment with the downward slant of tapered ends  75  of truss ribs  74 , and the length of the tapered sides  83  correspond to the biased distance between tapered ends  65  of panel ribs  64 . The upward slant of tapered sides  84  are formed in opposing orientation to and in mating alignment with the downward slant of tapered ends  65  of panel ribs  64 , and the length of the tapered sides  84  correspond to the biased distance between tapered ends  75  of truss ribs  74 . In lieu of tapered sides  83  and  84 , center core bell can be formed with extended flanges comprising tapered sides formed in opposing orientation to and in mating alignment with the slants and locations of tapered ends  65  and  75  with thicker mass trending upward, or mold assembly can be fashioned having spines that are attached to the top plate  54  and comprise tapered surfaces that are formed in opposing orientation to and in mating alignment with the locations and slants of the tapered ends  65  and  75  with thicker mass trending upward. 
         [0071]    As seen in  FIG. 9 , the truss-module  60  is placed on, and rest upon, pallet  50  prior to the pallet  50  being delivered beneath mold assembly  80  or the truss-module  60  can be placed on the pallet  50  when the pallet  50  is in fixed position immediately underneath the mold assembly  80  and the pallet  50  is set to be lifted. Once aligned and positioned below mold assembly  80 , the pallet  50  is raised which lifts the truss-module  60  thereon where it merges with the mold assembly  80 . Center core bell  43  installs within cavity  70  and truss-web components  71  install within cavity spaces  77  formed between the center core bell  43  and end core liners  42 . With additional reference to  FIGS. 7 and 8 , the truss-module  60  becomes aligned into specific position by tapered ends  65  of panel ribs  64  engaging contact with tapered sides  84  of the center core bell  43  and tapered ends  75  of truss ribs  74  engaging contact with tapered sides  83  of the center core bell  43 . 
         [0072]    Referring to  FIG. 10 , when the block forming device is in position as shown with pallet  50  raised and abutting mold assembly  80 , truss-module  60  is precisely situated within the mold assembly  80  being aligned, braced, and held fast from relative movement by end core liners  42  and center core bell  43  (as shown in  FIG. 9 ), bottom pallet  50 , and top plate  54  that can have gasket  79 . 
         [0073]    The tapered flanges  28  of truss-webs portions  71  mate with and tightly abut to tapered sides  83  of end core liners  42  and create secure seals between truss-module  60  and the end core liners  42  which confines the passage of cement mixture from flowing into cavity spaces  77  between the end core liners  42  and center core bell  43  (as shown in  FIG. 9 ) or portions thereof not occupied by truss-web components  71 . 
         [0074]    As shown in  FIG. 10  (with additional reference to  FIGS. 7 and 8 ), residual cavities  78  are formed with the cavities  78  being defined by the generally vertical walls of mold box  41 , generally vertical walls of end core liners  42 , outer surface  63  of panels  61 , truss ends  22 , and truss flanges  24 . Connector tongues  26  and studs  66  extend into the cavities  78 . The cavities  78  are open on the top and closed on the bottom being defined by bottom pallet  50 . 
         [0075]    As represented in  FIG. 11 , cement mixture  55  is placed from above mold assembly  80 , which is known. With additional reference to  FIGS. 7 ,  10 , and  12 , when the cement mixture  55  is placed into formed cavities  78 , the cement mixture  55  collectively flows above, around, and below extending tongues  26  on flanges  24  of truss-web portions  71 , collectively flows above, around, and below extended stud members  66  on the outer surface  63  of panels  61 , and forms facing panels  12 . with appendages  14 . Truss-web ends  22  and the flanges  24  surround and the truss tongues  26  and the studs  66  embed into a portion of the collective mass of the cement mixture  55  which integrates and bonds truss-module  60  to the cement mixture  55  that forms masonry facing panels  12  and thickset appendages  14 . 
