[0001] This application claims priority and the benefit thereof from U.S. Provisional Application No. 61/162,019, filed on March 20, 2009 and entitled SOLAR/STUD BLOCK, the entirety of which is herein incorporated by reference. This application also claims priority and the benefit from U.S. Provisional Application No. 61/172,931, filed on April 27, 2009 and entitled STUD BLOCK, the entirety of which is also herein incorporated by reference.

FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to a novel wall structure that provides unique, green, sustainable, and energy efficient benefits to residential, institutional and/or commercial structures. More particularly, the disclosure relates to novel structural elements, which may be configured to provide residential, institutional and/or commercial structures.

BACKGROUND OF THE DISCLOSURE

[0003] Concrete blocks are commonly used in building structures, including residential, institutional and commercial structures. In the U.S., concrete block are typically 8" x 8" x 16" in size, but other sizes are common. Concrete blocks are frequently used in exterior, as well as interior building walls. When reinforced with concrete columns and tie beams, concrete blocks may be used in load-bearing walls of building structures. Many types of concrete blocks are manufactured with hollow centers to reduce weight or improve insulation. [0004] The disclosure provides a novel wall structure, including novel structural elements, that provides unique, green, sustainable, and energy efficient benefits to residential, institutional and/or commercial structures.

SUMMARY OF THE DISCLOSURE

[0005] According to an aspect of the disclosure, a block is provided for use in a wall structure. The block comprises: a first block side which is configured to form a section of one side of the wall structure; a second block side which is configured to form a section of an opposite side of the wall structure; a plurality of ribs which are configured to receive a rib insert or a block corner insulation; and a stud component which is configured to accept a finishing material, wherein the stud component includes a recess portion. The block may further comprise a self-aligning core.

[0006] According to a further aspect of the disclosure, a block system is provided for use in a wall structure. The block system comprises: a first block side which is configured to form a section of one side of the wall structure; a second block side which is configured to form a section of an opposite side of the wall structure; a plurality of ribs which are configured to receive a rib insert or a block corner insulation; a stud component which is configured to accept a finishing material; and the rib insert or the block corner insulation, wherein the stud component includes a recess portion. The block may further comprise a self-aligning core. The rib insert may comprise an insert member. The rib insert may comprise a tongue that is configured to engage a groove in another rib insert, or a groove that is configured to engage a tongue in another rib insert. The block corner insulation may comprise a tongue that is configured to engage a groove in another rib insert, a groove that is configured to engage a tongue in another rib insert.

[0007] According to a further aspect of the disclosure, a block is provided for use in a wall structure. The block comprises: a first block side which is configured to form a section of one side of the wall structure; a second block side which is configured to form a section of an opposite side of the wall structure; and a stud component which is integrally formed with second block side. The block may further comprise a rib which is configured to receive a rib insert or a block corner insulation. The stud component may be configured to accept a finishing material, or to align with another stud component on a vertically adjacent block to form a stud. The stud component may include a recess portion. The block may further comprise a self- aligning core.

[0008] According to a still further aspect of the disclosure, a rib insert is provided for use in a block system that comprises a block having an integrally formed stud component. The rib insert comprises: a tongue that is configured to engage a groove in another rib insert; a groove that is configured to engage a tongue in the other rib insert; and an insert member that is configured to attach to a rib in the block. The rib insert may further comprise another insert member that is configured to attach to another rib in the block. The tongue may be further configured to engage a groove in a block corner insulation. The groove may be further configured to engage a tongue in a block corner insulation.

[0009] Additional features, advantages, and embodiments of the disclosure may be set forth or apparent from consideration of the detailed description and drawings. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the disclosure as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The accompanying drawings, which are included to provide a further understanding of the disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the detailed description serve to explain the principles of the disclosure. No attempt is made to show structural details of the disclosure in more detail than may be necessary for a fundamental understanding of the disclosure and the various ways in which it may be practiced. In the drawings:

[0011] FIG. 1 shows an inner corner view of an example of a pair of connecting walls, according to principles of the disclosure;

[0012] FIG. 2 shows an outer comer view of the pair of connecting walls shown in FIG. 1;

[0013] FIG. 3 shows an exploded view of the pair of connecting walls shown in FIG. 1;

[0014] FIG. 4 shows another exploded view of the pair of connecting walls shown in FIG. 1;

