Abstract:
An insulated concrete block and wall assembly. The primary element is an insulated block which consists of two rectangular concrete facings and a rigid solid insulating core. The concrete facings are attached by adhesive to the insulating core. The insulating core has apertures within it to allow vertical reinforcing rod support in a constructed wall. The invention additionally provides an indentation along the top of each insulating core to provide for horizontal re-rod support within the wall itself. The invention provides optimal decrease in thermal conductivity coupled with simplicity of design and transport.

Description:
BACKGROUND OF THE INVENTION 
     This invention relates to masonry blocks and, more specifically, to masonry blocks which decrease thermal conductivity by utilization of non-masonry core materials. 
     Traditional concrete blocks have been of unitary construction with cross members and face members all formed of the same material, namely, concrete. An important consideration in masonry blocks is thermal resistence. The thermal resistence of a particular material is a relative measure of how quickly the material, block or assembly will allow heat to pass through it. In building and engineering terms, thermal resistence is referred to in terms of R-value. The more slowly the heat is allowed to pass through a material, the higher that material&#39;s thermal resistence is and, correspondingly, the higher the R-value which will be assigned to that particular material. 
     Traditional concrete blocks have spaces between cross members which may be filled with insulating material to increase the R-value of a wall or other structure constructed with the blocks. Such installation applications, however, have no affect on the thermal resistance of the concrete cross members in traditional masonry blocks. Adaptations of traditional concrete masonry blocks have been made to facilitate insertion of foam or other insulation material still utilizing a traditional block structure. It is also known to utilize light-weight concrete forms and non-masonry connecting members for these forms, into which concrete is poured to form a central concrete core. Other approaches have utilized exterior insulation on existing support concrete walls with insulation materials which adhere to the outside of the concrete support wall. Variations on this include a decorative, protective “skin.” The prior art, however, does not disclose a block of traditional concrete size and load-bearing capability, attached to and separated by a uniform, solid insulating core which is manufactured and then delivered and installed as a one-piece unit. 
     While much of the prior art has been directed toward the construction of masonry walls using concrete blocks, with a goal of providing an ultimate wall of significantly increased R-value, the examples of prior art do not address the improvements of the present invention. 
     Traditional cement masonry building blocks generally contain rectangular face elements which, when utilized in construction of walls, are generally laid end to end and on top of each other in an essentially vertical plane to maintain structural and load-bearing support. Additionally, there are concrete cross members which hold the face elements of the block together at the desired interval. These are not essential elements, however, for load-bearing stability once the blocks are in place. 
     Examples of other attempts to address this problem include U.S. Pat. No. 5,697,189, to Millar et al, which discloses a monolithically poured concrete wall panel. U.S. Pat. No. 5,209,037, to Kennedy et al, for a building block insert, discloses a substantially serpentine integral insert and two outer supportive parts. U.S. Pat. No. 4,745,720, to Taylor, discloses an insulated cinder block split into two portions. U.S. Pat. No. 4,802,318, to Snitoviski, discloses an insulated block unit comprised of two building blocks strapped about an insulating core. 
     Any masonry block application which will allow for greater R-factor of an overall finished wall will result in lesser insulation requirements and the balance of construction and will result in significant cost savings and commercial advantage to the builder or, likewise, in the event that additional insulation is not added, in greater savings in cooling and/or heating costs to the owner of any completed structure. 
     Accordingly, irrespective of the prior art, a need continues to exist for an insulated masonry block which does not require separate assembly; which does not sacrifice vertical load-bearing capacity; yet which continues to provide a traditional two-sided exterior masonry surface which allows an overall uniform thermal resistence of the interior wall significantly greater than concrete. 
     Specifically, what is needed is an assembled masonry block having traditional load-bearing side elements, which may be stored, and utilized in construction in the same manner as traditional concrete blocks. 
     SUMMARY OF THE INVENTION 
     This invention is directed to the provision of a unitary masonry block wall which may be assembled in the same manner and which will provide the same appearance as a standard traditional concrete masonry block and wall but which will provide significant advantages with regard to uniform thermal resistence. 
