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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a construction block for use in masonry
walls and, more particularly, to an insulated concrete construction block
provided with improved insulating features which minimize thermal
conduction through the block itself and through mortar joints between
adjacent blocks in a masonry wall.
2. Description of the Prior Art
Conventional masonry construction of buildings employs pre-cast concrete
blocks arranged end to end in rows and secured together by vertical mortar
joints between adjacent blocks. Successive rows of blocks are secured to
those below by horizontal mortar joints. Generally, the concrete blocks
have a hollow interior to reduce the weight and facilitate handling of the
blocks by workmen. One widely used construction block includes a central
web extending transversely across the hollow interior of the block to
connect the side walls of the block and preserve its strength.
Generally, such conventional construction blocks have relatively poor
insulative value. The concrete material of the block allows appreciable
thermal conduction, particularly at the end walls and central web where
straight conductive paths are provided which allow direct heat conduction
between the inner and outer side walls of the block. In addition, when
such conventional blocks are assembled in a masonry wall, the vertical
mortar joints between adjacent blocks and the horizontal mortar joints
between successive rows of blocks are poorly insulated. Typically, air
spaces in the mortar joints between the blocks allow sufficient air
circulation to result in loss of heat by convection. Similarly, air is
able to circulate through the hollow interior of the blocks resulting in
additional loss of heat. Thus, such a masonry wall has usually been
insulated by installation of a separate insulative barrier, e.g.,
conventional studs or furring strips with fiberglass or other insulation,
on the inner face of the wall.
Although it has been proposed to utilize insulation inserts in the hollow
interior spaces of conventional masonry blocks, such arrangements have not
provided satisfactory insulative characteristics because of the loss of
heat by conduction through the central web and end walls of the block.
Further, no provision has been made to prevent loss of heat through the
mortar joints between adjacent blocks.
In addition, various proposals have been made in the prior art to provide
alternate forms of insulated masonry blocks by eliminating the centrally
located transverse web of the conventional block and providing other
interior configurations to achieve one or more hollow insulating spaces
for receiving insulating material within the block. However, such
proposals have generally sacrificed the overall strength of the
conventional block without appreciably improving its insulative
characteristics. Moreover, the complex internal configuration of such
insulated blocks has made the blocks difficult and expensive to
manufacture and install. Consequently, such insulated masonry blocks have
not received widespread acceptance in the construction industry.
Nevertheless, because of the presently increasing concern about dwindling
sources of conventional fossil fuels and the need to adequately insulate
building walls, there is definitely a need for an insulated construction
block which is simple and effective in design and capable of manufacture
and installation at reasonable cost. A primary consideration in the design
of a satisfactory insulated construction block is to maximize the
insulative properties without sacrificing the strength of the block. To
limit heat loss through the concrete material of the block itself, it is
necessary to achieve a concrete block structure which eliminates direct
paths for thermal conduction through the block. Furthermore, it is
important that the construction block achieve adequate insulation in the
mortar joints between adjacent blocks in the same row and between
successive rows of blocks.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an insulated construction
block having enhanced insulating characteristics and preserving the
strength of conventional blocks.
Another object of the invention is to achieve an insulated construction
block which effectively provides insulation in the mortar joints between
adjacent blocks and between successive rows of blocks in a masonry wall.
It is also an object of the invention to provide an insulated construction
block having a recessed end face designed to receive insulating material
between adjacent blocks to maximize the amount of insulation provided in
the mortar joint between the blocks.
Another object of the invention is to achieve an insulated construction
block provided with a central recess in its end face which overlaps one or
more interior insulating spaces to minimize thermal conduction through the
block.
A further object of the invention is to provide an insulated construction
block having hollow interior regions designed to accommodate an optimum
amount of insulating material.
