Composite Concrete Masonry Unit and Method
A composite concrete masonry unit having first and second block members separated from one another and interlocked to one another by an insulating body. The first block and a first block interior side and the second block has a second block interior side that are spaced apart from one another as substantially the same distance by the insulating portion such that there is no easy path for heat transfer through the composite concrete masonry unit. The composite concrete masonry unit is designed to minimize thermal transmittance coincidental to maximizing structural integrity when assembled into a wall.
This application claims priority to U.S. provisional patent application Ser. No. 60/857,304 filed Nov. 7, 2006 to Schmid, for a composite concrete masonry unit, the contents of which are hereby incorporated by reference.
BACKGROUNDThis 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. Pat. No. 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.
SUMMARYThe 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 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 FIGURESA 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:
As shown in
As shown in
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
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 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
Reference is now made to
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
The first block interior side 23 includes surface portions 29 that meet with one another and includes, moving from left to right in
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 51a. 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
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
As shown in
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
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 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
The composite concrete masonry units 20 are laid in an row adjacent to one another, as shown in
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. 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.
Claims
1. A composite concrete masonry unit comprising:
- a first block member having a opposed first and second load support sides with a first block member interior side that meets with the first load support side at a peripheral edge;
- a second block member having opposed first and second load support sides with a second block member interior side that meets with the first load support side at a peripheral edge;
- an insulating body positioned between the first block member interior side and the second block member interior side to interlock the first and second block members; and
- wherein the peripheral edge of the first block member and the peripheral edge of the second block member are spaced a distance from one another such that no portion of the first block member is significantly closer to the second block member such thermal transmittance through the composite concrete masonry unit is minimized.
2. A composite concrete masonry unit according claim 1 wherein the first block member has first edge portion and the second block member has a facing second edge portion that are spaced from one another by the distance, and the first block member has a third edge portion and the second block member has a facing fourth edge portion that are spaced apart from one another by the distance in order to not increase heat transfer.
3. The composite concrete masonry unit according to claim 2 wherein the first block member has a fifth edge portion and the second block member has a facing sixth edge portion that are spaced apart from one another by the distance in order to not increase heat transfer.
4. The composite concrete masonry unit according to claim 3 wherein the first block member has a seventh edge portion and the second block member has a facing eighth edge portion that are spaced apart from one other by the distance in order to not increase heat transfer.
5. The composite concrete masonry unit according to claim 4 wherein the first block member has a ninth edge portion and the second block member has a facing tenth edge portion that are spaced apart from one another by the distance in order to not increase heat transfer.
6. A composite concrete masonry unit according claim 2 wherein the first block member has a eleventh edge portion and the second block member has a facing twelfth edge portion that are spaced apart from one another by a second distance, the first block member has a thirteenth edge portion and the second block member has a facing fourteenth edge portion that are spaced apart from one another by the second distance in order to not increase heat transfer through the composite concrete masonry unit and wherein the second distance is less than the first distance.
7. The composite concrete masonry unit according to claim 6 wherein the first block member has a fifteenth edge portion and the second block member a facing sixteenth edge portion that are spaced apart from one another by the second distance in order to not increase heat transfer.
8. The composite concrete masonry unit according to claim 7 wherein the first block member has a seventeenth edge portion and the facing second block member has a eighteenth edge portion that are spaced apart from one other by the second distance in order to not increase heat transfer.
9. The composite concrete masonry unit according to claim 8 wherein the first block member has a nineteenth edge portion and the second block member has a facing twentieth edge portion that are spaced apart from one another by the second distance in order to not increase heat transfer.
10. The composite concrete masonry unit according to claim 1 wherein the insulating body has a serpentine shape.
11. The composite concrete masonry unit according to claim 1 wherein first block member interior side faces the second block member interior side and no portion of the first block member interior side is significantly closer to the second block member interior side such thermal transmittance through the composite concrete masonry unit is minimized.
12. A unit comprising:
- a first block member having a opposed first and second load support sides with an first block member interior side that meets with the first load support side at a peripheral edge;
- a second block member having opposed first and second load support sides with an second block member interior side that meets with the first load support side at a peripheral edge;
- an insulating body positioned between the first block member and the second block member interior sides to interlock the first and second block members;
- a protrusion extending from the first block interior side and protrusion halves extending from the second block member interior side and wherein the insulating body has protrusion recesses for receiving the protrusion and protrusion halves in order to interlock the first and second block members; and
- and wherein the peripheral edge of the first block member and the peripheral edge of the second block member are spaced from one another such that no portion of the first block member is significantly closer to the second block member such that thermal transmittance through the composite concrete masonry unit is minimized.
13. The unit according to claim 12 wherein the first and second block members are tapered.
14. The unit according to claim 12 wherein the first block member has first edge portion and the second block member has a facing second edge portion that are spaced from one another by the distance, and the first block member has a third edge portion and the second block member has a facing fourth edge portion that are spaced apart from one another by the distance in order to not increase heat transfer.
15. The unit according to claim 14 wherein the first block member has a fifth edge portion and the second block member has a facing sixth edge portion that are spaced apart from one another by the distance in order to not increase heat transfer.
16. The composite concrete masonry unite according to claim 12 wherein first block member interior side faces the second block member interior side and no portion of the first block member interior side is significantly closer to the second block member interior side such thermal transmittance through the composite concrete masonry unit is minimized.
17. A method of making a composite concrete masonry unit comprising:
- providing a first block member having a opposed first and second load support sides with an first block member interior side that meets with the first load support side at a peripheral edge;
- providing a second block member having opposed first and second load support sides with an second block member interior side that meets with the first load support side at a peripheral edge;
- providing an insulating body and positioning the insulating body between the first block member and the second block member and interlocking the first and second block members;
- providing a protrusion extending from the first block interior side and providing protrusion halves extending from the second block member interior side and providing the insulating body with protrusion recesses for receiving the protrusion and protrusion halves in order to interlock the first and second block members; and
- spacing the peripheral edge of the first block member and the peripheral edge of the second block member apart from one another such that no portion of the first block member interior side is significantly closer to the second block member interior side such that thermal transmittance through the composite concrete masonry unit is minimized.
Type: Application
Filed: Nov 7, 2007
Publication Date: May 8, 2008
Inventor: Donald Schmid (Clarence, NY)
Application Number: 11/936,191
International Classification: E04B 1/74 (20060101);