Source: http://www.google.com/patents/US5209037?dq=6721967
Timestamp: 2015-05-30 13:53:27
Document Index: 506103366

Matched Legal Cases: ['arts 12', 'arts 12', 'arts 12', 'arts 12', 'arts 12', 'arts 12', 'arts 12', 'arts 240', 'art 242', 'arts 240']

Patent US5209037 - Building block insert - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsAn insert for use in a building block is disclosed. This insert has a substantially serpentine shape, is integral, and contains three substantially T-shaped sections and a multiplicity of curvilinear surfaces. Each of the T-shaped sections is defined by walls which extend continuously and divergingly...http://www.google.com/patents/US5209037?utm_source=gb-gplus-sharePatent US5209037 - Building block insertAdvanced Patent SearchPublication numberUS5209037 APublication typeGrantApplication numberUS 07/793,804Publication dateMay 11, 1993Filing dateNov 18, 1991Priority dateNov 9, 1989Fee statusLapsedPublication number07793804, 793804, US 5209037 A, US 5209037A, US-A-5209037, US5209037 A, US5209037AInventorsFrancis A. Kennedy, John P. Neff, Kenneth J. BlakeOriginal AssigneeThermalock Products, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (4), Referenced by (21), Classifications (15), Legal Events (6) External Links: USPTO, USPTO Assignment, EspacenetBuilding block insert
US 5209037 AAbstract
An insert for use in a building block is disclosed. This insert has a substantially serpentine shape, is integral, and contains three substantially T-shaped sections and a multiplicity of curvilinear surfaces. Each of the T-shaped sections is defined by walls which extend continuously and divergingly from the top of the insert to the bottom of the insert.
1. A substantially serpentine, integral insert comprised of three substantially T-shaped sections and a multiplicity of curvilinear surfaces, wherein:(a) said insert is substantially curvilinear in cross section as viewed from the top of said insert, and (b) said insert is wedge-shaped and is defined by walls which extend outwardly from said top of said insert to the bottom of said insert. 2. The insert as recited in claim 1, wherein said insert is comprised of from about 1 to about 100 ribs, each of which protrudes from at least one of the sides of said insert by from about 0.063 to about 0.375 inches.
3. The insert as recited in claim 1, wherein said insert consists essentially of a material with a density of from about 0.5 to about 4.0 pounds per cubic foot, a flexural strength of from about 25 to about 125 pounds per square inch, and a shear strength of from about 25 to about 175 pounds per square inch.
4. The insert as recited in claim 1, wherein said insert is comprised of a horizontal reinforcement channel with a depth of from about 0.125 to about 0.375 inches, a width of from about 0.25 to about 0.75 inches, and a length of from about 3 to about 4 inches.
5. The insert as recited in claim 1, wherein said insert is comprised of two end slots, each of which extends from the top of said insert to its bottom and has a width of from about 0.003 to about 0.2 inches and a length of from about 1.0 to about 1.5 inches.
6. The insert as recited in claim 1, wherein said insert is comprises of a thumb hole with a depth of from about 1 to about 2 inches.
7. The insert as recited in claim 1, wherein the top of said insert is comprised of a multiplicity of recessed surfaces.
8. A substantially serpentine, integral insert comprised of three substantially T-shaped sections and a multiplicity of curvilinear surfaces, wherein each of said T-shaped sections is defined by walls which extend continuously and divergingly from the top of said insert to the bottom of said insert, and wherein said insert is comprised of a chamfered surface on the bottom portion of said insert.
