Note: Descriptions are shown in the official language in which they were submitted.
CA 02609949 2007-11-07
Composite Concrete Masonry Unit and Method
Background
This composite concrete masonry unit invention relates generally to a building
block and
deals more particularly with a building block having advantageous insulating
and structural
properties.
It is known that in order to minimize the thermal conductivity between two
sidewalls of a
building block, the block may be constructed with a quantity of insulating
material positioned
between its two sidewalls. An illustrative example of such a block is
described in U.S. Patent
Number 4,185,434 which discloses two members that are spaced from one another
so as to
define a continuous gap therebetween in which insulating material is disposed.
One of the
problems associated with such blocks is that heat transfer through the block
may be significant
which has the disadvantageous result of increased energy consumption when
attempting to heat
or cool the interior of a structure built with such blocks. Another problem
associated with such
blocks is that they may fracture or break prior to or during installation.
Accordingly, there is a need for a block that is sturdy and which has improved
insulating
properties.
Summary
The invention includes a composite concrete masonry unit configured to
minimize
thermal transmittance coincidental to maximizing structural integrity when
assembled into a
wall. The composite concrete masonry unit has a first block member and a
second block
member each made of concrete and spaced from one another by a distance, such
that there is a
gap between the first and second block members. An insulating body is
positioned in the gap
and interlocks the first and second block members together. Heat transfer
through the composite
concrete masonry unit is minimized because the distance between the first
block member and
second block member is substantially the same throughout the composite
concrete masonry unit.
Thus, there is no heat transfer path through concrete from a first side of the
composite concrete
masonry unit to a second side of the concrete masonry unit by which heat
energy may readily
flow from one side of the composite concrete masonry unit to the other side of
the concrete
composite masonry unit. As a result, the composite concrete masonry unit
advantageously
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provides for superior insulation, while retaining structural integrity. The
composite concrete
masonry unit may be used in the construction of walls of a building, house or
other structure.
Brief Description of the Drawing Figures
A composite concrete masonry unit invention is illustrated throughout the
drawing
Figures. The same reference number is used to call out the same or similar
surfaces, structures
or features throughout the drawing figures of the embodiments of the composite
concrete
masonry unit, wherein:
Fig. 1 is a perspective view of a composite concrete masonry unit.
Fig. 2 is a top plan view of the composite concrete masonry unit without the
insulating
body.
Fig. 3 is a is a perspective view of the first and second block members
wherein the
insulating body is not present.
Fig. 4 is a top plan view of composite concrete masonry units positioned
adjacent to one
another without insulating bodies.
Fig. 5 is a perspective view, partly in broken line, of the insulating body.
Fig. 6 is a perspective view, partly in broken line, of the concrete masonry
unit detailing
the insulating body.
Description
As shown in Figs. 1-3, the composite concrete masonry unit 20 invention
comprises a
first block member 22, a second block member 24 and an insulating body 26
(also referred to
herein as insulating portion 26) positioned between the first block member 22
and the second
block member 24. The insulating body 26 interlocks the first and second block
members 22, 24
to hold the composite concrete masonry unit 20 together. The composite
concrete masonry unit
20 is configured to minimize thermal transmittance coincidental to maximizing
structural
integrity when assembled into a wall. The first and second block members 22,
24, respectively,
are separated from one another by the insulating body 26. The insulating body
26 abuts against
each of the first and second block members 22, 24, respectively, which
advantageously
decreases the possibility of air currents being formed internal to the
composite concrete masonry
unit 20. In addition, because the first and second block members 22, 24,
respectively, and the
insulating body 26 are interlocked to form the composite concrete masonry unit
20, the
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composite concrete masonry unit 20 is structurally sound and advantageously
has low thermal
conductivity. In addition, the composite concrete masonry unit 20 is
advantageously well suited
for use in the construction of structures, for example, houses, office
buildings, modular panels,
etc.
As shown in Fig. 1, the composite concrete masonry unit 20 has opposed first
and second
side walls 30, 32, respectively, opposed end walls 34, 36, respectively, and
opposed first and
second support walls 38, 40, respectively, that are separated by the first and
second side walls
30, 32. In one of the preferred embodiments the first and second side walls
30, 32, respectively,
are planar and parallel to one another, and the opposed end walls 34, 36,
respectively may be
substantially parallel to one another. When the composite concrete masonry
unit 20 is placed on
a surface 200 the second support wall 40 contacts the surface 200, and the
first block member
22, second block member 24 and insulating body 26 extend in a vertical
direction relative to the
surface 200, as shown in Fig. 1.
