GB2088923A - Insulated constructional block - Google Patents
Insulated constructional block Download PDFInfo
- Publication number
- GB2088923A GB2088923A GB8039389A GB8039389A GB2088923A GB 2088923 A GB2088923 A GB 2088923A GB 8039389 A GB8039389 A GB 8039389A GB 8039389 A GB8039389 A GB 8039389A GB 2088923 A GB2088923 A GB 2088923A
- Authority
- GB
- United Kingdom
- Prior art keywords
- block
- insulating material
- layer
- grooves
- concrete
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000011810 insulating material Substances 0.000 claims abstract description 51
- 210000002105 tongue Anatomy 0.000 claims abstract description 21
- 239000004793 Polystyrene Substances 0.000 claims abstract description 15
- 229920002223 polystyrene Polymers 0.000 claims abstract description 15
- 239000000463 material Substances 0.000 claims abstract description 13
- 239000004033 plastic Substances 0.000 claims abstract description 7
- 229920003023 plastic Polymers 0.000 claims abstract description 7
- 230000015572 biosynthetic process Effects 0.000 claims description 8
- 238000005755 formation reaction Methods 0.000 claims description 8
- 238000000034 method Methods 0.000 claims description 8
- 238000001125 extrusion Methods 0.000 claims description 5
- 238000005266 casting Methods 0.000 claims description 4
- 230000004888 barrier function Effects 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 239000000853 adhesive Substances 0.000 claims description 2
- 230000001070 adhesive effect Effects 0.000 claims description 2
- 230000000295 complement effect Effects 0.000 claims description 2
- 239000011159 matrix material Substances 0.000 claims description 2
- 238000009413 insulation Methods 0.000 description 5
- 239000004570 mortar (masonry) Substances 0.000 description 3
- 239000011449 brick Substances 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000012774 insulation material Substances 0.000 description 2
- 229920006328 Styrofoam Polymers 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000008261 styrofoam Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C1/00—Building elements of block or other shape for the construction of parts of buildings
- E04C1/40—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts
- E04C1/41—Building elements of block or other shape for the construction of parts of buildings built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts composed of insulating material and load-bearing concrete, stone or stone-like material
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Acoustics & Sound (AREA)
- Electromagnetism (AREA)
- Building Environments (AREA)
Abstract
The invention relates to a constructional block comprising a generally parallelepiped concrete body 10 with a layer of insulating material 12 attached to one of the oblong major faces of the body 10. The insulating material, which covers the whole of the face, may comprise a synthetic plastics material for example polystyrene. A rectangular opening 14 may extend longitudinally through the concrete body 10. The juxtaposed surfaces of the concrete body 10 and the polystyrene layer 12 may be interlocked mechanically by means of dovetail section tongues and grooves 16, 18 extending parallel to each other through the entire length of the block. <IMAGE>
Description
SPECIFICATION
Improvements in or relating to constructional blocks
This invention relates to constructional blocks and is applicable especially, but not exclusively to building blocks for cavity wall constructions.
Heat loss through cavity walls often is reduced by installing insulating material in the cavity. In existing structures this is usually achieved by injecting foam into the cavity through holes drilled in one of the walls. In new structures, however, it is preferable to install the insulation during erection of the wall. In one known method, this involves assembling several building blocks to form part of the cavity wall and then lowering a sheet of insulating material into the cavity. The sheet is then attached to the interior surface of one of the walls. Typically the width of the sheet will be an exact multiple of the width of each block. Then the sheet will fit between the usual wire ties which are inserted into the mortar joints, and extend across the cavity to hold the walls together. Spring-loaded collars on the ties then press the sheet into contact with one of the walls.
Difficulties arise with this method because the joints between the sheets of insulation material must register with joints between the blocks, the spacing of which is not always consistent, and if the ties are wrongly inserted or omitted the insulation material can sag away from the wall.
Also the additional time taken to insert the sheet of insulation increases building costs enormously.
An object of the present invention is to mitigate or eliminate one or more of the aforesaid problems.
According to the present invention a constructional block comprises a generally parallelepiped body of concrete or like structural or load bearing material, and a layer of insulating material attached to at least one face thereof.
The insulating material, for example a synthetic plastics material such as polystyrene, may be bonded to the face of the body by a suitable adhesive. However, in preferred embodiments the layer of insulating material additionally or alternatively is attached by mechanical interengagement of juxtaposed suffaces of the layer and the face of the body, respectively.