9. The insert as recited in claim 8, wherein said chamfered surface forms an angle of from about 30 to about 60 degrees.
10. An insulated building block of substantially rectangular shape comprised of a first spaced outer supportive part, a second spaced outer supportive part, curvilinear means for laterally interlockably connecting said first spaced outer supportive part and said second spaced outer supportive part, and a substantially serpentine, integral insert, wherein:(a) each of said first spaced outer supportive part and said second spaced outer supportive part extends along the length of said building block, is comprised of an inner surface defining a side of the space between said parts, and has a configuration which differs from the configuration of the other of said spaced outer supportive parts; (b) said space between said first and second spaced outer supportive parts is substantially curvilinear in cross section as viewed from the top of said building block; (c) said space between said first and second spaced outer supported walls is wedge-shaped and is defined by walls which extend inwardly from the top of said building block to the bottom of said building block; (d) said insert is positioned within and substantially fills the space between said first spaced outer supportive part and said second spaced outer supportive part, thereby forming said substantially rectangular building block; (e) said building block is comprised of two opposite planar sidewalls, two opposite planar ends, a planar top, and a planar bottom; (f) each of said planar sidewalls is parallel to the other of said planar sidewalls, each of said planar ends is parallel to the other of said planar ends, and said planar top is parallel to said planar bottom; (g) said insulating portion is substantially centered between and extends beyond each of said two planar ends; (h) said insulating portion extends beyond at least one of said planar top surface and said planar bottom surface of said building block; and (i) said insert is comprised of from about 1 to about 100 ribs, each of which protrudes from at least one of the sides of said insert by from about 0.063 to about 0.375 inches. 11. An insulated building block of substantially rectangular shape comprised of a first spaced outer supportive part, a second spaced outer supportive part, curvilinear means for laterally interlockably connecting said first spaced outer supportive part and said second spaced outer supportive part, and a substantially serpentine, integral insert, wherein:(a) each of said first spaced outer supportive part and said second spaced outer supportive part extends along the length of said building block, is comprised of an inner surface defining a side of the space between said parts, and has a configuration which differs from the configuration of the other of said spaced outer supportive parts; (b) said space between said first and second spaced outer supportive parts is substantially curvilinear in cross section as viewed from the top of said building block; (c) said space between said first and second spaced outer supported walls is wedge-shaped and is defined by walls which extend inwardly from the top of said building block to the bottom of said building block; (d) said insert is positioned within and substantially fills the space between said first spaced outer supportive part and said second spaced outer supportive part, thereby forming said substantially rectangular building block; (e) said building block is comprised of two opposite planar sidewalls, two opposite planar ends, a planar top, and a planar bottom; (f) each of said planar sidewalls is parallel to the other of said planar sidewalls, each of said planar ends is parallel to the other of said planar ends, and said planar top is parallel to said planar bottom; (g) said insulating portion is substantially centered between and extends beyond each of said two planar ends; (h) said insulating portion extends beyond at least one of said planar top surface and said planar bottom surface of said building block; and (i) said insert is comprised of a horizontal reinforcement channel with a depth of from about 0.125 to about 0.375 inches, a width of from about 0.25 to about 0.75 inches, and a length of from about 3 to about 4 inches. 12. An insulated building block of substantially rectangular shape comprised of a first spaced outer supportive part, a second spaced outer supportive part, curvilinear means for laterally interlockably connecting said first spaced outer supportive part and said second spaced outer supportive part, and a substantially serpentine, integral insert, wherein:(a) each of said first spaced outer supportive part and said second spaced outer supportive part extends along the length of said building block, is comprised of an inner surface defining a side of the space between said parts, and has a configuration which differs from the configuration of the other of said spaced outer supportive parts; (b) said space between said first and second spaced outer supportive parts is substantially curvilinear in cross section as viewed from the top of said building block; (c) said space between said first and second spaced outer supported walls is wedge-shaped and is defined by walls which extend inwardly from the top of said building block to the bottom of said building block; (d) said insert is positioned within and substantially fills the space between said first spaced outer supportive part and said second spaced outer supportive