Each of the first and second block members 22, 24, respectively, is comprised
of a
cementitious material or baked clay capable of supporting a compressive load,
or may comprise
concrete or other suitable material. The insulating body 26 is comprised of a
quantity of
insulating material. The insulating material may be urea or phenol
formaldehyde, polystyrene,
phenolic resins, or polyurethane foam or other suitable material with low
thermal transmittance.
As shown in FIGS. 1 and 5, the insulation body 26 extends slightly beyond the
opposed end
walls 34, 36 a mating distance X, and extends beyond the second load
supporting wall 40 to
effect mating of adjacent insulating portions 26 with the thickness of the
mortar between
composite concrete masonry unit 20 taken into account. The insulation portion
26 may be flush
with the first and second support walls 38, 40, as shown in Figs. I and 5 for
ease of handling and
so that the block may thereby be readily laid down flat on a surface. In
addition, the composite
concrete masonry unit 20 has an grout opening 120 defined by a grout opening
sidewall 121 that
flares inwardly moving in the direction first support wall 38 to the second
support wal140 of the
composite concrete masonry unit 20, as shown in Fig. 2.
In order that the first and second block members 22, 24, respectively, can be
assembled
and interlocked quickly to form the composite concrete masonry unit 20, in one
of the preferred
embodiments the material from which the insulating body 26 is made is
preferably a type of
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premolded insulation such as expanded polystyrene. If desired, foam-in-place
insulation such as
polyurethane foam or any other suitable insulation may be used. To assemble
the composite
concrete masonry unit 20 with the premolded insulating body 26, the first and
second block
members 22, 24, respectively are initially arranged in their desired spaced
apart relationship
relative to one another and subsequently held in such relation, such that a
space or gap 27
extends from the first block member 22 to the second block member 24, as shown
in Fig. 3. The
gap 27 has a serpentine shape. The insulating body 26 is then inserted into
the gap 27 to thus
interlock the first and second block members 22, 24 together, and the result
is the assembled
composite concrete masonry unit 20. In one of the preferred embodiments, the
insulating body
26 is tapered and the taper matches a taper of the first and second block
members 22, 24,
respectively, which provides for a close fit between the first and second
block members 22, 24,
respectively, and the insulating body 26.
Reference is now made to Figs. 2-4, and it is pointed out that the insulation
portion 26 is
not shown. The first and second block members 22, 24, respectively, are in
their spaced apart
relationship immediately prior to the insertion of the insulating body 26
between them. As
shown, the first block member 22 has a first block interior side 23 that that
has curved and linear
portions, and the second block member 24 has a second block member interior
side 25 that has
curved and linear portions, and the gap 27 is defined between the first and
second block member
interior sides 23, 25.
The first block member interior side 23 is opposite the first side wall 30,
and the first
block member 22 has first block member ends 52, 53. The first block member
interior side 23
has a protrusion 50 extending therefrom that is part of the first block member
23. The protrusion
50 has first and second spaced apart end portions commonly designated 51. The
first block
member 22 has opposed first and second load support sides 54, 56. The first
block member
interior side 23 and associated protrusion 50 flare outwardly moving in a
direction from the first
load support side 54 to the second load support side 56. Thus, the thickness
of the first block
member 22 and the associated protrusion 50 increases moving in a direction
from the first load
support side 54 to the second load support side 56. In other words, the first
block member 22
has a taper 58 in a direction moving from the second load support side 56 to
the first load
support side 54, as shown in Fig. 2.