[0015] FIG. 5 shows a perspective view of an example of a block, according to principles of the disclosure; [0016] FIG. 6 shows a perspective view of another example of a block, according to principles of the disclosure;

[0017] FIG. 7 shows an example the block of FIG. 5 with optional core inserts, according to p

[0018] FIG. 8 shows a perspective view of an example of a rib insert, according to principles of the disclosure;

[0019] FIG. 9 shows another view of the rib insert shown in FIG. 8;

[0020] FIG. 10 shows an example of the rib insert shown in FIG. 8 being affixed to the block shown in FIG. 5;

[0021] FIG. 11 shows another view of the rib insert shown in FIG. 8 being affixed to the block shown in FIG. 5; and

[0022] FIG. 12 shows an example of a block corner insulator, according to principles of the disclosure.

[0023] The present disclosure is further described in the detailed description that follows.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0024] The disclosure and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and detailed in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiments of the disclosure. The examples used herein are intended merely to facilitate an understanding of ways in which the disclosure may be practiced and to further enable those of skill in the art to practice the embodiments of the disclosure. Accordingly, the examples and embodiments herein should not be construed as limiting the scope of the disclosure. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.

[0025] The terms "including," "comprising" and variations thereof, as used in this disclosure, mean "including, but not limited to", unless expressly specified otherwise.

[0026] The terms "a", "an", and "the", as used in this disclosure, means "one or more", unless expressly specified otherwise.

[0027] Although process steps, method steps, algorithms, or the like, may be described in a sequential order, such processes, methods and algorithms may be configured to work in alternate orders. In other words, any sequence or order of steps that may be described does not necessarily indicate a requirement that the steps be performed in that order. The steps of the processes, methods or algorithms described herein may be performed in any order practical. Further, some steps may be performed simultaneously.

[0028] When a single device or article is described herein, it will be readily apparent that more than one device or article may be used in place of a single device or article. Similarly, where more than one device or article is described herein, it will be readily apparent that a single device or article may be used in place of the more than one device or article. The functionality or the features of a device may be alternatively embodied by one or more other devices which are not explicitly described as having such functionality or features.

[0029] The disclosure provides a novel, green, sustainable and energy efficient approach to construction.

[0030] FIG. 1 shows an example of a partial corner view IOOA of a pair of connecting walls 110. As seen, the walls 1 10 are constructed from a plurality of blocks 120, which may be arranged in a layered configuration, forming a corner section 140. Each of the blocks 120 has six sides, including two longitudinal sides, two transverse sides, a top side and a bottom side. Each of the blocks 120 may include one or more stud components 142 on either (or both) longitudinal sides. The stud component 142 may include a recessed portion 144. The blocks 120 may be configured so that when, e.g., two or more blocks 120 are layered, the stud components 142 of the vertically adjacent blocks 120 are aligned to form studs. In this configuration, the recessed portions 144 of the two vertically adjacent blocks 120 may be aligned and joined to form a chase (or opening) 145.

[0031] The chase 145 may be configured to pass there-through, e.g., plumbing pipes, electrical wires, electrical pipes, fiber optic lines, and the like. A conduit sleeve (not shown) may be installed in the chase 145 to protect, e.g., plumbing pipes, electrical wires, electrical pies, fiber optic lines, or the like, from penetration by various fasteners.

[0032] It is noted that the stud component 142 may include a further recessed portion (not shown) that is provided on the end opposite to the end with the recessed portion 144. It is further noted that the stud component 142 may measure, for example, about two inches in width, about two inches in depth and about eight inches in height when used in a block 120 having dimensions of, for example, about eight inches in depth, about sixteen inches in width (or length) and about eight inches in height.

[0033] The walls 110 may include a plurality of rib inserts 130, which may be affixed to the longitudinal sides of the blocks 120 to form a continuous, uninterrupted insulation layer. The rib inserts 130 may be affixed between one or more projecting ribs 121, 123, and 125, of the blocks 120. The rib inserts 130 may include a plurality of insert members 134, 136, each of which may be affixed to a recess 122 or 126, which are formed by the ribs 121, 123, and 125, of the blocks 120. The rib inserts 130 may be affixed to the recesses 122, 126 by a fastening mechanism, such as, for example, mortar, cement, adhesive, glue, or the like, and/or the rib inserts 130 may be affixed using a fastener, such as, for example, a nail, a screw, a bolt, a pin, a nut, or the like. The rib inserts 130 also may be affixed to the ribs 121, 123, and 125 by the fastening mechanism. Similarly, the block corner insulators 138 may be affixed to the outer side of the ribs 121 or 125.

