INSULATED CONCRETE MASONRY SYSTEM

• US 20140260029A1
• Filed: 03/14/2014
• Published: 09/18/2014
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Oldcastle Architectural Incorporated (CRH PLC)
• Original Assignee: Oldcastle Architectural Incorporated (CRH PLC)
• Inventors: Browning, Leonard, Lundell, Robert J., Beliveau, Stephane
• Granted Patent: US 9,482,003 B2
• Time in Patent Office: Days
• US Class Current: 52/309.4
• CPC Class Codes: E04B 1/04 the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material
• CPC Class Codes: E04B 1/043 Connections specially adapted therefor
• CPC Class Codes: E04B 1/388 Separate connecting elements Connecting devices specially adapted for embedding in concrete E04B1/41; Dowels, i.e. members adapted to penetrate the surfaces of two parts and to take the shear stresses E04B1/48
• CPC Class Codes: E04B 1/7629 Details of the mechanical connection of the insulation to the wall
• CPC Class Codes: E04B 1/78 Heat insulating elements E04B1/7662 takes precedence
• CPC Class Codes: E04B 2/14 Walls having cavities in, but not between, the elements, i.e. each cavity being enclosed by at least four sides forming part of one single element
• CPC Class Codes: E04B 2/18 by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
• CPC Class Codes: E04B 2/26 the walls being characterised by fillings in all cavities in order to form a wall construction
• CPC Class Codes: E04B 2001/7679 Means preventing cold bridging at the junction of an exterior wall with an interior wall or a floor
• CPC Class Codes: E04B 2002/0234 Angular dovetails
• CPC Class Codes: E04B 2002/0236 tapered, i.e. dovetail narrows in the direction of tongue or groove
• CPC Class Codes: E04B 2002/0247 Strips or bars
• CPC Class Codes: E04B 2002/0252 Dovetail keys
• CPC Class Codes: E04B 2002/0256 Special features of building elements
• CPC Class Codes: E04B 2002/0276 Separate layers or strips
• CPC Class Codes: E04B 2103/02 of ceramics, concrete or other stone-like material
• CPC Class Codes: E04B 2103/04 of plastics, fibrous material or wood
• CPC Class Codes: E04C 1/397 serving for locating conduits E04C1/392 takes precedence
• CPC Class Codes: E04C 1/41 composed of insulating material and load-bearing concrete, stone or stone-like material
• CPC Class Codes: E04F 13/0832 without load-supporting elongated furring elements between wall and covering elements
• CPC Class Codes: E04F 13/14 : stone or stone-like materials, e.g. ceramics concrete,; of glass or with an outer layer of stone or stone-like materials or glass E04F13/0864 takes precedence; producing shaped elements from concrete, ceramic compositions or other stone-like materials B28B; prefabricated panels in general E04C2/00

Abstract

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

Claims

1. A block system, comprising:

a. structural blocks,

b. face blocks, and

c. insulation blocks between the structural blocks and the face blocks.

2. The block system of claim 1, further comprising keys on the insulation blocks positionable in grooves on the structural and face blocks.

3. The block system of claim 2, further comprising at least one anchor embedded in each of a plurality of the insulation blocks linking one key on one face of the insulation block to another key on the opposite face of the insulation block.

4. The block system of claim 3, wherein the at least one anchor comprises two anchors embedded in each of a plurality of the insulation blocks.

5. The block system of claim 3, wherein the anchor comprises sheet metal.

6. The block system of claim 1, wherein the cross-sectional shapes of the keys and grooves are generally that of a dovetail.

7. The block system of claim 1 wherein the each key further comprises at least one protruding rub rib.

8. The block system of claim 6, wherein each key further comprises two protruding rub ribs.

9. The block system of claim 2, where the leading end of each of the keys is sloping.

10. The block system of claim 9, wherein at least one of the grooves is stopped with a sloping surface complementary to the sloping end of at least one of the keys.

11. The block system of claim 1, wherein the structural blocks comprise concrete.

12. The block system of claim 1, wherein the insulation blocks comprise polystyrene foam.

13. The block system of claim 1, wherein the insulation blocks comprise polystyrene foam with graphite.

14. The block system of claim 1, wherein portions of the insulation blocks lap end to end.

15. The block system of claim 1, wherein the tops and bottoms of the thermal insulation blocks comprise grooves.

16. The block system of claim 1, further comprising gasket material between at least some insulation blocks.

17. The block system of claim 1, wherein each insulation block has a front face and a rear face and each face comprises at least one vertical water drainage slot.

18. An insulation block for use in a structure comprising structural blocks, insulation blocks and face blocks, each of which structural and face blocks has at least one groove, the insulation blocks comprising thermal insulation material comprising at least one elongated key on each side, each adapted to be received in one of the grooves.

19. The insulation block of claim 18, further comprising polystyrene foam.

20. The insulation block of claim 18, further comprising polystyrene foam and graphite.

21. The insulation block of claim 18, further comprising a plate-shaped or slab-shaped body with two opposed, generally parallel faces, from which two faces one of the at least two elongated keys projects.

22. The insulation block of claim 18, further comprising two opposed ends and a tongue on one end and a tongue-receiving groove on the other end.

23. The insulation block of claim 18, further comprising at least one rub rib on at least one elongated key.

24. The insulation block of claim 18, further comprising at least one anchor embedded in the block, the anchor comprising two ends, one of which is embedded in each of the at least two elongated keys.

25. The insulation block of claim 24, wherein the anchor is formed of sheet metal.

26. The insulation block of claim 24, wherein the two ends of the anchor each comprise a dovetail shape.

27. A structural block for use in a structure comprising structural blocks, insulation blocks and face blocks, each of which face blocks comprises at least one groove, and each of which insulation blocks has at least one elongated tail or key, the structural block comprising a concrete masonry unit having a first vertical wall, a second vertical wall and at least one web extending between the first and second vertical walls, and one of the vertical walls further comprising at least one vertically extending groove adapted to receive the at least one elongated tail or key.

28. A facing block for use in a structure comprising structural blocks, insulation blocks and face blocks, each of which structural blocks has at least one groove, and each of which insulation blocks has at least two elongated tails or keys, the facing block comprising a face and a back, the back further comprising at least one vertically extending groove or slot adapted to receive one of the insulation block tails or keys.

i. a front face,

ii. an end face,

iii. a back and

iv. an end inside face, and

b. each of the back and the end inside faces further comprising at least one vertically extending groove or slot adapted to receive one of the insulation block tails or keys.