part, thereby forming said substantially rectangular building block; (e) said building block is comprised of two opposite planar sidewalls, two opposite planar ends, a planar top, and a planar bottom; (f) each of said planar sidewalls is parallel to the other of said planar sidewalls, each of said planar ends is parallel to the other of said planar ends, and said planar top is parallel to said planar bottom; (g) said insulating portion is substantially centered between and extends beyond each of said two planar ends; (h) said insulating portion extends beyond at least one of said planar top surface and said planar bottom surface of said building block; and (i) said insert is comprised of two end slots, each of which extends from the top of said insert to its bottom and has a width of from about 0.003 to about 0.2 inches and a length of from about 1.0 to about 1.5 inches. 13. An insulated building block of substantially rectangular shape comprised of a first spaced outer supportive part, a second spaced outer supportive part, curvilinear means for laterally interlockably connecting said first spaced outer supportive part and said second spaced outer supportive part, and a substantially serpentine, integral insert, wherein:(a) each of said first spaced outer supportive part and said second spaced outer supportive part extends along the length of said building block, is comprised of an inner surface defining a side of the space between said parts, and has a configuration which differs from the configuration of the other of said spaced outer supportive parts; (b) said space between said first and second spaced outer supportive parts is substantially curvilinear in cross section as viewed from the top of said building block; (c) said space between said first and second spaced outer supported walls is wedge-shaped and is defined by walls which extend inwardly from the top of said building block to the bottom of said building block; (d) said insert is positioned within and substantially fills the space between said first spaced outer supportive part and said second spaced outer supportive part, thereby forming said substantially rectangular building block; (e) said building block is comprised of two opposite planar sidewalls, two opposite planar ends, a planar top, and a planar bottom; (f) each of said planar sidewalls is parallel to the other of said planar sidewalls, each of said planar ends is parallel to the other of said planar ends, and said planar top is parallel to said planar bottom; (g) said insulating portion is substantially centered between and extends beyond each of said two planar ends; (h) said insulating portion extends beyond at least one of said planar top surface and said planar bottom surface of said building block; and (i) said insert is comprised of a thumb hole with a depth of from about 1 to about 2 inches. Description
This application is a continuation-in-part of applicants' copending application U.S. Ser. No. 07/605,576, filed on Oct. 29, 1990 now U.S. Pat. No. 5,066,440, which, in turn, was a continuation-in-part of applicants' copending application U.S. Ser. No. 07/433,842, filed Nov. 9, 1989 now U.S. Pat. No. 4,986,049.
A substantially serpentine, integral insert which may be used to produce a building block which contains two interlocking block parts separated from each other by an insulating material.
U.S. Pat. No. 4,551,959 of Schmid discloses a building block with two spaced supportive parts separated from one another by a quantity of insulating material positioned between the parts. At column 2 of his patent, Schmid discloses that his insulating material 54 is foamed in place. He states that: ". . . to assemble the block 10 with foam in place insulation, the block parts . . . are initially arranged in their desired spaced relation relative to one another and subsequently held in such relation while the insulating material, in its uncured condition, is directed into the space between the block parts. . . . After filling the space with the foam insulation and allowing it to cure to a hardened condition, any excess insulation can be cut or trimmed away as desired."
The process of the Schmid patent is not commercially practical. In the first place, the foam material, prior to the time it is cured, acts as an adhesive; and the block/foam structure thus tends to adhere to the pallet on which the block is sitting. In the second place, the rate of curing of the polyurethane foam is very dependent upon factors such as temperature, relative humidity, and barometric pressure; inasmuch as most block manufacturing plants do not carefully control these variables, it is difficult to consistently obtain building blocks having uniform properties with the process of Schmid. In the third place, where it is desired to have the foam extend beyond the surface(s) of the cement block, one must overfoam and subsequently cut the foam to size (a labor- intensive activity) and/or utilize a form which will help shape the foam to the required dimensions. In the latter instance, however, the foam tends to stick to the form.
In accordance with this invention, there is provided a susbstantially serpentine, integral insert which contains T-shaped sections and curvilinear surfaces. Each T-shaped section is defined by walls which extend continuously and divergingly from the top of the insert to its bottom. The insert also contains from 1 to 100 crushed ribs, each of which protrudes from one of the sides of the insert by from about 0.063 to about 0.375 inches.