The invention is embodied in a construction block comprising a pair of
spaced vertical side walls which provide an inner side wall and an outer
side wall of the block and a pair of end walls connected to opposite ends
of the vertical side walls to define a hollow interior region within the
block for receiving insulating material wherein at least one of the end
walls includes an intermediate portion offset inwardly into the hollow
interior region to provide a vertical recess on the exterior of the end
wall for receiving insulating material. The recess includes an enlarged
portion adjacent to the exterior of the end wall to increase the amount of
insulating material received therein.
A preferred embodiment of the construction block includes a longitudinal
web extending from the offset portion of one end wall to the opposite end
wall and spaced from the vertical side walls to form longitudinal
insulating spaces adjacent to the inner side wall and the outer side wall.
In addition, the recess includes an outwardly flared portion adjacent to
the exterior of the end wall and an inner portion overlapping the
longitudinal insulating spaces to minimize thermal conduction through the
block. Preferably, the longitudinal web is reduced in thickness relative
to the side walls to accommodate an increased amount of insulating
material within the longitudinal insulating spaces.
The preferred embodiment also includes an insert of insulating material
adapted for insertion into the recess to provide insulation in a mortar
joint adjacent to the end wall of the block. In addition, a pair of
inserts of insulating material is adapted for insertion into the
longitudinal insulating spaces to provide insulation inside the block.
Each insulating insert exceeds the vertical side walls and end walls in
height allowing the insert to project above or below the block to provide
insulation in the horizontal mortar joints between successive rows of
blocks.
In an alternative embodiment, a connecting web extends transversely between
the vertical side walls and includes first and second transverse portions
projecting inwardly at longitudinally spaced locations from the inner side
wall and the outer side wall, respectively, and a third longitudinal
portion connecting the first and second transverse portions. Another
alternative embodiment includes a pair of connecting webs extending in a
crisscross configuration between the opposite end walls of the block.
The invention provides insulated construction blocks which achieve high
levels of insulative value without reduction in the strength of the block.
In addition, the insulated construction blocks are particularly effective
in providing insulation in the mortar joints of a masonry wall to minimize
thermal conduction through the wall. The specifically disclosed
embodiments provide configurations which are suitable not only for large
eight inch (8") and twelve inch (12") construction blocks, but also for
smaller four inch (4") and six inch (6") blocks usually used as a backup
for a brick face wall.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate preferred embodiments of the present
invention and, together with the description, serve to explain the
principles of the invention.
FIG. 1 is a perspective view of a construction block constructed in
accordance with the principles of the invention;
FIG. 2 is a plan view of a row of construction blocks in a masonry wall
illustrating a full block, half block, corner block and jamb block,
together with suitable inserts of insulating material adapted to be
inserted into the insulating spaces provided within the blocks and between
adjacent blocks;
FIG. 3 is a vertical section of a full construction block taken along line
3--3 of FIG. 2;
FIGS. 4-9 are perspective views of the various insulating inserts required
for the construction blocks shown in FIG. 2;
FIG. 10 is a perspective view of a masonry wall including an alternative
embodiment of the construction block constructed in accordance with the
present invention;
FIG. 11 is an enlarged plan view of a portion of the masonry wall of FIG.
10;
FIG. 12 is a vertical section of the construction block taken along line
12--12 of FIG. 11;
FIG. 13 is a perspective view of an insert of insulating material adapted
to be inserted into hollow interior spaces provided in the construction
block of FIGS. 10 and 11;
FIG. 14 is a perspective view of an insulating insert adapted to be
inserted between adjacent construction blocks;
FIG. 15 is an enlarged plan view of a masonry wall including a corner block
similar in structure to the construction block of FIGS. 10 and 11;
FIG. 16 is a perspective view of an insert of insulating material adapted
to be inserted inside the corner block of FIG. 15; and
FIGS. 17 and 18 illustrate further alternative embodiments of the
construction block of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a preferred embodiment of the insulated construction
block, generally 20, provides a configuration especially suitable for
large eight inch and twelve inch concrete blocks. Construction block 20,
illustrated as a full block, includes a pair of spaced vertical side walls
22 and 24 which provide an inner side wall and an outer side wall,
respectively, of the block. A pair of end walls 26 and 28 is connected to
opposite ends of the vertical side walls. Side walls 22 and 24 and end
walls 26 and 28 define a hollow interior region within the block for
receiving insulating material.