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The first block interior side 23 includes surface portions 29 that meet with
one another
and includes, moving from left to right in Fig. 2, a first generally straight
surface portion 60 that
extends to a first concave surface portion 62, which extends to a second
straight surface portion
64. The second straight surface portion 64 extends to a second concave surface
portion 66
which extends to a first convex surface portion 68. The first convex surface
portion 68 extends
to a third straight surface portion 70 which extends to a second convex
surface portion 72. The
second convex surface portion 72 extends to a fourth straight surface portion
74 which extends
to a third concave surface portion 76. The third concave surface portion 76
extends to a recessed
surface portion 78 which extends to a fourth concave surface portion 77. The
fourth concave
surface portion 77 extends to a fifth straight surface portion 80 which
extends to a third convex
portion 82. The third convex surface portion 82 extends to a sixth straight
surface portion 84
which extends to a fourth convex surface portion 86. The fourth convex surface
portion 86
extends to a fifth concave surface portion 88 which extends to a seventh
straight surface portion
90. The seventh straight surface portion 90 extends to a sixth concave surface
portion 92, which
extends to an eighth straight surface portion 94, as shown.
The second block member interior side 25 is opposite the second side wall 32,
and the
second block member 22 has opposed second block member ends 102, 104. The
second block
member 24 interior side 25 has protrusion halves, commonly designated 50a
extending
therefrom. Each protrusion half 50a has an end portion 51 a. The second block
member 24 has
opposed first and second load support sides 106, 108. The second block member
interior side 25
and associated protrusion halves 50a flare outwardly moving in a direction
from the first load
support side 106 to the second load support side 108. Thus, the thickness of
the second block
member 24 and associated protrusion halves 50a increase moving in a direction
from the first
load support side 106 to the second load support side 108. In other words, the
second block
member 24 has a taper 58a in a direction moving from the second load support
side 108 to the
first load support side 106, as shown in Fig. 2. It is pointed out that when
composite concrete
masonry units 20 are aligned such that they are adjacent to one another, as
shown in Fig. 4, the
protrusions halves 50a of adjacent second block members 24 are adjacent and
form the shape of
a protrusion 50b that has the substantially the same shape as the protrusion
50 shown in Fig. 2.
A grout space 57 extends between the adjacent composite concrete masonry units
20.
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The second block interior side 25 includes a surface portions 29a that meet
with one
another and face the interior surface 23 of the first block 22. Moving from
left to right in Fig. 2,
the second block interior side 25 includes a recessed surface portion 78a
which extends to a third
concave surface portion 76a. The third concave surface portion 76a extends to
a fourth straight
surface portion 74a which extends to a second convex surface portion 72a. The
second convex
surface portion 72a extends to a third straight surface portion 70a which
extends to a first convex
surface portion 68a. The first convex surface portion 68a extends to a second
concave surface
portion 66a which extends to a second straight surface portion 64a. The second
straight surface
portion 64a extends to a first concave surface portion 62a, which extends to a
first straight
surface portion 60a. The first straight surface portion 60a extends to a sixth
concave surface
portion 92a which extends to a seventh straight surface portion 90a. The
straight surface portion
90a extends to a fifth concave surface portion 88a which extends to a fourth
convex surface
portion 86a. The fourth convex surface portion 86a extends to a sixth straight
surface portion
84a which extends to a third convex surface portion 82a. The third convex
surface portion 82a
extends to a fifth straight surface portion 80a which extends to a fourth
concave surface portion
77a. The fourth concave surface portion 77a extends to a recessed surface
portion 78a.
As shown in Figs. 1-3, there are line segments designated A, B, C, D and E
that indicate
a distance from the first block member 22 to the second block member 24 at the
first load
support side 54,106 of each, when they are spaced apart prior to the
introduction of the
insulating body 26 in the gap 27. There are also line segments A', B', C', D',
and E' that
indicate a second distance from the first block member 22 to the second block
member 24 at the
second load support side 56, 108 of each, when they are spaced apart prior to
the introduction of
the insulating body 26 in the gap 27. The lengths of lines segments A, B, C,
D, and E are all
equal to one another, and the lengths of lines segments A', B', C', D', and E'
are all equal to one
another, in order to decrease heat transfer through the composite concrete
masonry unit 20 by
providing no portion or surface in the composite concrete masonry unit 20
wherein the first and
second block members 22, 24 are significantly closer to one another. No
portions of the first and
second block members 22, 24 are closer to one another to such an extent that
there would be an
impact on overall heat transfer through the composite concrete masonry unit
20. In addition,
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line segments A', B', C', D', and E' have a shorter length than line segments
A, B, C, D, and E
due to the taper 58, 58a of the first and second block members 22, 24.