[0034] The walls 110 may also include one or more block corner insulators 138 affixed to a side portion of the block 120.

[0035] The blocks 120 may be pre-insulated at the production facility, using, e.g., the rib inserts 130 and/or block corner insulators 138. The rib inserts 130 and/or block corner insulators 138 may include, e.g., expanded polystyrene, or the like. The rib inserts 130 and block comer insulators 138 may be configured to overlap or engage each other so as to provide a continuous, uninterrupted layer of exterior (or interior) insulation, as shown, e.g., in FIG. 2.

[0036] The block 120 may further include a plurality of openings 124, 128.

[0037] When the blocks 120 are assembled into a wall, the stud components 142 may be aligned to provide studs that may accept finishing materials such as, e.g., conventional sheetrock, wallboard, paneling, or the like, which may be fastened by screw, nail, adhesive, or the like, or any combination thereof, to the studs. Accordingly, wood or steel studs may not be necessary, since the stud components 142 align to form studs.

[0038] FIG. 2 shows a partial corner view IOOB of the pair of connecting walls 110 shown in FIG. 1. In particular, FIG. 2 shows the sides HOA and HOC of the walls 110 shown in FIG. 1. As seen, the rib inserts 130 and block corner insulators 138 are assembled with the blocks 120 to form an exterior (or interior) continuous and uninterrupted insulation layer for the connecting walls 110. The insulation layer formed by the rib inserts 130 and block corner insulators 138 may provide thermal and acoustical insulation, as well as mold and mildew resistance. Additionally, the insulation layer may provide fire resistance and improve indoor air quality by preventing or minimizing, e.g., mold or mildew buildup.

[0039] The rib inserts 130 and block corner insulators 138 may be configured to absorb a substantial amount of heat during the daylight hours. This stored heat may then be released slowly to the interior of a building during the evening hours. Alternatively, the rib inserts 130 and block corner insulators 138 may be configured to reflect a substantial amount of solar power, thereby minimizing absorption of heat due to, e.g., solar irradiation.

[0040] The outer surfaces of the rib inserts 130 and the block corner insulators 138 may be finished with, e.g., cedar, vinyl siding, cement board (Hardy Board), exterior stucco, masonry, wood, glass, metal, plastic, or the like. Alternatively, the outer surfaces of the rib inserts 130 and the block corner insulators 138 may include a finish such as, e.g., a cedar finish, a vinyl siding finish, a cement board finish, an exterior stucco finish, a masonry finish, a wood grain finish, a glass finish, a metal finish, a plastic finish, or the like.

[0041] FIG. 3 shows an exploded view IOOC of the pair of connecting walls 110 shown in FIG. 1, including a plurality of blocks 120, rib inserts 130 and block corner insulators 138.

[0042] FIG. 4 shows another exploded view IOOD of the pair of connecting walls 110 shown in FIG. 1, including the plurality of blocks 120, rib inserts 130 and block corner insulators 138.

[0043] FIG. 5 shows a perspective view of an example of a block 120 that may be used to construct the walls 110 in FIG. 1. The block 120 may include the plurality of recesses 122, 126, which are formed by the projecting ribs 121, 123 and 125. The block 120 may further include the plurality of openings 124, 128 and the stud component 142. The stud component 142 may include the recessed portion 144. The recessed portion 144 may include a semi -cylindrical recess (or half-round depression), as seen in FIG. 5, or a recess (or depression) having any other shape, without departing from the scope and/or spirit of the disclosure. [0044] The block 120 may include one, two, three, or more projecting ribs 121, 123, 125, on at least one of the two longitudinal sides. The projecting ribs 121, 123, 125, may be configured to provide support for the rib inserts 130 and/or block corner insulator 138. The ribs 121, 123, 125, also may be configured to provide a fastening surface for attachment of the exterior finish to the wall 110. The projecting ribs 121, 123, 125, may be spaced at predetermined intervals (e.g., about every 8 inches) for convenient, accurate and effective attachment of the exterior finish.