As shown in FIGS. 1 and 2, end wall 26 of the construction block includes
an intermediate portion 30 offset inwardly into the hollow interior
region. Offset portion 30 is centrally located on end wall 26 and
connected by a pair of longitudinally extending legs 32 and 34 to the main
portion of the end wall. Offset portion 30 and longitudinal legs 32 and 34
provide a vertical recess 36 on the exterior of end wall 26 for receiving
insulating material. Similarly, end wall 28 includes an intermediate
portion 40 offset inwardly into the hollow interior region and connected
by a pair of longitudinal legs 42 and 44 to the main portion of the end
wall. Offset central portion 40 and longitudinal legs 42 and 44 provide a
vertical recess 46 on the exterior of end wall 28 for receiving insulating
material.
In accordance with a preferred feature of the present invention, each
recess has an enlarged portion adjacent to the exterior of its end wall to
increase the amount of insulating material received therein. Referring to
FIGS. 1 and 2, recess 36 includes an outer enlarged portion provided by
outwardly flared surfaces 48 and 50 formed at the outer ends of
longitudinal legs 32 and 34, respectively. The recess also includes an
inner rectangular portion defined by outside vertical edges 52 and 54 of
legs 32 and 34, respectively, and the outside vertical edge of offset
portion 30 of the end wall 26. Similarly, recess 46 includes an outer
enlarged portion defined by outwardly flared surfaces 58 and 60 at the
outer ends of longitudinal legs 42 and 44, respectively, and an inner
rectangular portion defined by outside vertical edges 62 and 64 of legs 42
and 44, respectively, and the outside vertical edge of offset portion 40
of end wall 28. Recesses 36 and 46 are identical in size and
configuration. The outer flared portion of each recess reduces the weight
of block 20.
In the preferred embodiment of FIGS. 1 and 2, a longitudinal web 66 extends
between offset portion 30 of end wall 26 and offset portion 40 of end wall
28. Longitudinal web 66 is centrally located and spaced from vertical side
walls 22 and 24 to form longitudinal insulating spaces 68 and 70,
respectively, adjacent to the inner side wall and outer side wall of the
block. Insulating space 68 includes a pair of longitudinal extensions 72
and 74 located in the spaces between the inside edges of legs 32 and 42
and side wall 22. Similarly, insulating space 70 includes a pair of
longitudinal extensions 76 and 78 formed in the spaces between the inside
edges of legs 34 and 44 and side wall 24. Longitudinal web 66 serves to
provide rigidity to end walls 26 and 28 and to preserve the strength of
the block.
As shown in FIGS. 1 and 2, offset portion 30 of end wall 26 extends
sufficiently inward into the hollow interior region of block 20 to allow
the inner rectangular portion of recess 36 to overlap extensions 72 and 76
of longitudinal insulating spaces 68 and 70, respectively. As a result,
there is no direct path for thermal conduction between inner side wall 22
and outer side wall 24. Any heat conducted through end wall 26 must travel
along the extended path provided by offset portion 30 and longitudinal
legs 32 and 34. The same configuration exists at opposite end wall 28
where any heat conduction through the end wall must follow the path
provided by offset portion 40 and longitudinal legs 42 and 44.
Consequently, thermal conduction through end walls 26 and 28 is minimized.
In addition, longitudinal web 66 is reduced in thickness relative to side
walls 22 and 24 to accommodate an increased amount of insulating material
within longitudinal insulating spaces 68 and 70. For example, side walls
22 and 24 may be made one and one-quarter inches in thickness, while
longitudinal web 66 may be made one inch or less in thickness. The
reduction in thickness of the longitudinal web allows the insulative
characteristics of the block to be optimized.