Each of the opposed first and second load support sides 54, 56, of the first
block member
24 has a peripheral edge 33a, 33b, respectively, with edge portions where each
meets the interior
side wall 23, as will be described in greater detail presently. Similarly,
each of the opposed first
and second load support sides 106, 108, of the second block member 24 has a
peripheral edge
35a, 35b, respectively, with edge portions where each meets the interior side
wall 25.
As shown in Figs. 2 and 3, the line segment designated A indicates a distance
from the
first load support side 54 of the first block member 22 where it meets the
fourth convex surface
portion 86 at a first edge portion 87, to the first load side 106 of the
second block member 24
where it meets the fourth convex surface portion 86a at a facing second edge
portion 89.
The line segment designated B indicates the distance from the first load
support side 54
of the first block member 22 at another point where the first load support
side 54 meets the
fourth convex surface portion 86 at a third edge portion 91, to the first load
support side 106 of
the second block member 24 where the first load support side 106 meets the
straight surface
portion 90a at a facing fourth edge portion 93.
The line segment designated C indicates the distance from the first load
support side 54
of the first block member 22 where it meets the seventh straight surface
portion 90 at a fifth edge
portion 95, to the first load support side 106 of the second block member 24
where it meets the
forth convex surface portion 86a at a facing sixth edge portion 97.
The line segment designated D indicates the distance from the first load
support side 54
of the first block member 22 where it meet the sixth straight surface portion
84 at a seventh edge
portion 99, to the first load support side 106 of the second block member 24
where it meets the
first straight surface portion 60a at a facing eighth edge portion 101.
The line segment designated E indicates the distance from the first load
support side 54
of the first block member 22 where it meets the eighth straight surface
portion 94 at a ninth edge
portion 111 to the first load support side 106 of the second block member 24
where it meets the
sixth straight surface portion 84a at a facing tenth edge portion 113.
In a like manner, the line segment designated A' indicates a second distance
from the
second load support side 56 of the first block member 22 where it meets the
fourth convex
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surface portion 86 at an eleventh edge portion 115, to the second load side
108 of the second
block member 24 where it meets the fourth convex surface portion 86a at a
facing twelfth edge
portion 117.
The line segment B' indicates the second distance from the second load support
side 56
of the first block member 22 where it meets the fourth convex surface portion
86 at a thirteenth
edge portion 119, to the load support side 108 of the second block member 24
where it meets the
straight surface portion 90a at a facing fourteenth edge portion 121.
The line segment designated C' indicates the second distance between the
second load
support side 56 of the first block member 22 where it meets the seventh
straight surface portion
90 at a fifteenth edge portion 123, to the second load support side 108 of the
second block
member 24 where it meets the fourth convex surface portion 86a at a facing
sixteenth edge
portion 125
The line segment designates D' indicates the second distance between the
second load
support side 56 of the first block member 22 where it meets the sixth straight
surface portion 84
at a seventeenth edge portion 127, to the second load support side 108 of the
second block
member 24 where it meets the first straight surface portion 60a at an facing
eighteenth edge
portion 129.
Line segment E' indicates the second distance from the second load support
side 56 of
the first block member 22 where it meets the eighth straight surface portion
94 at a nineteenth
edge portion 131, to the second load support side 108 of the second block
member 24 where it
meets the sixth straight surface portion 84a at a facing twentieth edge
portion 133.
As previously mentioned the distances indicated by line segments A, B, C, D
and E are
all equal. The second distances indicated by line segments A', B', C', D' and
E' are all equal.
As shown in Figs. 2 and 3, the second distance indicated by line segments A',
B', C', D' and E'
is greater than the distance indicated by line segments A, B, C, D and E, as
shown in Figs. 2 and
3 due to the tapers 58, 58a. It is to be understood that the above-described
spaced apart
relationship between the first and second interior side walls 23, 25 of the
first and second block
members 22, 24, is maintained along the tapers 58, 58a, adjacent the above-
described edge
portions.
