Insulated building block

• US 4,134,241 A
• Filed: 07/07/1977
• Issued: 01/16/1979
• Est. Priority Date: 07/07/1977
• Status: Expired due to Term

• Current Assignee: Energy Block Limited
• Original Assignee: Energy Block Limited
• Inventors: Walton, Robert J.
• Primary Examiner(s): Bell, J. Karl
• Application Number:
  US05/813,736
• Time in Patent Office: 558 Days
• Field of Search: 52/275, 52/574, 52/405, 52/404, 52/438, 52/309.3, 52/309.5, 52/743, 52/747
• US Class Current: 52/275
• CPC Class Codes: E04B 2/16 using elements having specially-designed means for stabilising the position
• CPC Class Codes: E04B 2002/023 with rabbets, e.g. stepped

Abstract

A hollow building block filled with insulation is shaped as a pair of proximal but offset rectangles thereby to form steps at diagonal corners for fitting adjoining blocks together. A continuous insulation effect is obtained because the insulation in each rectangle extends beyond that of its proximal rectangle and overlaps with the insulation in the proximal rectangle of each adjoining block. Aligning holes and reinforcing grooves are provided for rapidly constructing strong structures from the blocks.

Claims

1. A building block comprising a walled shell of finite thickness thereby defining a continuous cavity therewithin, the inner surface of said walled shell including a continuum of at least eight sides, two of said sides comprising a pair of laterally spaced opposing faces offset longitudinally one from the other, four of said sides comprising 2 pairs of adjacent ends connected to the 4 extremities of said faces, and two of said sides forming a joinder connecting each pair of adjacent ends, the outer surface of said walled shell including at least eight sides adjacent to and extending in substantially the same direction as their respective inner sides thereby to form a hollow block in which the continuous cavity and outer surface are of a generally offset shape, the amount of offset and thickness of the walls being such that when the cavity is filled with insulation and an offset end is matingly abutted with the offset end of a similar block, the structure so formed will have an overlapping cavity arrangement such that any straight vector heat flow striking the structure will always meet insulation regardless of what point on the structure the vector seeks to go through in a straight line.

2. A building block according to claim 1 wherein the outer surface of said walled shell is defined by a continuum of said at least eight sides, said outer eight sides being substantially parallel with said inner eight sides.

3. A building block according to claim 1 wherein at least one of said sides of said inner surface has projecting inwardly therefrom into said cavity a support member, said support member being integral with said inner surface.

4. A building block according to claim 1 in which said cavity is filled with insulation.

5. A building block according to claim 1 wherein said offset forms an opposing "L" shaped inset at either end of said block thereby to form an inner and outer surface of substantially "Z" shape wherein the top and bottom legs of the "Z" extend beyond its confines.

6. A building block according to claim 5 wherein the legs of said "L" are substantially of the same length and are substantially perpendicular one to the other.

7. A building block according to claim 1 wherein the end walls are substantially thinner than the face walls.

8. A building block according to claim 4 wherein said block is open at its top and bottom sides.

9. A building block according to claim 4 wherein said insulation is an in situ foamed plastic.

10. A building block according to claim 4 wherein the shell defines a shell cavity in the general shape of a "Z" wherein the legs of the "Z" exceed the normal confines thereof, thus to define an offset area of insulation capable of overlapping in the longitudinal direction from a lateral view with the offset area of a similar block in longitudinal abutment therewith.

11. A building block according to claim 8 wherein, in one of said walls there is provided an orifice means extending from the top to bottom side of said block for retaining an aligning or reinforcing rod therein.

12. A building block according to claim 11 wherein said orifice is provided in an enlarged extension of the connection between a joining wall and its innermost end wall.

13. A building block according to claim 12 wherein said orifice is provided in an enlarged extension of the connection between each of said joining walls and its innermost end wall.

14. A wall construction having a continuous insulation effect comprised of a plurality of blocks of claim 4.

15. A wall construction having a continuous insulation effect comprised a plurality of blocks of claim 8.

16. A wall construction having a continuous insulation effect comprised of a plurality of blocks of claim 11, wherein said blocks are aligned by a rod located in said orifice means and extending between the orifice means of one block and the orifice means of the next proximal block.

17. A wall construction having a continuous insulation effect comprised of a plurality of blocks of claim 10 connected such that their respective offsets abut in mating fashion.

18. A wall construction according to claim 17 wherein an abutting end wall of each block has located therein an orifice extending therethrough filled with insulation material.

19. A wall construction having a continuous insulation effect comprised of a plurality of blocks of claim 17 wherein the ends of the blocks forming one row are supported by respective support members of the blocks of the proximal row.

20. a method of constructing the wall construction of claim 16 comprising forming a bottom row of said blocks unfilled with insulation material, said blocks having upwardly extending from said orifice means aligning rods, stacking another row of blocks unfilled with insulation material on said first row by inserting said aligning rods in their respective orifice means, the unfilled stacked blocks having aligned cavities, and thereafter filling said aligned cavities with insulation material.

21. A method according to claim 20 which further includes inserting a reinforcing rod in said cavities.

22. A method according to claim 20 which further includes providing reinforcing rods along the length of at least one row before stacking another row thereupon.

23. A method according to claim 20 wherein said insulation material used to fill said cavities is also an adhesive for said blocks, and no joint adhesive material is used to join the blocks during stacking.