Typically, the overall dimensions of a nominal eight inch construction
block 20 are 75/8".times.75/8".times.155/8". Preferably, the block walls
are tapered vertically to provide increased thickness of the concrete
material at the bottom of the block. For example, each side wall may be
tapered from a top thickness of one and one-quarter inches to a bottom
thickness of one and one-half inches. Similarly, longitudinal web 66 may
also be tapered from a top thickness of one inch to a bottom thickness of
one and one-quarter inches. The tapered walls and longitudinal web enhance
the load bearing capacity of the block.
As shown in FIG. 1, construction block 20 includes a pair of vertical
notches 80 and 82 formed adjacent to the opposite outer edges of end wall
26. Similar vertical notches 84 and 86 are formed adjacent to the opposite
outer edges of end wall 28. When block 20 is assembled by a set of mortar
joints 88 (FIG. 2) to adjacent blocks in a masonry wall, these vertical
notches are filled with mortar to securely hold the blocks together.
Referring to FIG. 2, it is also contemplated that the preferred structure
exemplified by full construction block 20 may also be embodied in a jamb
block 90, a half block 110 and a corner block 130. The wall also includes
an additional full block 120 which is identical in structure to block 20.
Although jamb block 90 (FIG. 2) is illustrated in the form of a half jamb
block, its basic structure is also representative of a full jamb block.
Jamb block 90 includes an inner side wall 92, an outer side wall 94, and a
longitudinal central web 96 which is preferably reduced in thickness
relative to the side walls. One end wall 98 of the jamb block includes an
offset portion 100 joined by a pair of longitudinal legs 102 to the main
portion of end wall 98. Offset portion 100 and longitudinal legs 102 form
a recess 104 which is identical in size and configuration to recess 36
provided in full construction block 20. Longitudinal web 96 divides the
hollow interior of jamb block 90 into two identical insulating spaces or
cavities 106, each having a longitudinal extension formed by the space
between legs 102 and side walls 92 and 94, respectively. An opposite end
wall 108 of jamb block 90 has a flat exterior face to allow the block to
abut an opening in the masonry wall for a window or door.
Half block 110 is substantially identical in configuration to full block
20, but only one-half of the length of the full block. Half block 110
includes an inner side wall 112, an outer side wall 114 and a pair of end
walls 115. Each end wall 115 includes an intermediate portion 116 offset
inwardly into the hollow interior region of the block and connected by a
pair of longitudinal legs 118 to the main portion of the end wall. Offset
portion 116 and legs 118 define a vertical recess 122 in each end wall
which is identical in configuration to recess 36 of full construction
block 20. A longitudinal central web 124, which is preferably reduced in
thickness relative to side walls 112 and 114, connects central offset
portions 118 of the end walls. Longitudinal web 124 divides the hollow
interior of half block 110 into two identical insulating spaces or
cavities 126, each having a pair of narrow extensions at its opposite ends
in the spaces between legs 116 and side walls 112 and 114.
Corner block 130 includes an inner side wall 132, an outer side wall 134
and an end wall 136 having a flat exterior face to be located at the
corner of a masonry wall. An opposite end wall 138 includes an
intermediate portion 140 offset inwardly into the hollow interior of the
block and connected by a pair of longitudinal legs 142 and 144 to the main
portion of the end wall. Offset portion 140 and longitudinal legs 142 and
144 provide a vertical recess 145 on the exterior of end wall 138 which is
identical in configuration to recess 36 of full construction block 20. A
longitudinal central web 146 extending between central offset portion 140
and end wall 136 divides the hollow interior of corner block 130 into a
pair of longitudinal insulating spaces 148 and 150 for receiving
insulating material.
To allow corner block 130 to perpendicularly abut an adjacent block, e.g.,
full block 20, a portion 152 of side wall 132 is offset inwardly into
insulating space 148 and connected by a pair of laterally extending legs
154 and 156 to the main portion of the side wall. Offset portion 152 and
lateral legs 154 and 156 provide a vertical recess 158 on the exterior of
side wall 132 which is identical in configuration to recess 36 of full
construction block 20. In an alternative form of corner block 130 (not
shown), a portion of opposite side wall 134 is offset inwardly to provide
an exterior vertical recess, while side wall 132 is straight to allow the
corner to be formed on the opposite side of the block.