Suitable mechanical interengagement may be provided by tongue formations of one of the juxtaposed surfaces engaging in grooves or recesses in the other.
Conveniently the tongues and grooves or slots are undercut, for example in the manner of a full or half dovetail joint, to give interlocking of the layer and the body.
Preferably the tongues and grooves extend across the whole length or width of the layer of insulating material allowing the material to be formed as a continuous strip, for example by extrusion. The grooves could then be formed during extrusion, although it is envisaged that grooves, even of dovetail section, could be cut into a flat slab or strip of the insulating material especially if made of polystyrene or similar synthetic plastics.
Advantageously, the interlocking formations are provided at least at the middle of the blocks and preferably distributed across its entire width, conveniently as a plurality of parallel grooves.
Such an arrangement, providing distributed attachment of the layer to the body of concrete, reduces the risk of their separation when the block is cut, for example halved or quartered, as is commonly necessary during use.
The layer of insulating material may be slightly larger in area than the concrete to ensure that, when installed in the wall, a substantially continuous insulating barrier is formed by abutting edges of the insulating material layers of adjacent blocks.
According to a second aspect of the invention a method of making a constructional block according to the first aspect includes the step of casting a generally parallelepiped body of concrete or like structural material onto a layer of insulating material such that when the concrete or like material sets the layer of insulating material is attached to one face of the body.
Preferably the insulating material forms one wall of a mould into which the concrete is admitted to form the body. The surface of the insulating material presented to the interior of the mould may have formations, for example tongues or grooves, serving to mould in the concrete complementary formations which, when the concrete sets, cooperate with the tongues or grooves to secure the insulating material to the block.
Preferably the insulating material has continuous grooves, conveniently of half or full dovetail section, extending across one surface.
In one embodiment the concrete blocks are cast onto a continuous strip of the insulating material which is then severed from the rest of the strip when the concrete has set. Alternatively pieces of insulating material corresponding in size to a finished block may be located in separate moulds, perhaps in the form of a matrix.
Embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings in which: Figure 1 is a perspective view of a constructional block according to one embodiment of the invention,
Figure 2 is a partial section through the insulating layer of the block of Figure 1; and
Figure 3 is a partial sectional view through a cavity wall showing the block installed.
Figures 4, 5 and 6 are the views corresponding to Figures 1, 2 and 3 but of a second embodiment.
Figures 7 and 8 are views corresponding to
Figure 1 and 3 but of a third embodiment of the invention; and Figure 9 shows two blocks secured together for transportation purposes.
Referring first to Figures 1, 2 and 3, a constructional block comprises a generally parallelepiped concrete body 10 with a layer of insulating material 12 attached to one of the oblong major faces of the body 1 0. The insulating material, which covers the whole of the face, may comprise a synthetic plastics material for example polystyrene, as marketed under the trade name "Styrofoam" (Registered Trade Mark). A rectangular opening 14 extends longitudinally through the concrete body 10. The juxtaposed surfaces of the concrete body 10 and the polystyrene layer 12 are interlocked mechanically by means of dovetail section tongues and grooves 16, 18 extending parallel to each other, throughout the entire length of the block.
Figure 3 shows a section through a cavity wall comprising bricks 20, forming an outer layer of the cavity wall, and a plurality of the constructional blocks 10 assembled to form the inner leaf of the cavity wall. As seen from Figure 3, the insulated layers 1 2 of polystyrene are presented to the cavity 21, thus forming a substantially continuous layer of insulation along one surface of the cavity.
As shown in Figures 1 and Figure 3, each polystyrene layer 12 is exactly the same area as the face of concrete body 10. Consequently the mortar joints 22, typically about 8^t thick, will result in corresponding gaps between adjacent edges of the layers of polystyrene. If preferred, however, the polystyrene could be of slightly larger area than the concrete body of the block so that, when installed, the polystyrene layers abut to provide a substantially continuous barrier.
The constructional block shown in Figure 4 is similar generally to that shown in Figure 1, in that it comprises a concrete parallelepiped body portion 30 insulating layer 32 on one face thereof and a rectangular through opening 34. The layer 32 is again attached to the concrete block by dovetail section tongues and grooves 36, 38.