     More specifically, the present invention is directed to the provision of a concrete masonry block and a wall constructed of concrete masonry blocks which provide standard, traditional rectangular outer concrete surfaces which provide the same appearance and surface integrity as traditional concrete blocks and provide the same structural and load-bearing capacity as well, but which blocks have a completely unitary rigid insulating core, lighter in weight than traditional concrete, but which is sufficient, with the use of adhesive, to hold the block together for shipping, storage and assembly within a wall. 
     The present invention will provide a masonry block, and completed masonry wall, with a high thermal resistence rating (R-factor) between the external surface faces of the block. 
     According to another important feature of the present invention, the insulating core of the block may be formed of apertures or grooves to facilitate the insertion of reinforcing rod, or other structural supports, to provide further vertical and horizontal integrity to a finished wall. 
     According to a further feature of the invention, the cavities provided for utilization of reinforcing rod, may be further utilized for fill with concrete material for further stability, or with insulation material for further thermal resistence. 
     The above and additional features of the invention may be considered and will become apparent in conjunction with the drawings in particular, and the detailed description which follows: 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The following detailed description is best understood by reference to the following drawings, in which: 
     FIG. 1 is a perspective view of an insulated masonry block device, additionally depicting the greater depth of the surface indentation in an alternative preferred embodiment; 
     FIG. 2 is an end view of an alternative preferred embodiment of an insulated masonry block device showing the slot defined by the upper surface of the rigid insulation core and the protrusion on the base of said core; 
     FIG. 3 is a top view of the insulated masonry block device; 
     FIG. 4 is a perspective view of the insulated masonry block device with hidden lines showing the vertical apertures defined by the insulating core member; 
     FIG. 5 is a perspective view of the insulated corner block embodiment of the invention, showing a rigid support member in exploded relationship to the corner block; 
     FIG. 6 is a cut-away view of a section of an insulated masonry block wall assembly showing a vertical and horizontal support rod within said assembly and further showing mortar being poured within said assembly to complete the vertical and horizontal support members; 
     FIG. 7 is an exploded perspective view of an insulated masonry block device; 
     FIG. 8 is a top view of an insulated masonry block device having a single vertical aperture; 
     FIG. 9 is a perspective view of an insulated masonry block device, showing the same, in relationship with a pair of vertical support members, and adjoining masonry blocks in two courses of a masonry block wall assembly; 
     FIG. 10 is top view of an adjusting insulated masonry block device; 
     FIG. 11 is a perspective view of an adjusting insulated masonry block device showing alternative depths of the indentation in the surface of the insulating core member; 
     FIG. 12 is a cut-away view of a section of an insulated masonry block wall assembly showing horizontal and vertical support members comprised of a combination of poured mortar and rigid support rods; 
     FIG. 13 is a top view of an alternative embodiment of an insulated masonry corner block device; 
     FIG. 14 is a top view of an alternative embodiment of an insulated masonry corner block device forming a corner in conjunction with a pair of standard insulating masonry blocks and a rigid support member within the surface indentation on all of said blocks. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The invention insulated masonry block, broadly considered, includes a block  10  and an insulated block wall assembly  80 . 
     Block  10  includes a first masonry facing member  11 , a second masonry facing member  12  and a core member  13 . Facing members  11  and  12  are formed of concrete in the preferred embodiment. Core member  13  is comprised of a rigid insulating material which, in the preferred embodiment, may be polystyrene or a similar substance. 
     Each of the facing members  11  and  12 , is substantially rectangular in three dimensions as shown in the exploded view of FIG.  7 . Each of the facing members  11  and  12  has a substantially flat or planar surface,  11   a  and  12   a , respectively, and a substantially flat or planar inner surface  11   b  and  12   b , respectively which define a width dimension A, the inner surfaces,  11   b  and  12   b , opposing each other; the facing members  11  and  12  additionally each have an upper substantially flat or planar surface  11   c  and  12   c , respectively, and a lower substantially flat or planar surface  11   d  and  12   d , respectively, which define a height dimension B, and a first end substantially flat or planar surface  11   e  and  12   e , respectively, and a second end substantially flat or planar surface  11   f  and  12   f , respectively, defining a length dimension C. As is inherent in a three dimensionally rectangular figure, the planar surfaces  11   c ,  11   d ,  11   e  and  11   f  and  12   c ,  12   d ,  12   e  and  12   f , respectively, are at substantially right angles to the planar surfaces  11   a  and  11   b  and  12   a  and  12   b , respectively. 