Although it is possible to fill the various insulating spaces within and
between the blocks with loose insulation, a preferred form of the
invention utilizes rigid panels or inserts of insulating material, e.g.,
polystyrene or polyurethane, to provide the desired insulation. Referring
to FIG. 4, an insulating insert, generally 160, adapted for insertion into
longitudinal insulating spaces 68 and 70 of full construction block 20
(FIGS. 1 and 2) includes a wide central portion 162 to be located adjacent
to longitudinal web 66. Insert 160 also includes a pair of narrow
extensions 164 at its opposite ends suitably shaped to be received in the
spaces between the inside edges of longitudinal legs 32 and 42 and side
wall 22 and, similarly, in the spaces between the inside edges of
longitudinal legs 34 and 44 and outer side wall 24.
As shown in FIG. 3, each insulating insert 160 is slightly greater in
height than vertical side walls 22 and 24 of the construction block. For
example, the block may be 75/8 inches in height while the insulating
inserts are each eight inches (8") high. The extra height of insulating
insert 160 allows each insert to extend into the horizontal mortar joint
below the bottom of construction block 20 to provide insulation in the
mortar joint. Alternatively, the insulating insert may extend above the
top of the block to provide insulation in the mortar joint above the
block.
Referring to FIGS. 5 and 6, a pair of insulating inserts 170 and 180 is
provided to fill insulating spaces 148 and 150 (FIG. 2), respectively, of
corner block 130. Insulating insert 170 (FIG. 5) includes a wide elongated
portion 172 adapted to be located adjacent to central web 146 to fill the
space between offset portion 140 and lateral leg 154. The insert also
includes a narrow extension 174 adapted to fill the space between the
inside edge of longitudinal leg 142 and inner side wall 132. The narrow
space between the inner edge of offset portion 152 and central web 146 and
the space between lateral leg 156 and end wall 136 may be left empty or,
if desired, filled with insulating material. Insulating insert 180 (FIG.
6) is longer than insert 170 to fill insulating space 150 located between
central web 146 and outer side wall 134. In addition, insert 180 includes
a narrow extension 184 shaped to fill the space between the inside edge of
longitudinal leg 144 and outer side wall 134.
As shown in FIG. 7, an insulating insert 190 is adapted to fill each cavity
106 within half jamb block 90 (FIG. 2). Insert 190 includes a wide
rectangular portion 192 adapted to fill the space between central web 96
and side walls 92 and 94. The insert also includes a narrow extension 194
adapted to fill each space between longitudinal legs 102 and 104 and the
side walls. In the case of a full jamb block, a pair of elongated
insulating inserts identical to insert 180 (FIG. 6) is employed.
Referring to FIG. 8, an insulating insert 200 is provided for insertion
into each cavity 126 within half block 110 (FIG. 2). Insulating insert 200
includes a widened central portion 202 adapted to fill the space between
central web 124 and side walls 112 and 114. The insert also includes a
pair of narrow extensions 204 adapted to fill the spaces between
longitudinal legs 118 and the side walls.
Each of the insulating inserts (FIGS. 5-8) provided for insertion into the
interior spaces of the corner block, jamb block and half block, line
inserts 160 (FIGS. 3 and 4) for the full construction block, is slightly
greater in height than the walls of the block. The extra height of the
insulating inserts allows each insert to project above or below the block
to provide insulation in the horizontal mortar joint between successive
rows of blocks. If desired, the insulating inserts may be tapered to
compensate for the tapered thickness of the side and end walls and the
longitudinal web of the construction blocks. Otherwise, the inserts may be
uniform in thickness and forced downward into the various insulating
spaces in the blocks.