         [0076]    Mold assembly  80  is mechanically vibrated and cement mixture  55  is mechanically compacted with tamping shoes not shown) that are configured to match the horizontal profile of cavities  78 , which is known in the art of block making. The truss-module  60  is securely confined from movement relative to the mold assembly  80 , horizontally by center core bell  43  and end core liners  42 , and vertically by bottom pallet  50  and top plate  54  that can have gaskets  79 , which results in the truss-module  60  to utterly communicate with the movement of the mold assembly  80  during mechanical vibration and compaction without independent wiggle and provides for the cement mixture  55  to become tightly formed around truss tongues  26 , stud members  66 , and completely filled within the space between extended end flanges  24  without forming consequential gaps between the components. 
         [0077]    As shown in  FIG. 12 , alter cement mixture  55  is allowed to set for approximately five (5) seconds, pallet  50  is lowered down and away from mold assembly  80  while tamping shoes (not shown) simultaneously push down from above to aid in the release of formed cement mixture in a downward stripping process from the mold assembly  80 , which is known. The stiffened—from vibration and compaction—cement mixture  55  becomes contiguous and integrally joined with truss-module  60  and both the cement mixture  55  and the truss-module  60  are concurrently lowered and released together from the mold assembly  80 . 
         [0078]    According to the disclosure an assembled composite block unit, generally designated by reference numeral  88 , is thereby produced comprising two generally planner masonry facing panels  12  contiguous and integrally joined with coupling truss-module  60 . Pallet  50  with the composite block unit  88  thereon is then delivered to a kiln where cement mixture  55  is cured and hardened in accordance with blown practices. 
         [0079]      FIG. 13  illustrates an alternate embodiment of a truss-module according to the present disclosure generally designated by reference numeral  90 , which incorporates truss-module features as disclosed above including, but not limited to, truss-web components  71 , truss ends  22 , vertical cavities  23 , flanges  24 , truss tongues  26 , extended tapered flanges  28 , panels  61  having inner surfaces  62  and outer surfaces  63 , extended tapered ribs  64 , and extended tapered ribs  74 . 
         [0080]    Truss-module  90  can comprise indentations  36  formed on truss-web components  71 , which are purposed for improved grip during handling of a composite block unit. The truss-module  90  can also comprise indentations  91  on truss ends  22  and on outer surfaces  63  of panels  61 , which may be formed in various configurations positioned at various locations. The intent of the indentations  91  is such that when plastic cement material is added to the molds during forming of concrete face panels  12  (as shown in  FIG. 12 ), it dispenses within the indentations  91  and integrates and bonds together truss-module  90  with the formed masonry face panels  12 , which further resists lateral and vertical movement relative to the facing panels  12  and provides torsional stiffness to the composite block unit  90 . 
         [0081]    Truss-module  90  can further comprise indentations  92  on inner surfaces  62  of panels  61  to which concrete grout mixture can flow within and more readily bond to when masonry walls constructed with the composite block are filled with the grout mixture to strengthen the walls. This improved bonding of the concrete grout to the truss-module, which is integrated to the face shell panels, provides increased flexural strength to the masonry walls. 
         [0082]    Truss-module  90  can further comprises one, two or more horizontal cavities  93  within truss-web portions  71 , which may be formed in various configurations and positioned at various locations within the body thereof, that allow vertical cavities  23  to communicate with other adjoining vertical cavities  23 , interior vertical cavity  70 , and to the exterior of the truss-web portions  71 . The horizontal cavities  93  are preferably sized with a ⅜″ diameter, but can be sized from ⅛″ to 1″ diameter, the cavity opening size being small enough to prevent the passage of plastic cement grout from passing through walls of the truss-web portions  71 , but is also large enough to allow the passage of injected foam insulation to pass through walls of the truss-web portions  71 , conditions that occur when composite block units are used to construct a reinforced and/or insulated masonry wall. 
         [0083]    Truss-module  90  can further comprise retaining grooves  95  and  96  formed on truss-web portions  71  extending vertically over the entire height of the truss-web portions  71 , which are useful in securing dividing members (not shown) spanning between interior facing retaining grooves  95  of the same truss-module  90  or spanning between exterior facing retaining grooves  96  of two separate adjacent truss-modules when used in a wall built with composite block units. Having the dividing members inserted into the retaining grooves  95  divides interior vertical cavity  70  into two separate vertical cavities that can he used, one, for the confined placement of vertical steel reinforcing and cement grout mixture and, the other, for the confined placement of insulation material. 