FIG. 20 is a ribbed building block made from the split block of FIG. 19;
FIG. 21 illustrates a process for producing a building block structure comprised of reinforcing rods;
FIG. 22 is a top view of one preferred insert used in applicants' invention;
FIG. 23 is a sectional view of the insert of FIG. 22;
FIG. 24 is an end view of the insert of FIG. 22;
FIG. 25 is a sectional view of the thumb hole of the insert of FIG. 22;
FIG. 26 is a sectional view of the crushed ribs of the insert of FIG. 22;
FIG. 27 is a sectional top view of the crushed ribs of FIG. 26;
FIG. 28 is a sectional view of the channel of the insert of FIG. 22;
FIG. 29 the top view of one preferred building block of this invention; and
FIG. 30 is a sectional view of the block of FIG. 29.
FIG. 1 is a perspective view of one preferred embodiment of the building block 10 of applicants' invention. Building block 10 preferably has a rectangular shape and is comprised of two interlocking outer supportive parts, 12 and 14, and an inner insulating portion 16.
In one embodiment, outer supportive parts 12 and 14 are made with a CINVA-Ram block press using a mixture of soil, sand, silt, clay, and cement; the press has a mold box in which a hand-operated piston compresses a slightly moistened mixture of soil and cement or lime. This process is described in, e.g., a publication entitled "Making Building Blocks with the CINVA-Ram Block Press," (Volunteers in Technical Assistance, Mt. Ranier, Md., 1977).
Hydraulic cements are produced by burning an intimate mixture of finely divided calcareous and argillaceous materials and grinding the resulting clinker to a fine powder, usually with gypsum to retard the set. The calcining process produces calcium silicates and calcium aluminates that can react chemically with water to form a hard, stone-like mass. When mixed with sand, coarse aggregate, and water, these cements produce mortars and concretes. See, e.g., pages 534 to 538 of Volume 4 of "The Illustrated Science and Invention Encyclopedia" (H. S. Stuffman Inc., Westport, Conn., 1983).
In one preferred embodiment, outer supportive parts 12 and 14 each consist essentially of concrete. Concrete is a composite material composed of coarse granular material (the aggregate or filler) embedded in a hard matrix of material (the cement or binder) that fills the space between the aggregate particles and glues them together. Any of the concretes known to those skilled in the art may be used to prepare parts 12 and 14. Thus, by way of illustration and not limitation, one may use any of the concretes disclosed in S. Mindess' "Concrete" (Prentice Hall, Inc., Englewood Cliffs, N.J. 1981).
The building block 10 is preferably sized on a multiple of 2 inches and preferably has the same dimensions of concrete blocks in common use; see, e.g., pages 179-181 of L. M. Detzettel's "Masons and Builders Library," Volume 1 (Macmillan Publishing Company, N.Y., 1986).
In one embodiment, building block 10 has a length 6 of from about 15 to about 24 inches and, more preferably, from about 15.3 to about 15.8 inches. In this embodiment, the height 18 of building block 10 may be from 3.5 to about 9 inches (and, preferably, from about 7.4 to about 8.2 inches) or, alternatively, from about 3 to about 4.5 inches (and, preferably, from about 3.3 to about 3.8 inches). In this embodiment, the width 20 of building block 10 is from about 7 to about 14 inches and, preferably, from about 7.3 to about 7.8 inches. In another embodiment, not shown, width 20 may be from about 4 to about 12 inches.
Building block 10 is comprised of means for preventing the separation of outer supportive parts 12 and 14. Any means for preventing the separation of such parts 12 and 14 known to those skilled in the art may be used. Thus, by way of illustration and not limitation, one may use the means described in "Ingenious Mechanisms for Designers and Inventors," Volumes I, II, III, and IV (Industrial Press Inc., N.Y., 1978).
In one preferred embodiment, each of outer supportive parts 12 and 14 are so shaped that they contain curvilinear interlocking structure associated with them; this embodiment is illustrated, e.g., in FIGS. 2, 4, 5, 6, 7, 8, 9, 10, 14, 19, 20, and 21.