However, in the block 30, the first tongue 40 of the insulating layer 32 is set inwardly from the edge. Thus, in effect the layer has a groove 42 along the edge adjacent the longitudinal edge of the block whereas, as shown in Figure 2, in the first embodiment the insulating material had a tongue 44 along the corresponding edge. The significance of this modification is that the block shown in Figure 4 should be less susceptible to damage due to handling, since any tendency to separate the longitudinal edges of the insulating material and the block, as indicated by the arrow A in Figure 5, will tend to be resisted by the inclined surface 46 of the first tongue acting against the corresponding side surface (not shown) of the groove in the concrete block. The corresponding movement in the first embodiment might tend to separate the corresponding mating surfaces.
It should be noted that in both embodiments, although the thickness of the insulating material is different at the edges, their insulating properties are proportional to the mean thickness of the insulation, which can thus be the same in both embodiments for the same or equal cross-section of area of the tongues and grooves.
It should be appreciated that the configurations of the blocks may be varied according to their application. For example, the tongues and grooves may be different in number, size or shape, or even replaced by discrete spigots and holes distributed about the corresponding juxtaposed surfaces.The tongues and grooves could extend across the width of the block, as illustrated in Figures 7 and 8 which show an oblong parallelepiped block comprising a concrete body 50 with two rectangular apertures 52 and 54 extending parallel to each other transversely through the body and a layer of insulating material 56 secured to one oblong major face of the block by means of tongues and grooves 58, 60. Such a constructional block is often preferred since, as shown in Figure 8, it allows mortar to penetrate slightly into the through openings 52, 54 to assist bonding. It will be appreciated, of course, that this block may be modified in like manner to those described above.
It is envisaged that the blocks will be dimensioned to enable one-handed installation in normal brick-laying fashion, a specific combination of dimensions being, for example, 440 mm long, 215 mm high and 125 mm thick, including the insulating layer. Naturally the thickness of the concrete body and/or insulating layer can be varied to suit particular insulation requirements.
Figure 9 illustrates a preferred way of transporting pairs of the blocks, by fastening them together with their insulating layers juxtaposed and securing them by a binding strap 62. Such an arrangement protects the edges of the insulating material from damage during general transportation and handling. The binding strap can be readily removed, for example by means of cutting with a trowel, immediately prior to use. A
U-shaped handle 64 having hooked ends is used to engage the binding strap as it crosses the ends of the through apertures 34.
Whilst it is generally intended that the blocks will be used in constructing cavity walls wherein the plastics material is provided at one of the interior surfaces of the cavity, the blocks could be used with the insulating material on the interior wall surface of the cavity wall structure.
It should be noted that the invention is not limited to constructional blocks for building cavity walls, but could be used for any structure wherein it is required to provide insulating material on one surface of a wall. For example, a layer of heatinsulating material, such as ceramic fibres, might be provided in similar manner on the surface of a block of refractory material such as used for lining boilers or furnaces.
Constructional blocks embodying the invention may be made by preforming the insulating material, and then using it as part of a mould in which the concrete block is cast. Thus the insulating layer, having a cross-section as shown in Figure 2 or Figure 5, will be placed with its grooved surface forming one wall of the mould.
When the concrete is poured into the mould the grooves 1 6 in the insulating material will mould corresponding tongues 1 8 in the concrete. When the block has set the insulating material will be bonded mechanically to the concrete by the dovetail joint.
It is envisaged that the grooves will be formed in the insulating material by and during extrusion.
However they could be cut into an otherwise flat strip, for example by means of a hot wire where the insulating material is polystyrene.
The individual block-lengths of the polystyrene may be cut from a continuous extruded strip and be inserted into individual moulds prior to the casting step. Alternatively a continuous strip at least several blocks long, could have several blocks cast side-by-side along its length, to be severed later.
A continuous production line might be provided wherein the insulating material is formed in a continuous strip, and supplied directly to a casting station, where a plurality of the aforesaid blocks are cast onto parts of the strip either before or after severing them from the continuous strip.
It should be appreciated that constructional blocks embodying the present invention can be layed by a bricklayer in much the same way as conventional bricks or blocks. Thus there is no significant increase in labour costs as compared with the initially mentioned methods in which installation of the insulating material constitutes a completely independent operation additional to the actual bricklaying step.
Claims (20)
1. A constructional block comprising a generally parallelepiped body of concrete [or like] structural or load bearing matrial, and a layer of insulating material attached to at least one face thereof.