The invention also contemplates an insert of insulating material adapted
for insertion into the insulating space formed by the recesses of adjacent
blocks to provide insulation in the vertical mortar joint between the
blocks. As shown in FIG. 9, an insulating insert 210, which is generally
rectangular in configuration, includes a pair of opposed rectangular ends
212 and a pair of enlarged center portions 214 formed on opposite sides of
the insert. Each rectangular portion 212 of the insert is adapted to be
received within the inner rectangular portion of recess 36 of full
construction block 20 (FIGS. 1 and 2). Each enlarged center portion 214
includes a pair of outwardly tapered walls 216 (FIG. 9) adapted to fill
the outer enlarged portion of recess 36 (FIG. 2) defined by flared edges
48 and 50.
As shown in FIG. 2, since recess 36 is identical in size and configuration
to recess 46 of full block 20 and the other recesses provided in the jamb
block, half block and corner block, one insulating insert 210 may be
inserted in the space provided by the recesses at each mortar joint to
provide insulation between each adjacent pair of blocks. For example, at
the mortar joint between full block 20 and half jamb block 90, rectangular
portions 212 of insulating insert 210 overlap extensions 164 of insert 160
and extensions 194 of insulating insert 190 to minimize thermal conduction
through the end walls of the block. In addition, enlarged center portions
214 of insulating insert 210 provide an increased amount of insulation in
the mortar joint itself to minimize thermal conductivity through the
mortar joint. Furthermore, insulating insert 210 is slightly greater in
height than the end walls of the blocks to allow the insert to extend into
the horizontal mortar joint above or below the blocks.
An alternative embodiment (FIGS. 10 and 11) provides a configuration
particularly suitable for four inch and six inch construction blocks
typically employed to construct a backup masonry wall for a brick face.
However, it is also possible to employ the same configuration in larger
eight inch and twelve inch construction blocks.
Referring to FIG. 10, an alternative embodiment of the insulated
construction block, generally 220, includes a pair of spaced vertical side
walls 222 and 224 which provide an inner side wall and an outer side wall,
respectively, of the block and a pair of end walls 226 and 228 connected
to opposite ends of the vertical side walls. Side walls 222 and 224 and
end walls 226 and 228 define a hollow interior region within the block for
receiving insulating material.
As shown in FIGS. 10 and 11, end wall 226 of the construction block
includes an intermediate portion 230 offset inwardly into the hollow
interior region. Offset portion 230 is centrally located on end wall 226
and connected by a pair of longitudinally extending legs 232 and 234 to
the main portion of the end wall. Offset portion 230 and longitudinal legs
232 and 234 provide a vertical recess 236 on the exterior of end wall 226
for receiving insulating material. Similarly, end wall 228 includes an
intermediate portion 240 offset inwardly into the hollow interior region
and connected by a pair of longitudinal legs 242 and 244 to the main
portion of the end wall. Offset portion 240 and longitudinal legs 242 and
244 provide a vertical recess 246 on the exterior of end wall 228 for
receiving insulating material.
In accordance with a preferred feature of the present invention, each
recess has an enlarged portion adjacent to the exterior of its end wall to
increase the amount of insulating material received therein. Referring to
FIGS. 10 and 11, recess 236 includes an outer enlarged portion provided by
outwardly flared surfaces 248 and 250 formed at the outer ends of
longitudinal legs 232 and 234, respectively. The recess also includes an
inner rectangular portion defined by outside vertical edges 252 and 254 of
legs 232 and 234, respectively, and the outside vertical edge of offset
portion 230 of end wall 226. Similarly, recess 246 includes an outer
enlarged portion defined by outwardly flared surfaces 258 and 260 formed
at the outer ends of longitudinal legs 242 and 244, respectively, and an
inner rectangular portion defined by outside vertical edges 262 and 264 of
legs 242 and 244, respectively, and the outside vertical edge of offset
portion 240 of end wall 228. Recesses 236 and 246 are identical. The outer
flared portion of each recess reduces the weight of block 220.