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Fig. 5 shows one of the preferred embodiments of the insulating body 26 in
detail. The
insulating body 26 has protrusion recesses 130 for receiving the first block
protrusion 50 and
protrusion halves 50a, such that it may be aligned with and forced into the
gap 27, to interlock
the insulating body 26 and first and second members 22, 24. The insulating
body 26 that has
opposed first and second contact walls 146, 148, respectively, such that the
first contact wall 146
abuts against the interior side 23 of the first block member 22, and the
second contact wall 148
abuts against the interior side 25 of the second block member 24. The
insulating body 26 also
has opposed first and second end walls 145, 147, respectively, and opposed
first and second
exposed walls 149, 151. The first and second contact walls 146, 148 are each
provided with
elevated portions 150 and adjacent recesses 152 that extend longitudinally in
the direction of the
arrow designated VL in Fig. 6, i.e., the length of the insulation body 26. The
recesses 152 are
advantageous, because as the molds (not shown) that are used to manufacture
the first and
second block members 22, 24, wear over time, that is, as more and more first
and second block
members 22, 24, are made the molds used to make them wear out. As a result,
the first block
member 22 and the second block member 24 that are made in the molds become
thicker as the
mold wears out. Thus, the distance between the first and second block members
22, 24,
respectively, decreases as the molds wear. The recesses 152 and elevated
portions 150
advantageously provide a compression mechanism 153 for the insulating member
26 to
compress as the first and second block members 22, 24, respectively, become
thicker as the
molds used to make them wear out.
Figs. 6 shows the assembled composite concrete masonry unit 20 in detail. As
previously mentioned, after the insulation portion 26 has been introduced into
the spaced apart
first and second block members 22, 24, and the insulation portion 26 are
interlocked to form as
strong and durable composite concrete masonry unit 20. In addition, after the
insulation portion
26 has been interlocked with the first and second block member 22, 24, the
distances indicated
by line segments A, B, C, D and E are all equal, and the distances indicated
by line segments A',
B', C', D' and E' are all equal which advantageously provides for improved
insulating
properties of the composite concrete masonry unit 20. The first and second
block members 22,
24, respectively, are separated by the distance indicated by line segments A,
B, C, D, and E, and
are separated by the second distance indicated by line segments A', B', C', D'
and E'. This
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advantageously decreases the heat transfer through the composite concrete
masonry unit 20 after
it has been assembled, because there is no easy path for heat transfer through
the insulation body
26. In other words, because the lengths of lines segments A, B, C, D and E are
all equal, and the
lengths of line segments A', B', C', D', and E' are all equal, there is no
portion or surface of the
first and second interior sides 23, 25 of the first and second block members
22, 24, that are
significantly closer together to allow for heat transfer. Thus, there is no
shortest route through
the insulation body 26 for heat to transfer from the first planar side wal130
to the second planar
side wall 32 through the composite concrete masonry unit 20. This
advantageously provides for
improved insulating capability when compared to a block with no insulation or
a block having
insulation and concrete portions that are both in close proximity to one
another and farther from
another. Thus, the composite concrete masonry unit 20 is configured to
minimize thermal
transmittance coincidental to maximizing structural integrity when assembled
into a wall.
The composite concrete masonry units 20 are laid in an row adjacent to one
another, as
shown in Fig. 4. The next course or layer of composite concrete masonry units
20 is indexed
180 degrees to facilitate stacking in half bond symmetry. The composite
concrete masonry
units 20 are offset half a block length when stacked on top of one another to
form the rows of a
wall. Each alternating course is indexed 180 degrees to facilitate down
through the wall
stacking symmetry of the masonry component, insulating component, as well as
the aperture
openings 120. In addition, the opening 120 may be filled with grout and rebar
may be installed
in the structure or building through the openings 120 such that they may be
surrounded by grout.
As previously mentioned, in another preferred embodiment, foam-in-place
insulation
such as polyurethane foam or any other suitable insulation may be used. Foam-
in-place
comprises injection of foamable compositions that are injected from, for
example a dispenser.
The compounds once dispensed expand to form, for example, polyurethane. Foam-
in-place and
its manufacture and use are well known to those having ordinary skill in the
art. To assemble
the block composite concrete masonry unit 20 with foam-in-place insulation,
the first and second
block members 22, 24, 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 defined between the first and second
block members 22, 24.
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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.
It will be appreciated by those skilled in the art that while a composite
concrete masonry
unit invention has been described above in connection with particular
embodiments and
examples, the invention is not necessarily so limited, and other embodiments,
examples, uses,
and modifications and departures from the described embodiments, examples, and
uses may be
made without departing from the composite concrete masonry unit of this
invention. All of
these embodiments are intended to be within the scope and spirit of the
present composite
concrete masonry unit invention.
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