In one preferred embodiment, the insulating portion 16 is both uniformly undersized (as defined above) and also contains one or more crushed ribs and/or projections. In this embodiment, the insert may be made by means well known to those skilled in the art. Thus, for example, one may score and/or mark the interior surface of the mold used to make the insert. The insert made from this mold will then contain a multiplicity of ribs and/or projections corresponding to the scores and/or marks made on the mold. It is preferred, in this embodiment, that the insert contain ribs which may (but need not) extend the entire length of the insert; thus, for an insert which is 8" long, the crushed ribs may be from about 7.5 to about 8.0 inches long. The width of the crushed rib (the distance it protrudes from the side of the insert) may be from about 0.063 to about 0.375 inches; as will be apparent to those skilled in the art, this width is a function of how deeply the mold is scored. The insert may have from about 1 to about 100 crushed ribs. Alternatively, or additionally, it may have from about 1 to about 100 projections.
Without wishing to be bound to any particular theory, applicants believe that the air spaces created between the ribs of the insert and the walls of the building block tend to increase the insulating ("R") value of the building block. Insulating portion 16 of building block 10 is preferably so dimensioned so that it extends slightly beyond the confines of endwalls 26 and 28, block top 30, and/or block bottom 32. Because of this feature, when one of building blocks 10 is joined to another of such blocks either endwall to endwall or top to bottom, a continuous thermal barrier is formed between the adjacent blocks. There is no thermal pathway through which heat can easily travel from one side of a wall built with building block 10 to another side of a wall built with building block 10.
In one embodiment, not shown, insulating portion 16 has two mating ends which are adapted to fit together. In one embodiment, one of such ends may be male, and the other of such ends may be female. These mating ends are adapted to fit together and facilitate the joining of adjacent blocks. In one embodiment, one end has a substantially convex shape, and the other end has a substantially concave shape. At the point at which ends 96 and 98 extend past the ends of walls 26 and 28, the width of insulating portion 110 at its midpoint is preferably from about 1 to about 3 inches and, more preferably, from about 1.25 to about 2.5 inches.
In one preferred embodiment, where the insert consists essentially of expanded polystyrene, the insert is made by a steam chest molding process in which beads of expandable polystyrene are exposed to heat in a confined space configured to produce the desired shape. The preferred medium is steam; it is directly diffused through the preexpanded beads in a mold cavity. See, e.g., pages 534-538 of Joel Frados, "Plastics Engineering Handbook," Fourth Edition (Van Nostrand Reinhold Company, New York, 1976).
Referring again to FIG. 13, insert 16 is comprised of at least one projection 152 which is curvilinear. It also preferably is comprised of at least two thumb holes 154 which facilitate the lifting of building block 10 once the insert has been wedged into place between block parts 12 and 14.
Insert 16 preferably consists of material with a density of from about 0.5 to about 4.0 pounds per cubic foot, a flexural strength of from 25 to 125 pounds per square inch and a shear strength from 25 to 175 pounds per square inch. In a more preferred embodiment, insert 16 consists of material with a density of from about 1.0 to about 3.0 pounds per cubic foot, a tensile strength of from about 27 to about 125 pounds per square inch, a compressive strength of from about 11 to about 92 pounds per square inch, a melting point not lower then about 140 degrees Fahrenheit and an R value of at least 3.5 R per inch. In an even more preferred embodiment, the material in the insert has a density of from about 1.0 to about 2.0 pounds per cubic foot, a tensile strength of from about 42 to about 80 pounds per square inch, a compressive strength of from about 20 to about 53 pounds per square foot, a melting point not less then 160 degrees Fahrenheit, and an R value of at least about 5.5 R per inch. Some of these properties are discussed on pages 180-181 of Volume 7 of the "McGraw Hill Encyclopedia of Science and Technology," supra, as well as in the references cited at the end of the article appearing in this document.
In one embodiment, the material in insert 16 consists essentially of at least one foam material. The term foam, as used in this specification, refers to a material with a spongelike, cellular structure and includes materials such as polystyrene foam, polyurethane foam, flexible foamed thermoplastic elastomers, and the like. Reference may be had to, e.g., George S. Brady et al.'s "Materials Handbook," Twelfth Edition (McGraw-Hill Book Company, New York, 1986).
