BLOCK AND FOAM WALL SYSTEM

• US 20150308113A1
• Filed: 04/23/2014
• Published: 10/29/2015
• Est. Priority Date: 04/23/2014
• Status: Abandoned Application

• Current Assignee: Kurt E. Blum
• Original Assignee: Kurt E. Blum
• Inventors: Blum, Kurt E.
• Application Number:
  US14/260,080
• Publication Number:
  US 20150308113A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: E04B 1/7604 fillings for cavity walls
• CPC Class Codes: E04B 2/32 by interlocking of projections or inserts with indentations, e.g. of tongues, grooves, dovetails
• CPC Class Codes: E04B 2/8617 with spacers being embedded in both form leaves
• CPC Class Codes: E04B 2/8635 with ties attached to the inner faces of the forms E04B2/8611 and E04B2/8623 take precedence
• CPC Class Codes: E04B 2002/023 with rabbets, e.g. stepped
• CPC Class Codes: E04B 2002/0247 Strips or bars
• CPC Class Codes: E04C 1/40 built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts

Abstract

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

Claims

1. A block for forming a wall when stacked with a plurality of other blocks, said block comprising:

a first plate formed from a cement mixture, the first plate having an inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end, wherein the top end of the first plate has a tongue or groove and the bottom end of the first plate has a tongue or groove substantially complementary to the tongue or groove of the top end of the first plate;

a second plate formed from a cement mixture, the second plate having an inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end, wherein the top end of the second plate has a tongue or groove and the bottom end of the second plate has a tongue or groove substantially complementary to the tongue or groove of the top end of the second plate; and

a spacer operable to attach to the inside face of the first plate and the inside face of the second plate and maintain the inside face of the first plate at a predetermined distance from the inside face of the second plate.

2. The block of claim 1, wherein the tongue or groove of the bottom end of the first plate is substantially complementary to the tongue or groove of the top end of the first plate, and the tongue or groove of the bottom end of the second plate is substantially complementary to the tongue or groove of the top end of the second plate such that when the block is stacked with the plurality of other blocks, all of which are upright or upside down, each tongue or groove interlocks with the tongue or groove of an adjacent block.

3. The block of claim 1, wherein:

the first end of the first plate has a tongue or groove;

the second end of the first plate has a tongue or groove substantially complementary to the tongue or groove of the first end of the first plate;

the first end of the second plate has a tongue or groove; and

the second end of the second plate has a tongue or groove substantially complementary to the tongue or groove of the first end of the second plate.

4. The block of claim 1, wherein:

the inside face of the first plate has an indentation configured to receive a first end of the spacer;

the inside face of the second plate has an indentation configured to receive a second end of the spacer opposite the first end of the spacer; and

the indentation in the inside face of the first plate corresponds to the indentation in the inside face of the second plate.

5. The block of claim 1, wherein:

the first end of the first plate has a tongue or groove;

the second end of the first plate has a tongue or groove substantially complementary to the tongue or groove of the first end of the first plate;

the first end of the second plate has a tongue or groove;

the second end of the first plate has a tongue or groove substantially complementary to the tongue or groove of the first end of the first plate; and

the tongue or groove of the first end of the first plate is substantially complementary to the tongue or groove of the second end of the first plate, and the tongue or groove of the first end of the second plate is substantially complementary to the tongue or groove of the second end of the second plate such that when the block is stacked with the plurality of other blocks, all of which are upright or upside down, each tongue or groove interlocks with the tongue or groove of an adjacent block.

6. The block of claim 1, wherein:

the first plate has an outside face opposite the inside face;

the second plate has an outside face opposite the inside face;

the outside face of the first plate at the first end of the first plate has a first indentation from the top end to the bottom end;

the outside face of the second plate at the first end of the second plate has a second indentation from the top end to the bottom end;

the outside face of the first plate at the second end of the first plate has a first protrusion substantially complementary to the first indentation;

the outside face of the second plate at the second end of the second plate has a second protrusion substantially complementary to the second indentation such that when the block is stacked with the plurality of other blocks, all of which are have their first ends oriented in the same direction, the first end of the block nests inside a second end of an adjacent block.

7. The block of claim 1, wherein the cement mixture of the first plate and the cement mixture of the second plate include at least one of perlite or polypropylene fibers.

8. The block of claim 1, wherein the spacer is formed from at least one of wood, PVC pipe, metal pipe, metal strapping, plastic strapping, welded metal wire, metal lathe, or brick ties.

9. A block for forming a wall when stacked with a plurality of other blocks, said block comprising:

a first plate formed from a cement mixture, the first plate having an inside face, an outside face opposite the inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end, wherein the outside face of the first plate at the first end of the first plate has a first indentation extending from the top end to the bottom end and the outside face of the first plate at the second end of the first plate has a first protrusion substantially complementary to the first indentation;

a second plate formed from a cement mixture, the second plate having an inside face, an outside face opposite the inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end, wherein the outside face of the second plate at the first end of the second plate has a second indentation extending from the top end to the bottom end and the outside face of the second plate at the second end of the second plate has a second protrusion substantially complementary to the second indentation; and

a spacer operable to attach to the inside face of the first plate and the inside face of the second plate and maintain the inside face of the first plate at a predetermined distance from the inside face of the second plate.

