Insulated masonry block and method for producing same

Abstract

An insulated masonry block which has very high insulating properties, is water resistant, and is light-weight being easier for masons to handle and lay, and a method for producing such an insulated masonry block. Wherein, a pre-formed, high-strength foam core, which is the insulating material, sandwiches and joins two inner walls of the insulated masonry block together. A method for producing such an insulated masonry block comprises: placing a pre-formed insulating foam core in the middle of a standard block form; filling it with concrete, cinder, or any other known building compound aggregate, and allowing it to cure. An end block can be produced using this method with the exception that a shorter length insulating foam core is used allowing for the formation of concrete at one end of the block. Various sizes and shapes of an insulated masonry block can be produced using this method.

1 . An insulated masonry block comprising: 
 a six-sided body, generally rectangular in shape, with a top, bottom, two spaced, parallel, rectangular shaped side walls, and an insulating foam core, sandwiched between said side walls.    
   
   
       2 . said side walls of  claim 1  have inner sides and outer sides.  
   
   
       3 . said insulating foam core of  claim 1  is a pre-formed, six-sided body, generally rectangular in shape with a top, a bottom, two sides with a series of dovetail type shaped tenons and mortises running vertically top to bottom, a center hole running vertically top to bottom, and two ends with half circular shaped cavities running vertically top to bottom.  
   
   
       4 . said center hole of said insulating foam core of  claim 2  can be used for electrical wiring, steel bars for reinforcement, or filled with mortar.  
   
   
       5 . said half circular shaped cavities of said ends of the insulating foam core of  claim 2  are half the diameter of said center hole.  
   
   
       6 . said rectangular shaped side walls of  claim 1  have a series of dovetail shaped tenons and mortises running vertically top to bottom on their inner sides which are formed by inserting the insulating foam core of  claim 1  into a standard concrete block form and allowing concrete, cinder, or any other known building compound aggregate to fill and cure around it.  
   
   
       7 . said tenons and mortises of said insulating foam core sandwiches and interlocks with said tenons and mortises of said inner sides of said side walls of  claim 1   
   
   
       8 . the rectangular shaped side walls of  claim 4  have a uniform thickness.  
   
   
       9 . an end block with an end wall is formed by allowing concrete, cinder, or any other known building compound aggregate to fill and cure around a longitudinally shorter insulating foam core of  claim 1 .  
   
   
       10 . the insulating foam core of  claim 1  may be constructed out of polyeurethane, polystyrene, or any other known insulating foam material.  
   
   
       11 . an insulated masonry block of  claim 1  can be constructed by an alternate method of pressing a pre-formed insulating foam core, which has tennons and mortises on its outer walls, between the inner walls, which have tenons and mortises, of two pre-formed masonry walls.