The mixture which is poured around insert 16 is comprised of at least about 30 weight percent of aggregate. It is preferred that the mixture contain at least about 40 weight percent of aggregate. As is known to those skilled in the art, the term aggregate refers to one or more inorganic materials such as such as sand, gravel, clay, exploded shale, glass, pumice, granite, and the like.
Referring to FIG. 16, the cementitious material 158 is poured around the insert 16. In one emboidment, illustrated in FIG. 16, such material is manually poured from a container. In another embodiment, not shown, cementitious material 158 is discharged from a hopper (not shown) into mold 157.
In one embodiment, illustrated in FIGS. 19 and 20, a split block 190 comprised of inserts 192 and 194 is split along line 196 to yield a ribbed, split- faced units 198 and 200. Thus, by this process, one may prepare an insulated building block of this invention which is three score, five score, three-wide score, etc. See, e.g., page 87 of "Bricklaying: Brick and Block Masonry: (Brick Institute of America, Reston, Va., 1988).
In one embodiment of this invention, the face of the building block produced by the process of this invention is coated with an inorganic coating known to those in the trade as "MINERALITE" (a coating consisting of aggregate which is available from Mineralite Limited, Bridgewater House, Surrey, England.). The coating is an aggregate (such as granite and glass) mixed with cement and non-resinous additives. The additive is described in a publication entitled "Mineralite Covers The World" (published by Mineralite Ltd, Surrey, England, in 1986).
In another embodiment of this invention, not shown, the insulating insert 16 is replaced by aerogel. As is known to those skilled in the art, aerogels are gel materials which are dried under high pressure and temperature and which produce one of the lightest solid materials. See, e.g., an article by James Dulley appearing the "Helpful Hints" section of the Oct. 13, 1990 issue of the Buffalo News.
ANOTHER PREFERRED BUILDING BLOCK INSERT OF THE INVENTION
FIG. 22 illustrates a preferred building block insert 230 which may be used to make a building block of this invention. Insert 230 is similar in manner respects to the insert illustrated in FIG. 5 of this case. Thus, for example, both of such inserts are substantially serpentine, both of such inserts are integral, both of said inserts are preferably comprised of at least three substantially T-shaped sections (see, e.g., sections 232, 234, and 236 of FIG. 22), and both of such inserts are comprised of a multiplicity of curvilinear surfaces have no intersecting surfaces defining right angles. Furthermore, each of the T-shaped sections of the inserts is defined by walls which extend continuously and divergingly from the top of the insert to its bottom. Each of the inserts is preferably comprised of from about 1 to about 100 crushed ribs, each of which protrudes from at least one of the sides of the insert by from about 0.063 to about 0.375 inches. Lastly, each of the inserts consists essentially of a material with a density of from about 0.5 to about 4.0 pounds per cubic foot, a flexural strength of from about 25 to abut 125 pounds per square inch, and a shear strength of from about 25 to about 175 pounds per square inch.
However, the insert of FIG. 22 contains some preferred features which are not present in the insert of FIG. 5.
In the first place, the insert 230 of FIG. 22 is comprised of curvilinear interior surfaces 236 and 238 which, in combination with the concrete parts 240 and 242 (see FIG. 29), form thumb holes 244 and 246 (see FIG. 29). Thumb holes 244 and 246, in addition to making it easier for one to lift the building block, also allow for the release of moisture.
In the second place, and referring again to FIG. 22, insert 230 is comprised of horizontal reinforcement channels 248 and 250. These channels, which are preferably from about 0.125 to about 0.375 inches deep, from about 0.25 to about 0.75 inches wide, and from about 3 to about 4 inches long, provide a receptacle for truss materials, such as the "DUR-O-WAL" truss (manufactured by the DUR-O-WAL, INC. of Arlington Heights, Ill.). This type of building material is described, e.g., in "Sweet's Catalog File"(McGraw-Hill Book Company, New York, 1990). When the truss material, not shown, is inserted into the channels of adjacent blocks, a reinforced structure (not shown) is produced.