2. A block as claimed in claim 1 , wherein the layer of insulating material, for example a synthetic plastics material such as polystyrene, is bonded to the face of the body by a suitable adhesive.
3. A block as claimed in claim 1, wherein the layer of insulating material is attached by mechanical interengagement of juxtaposed surfaces of the layer and the face of the body, respectively.
4. A block as claimed in claim 1 or 2, wherein the layer of insulating material is additionally attached by mechanical interengagement of juxtaposed surfaces of the layer and the face of the body, respectively.
5. A block as claimed in claim 3 or 4, wherein suitable mechanical interengagement is provided by tongue formations of one of the juxtaposed surfaces engaging in grooves or recesses in the other.
6. A block as claimed in claim 5, wherein the tongues and grooves or slots are undercut, for example in the manner of a full or half dovetail joint, to give interlocking of the layer and the body
7. A block as claimed in claim 5 or 6, wherein
the tongues and grooves extend across the whole
length or width of the layer of insulating material
allowing the material to be formed as a
continuous strip, for example by extrusion.
8. A block as claimed in claim 7, wherein the
grooves are formed during extrusion.
9. A block as claimed in claim 7, wherein the
grooves are cut into a flat slab or strip of the
insulating material especially if made of
polystyrene or similar synthetic plastics.
10. A block as claimed in claim 8 or 9, wherein
the grooves are of dovetail section.
11. A block as claimed in any one of claims 5 to
10, wherein the interlocking formations are
provided at least at the middle of the block and
distributed across its entire width, conveniently as
a plurality of parallel grooves.
12. A block as claimed in any one of the
preceding claims, wherein the layer of insulating
material is slightly larger in area than the concrete to ensure that, when installed in the wall, a substantially continuous insulating barrier is formed by abutting edges of the insulating material layers of adjacent blocks.
1 3. A constructional block substantially as herein described with reference to and as illustrated in the accompanying drawings.
14. A method of making a constructional block as claimed in any one of claims 1 to 12, including the step of casting a generally parallelepiped body of concrete or like structural material onto a layer of insulating material such that when the concrete or like material sets the layer of insulating material is attached to one face of the body.
1 5. A method as claimed in claim 14, wherein the insulating material forms one wall of a mould into which the concrete is admitted to form the body.
1 6. A method as claimed in claim 15, wherein the surface of the insulating material presented to the interior of the mould has formations, for example tongues or grooves, serving to mould in the concrete complementary formations which, when the concrete sets, cooperate with the tongues or grooves to secure the insulating material to the block.
17. A method as claimed in any one of claims 14 to 16 wherein the insulating material has continuous grooves, conveniently of half or full dovetail section, extending across one surface.
1 8. A method as claimed in claim 14 wherein the concrete blocks are last onto a continuous strip of the insulating material which is then severed from the rest of the strip when the concrete has set.
1 9. A method as claimed in claim 14 wherein pieces of insulating material corresponding in size to a finished block are located in separate moulds, perhaps in the form of a matrix.
20. A method of making a constructional block substantially as herein described with reference to and as illustrated in the accompanying drawings.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8039389A GB2088923A (en) | 1980-12-09 | 1980-12-09 | Insulated constructional block |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8039389A GB2088923A (en) | 1980-12-09 | 1980-12-09 | Insulated constructional block |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| GB2088923A true GB2088923A (en) | 1982-06-16 |
Family
ID=10517851
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8039389A Withdrawn GB2088923A (en) | 1980-12-09 | 1980-12-09 | Insulated constructional block |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2088923A (en) |