         [0084]    Truss-module  90  can further comprise thickened wall segments  97  on truss-web portions  71  that do not expand outside the profile of extended tapered ribs  74 , and thickened wall segment  98  on interior surfaces  62  of panels  61  that do not expand outside the profile of extended tapered ribs  64 . The wall segments  97  and segment  98  extend vertically over only a portion of the height of the truss-module  90  and are purposed for improved pip during handling of a composite block. 
         [0085]    The present disclosure reveals modules and method for constructing a structural composite block. While specific embodiments and advantages of the disclosure, its components, assembly, and making have been conveyed in the foregoing description, it is apparent that alterations, modifications, and variations will be apparent to those skilled in the art of the ideas presented. Accordingly. it is intended to embrace any and all such alterations, modifications, and variations as fall within the broad scope and spirit of the present disclosure. 
         [0086]    In some embodiments of the present disclosure, novel block structure and composition and block making methods comprise a structural composite block unit containing two spaced apart generally planer and parallel facing panels consisting of masonry material including concrete, which can have inwardly oriented thickset segments integrally formed thereon, the thickset segments are spaced apart along the length of the facing panels such that When multiple composite block units are laid in a one-half running bond pattern (the pattern being commonly understood in the industry as the placement of masonry units so that the vertical mortar joints between ends of adjacent units in successive courses are horizontally offset one-half the unit length in courses above and below) the first thickset segment of one block is stacked and in direct vertical alignment with the second thickset segment of the other block units above and below; and extending between, joined together, and contiguous with the facing panels that can have thickset segments are two non-masonry material connective coupling truss-web members formed of equal length with respect to each other and comprising connecting member elements including various configured protrusions, indentations, and/or holes thereon allowing the concrete material to be formed around, in, and/or through the connecting member elements during the molding process of the masonry facing panels that integrally joins and interlocks the truss-web members and the facing panels together. 
         [0087]    In some embodiments of the present disclosure can comprise a truss-web module containing non-masonry material truss-web components connected and spaced apart with solid partially void, indented, and/or textured contiguous non-masonry material panels or other configured elements extending between the truss-web components, the panels and truss-web components of truss-module comprising connecting member elements including various configured projections, indentations and/or holes thereon allowing concrete material to be formed in, above, below, to the sides, and/or around the connecting member elements during the casting and molding process of masonry facing panels which integrally joins together and interlocks the truss-module with the masonry facing panels. 
         [0088]    Truss-webs members and/or truss-web components of a truss-module can be solid, or have one, or a plurality of vertical holes or other shaped hollow cavities located within the truss-web body, and/or have one or a plurality of horizontal holes, indents, or other shaped hollow cavities located within the truss-web body, and/or one or a plurality of protrusions or have textured surfaces on the truss-web body. 
         [0089]    Truss-web members and/or truss-web components of a truss-module can have vertical holes or other shaped hollow cavities within the body thereof and can have horizontal holes or other shaped hollow cavities within the body thereof the horizontal hole openings sized from ⅛″ to 1″ diameter. 
         [0090]    Truss-web members and/or truss-web components of a truss-module can have tapered extended flanges, ribs, and/or tapered extended sides having thicker mass trending downward which extend vertically either partially or over the entire height of the truss-web members; the tapered flanges and ribs can include having one, two, or more tapered flanges of ribs of any variety of widths, or a continuously formed tapered flange or rib along entire the sides the flanges, ribs, and sides can comprise a planer taper with thicker mass trending downward or alternately can comprise an arc, curve, obtuse angle segments, and other such configurations that provide a contour with thicker mass trending downward; and the flanges, ribs, and/or sides can be formed in opposing orientation to and in mating alignment with tapered mold assembly apparatuses having tapered flanges and/or sides having thicker mass trending upward. 
         [0091]    Truss-web members and/or truss-web components of a truss-module can comprise tapered sections with thicker mass trending downward formed on the interior faces of wall segments that define vertical cavities within body of the truss-webs and/or truss module; the tapered sections can comprise a planer taper with thicker mass trending downward or alternately can comprise an arc, curve, obtuse angle segments, and other such configurations that provide a contour with thicker mass trending downward; and the tapered sections can be formed in opposing orientation to and in mating alignment with tapered mold assembly apparatuses having tapered flanges and/or sides having thicker mass trending upward. 
         [0092]    Apparatuses of a mold assembly can have tapered flanges, spikes, and/or tapered sides having thicker mass trending upward formed on, suspended, and/or fixed to the mold assembly, which extend vertically either partially or over the entire height of the mold assembly; the mold assembly apparatuses can be formed in opposing orientation to and in mating alignment with tapered truss-web flanges and/or tapered truss-web sides having a thicker mass trending downward; and the mold assembly apparatuses can be formed in opposing orientation to and in mating alignment with tapered rib and/or flange components of a truss-module having a thicker mass trending downward. 
         [0093]    Truss-web members and/or truss-web components of truss-module can have a top width dimension narrower than the widest width dimension of mold assembly cavity spaces they are inserted into, and truss-web members and/or truss-web components of truss-module can have a vertical section profile dimension that is equivalent to the vertical section profile of the mold assembly cavity spaces they are inserted into.. 
         [0094]    In some embodiments of the present disclosure, novel block composition and block making methods for forming a structural composite block consists of placing individual synthetic truss-web components or truss-module consisting of truss-web members joined with connecting panel or panels or other configured components extending between the truss-web components on a lower support member and conveying the support Member with the truss-web members or the truss-module thereon to a position beneath a mold assembly, or placing the truss-web members or the truss-module on support Member When the. support member is in a stationary position beneath the mold assembly; the truss-web members or truss-web components of truss-module can consist of a solid or cored body, ends haying formed flanges, tongues, protrusions and/or voids, and solid tapered portions thereof with thicker mass trending downward and the connecting panels can consist of a solid or cored body having formed anchors, protrusions, cavities, and/or voids; and the mold assembly consisting of solid walls and apparatuses with tapered portions thereof with thicker mass trending upward and providing a conterminous cavity comprising interconnected cavity space segments; raising the support member with the truss-web members and/or the truss-module thereon to abut bottom of the mold assembly causing the truss-web members and/or the truss-module to be guided and inserted into the conterminous cavity of the mold assembly by the mating contact of the tapered portions of the truss-webs and/or the truss-module with the tapered portions of the mold assembly apparatuses; the installation of the truss-webs and/or the truss-module into the mold assembly consequently fashions two separated independent residual cavity spaces each defined by the lower support member, some walls of the mold assembly. some walls of the apparatuses, ends of the truss-web members and/or the truss-module, flanges of the truss-web members and/or the truss-module, and/or walls of the connecting panels; placing block forming material into the formed residual cavities, the block forming material flowing in, by, above, below, and/or around formed the flanges, tongues, protrusions, and/or voids of the truss-web members and/or the truss-module and/or connecting panels; vibrating and/or compacting the block forming material; and lowering the support member with the truss-web members and/or truss-module connected and united together with the block forming material thereon providing a composite block unit. 
         [0095]    In some embodiments, the step wherein once truss webs and/or truss-module are inserted into the mold assembly the truss webs and/or truss-module are securely held in horizontal and vertical fixed position relative to the mold assembly by mold assembly apparatuses in order for the truss-webs and/or truss-module to communicate with the movement and vibration of the mold assembly. 
         [0096]    In some embodiments, the step wherein once truss-webs and/or truss-module are inserted into the mold assembly portions of the truss-webs and/or truss-module register together with other mold assembly apparatuses to form partitions that create and define distinctive cavities for the placement of cement material cast generally rectangular masonry face panels that can have thickset appendages. 
         [0097]    In some embodiments, the step wherein once truss webs and/or truss-module are inserted into the mold assembly portions of the truss-webs and/or truss-module register together with other mold assembly apparatuses to create a seal to prevent passage of masonry material into other cavity and/or hollow portions of the mold assembly.

Technology Classification (CPC): 4