In the alternative embodiment of FIGS. 10 and 11, a connecting web,
generally 270, extends transversely between inner side wall 222 and outer
side wall 224. Transverse connecting web 270 includes a first transverse
portion 272 extending inwardly from inner side wall 222 and a second
transverse portion 274 extending inwardly from outer side wall 224 at a
position spaced longitudinally from first transverse portion 272. The
connecting web includes a third longitudinal portion 276 connecting first
and second transverse portions 272 and 274, respectively.
Transverse connecting web 270 is located at a central position within
construction block 220 to divide its hollow interior region into two
insulating spaces 278 and 280 which are substantially identical in
configuration. Insulating space 278 includes a pair of longitudinal
extensions 282 and 284 located in the spaces between the inside edges of
legs 232 and 234 and side walls 222 and 224, respectively (FIG. 11).
Similarly, insulating space 280 includes a pair of longitudinal extensions
286 and 288 formed in the spaces between the inside edges of legs 242 and
244 and side walls 222 and 224, respectively. Transverse web 270 also
serves to strengthen the side walls and enhance the rigidity of the block.
Preferably, the block walls and transverse web are vertically tapered to
enhance its load bearing strength.
As shown in FIGS. 10 and 11, offset portion 230 of end wall 226 extends
sufficiently inward into the hollow interior region of block 220 to allow
the inner portion of recess 236 to overlap extensions 282 and 284 of
interior insulating space 278. As a result, there is no direct path for
thermal conduction between inner side wall 222 and outer side wall 224.
Any heat conducted through end wall 226 must travel along the extended
path provided by offset portion 230 and longitudinal legs 232 and 234. The
same configuration exists at opposite end wall 228 where any heat
conduction through the end wall must follow the path provided by offset
portion 240 and longitudinal legs 242 and 244. Consequently, thermal
conduction through end walls 226 and 228 is minimized.
Construction block 220 includes a pair of vertical notches 290 and 292
(FIG. 10) formed adjacent to the opposite outer edges of end wall 226.
Similar vertical notches 294 and 296 (FIG. 11) are formed adjacent to the
opposite outer edges of end wall 228. As shown in FIG. 11, when a row of
blocks 220 is assembled by a set of mortar joints 298 in a masonry wall,
these vertical notches are filled with mortar to securely hold the blocks
together.
Referring to FIG. 15, it is also contemplated that the alternative
structure exemplified by full construction block 220 may also be embodied
in a corner block 300. The corner block includes an inner side wall 302,
an outer side wall 304 and an end wall 306 having a flat exterior face to
be located at the corner of a masonry wall. An opposite end wall 308
includes an intermediate portion 310 offset inwardly into the hollow
interior of the block and connected by a pair of longitudinal legs 312 to
the main portion of the end wall. Offset portion 310 and longitudinal legs
312 provide a vertical recess 314 on the exterior of end wall 308 which is
identical in configuration to recess 236 of full construction block 220.
A connecting web, generally 320, extends transversely between inner side
wall 302 and outer side wall 304. Transverse connecting web 320 includes a
first transverse portion 322 extending inwardly from inner side wall 302
and a second transverse portion 324 extending inwardly from outer side
wall 304 at a position spaced longitudinally from first transverse portion
322. A third longitudinal portion 326 connects first and second transverse
portions 322 and 324, respectively. The transverse connecting web is
centrally located to divide the hollow interior of corner block 300 into
two insulating spaces 328 and 330 for receiving insulating material. The
connecting web also serves to strengthen the side walls and enhance the
rigidity of the block.
To allow corner block 300 to perpendicularly abut an adjacent block, e.g.,
a full block 220', a portion 332 of side wall 302 is offset inwardly into
insulating space 330 and connected by a pair of laterally extending legs
334 and 336 to the main portion of the side wall. Offset portion 332 and
lateral legs 334 and 336 provide a vertical recess 338 on the exterior of
side wall 302 which is identical in configuration to recess 236 of full
construction block 220. In an alternative form of corner block 300 (not
shown), a portion of opposite side wall 304 is offset inwardly to provide
an exterior vertical recess, while side wall 302 is straight to allow the
corner to be formed on the opposite side of the block.
Although the various insulating spaces within and between the blocks may be
filled with loose insulation, it is preferable to utilize rigid panels or
inserts of insulating material, e.g., polystyrene or polyurethane, to
provide the desired insulation. Referring to FIG. 13, an insulating
insert, generally 340, is provided with a suitable exterior shape for
insertion into interior insulating spaces 278 and 280 (FIGS. 10 and 11) of
full construction block 220. The insulating insert 340 includes an
indentation 342 on an end face of the insert which provides a pair of
narrow extensions 344 suitably shaped to be received in the spaces between
the inside edges of longitudinal legs 232 and 234 and side walls 222 and
244, respectively. Since interior insulating spaces 278 and 280 are
identical, extensions 344 and also adapted to fill the spaces between the
inside edges of longitudinal legs 242 and 244 and the side walls. In
addition, insulating insert 340 includes an extended portion 346 at its
opposite end face to conform to the shape of transverse connecting web
270.
As shown in FIG. 12, each insulating insert 340 is slightly greater in
height than vertical side walls 222 and 224 of the construction block. The
extra height of insulating insert 340 allows each insert to extend into
the horizontal mortar joint below construction block 220 to provide
insulation in the mortar joint. Alternatively, the insulating insert may
extend above the top of the block to provide insulation in the mortar
joint above the block.
Referring to FIG. 16, an insulating insert 350 is provided to fill interior
insulating space 330 (FIG. 15) of corner block 300. Insulating insert
includes an indentation 352 on a side face of the insert which provides a
first, narrow extension 354 suitably shaped to fill the space between the
inside edge of lateral leg 334 and end wall 306 of corner block 300. A
second, enlarged extension 356 is also provided to fill the space between
lateral leg 336 and transverse portion 322 of connecting web 320.
Insulating insert 350 is also slightly greater in height than the side and
end walls of corner block 300 to allow a portion of the insert to project
above or below the block.
The alternative embodiment also includes an insert of insulating material
adapted for insertion into the insulating space formed by the recesses of
adjacent blocks to provide insulation in the vertical mortar joint between
the blocks. Referring to FIG. 14, an insulation insert, generally 360, is
provided for insertion into the various insulating spaces between adjacent
blocks in the masonry wall. Insulating insert 360 is generally rectangular
in configuration and includes a pair of opposed rectangular ends 362
suitably shaped to conform to the inner rectangular portions of recesses
236 and 246 in full construction block 220 and to the inner rectangular
portions of recesses 314 and 338 of corner block 300. The insulating
insert also includes a pair of enlarged center portions 364 formed on its
opposite sides. Each extension 364 includes a pair of outwardly tapered
walls 366 adapted to fill the outer enlarged portion of recess 236 (FIG.
11) defined by flared edges 248 and 250.
As shown in FIGS. 11 and 15, with the insulating inserts assembled in the
masonry wall, rectangular portion 362 of insert 360 overlaps extensions
344 of insert 340 to prevent any direct thermal conduction through the end
walls of the blocks. In addition, enlarged center portions 364 of insert
360 are located in the vertical mortar joint to provide maximum insulation
in the mortar joint itself. Moreover, extensions 346 of insulating inserts
340 overlap adjacent to longitudinal portion 276 of connecting web 270 to
reduce thermal conduction through the center of the blocks. Consequently,
each construction block is thoroughly insulated against thermal conduction
through the concrete material of the block and through the mortar joints
between adjacent blocks.
Referring to FIG. 17, another alternative embodiment of the insulated
construction block, generally 420, provides a configuration especially
suitable for use in connection with narrow four inch concrete blocks.
Construction block 420 includes a pair of spaced vertical side walls 422
and a pair of end walls 424 connected to opposite ends of the vertical
side walls. Side walls 422 and end walls 42 | | |