In the third place, the building insert 230 of FIG. 22 is comprised of end slots 252 and 254. These slots provide an increased amount of flexibility to a user so that, when insert end 258 and/or insert end 260 is adjacent another insert end, and the mason desires to vary the mortar joint width between adjacent blocks, it is possible to compress slot 252 and/or 254 so as the adjust such mortar joint width.
Referring again to FIG. 22, it will be seen that each of slots 252 and 254 are preferably from about 0.003 to about 0.4 inches wide and, more preferably, from about 0.06 to about 0.2 inches wide. It will also be seen that each of slots 252 and 254 extends substantially from the top of the insert 230 to its bottom.
It is preferred that the length of each of slots 252 and 254 be from about 1.0 to about 1.5 inches.
In the fourth place, in the preferred embodiment illustrated in FIG. 22, it will be seen that insert 230 is also preferably comprised of thumb holes 264, 266, 268, and 270.
These thumb preferably are from about 1 to about 3 inches deep and have a diameter of from about 0.5 to about 1.5 inches.
Referring again to FIG. 22, it will be seen that insert 230 is comprised of crushed ribs within curvilinear interior surfaces 272, 274, 276, 278, 280, and 282.
FIG. 23 is a partial sectional view of insert 230. Referring to FIG. 23, it will be seen that crushed rib 284 preferably extends along a curvilinear interior wall 274 of insert 230. FIG. 23 also illustrates slot 252, thumb hole 268, and channel 248.
FIG. 23 also illustrates that, in the preferred embodiment illustrated in FIG. 22, there is chamfered surface 286 extending along a portion of the exterior walls of the bottom of each of the T-shaped sections of the insert.
As is known to those skilled in the art, a chamfer is the surface produced by beveling away the right angle between two surfaces Chamfered surfaces are illustrated in FIG. 30.
Referring to FIG. 30, it will be seen that insert 230 is disposed between concrete portions 240 and 242. There is a chamfer 286 on the bottom surface 288 of insert 230. There also preferably is a chamfer 290 on the top surface 292 of the concrete portion 240 of the building block.
The chamfered surface(s) appearing on either the bottom surface 288 of the insert 230 and/or the top surface of the concrete portion of the building block generally will form an angle of from about 30 to about 60 degrees. This angle is formed between bottom surface 288 and chamfered surface 286 or, alternatively, between top surface 292 and chamfered surface 290.
It is preferred that, when forming chamfered surface 286 and/or 290, only a certain amount of material be removed from either the insert 230 and/or the concrete part 242 or 240. Thus, referring to FIG. 30, it is preferred that, once the chamfered surface has been formed, the distances 294 and 296 between each end of the chamfered surface (such as end 298 or end 300) and that point 302 which existed at the intersection of the walls of the body prior to the time the right angle surface was beveled, be from about 0.1 to about 0.5 inches and, more preferably, be form about 0.2 to about 0.3 inches. In one embodiment, distance 294 is 0.25 inches, distance 296 is 0.25 inches, and a 45 degree chamfered surface is produced.
Referring again to FIG. 30, it will be seen that, in the preferred embodiment depicted therein, the chamfered surface 286 appears in one or more positions on the bottom surface of the insert 230 and on the top surface of the concrete portion of the block. These chamfered surfaces, which are also referred to as "mortar overflow containment areas," provide a relief for mortar when the building blocks are compressed during the laying up process. The use of these chamfered surfaces unexpectedly produces structures with improved bonded surfaces. In one experiment, the shear strength of a bonded structure was improved about 26 percent by the use of these chamfered surfaces.
The chamfered surfaces 286 and/or 290 preferably appear in a multiplicity of positions in the insert and the block. Thus, referring to FIG. 29, it will be seen that chamfered surfaces appear on the interior walls which form the T-shaped sections of the concrete block comprising parts 240 and 242. Although not shown in FIG. 29, corresponding chamfered sections 286 preferably appear in corresponding areas of the bottom surface 288 of the insert 230. Thus, in this embodiment, five chamfered portions 290 appear in the top of the concrete portion of the block, and five corresponding chamfered portions 286 appear in the bottom of the insert 230.