[0045] The block 120 may be manufactured using, e.g., water, Portland cement, about 100% lightweight aggregates, other cementitious materials, chemicals and admixtures. These components may be mixed and fed into molds under simultaneous vibration and compaction to yield the blocks 120, which are fire resistant, mold resistant, sound absorptive, heat absorptive, fastener receptive, and the like. The blocks 120 are fastener receptive in that other components, including e.g., sheet rock, wallboard, paneling, or the like, may be glued, nailed or screwed to the blocks 120.

[0046] For example, the blocks 120 may be manufactured using a mixture of Portland cement, expanded clay or shale lightweight aggregate, an integral water repellent, a pozzolan (e.g., fly ash, or the like), a concrete additive (e.g., Elemix®, expanded polystyrene beads, or the like), and the like.

[0047] The block 120 may be constructed to include superior thermal and acoustical performance, indoor air quality, mold and mildew resistance, fire resistance and the like. For example, the block 120 may be constructed of a mix design that includes a concrete additive such as, e.g., Elemix®, or the like, that utilizes the maximum benefit of thermal diffusivity, whether in a heating or cooling mode. For example, the block 120 may absorb a significant amount of heat during the daylight hours. This stored heat may then be released slowly to the interior of the building during the evening hours. The block 120 may be used wherever there is a need for sustainable, green energy efficient structures.

[0048] The block 120 may be composed entirely of, e.g., inert materials, thereby providing an environment that is not conducive to the growth of mold spores. The interior longitudinal side of the block 120 may be coated with, e.g., a water-based epoxy after assembly to act as an optional additional vapor barrier on the interior side of a wall structure.

[0049] The block 120 may contain a concrete mixture that may optionally contain an integral water repellant. This water repellent may chemically bond with the concrete aggregates to form a barrier to moisture migration into the block 120.

[0050] The block 120 may be manufactured in modular dimensions to allow for assembly using, e.g., cement/lime mortar as the bonding material. The dimensions of the block 120 may be changed to allow assembly by other methods such as, e.g., thin set adhesive.

[0051] The center section of the block 120 may include self-aligning cores that provide additional reinforcement to comply with any and all extreme building codes. As seen in FIG. 5, the self-aligning cores may include the openings 124, 128, which are provided between the top and bottom sides of the block 120.

[0052] The blocks 120 may be used in, e.g., any wall structure. The studs 142, when assembled into a wall structure, line up vertically, e.g., every sixteen inches on center on one of the longitudinal sides of the wall. The blocks 120 may be assembled quickly into the wall structure due, in part, to the unique fastening properties. As noted earlier, the blocks 120 may be finished without any need for, e.g., steel or woods studs. When assembled into the wall structure, the blocks 120 may provide, e.g., secure fire protection and excellent sound absorbing qualities.

[0053] Further, the blocks 120 provide substantial construction efficiencies due in-part to the built-in concrete studs 142 that eliminate at least one step in the finishing process. That is, metal or wood studs may be unnecessary when using the blocks 120 to build wall structures, since the studs 142 are configured to receive the finishing materials, such as, e.g., sheet rock, wallboard, paneling, or the like.

[0054] FIG. 6 shows another example of a block 160, according to principles of the disclosure. The block 160 may be constructed in a manner similar to that of block 120. The block 160 includes an additional stud component 162 on the longitudinal side opposite the longitudinal side having the stud component 142. The additional stud component 162 includes a recess portion 164.

[0055] The block 160 (or block 120) may be used in, e.g., fire separation walls in any occupied structure. The off-setting studs 142, 162, when assembled into a wall structure, line up, e.g., every sixteen inches on center on either side of the wall. A plurality of blocks 160 may be assembled quickly into a wall structure due, in part, to the unique fastening properties. Additionally, the blocks 160 may be finished without any need for, e.g., steel or woods studs. When assembled into a wall structure, the blocks 160 may provide, e.g., secure fire protection and excellent sound absorbing qualities. [0056] Like the blocks 120, the blocks 160 provide substantial construction efficiencies due to the built-in concrete studs 142 that eliminate at least one step in the finishing process. The blocks 160 (or 120) may be utilized in applications where, e.g., superior structural fire walls are necessary or desirable.

[0057] Each block 160 may measure, for example, about twelve inches wide, about eight inches high and about sixteen inches long. In this example of the block 160, the off-setting studs 142, 162, may measure, for example, about two inches wide, about eight inches high and about two inches long.