     Core member  13  is also three dimensionally rectangular, with a first outer surface  14  and a second outer surface  15 , an upper surface  16 , a lower surface  17 , a first end surface  18  and a second end surface  19 . Core member  13  is shaped and configured to extend between the opposing inner surfaces  11   b  and  12   b  of facing members  11  and  12  which are aligned in parallel. The first and second outer surfaces  14  and  15  of core member  13  contact and correspond with the respective inner surfaces  11   b  and  12   b . An adhesive means  20  is utilized to affix surfaces  14  and  15  to surfaces  11   b  and  12   b , respectively. In the preferred embodiment of the invention, the adhesive means  20  may be an epoxy bonding agent or other means. While the facing members  11  and  12  are formed of concrete in the preferred embodiment, other material may be substituted. 
     In the preferred embodiment of the invention, as is shown in FIG. 2, the upper planar surface of the core member  13 , and the plane defined by it, extends a distance “E” above the plane defined by the parallel upper surfaces  11   c  and  12   c.    
     The core element  13  additionally contains one or more cavities or apertures  21  defined by the core member  13  and running between and through its upper surface  16  and lower surface  17  substantially parallel to surfaces  11   a  and  12   a  of facing members  11  and  12 . 
     The block  10  will optimally have a pair of such apertures  21 , but different embodiments may have none as shown in FIG. 1, one as shown in FIG. 8, or any other number. 
     In the preferred embodiment, one aperture  21  is centered approximately on line a—a longitudinally bisecting the upper surface of core member  13 , at a point  22   a  located equidistant between the first end surface  18  and a point equidistant between surface  18  and a point  22  equidistant between surfaces  18  and  19 , and another aperture  21  is centered approximately on line a—a at a point  22   b  equidistant between second end surface  19  and said point  22 . Stated otherwise, one aperture  21  is located at a point  22   a  at a distance from surface  18  equal to one quarter of the distance from end  18  to end  19  and a second aperture  21  is located at a point  22   b  at a distance from surface  19  equal to one quarter of the distance from end  18  to end  19  as shown in FIG  3 . 
     Another feature of the invention as particularly demonstrated in cross section in FIG. 2 includes a linear groove or indentation  30  having a defined depth “D” in the upper surface of core element  13  running through and between end surfaces  18  and  19 . In the preferred embodiment of the invention, this indentation  30  is approximately centered linearly between the facing members  11  and  12 , and is inwardly rectangular in shape. 
     The core element  13  also has a protrusion  40  of a defined height F on its lower surface  17 . In the preferred embodiment, this protrusion  40  is outwardly rectangular in configuration and is centered linearly on element  13  between facing members  11  and  12  and is equal in length to length dimension C. Protrusion  40  is configured to fit within an indentation equivalent to indentation  30  in a male-female relationship. 
     A further feature of the invention provides for an indentation  30  of substantially greater depth D than the height F of protrusion  40  so as to provide that when the protrusion  40  of a block  10  is filled within the indentation  30  of a like block  10  in male-female relationship, the depth D of indentation  30  beyond and the height F of the corresponding protrusion  40  of a like block  10  defines a linear aperture  41 , running between the end surfaces  18  and  19  of core element  13  of the block  10  in which the corresponding protrusion  40  is inserted this feature is demonstrated in FIG  6 . 