In another embodiment, shown, the chamfered portions appearing in the top of the concrete portion do not spatially correspond to the chamfered portions appearing in the bottom surface of the insert 230.
One may have a chamfered surface extending continuously around the entire bottom surface of insert 230. It is preferred, however, that the chamfered surface on insert 230 be discontinuous and that at least a portion of the bottom surface of insert 230 not contain such chamfered surface.
FIG. 24 is an end view of the insert 230 of FIG. 22.
FIG. 25 is a sectional view, taken along lines 25--25 of FIG. 22, which illustrates the thumb hole in insert 230.
Referring to FIG. 25, it will be seen that thumb hole 266 preferably has a depth 304 of from about 1.0 to about 2.0 inches and a diameter 306 of from about 0.5 to about 1.5 inches.
FIG. 26 is a sectional view of section 272 of insert 230, taken along lines 26--26. Referring to FIG. 26, it will be seen that section 272 is comprised of a crushed rib 308.
It is preferred that the crushed ribs (such as crushed rib 308) do not extend the entire height of insert 230. Thus, for example, it is preferred that crushed rib 308 start a distance 310 which is from about 1.5 to about 3.5 inches from the top 312 of insert 230.
FIG. 27 is a sectional view of section 272 of insert 230, taken along lines 27--27. Referring to FIG. 27, it will be seen that the interior surfaces 272, 274, 276, 278, 280, and 282 of insert 230 are each comprised of a multiplicity of crushed ribs 284, 314, 316, 318, and 320.
As is illustrated in FIG. 27, it is preferred that each of interior surfaces 272, 274, 276, 278, 280, and 282 be comprised of from about 3 to about 7 of said crushed ribs and, more preferably, from about 4 to about 6 of said crushed ribs.
The crushed ribs in applicants, insert 230 may be formed by conventional means such as, e.g., molding them. Thus, for example, strips of metal may be brazed onto curvilinear mold surfaces to produce crushed ribs in the molded body.
FIG. 28 is a sectional view of the insert 230 of FIG. 22, taken along lines 28--28; it illustrates channel 248.
In one preferred embodiment of the invention, which is illustrated in FIG. 22, 25, 26, and 28, a muliplicity of recessed surfaces are formed in the top surface of insert 230. These recessed surfaces facilitate the partial compression of the top surface of insert 230. Thus, for example, when a mason must force the bottom of a building block against the top surface of an adjacent insert, the presence of these recessed surfaces facilitates the compression of the top surface of the insert 230.
Referring to FIG. 22, and in the preferred embodiment shown therein, it will be seen that the shaded areas 322, 324, 326, 328, 330, 332, and 334 represent areas where the top surface of the insert is recessed. In general, the recess of these areas has a depth of from about 0.03 to about 0.2 inches and, more preferably, from about 0.03 to about 0.08 inches.
The recessed area 322 is also illustrated in FIGS. 25, 26, and 28.
An insulating insert was prepared on a steam chest molding machine from expanded polystyrene with a density of 1.5 pounds per cubic foot. The polystyrene was formed into a serpentine insert, with substantially the shape shown in FIG. 22. This insert had a height of 8.3 inches, a length of 16 inches, a top depth of 8.25 inches, a bottom depth of 8 inches, a top wall thickness of 1.875 inches, and a bottom wall thickness of 1.625 inches.
It is to be understood that the aforementioned description is illustrative only and that changes can be made in the apparatus, the ingredients and their proportions, and in the sequence of combinations and process steps as well as in other aspects of the invention discussed herein without departing from the scope of the invention as defined in the following claims. Thus, for example, one may use the aforementioned mold from ThermaLock Products, Inc. in the Besser Vibrapac V3R block machine to form the building block.
Thus, for example, one may use insert 230 as a mold component in the Besser Vibrapac V3R block machine to form the building block directly.
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