[0058] As seen in FIG. 6, the blocks 160 may each include, for example, two self- aligning cores. The cores in the blocks 160 (and/or 120) may be reinforced with additional concrete and/or reinforcing steel to meet or exceed building code requirements, including special building code requirements for areas vulnerable to, e.g., seismic or severe wind conditions. It is noted that more (or less) than two cores may be included in the blocks 160.

[0059] The cores also provide enhanced acoustical properties to substantially reduce, for example, the travel of sound through the blocks 160, as well as enhanced temperature properties to substantially reduce the transmission of heat through the block 160, which may be caused by, for example, a fire on one side of a wall containing the blocks 160. Sound and temperature transmission properties may be further enhanced by encapsulating the blocks 160 in drywall or similar surface treatments and/or filling the cores with, for example, Portland cement grout or insulating materials. [0060] FIG. 7 shows an example of a block 120 provided with core inserts 154, 156, which may be placed in the openings (or core spaces) 124, 128 of the block 120 (or 160). The core inserts 154, 156, may be made from the same (or different) material as the rib inserts 130 and/or block corner insulation 138.

[0061] The block 120 (or 160) may be designed to take advantage of thermal diffusivity. Thermal diffusivity is the property of a material to store heat or cold and release the stored heat in the case of the heating (cooling) mode, over a period of time. The block 120 (or 160) may be designed so that the insulation, including rib inserts 130 and block corner insulations 138, is in place on the outside of the a wall structure. Accordingly, the wall structure, including the blocks 120 (or 160), may absorb heat during the day, storing the heat within the mass of the block 120 (or 160), and releasing the heat overnight. This cycle repeats itself. The cooling (summer) cycle works in a similar manner. During the evening hours the wall structure cools. The block 120 (or 160) cools and delays the warming of the interior side of the wall structure during the warmth of the day.

[0062] The block 120 (or 160) may be composed entirely of inert materials. This presents an environment that is not conducive to the growth of mold spores. The interior side of the block 120 may be coated with a water based epoxy after assembly to act as an optional additional vapor barrier to the interior of the building.

[0063] The block 120 (or 160) may be designed to be assembled in running bond. That is, the block 120 (or 160) is configured in each horizontal course to overlap the center of the block 120 (or 160) below it. The block 120 (or 160) design also requires the inversion of every other course. [0064] FIG. 8 shows an outer perspective view of an example of a rib insert 130, according to principles of the disclosure. The rib insert 130 may include a planar surface 132 and one or more tongues 133, each of which may be configured to connect to, for example, a groove 131 of another rib insert 130 to form a continuous and relatively seamless modular wall. The rib insert 130 may further include one or more grooves 131, each of which may be configured to connect to, for example, a tongue 133 of another rib insert 130. The rib insert 130 may also include a plurality of insert members 134, 136, each of which may be configured to be affixed to, for example, the recesses 122, 126 of the block 120, shown in FIG. 5.

[0065] FIG. 9 shows an inner perspective view of the rib insert 130 shown in FIG. 8.

[0066] FIG. 10 shows a perspective view of an example of the rib insert 130 of FIG. 8 being mated (or affixed) to the block 120 shown in FIG. 5.

[0067] FIG. 11 shows another view of the rib insert 130 being mated (or affixed) to the block 120.

[0068] FIG. 12 shows a perspective view of an example of a block corner insulator 138, according to principles of the disclosure. The block corner insulator 138 may include a plurality of connecting sections 173, 193 for connectively engaging rib inserts 130 to form a continuous, relative seamless modular wall. For example, the connecting sections 173, 193 may include respective grooves 137, 139, each of which is configured to receive a tongue 133 of a respective rib insert 130 (shown in FIG. 8). The connecting sections 173, 193 may each also include a tongue (not shown) for engaging a corresponding grove 131 in the respective rib inserts 130 (shown in FIG. 8).

[0069] Furthermore, the block corner insulator 138 may include a connecting section 193 A (shown by cross-hatched line), which may include a groove and/or tongue (not shown) to connectively engage a further rib insert 130. The block corner insulator 138 may also include a connecting section (not shown) on the side opposite the connecting section 193 A, which may include a groove and/or tongue (not shown) to connectively engage a still further rib insert 130.

[0070] While the invention has been described in terms of exemplary embodiments, those skilled in the art will recognize that the invention can be practiced with modifications in the spirit and scope of the appended claims. These examples given above are merely illustrative and are not meant to be an exhaustive list of all possible designs, embodiments, applications or modifications of the invention.