     The invention may also be optimally configured as corner block  50 , as illustrated in FIGS. 13 and 14. Corner block  50  is configured so that the first facing member  11  comprises a first rectangular element  51  and a second rectangular element  52 . Each of the rectangular elements  51  and  52  has a lower surface  11   d  and an upper surface  11   c  defining its height B, an outer surface  11   a  and inner surface  11   b  defining its width A and a first end surface  11   e  and second end surface  11   f  defining its length C. The width A and height B of the first element  51  and second element  52  are uniform. The upper surfaces  11   c  and lower surfaces  11   d  of elements  51  and  52  correspond and said second element  52  extends outwardly at right angles from the inner surface  11   b  of the first element  51  such that the second end surface  11   f  of the first element  51  and the outer planar surface  11   a  of the second element  52  defines a unitary, singular plane  53 . The second facing member  12  of the corner block  50 , as in base block  10 , has a substantially outer planar surface  12   a , a substantially planar inner surface  12   b , a substantially planar upper surface  12   c , a substantially planar lower surface  12   d , a substantially planar first end surface  12   e  and a substantially planar second end surface  12   f . In the corner block  50  embodiment of the invention, the second member  12  has a length C substantially less than the length C of the first facing member  11 , with the first end planar surfaces  11   e  and  12   e  defining a singular plane, the upper surfaces  11   e  and  12   c  defining a singular plane and the lower surfaces  11   d  and  12   d  defining a singular plane. 
     The core element  13  in corner block  50  is generally configured as in block  10  except that its second end surface  19  abuts and is affixed to the inner surface  11   b  of the second element  52  of facing member  11 . Further, the linear groove or indentation  30  on the upper surface  16  of core member  13 , for corner block  50 , runs from and through end surface  18 , approximately centered linearly between the first element  51  of facing member  11  and facing member  12  to a point  54  on upper surface  16  approximately equidistant between the inner surfaces  11   b  of the first member  51  and second member  52  and then at right angles parallel to the inner surface  11   b  of second member  52  to and through the second outer surface  15  of core element  13 . It is additionally desirable to provide a linear protrusion  40  of defined depth D on corner block  50  essentially as provided for base block  10  except that protrusion  40  on block  50  shall be configured to fit within the linear indentation  30  of a like corner block  50  in a male-female relationship. Additionally, desirable features specifically provided for base block  10 , include, but are not limited to, such innovations as extending the height of core element  13  by E, providing for greater depth D of indentation  30  to allow formation of aperture  41 , and substitution of materials and means of affixing facing members  11  and  12  to core  13  are also applicable, and directed to block  50  in the preferred embodiment. FIGS. 13 and 14 demonstrate a top view of corner block  50 . 
     In a further embodiment of the invention an alternative corner block  60  is provided, as shown in FIG.  5 . Corner block  60  is comprised of a first facing member  61  and second facing member  62 . Each facing member  61  and  62  further comprises a first rectangular element  63  and second rectangular element  64 . Elements  63  and  64  each have a respective upper planar surface,  63   c  and  64   c , and a respective lower planar surface,  63   d  and  64   d , defining height dimension B, respective outer planar surfaces  63   a  and  64   a  and respective inner planar surfaces  63   b  and  64   b  defining width dimension “A,” and respective first end planar surfaces  63   e  and  64   e  and respective second end planar surfaces  63   f  and  64   f , defining respective length dimension C 1  as to first rectangular element  63  of first facing member  61 , C 2  as to first rectangular element  63  of second facing member  62 , C 3  as to second rectangular element  64  of first facing member  61 , and C 4  as to second rectangular element  64  of second facing member  62 . The upper surfaces  63   c  and  64   c  of each facing member  61  and  62  correspond and the inner surfaces  63   b  and  64   b  of each facing member  61  and  62  oppose each other, respectively, for elements  63  and  64  of each facing member  61  and  62 , in parallel. The second element  64  of the first facing member  61  extends outward at right angles from the inner surface  63   b  of the first element  61  such that the second end surface  63   f  of first rectangular element  63  and the outer surface  64   a  of the second element  64  form a singular plane, with the second element  64  of second facing member  62  extending outward at right angles from the outer surface  63   a  of second rectangular element  64 , so that the second end surface  63   f  of first element  63  of second facing member  62  and inner surface  64   b  of second element  64  of second facing member  62  define a singular plane. 