10. The block of claim 9, wherein:

the top end of the first plate has a tongue or groove and the bottom end of the first plate has a tongue or groove substantially complementary to the tongue or groove of the top end of the first plate; and

the top end of the second plate has a tongue or groove and the bottom end of the second plate has a tongue or groove substantially complementary to the tongue or groove of the top end of the second plate.

11. The block of claim 9, wherein the tongue or groove of the bottom end of the first plate is substantially complementary to the tongue or groove of the top end of the first plate, and the tongue or groove of the bottom end of the second plate is substantially complementary to the tongue or groove of the top end of the second plate such that when the block is stacked with the plurality of other blocks, all of which are upright or upside down, each tongue or groove interlocks with the tongue or groove of an adjacent block.

12. The block of claim 9, wherein:

the first indentation, second indentation, first protrusion, and second protrusion are configured such that when the block is stacked with the plurality of other blocks, all of which are have their first ends oriented in the same direction, the first end of the block nests inside a second end of an adjacent block.

13. The block of claim 9, wherein:

the inside face of the first plate has an indentation configured to receive a first end of the spacer;

the inside face of the second plate has an indentation configured to receive a second end of the spacer opposite the first end of the spacer; and

the indentation in the inside face of the first plate corresponds to the indentation in the inside face of the second plate.

14. The block of claim 9, wherein the cement mixture of the first plate and the cement mixture of the second plate include at least one of perlite or polypropylene fibers.

15. The block of claim 9, wherein the spacer is formed from at least one of wood, PVC pipe, metal pipe, metal strapping, plastic strapping, welded metal wire, metal lathe, or brick ties.

16. A system for forming a wall, said system comprising:

a plurality of blocks for forming the wall when stacked, each block of said plurality of blocks comprising;

a first plate having an inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end, wherein the top end of the first plate has a tongue or groove and the bottom end of the first plate has a tongue or groove substantially complementary to the tongue or groove of the top end of the first plate;

a second plate having an inside face, a top end, a bottom end opposite the top end, a first end, and a second end opposite the first end, wherein the top end of the second plate has a tongue or groove and the bottom end of the second plate has a tongue or groove substantially complementary to the tongue or groove of the top end of the second plate; and

a spacer operable to attach to the inside face of the first plate and the inside face of the second plate and maintain the inside face of the first plate at a predetermined distance from the inside face of the second plate, forming a space between the inside face of the first plate and the inside face of the second plate; and

spray insulation operable to substantially fill the space formed between the inside face of the first plate and the inside face of the second plate.

17. The system of claim 16, wherein:

the spray insulation is an expanding foam insulation comprising polyurethane; and

the expanding foam insulation is operable to affix the plurality of stacked blocks to one another and increase lateral strength of the wall formed by the stacked blocks and expanding foam insulation.

18. The system of claim 16, wherein the tongue or groove of the bottom end of the first plate is substantially complementary to the tongue or groove of the top end of the first plate, and the tongue or groove of the bottom end of the second plate is substantially complementary to the tongue or groove of the top end of the second plate such that when the block is stacked with the plurality of other blocks, all of which are upright or upside down, each tongue or groove interlocks with the tongue or groove of an adjacent block.

19. The system of claim 16, wherein:

the first plate has an outside face opposite the inside face;

the second plate has an outside face opposite the inside face;

the outside face of the first plate at the first end of the first plate has a first indentation from the top end to the bottom end;

the outside face of the second plate at the first end of the second plate has a second indentation from the top end to the bottom end;

the outside face of the first plate at the second end of the first plate has a first protrusion substantially complementary to the first indentation;

the outside face of the second plate at the second end of the second plate has a second protrusion substantially complementary to the second indentation such that when the block is stacked with the plurality of other blocks, all of which are have their first ends oriented in the same direction, the first end of the block nests inside a second end of an adjacent block.

20. The system of claim 16, wherein:

the first end of the first plate has a tongue or groove;

the second end of the first plate has a tongue or groove substantially complementary to the tongue or groove of the first end of the first plate;

the first end of the second plate has a tongue or groove;

the second end of the second plate has a tongue or groove substantially complementary to the tongue or groove of the first end of the second plate; and

the tongue or groove of the first end of the first plate is substantially complementary to the tongue or groove of the second end of the first plate, and the tongue or groove of the first end of the second plate is substantially complementary to the tongue or groove of the second end of the second plate such that when the block is stacked with the plurality of other blocks, all of which are upright or upside down, each tongue or groove interlocks with the tongue or groove of an adjacent block.