Insulated block with non-linearthermal paths for building energy efficient buildings

Abstract

According to one aspect of the invention, a block for building construction is provided. The block includes: a molded body formed of an inorganic material, wherein the molded body defines (a) a rectangular-box shape; (b) non-linear thermal paths of the body material across the block by offsetting and restricting the cross webbing of the block; and (c) at least two cavities in the block. According to another aspect, a block for building construction is provided, wherein the block includes: a molded body formed of an inorganic material, wherein the molded body defines (a) a rectangular-box shape; (b) at least two cavities in the block; and wherein the block has nominal dimensions of 6″×6″×24″.

1 . A block for building construction, the block comprising: a molded body formed of an inorganic material, wherein the molded body defines (a) a rectangular-box shape; (b) non-linear thermal paths of the body material across the block by offsetting and restricting the cross webbing of the block; and (c) at least two cavities in the block. 
   
   
       2 . The block according to  claim 1 , wherein the block has nominal dimensions of 6″×6″×24″. 
   
   
       3 . The block according to  claim 1 , wherein the inorganic material is a cement-based mix. 
   
   
       4 . The block according to  claim 1 , wherein the cavities of the block are open to a face of the block, whereby the cavities can be substantially filled with an insulating material to form an insulated concrete block. 
   
   
       5 . The block according to  claim 4 , further comprising an insulating material positioned in the cavities of the block. 
   
   
       6 . The block according to  claim 5 , wherein the insulating material is an insulating foam material. 
   
   
       7 . The block according to  claim 6 , wherein the insulating foam material is in the form of one or more inserts of a size and shape adapted to fit within the cavities of the block or the foam material is spray filled into the cavities of the block. 
   
   
       8 . The block according to  claim 7 , wherein at least one of the insulating foam inserts spans across more than one block, whereby any small gap between two adjacent blocks in a wall are insulated to help insulate the wall of blocks. 
   
   
       9 . The block according to  claim 6 , wherein the insulating foam comprises an insulating material selected from the group consisting of polystyrene and polyurethane. 
   
   
       10 . The block according to  claim 1 , wherein at least one of the cavities of the block allows for rebar to be positioned through the block, whereby, when a plurality of the blocks are stacked to define a wall, at least one rebar can be positioned through adjacent blocks to reinforce the wall of block. 
   
   
       11 . The block according to  claim 10 , wherein at least one rebar can be positioned through adjacent blocks in the wall of the blocks in a vertical orientation and at least one rebar can be positioned through adjacent blocks in the wall of blocks in a horizontal orientation. 
   
   
       12 . The block according to  claim 1 , wherein at least one of the cavities thereof allows electrical conduit to be positioned through the block, whereby, when a plurality of blocks are stacked to define a wall, at least one electrical conduit can be positioned through adjacent blocks for servicing an electrical junction box or outlet positioned in a cut-out made in a face of the block. 
   
   
       13 . The block according to  claim 1 , further comprising a pre-finish on at least one of the faces of the block. 
   
   
       14 . The block according to  claim 1 , further comprising a pre-insulated foam material in the cavities of the block. 
   
   
       15 . The block according to  claim 14 , wherein the cross webbing of the block is restricted to about one-half of the dimension of one of the shorter nominal dimensions of the block. 
   
   
       16 . The block according to  claim 1 , further comprising a vertical sealant groove in a middle rib of the head of the block. 
   
   
       17 . The block according to  claim 16 , wherein the vertical sealant groove in a middle rib of the head of the block is V-shaped. 
   
   
       18 . The block according to  claim 1 , further comprising a horizontal sealant groove in the top of a middle rib of the block. 
   
   
       19 . The block according to  claim 18 , wherein the horizontal sealant groove in the top of a middle rib of the block is V-shaped. 
   
   
       20 . The block according to  claim 1 , further comprising a vertical ground-screw clearance groove in a middle portion of a middle rib of the block to provide clearance for an electrical ground screw in the back side of an electrical outlet box positioned in the block. 
   
   
       21 . A mold for manufacturing a block,
 wherein the block comprises: a molded body formed of an inorganic material, wherein the molded body defines (a) a rectangular-box shape; (b) non-linear thermal paths of the body material across the block by offsetting and restricting the cross webbing of the block; and (c) at least two cavities in the block; and   wherein the mold comprises:   (a) a mold box adapted for receiving and molding an inorganic material on a manufacturing pallet into the form of at least one of the block; and   (b) a plunger head adapted for compacting and vibrating the inorganic material in the mold box, and after the inorganic material is sufficiently set, pushing the molded inorganic material through the bottom of the mold box as the mold box is raised off the manufacturing pallet.   
   
   
       22 . The mold according to  claim 21 , wherein the block has overall dimensions of about 6″×6″×24″ whereby three (3) blocks can be simultaneously molded on a typical manufacturing pallet that is 26″×18″. 
   
   
       23 . The mold according to  claim 21 , wherein the mold box does not have core bars across the top, whereby the block can be molded in the mold box sideways to the direction of normal raking across the top of the mold box without interference by any core bars. 
   
   
       24 . A wall system for a building construction comprising a plurality of blocks, wherein each of the blocks comprises: a molded body formed of an inorganic material, wherein the molded body defines (a) a rectangular-box shape; (b) non-linear thermal paths of the body material across the block by offsetting and restricting the cross webbing of the block; and (c) at least two cavities in the block. 
   
   
       25 . The wall system according to  claim 24 , wherein the blocks have nominal dimensions of about 6″×6″×24″. 
   
   
       26 . A building comprising a plurality of walls wherein at least one of the walls comprises a plurality of blocks, and wherein each of the blocks comprises: a molded body formed of an inorganic material, wherein the molded body defines (a) a rectangular-box shape; (b) non-linear thermal paths of the body material across the block by offsetting and restricting the cross webbing of the block; and (e) at least two cavities in the block. 
   
   
       27 . The building according to  claim 26 , wherein the block has nominal dimensions of about 6″×6″×24″, whereby three (3) blocks can be simultaneously molded on a typical molding pallet that is 26″×18″. 
   
   
       28 . A block for building construction, the block comprising: a molded body formed of an inorganic material, wherein the molded body defines (a) a rectangular-box shape; (b) at least two cavities in the block; and wherein the block has nominal dimensions of 6″×6″×24″.