     In a further embodiment of the present invention, an insulated masonry block wall assembly  80  may be constructed. A view of masonry block wall  80  is shown in FIG.  6 . The insulated masonry block wall assembly  80  comprises a series or plurality of masonry blocks  10  arranged in linear alignment as shown in FIG. 6 to form a base course  81  of masonry blocks  10 , as previously described herein, in detail, with each block  10  having a core member  13  and a uniformly planar lower surface  17 . The series of masonry blocks  10  are arranged in course  81  so that the second end surface  19  of each block  10  abuts and interfaces with, to form a common boundary  82 , with the next adjacent block  10 . The core member  13  of each block  10  in course  81  has a linear groove or indentation  30  of defined depth D as previously defined and one or more vertical apertures  21  as previously defined. 
     A second series of masonry blocks  10 , as defined for base course  81 , with the additional feature on each block  10  of a protrusion  40  on the lower surface  17 , as previously described in detail, is arranged substantially as course  81 , in linear alignment as shown in FIG. 6, to form a first upper course  83 . Course  83  is linearly aligned on course  81  so that the lower flat or substantially planar surfaces  11   d  and  12   d  of each block  10  of course  83 , oppose, approximate and interface, by forming a common boundary  84  with the flat upper surfaces  11   c  and  12   c  of one or more of blocks  10  of course  81 , with the linear protrusion  40  of each block  10  of course  83  configured with a portion of indentation  30  of one or more blocks  10  of course  81  in a male female relationship. In the preferred embodiment, the depth D of indentation  30  is substantially greater than the height F of protrusion  40 , so as to define a linear aperture  41  running the length  87  of each course  81  and  83 . In the preferred embodiment of insulated masonry block wall assembly  80 , each block  10  is linearly aligned in each course  81  and  83  so that the linear aperture  41  runs the entire length  87  of each course. Likewise, in the preferred embodiment, there is a plurality of sequential upper courses  88  constructed substantially as first upper course  83  with each course of the sequential courses  88  abutting and aligned linearly with the course below in substantially the same manner as the first upper course  83  abuts and is aligned with base course  81 . In the preferred embodiment, each block  10  of first upper course  83  is aligned so that its flat lower surfaces  11   d  and  12   d  oppose, approximate and interface with approximately equal portions  85  and  86  of the flat upper surfaces  11   c  and  12   c  of two adjoining blocks  10  of base course  81 . Each of the sequential upper courses  88  is similarly aligned with the course immediately below it, so that the apertures  21  of each block  10 , in each course  81 ,  83  and  88  are aligned so that each aperture  21  extends in combination the entire height  89  of the insulated block wall assembly  80 . In the primary embodiment, each block  10  of each course  81 ,  83  and  88  is joined to the next succeeding block in series at common boundary  82  by a concrete or mortar  90  joint and each block  10  of each course  81 ,  83  and  88  is joined to a portion of two blocks  10  of the preceding course and common boundary  84  by a concrete or mortar  90  joint. 
     In the preferred embodiment, a rigid support member or rod  91  commonly referred to in masonry trade as re-rod, reinforcing rod, rebar and/or reinforcing bar, is inserted within aperture  41  running through length  87  of one or more of the base course  81 , first upper course  83  and sequential upper courses  88 . The balance of any aperture  41 , to the extent that said rod does not completely fill such aperture  41 , may be filled with concrete or mortar  90  for increased linear strength and stability. Likewise, a rod  41  is inserted vertically through a plurality of the aligned apertures  21  of the blocks  10  of each course through the entire height for increased vertical strength and stability. These support members or rods, as described above, in both horizontal and vertical applications, are shown in FIGS. 5,  6 ,  9  and  12 . 
     In the preferred embodiment, the rod or member  91  is configured to fit within the entire aperture  41  or  21 , respectively, and may be entirely of concrete or mortar  90  or other pourable material, or a rod of metal or other rigid material, or a combination thereof. The invention wall assembly  80 , may also, optimally, permit angled walls by incorporating at an end of each course, a corner block  60  as shown on FIG. 5, and as described previously in detailed, or a corner block  50  as shown in FIGS. 13 and 14 and described previously in detail. 
     Whereas, a preferred embodiment of the invention has been illustrated and described in detail, it will be apparent that various changes may be made in the disclosed embodiment without departing from the spirit of the invention.