Cited By (14)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2584117A1 (en) * | 1985-06-27 | 1987-01-02 | Ind Regionale Batiment | Construction element intended to form a load-bearing wall of a building |
| FR2594158A1 (en) * | 1986-02-07 | 1987-08-14 | Humbert Bernard | Device for fastening insulation elements on building blocks |
| GB2291079A (en) * | 1994-06-23 | 1996-01-17 | Forticrete Ltd | Insulated building blocks |
| EP0708210A1 (en) * | 1994-10-22 | 1996-04-24 | Volker Schmidt | Brick |
| WO2000079068A1 (en) * | 1999-06-22 | 2000-12-28 | Jaime Enrique Jimenez Sanchez | Construction brick formed of an external expanded polystyrene box and a polystyrene-lightened concrete core |
| BE1015331A3 (en) * | 2003-01-28 | 2005-02-01 | Douterloigne Jan Albert | Brick for thermally insulated walls, comprises construction and insulating elements connected together |
| GB2405648A (en) * | 2003-09-05 | 2005-03-09 | Dennis John Partridge | Building block with insulation bonded to it |
| BE1015488A4 (en) * | 2001-09-27 | 2005-05-03 | Riffon Jean | Wall construction method for e.g. building, involves assembling wall blocks with oriented structure, and filling wall blocks with concrete for constituting base brickwork of building |
| WO2008037834A1 (en) * | 2006-09-26 | 2008-04-03 | Castane Callis Jordi | Large-format thermoacoustic stratified tile |
| CN101387149B (en) * | 2007-09-14 | 2010-06-02 | 扬州威奥重工机械有限公司 | Special synchronous core-building apparatus for processing concrete building block with vertical thermal insulation core layer |
| GB2480315A (en) * | 2010-05-14 | 2011-11-16 | Paul John Darrington | Construction element with insulating layer |
| US20160097198A1 (en) * | 2014-08-06 | 2016-04-07 | Gregory C. Walter | Block and Method for Constructing a Decorative Wall |
| EP3031592A1 (en) * | 2014-12-11 | 2016-06-15 | Orac Holding NV | Insulation boards and production thereof |
| WO2018231178A2 (en) | 2017-03-01 | 2018-12-20 | Akin Mermer Tekstil Insaat Makina Enerji Sanayi Ve Ticaret Ltd. Sti. | Apparatus and method for injecting insulation material |
-
1980
- 1980-12-09 GB GB8039389A patent/GB2088923A/en not_active Withdrawn
Cited By (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2584117A1 (en) * | 1985-06-27 | 1987-01-02 | Ind Regionale Batiment | Construction element intended to form a load-bearing wall of a building |
| FR2594158A1 (en) * | 1986-02-07 | 1987-08-14 | Humbert Bernard | Device for fastening insulation elements on building blocks |
| GB2291079A (en) * | 1994-06-23 | 1996-01-17 | Forticrete Ltd | Insulated building blocks |
| GB2291079B (en) * | 1994-06-23 | 1997-09-10 | Forticrete Ltd | Insulated building blocks |
| EP0708210A1 (en) * | 1994-10-22 | 1996-04-24 | Volker Schmidt | Brick |
| WO2000079068A1 (en) * | 1999-06-22 | 2000-12-28 | Jaime Enrique Jimenez Sanchez | Construction brick formed of an external expanded polystyrene box and a polystyrene-lightened concrete core |
| BE1015488A4 (en) * | 2001-09-27 | 2005-05-03 | Riffon Jean | Wall construction method for e.g. building, involves assembling wall blocks with oriented structure, and filling wall blocks with concrete for constituting base brickwork of building |
| BE1015331A3 (en) * | 2003-01-28 | 2005-02-01 | Douterloigne Jan Albert | Brick for thermally insulated walls, comprises construction and insulating elements connected together |
| GB2405648A (en) * | 2003-09-05 | 2005-03-09 | Dennis John Partridge | Building block with insulation bonded to it |
| WO2008037834A1 (en) * | 2006-09-26 | 2008-04-03 | Castane Callis Jordi | Large-format thermoacoustic stratified tile |
| CN101387149B (en) * | 2007-09-14 | 2010-06-02 | 扬州威奥重工机械有限公司 | Special synchronous core-building apparatus for processing concrete building block with vertical thermal insulation core layer |
| GB2480315A (en) * | 2010-05-14 | 2011-11-16 | Paul John Darrington | Construction element with insulating layer |
| US20160097198A1 (en) * | 2014-08-06 | 2016-04-07 | Gregory C. Walter | Block and Method for Constructing a Decorative Wall |
| EP3031592A1 (en) * | 2014-12-11 | 2016-06-15 | Orac Holding NV | Insulation boards and production thereof |
| BE1025811B1 (en) * | 2014-12-11 | 2019-11-18 | Orac Holding Nv | INSULATION PANELS AND THEIR PRODUCTION |
| WO2018231178A2 (en) | 2017-03-01 | 2018-12-20 | Akin Mermer Tekstil Insaat Makina Enerji Sanayi Ve Ticaret Ltd. Sti. | Apparatus and method for injecting insulation material |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |