WEB AND CONNECTION INSERT

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to interlocking construction panels or blocks, connecting webs and connection inserts for interlocking insulating construction panels or blocks as well as arcuate insulating construction panels or blocks having an interconnecting means which permit the interconnecting with like blocks or panels in a bi-directional and/or reversible manner.

2. Description of the Prior Art

U.S. Patent 4,229,920 discloses a foamed plastic concrete form which includes projecting tongues on one end and on one side and a corresponding groove on the opposite end and upon the opposite side edges so that adjacent forms can be interlocked in end to end relationship and will also interlock when placed one above the other. In such an arrangement, the forms will only interlock when placed in a bottom to top arrangement, i.e. the blocks must be arranged in a specific orientation for interconnection; this patent does not permit the bidirectional or reverse interlocking of forms.

U.S. Patent 4,894,969 discloses an insulating block form for constructing concrete wall structures including interlocking means to permit stacking of the blocks one on top of the other. The construction of this patent does not permit the stacking of a plurality of blocks in a reversible or a bi-directional manner.

SUMMARY OF THE INVENTION

In accordance with an embodiment of the present invention there is provided a connecting spacer web for an insulating construction block having a pair of spaced apart wall sections, each of said wall sections being provided with a connection insert having cooperating receiving means adapted to receive the spacer web. The spacer web comprising: a pair of vertical end members; an intermediate member joining the vertical end members; and cooperating engaging means projecting outwardly from said end members and adapted to matingly engage with a cooperating receiving means of a connection insert of an insulating construction block; wherein the cooperating engaging means are adapted to permit insertion of the web in an axial direction relative to walls of a construction block and into engagement with a cooperating receiving means of a connection insert of a construction block.

In accordance with another embodiment of the present invention there is provided an insulating construction block arrangement comprising: at least one construction block having a pair of spaced apart wall sections, each of the wall sections having at least one connection insert having a channel therein; at least one connecting web, the connecting web having cooperating engaging means on ends thereof; wherein the channels of the connection insert matingly receive the cooperating engaging means of the connecting web whereby the web joins the spaced apart wall sections together in spaced relationship.

In accordance with yet another embodiment of the present invention there is provided an arcuate insulating construction member comprising: a central section having top and bottom edges; a pair of arcuate end members, one end member being adjacent a lower portion of one side of

T e central section and the other end member being adjacent an upper portion on the opposite side of the central section; interconnecting means on the top and bottom edges of the central section, the interconnecting means comprising at least two rows of alternating projections and recesses, the projections and recesses being of substantially the same dimension, wherein the recess of one row is adjacent the projection of the other row, and wherein the interconnecting means on the top and bottom edges are offset such that the recess of one row on the top edge is opposed to the projection of an opposite row of the bottom edge, whereby the arcuate insulating construction member can be interconnected with a like member in a bi¬ directional or reversible manner.

Preferably, the arcuate insulating construction member includes at least one connection insert having a receiving channel on an inside surface of the construction member, the receiving channel adapted to receive a cooperating engaging means of a web as above described.

The spacer web and connection inserts can be used in connection with an insulating construction panel or block which is designed in such a manner to permit its interconnection with like panels or blocks in a bi¬ directional and/or reversible manner. Such a construction member is much easier to interconnect with like members, as there are a plurality of ways the members can be interconnected and this thus allows installers to proceed at a much faster pace then possible with previously known insulating construction panels or blocks. Further, with such insulating construction members, there is less waste as cut portions, for example portions cut for window or door openings, can be utilized anywhere due to the special interconnection means which permits bi-directional and/or

reversible interconnection.

The insulating construction member, in one embodiment of the present invention, has top and bottom edges and interconnecting means on the top and bottom edges. The interconnecting means comprise alternating projections and recesses, the projections and recesses being of substantially the same dimension, and wherein the interconnecting means on said top and bottom edges are symmetrical whereby the construction member can be interconnected with a like member in a bi-directional and/or reversible manner.

The insulating construction member can be in the form of an insulating construction block or an insulating construction panel.

In yet another embodiment of the present invention, an insulating construction block comprises: a pair of substantially parallel side members having top and bottom edges; at least one web interconnecting the side members; interconnecting means on the top and bottom edges, the interconnecting means including at least one row of alternating projections and recesses, the projections and recesses having substantially the same dimensions. The interconnecting means on the top and bottom edges are substantially offset such that the recess of one row on the top edge is opposed to the projection of an opposite row of the bottom edge, whereby the insulating construction block can be interlocked with a like block in a bi-directional and/or reversible manner. The web includes projecting end members and the side members include receiving means for receiving and releasably retaining the projecting end members of the web.

In a preferred form, the construction block includes end pieces which may preferably be readily inserted and removed from the block by way of a sliding

tongue and groove type arrangement. In this respect the side members may have grooves for slidably receiving projections on the ends of the end pieces. Any other suitable arrangement may be utilized. The end pieces may also be integral with the block if desired.

Preferably, the interconnection means on the top and bottom edges of the insulating construction panel or block includes two rows of alternating projections and recesses. Where two rows of alternating projections and recesses are provided, preferably the adjacent pairs of each row are opposites, i.e. a recess of one row is preferably adjacent a projection of the other row. Such an arrangement provides for a stronger interconnection between like insulating members.

There may also be provided sealing means positioned between or beside the rows of alternating projections and recesses. Such a sealing means is preferably in the form of a raised portion which extends along the length of the interconnection means and which is of a height less than the height of the projections, preferably about one-half the height of the projections.

The interconnecting means preferably extend along the entire length of the top and bottom edges of the insulating member although it is not necessary that the interconnecting means extend along the entire length as they may be present in just one or more sections.

The projections and recesses of the interconnecting means are of substantially the same shape and dimensions and, in one preferred form, are of a rectangular configuration, although it will be understood that any other configuration can be utilized, such as, for

example, circular, square, triangular, polygonal, etc.

In a preferred form of the insulating construction members, each of the projections and recesses preferably have a tapered configuration. For example, in the case of a rectangular projection, the side walls of the projection are preferably provided with a tapered outline running from the free top side walls towards the bottom wall connected to the main body of the insulating member. Preferably, at least two opposed walls of a rectangular configuration are provided with the tapered construction; all four side walls of the rectangular projection could be provided with such a feature.

In a like manner, the recesses will correspondingly be of a tapered construction where the two opposed walls of the projections are opposed walls extending in the axial direction of the insulating member. Such a tapered recess construction would be the reverse configuration where the recesses have a broader or wider open top tapering-to a narrower bottom construction.

This preferred tapered construction permits an easier assembly of one insulating member onto another like member during usage.

It is a particularly preferred feature that the interconnecting means have projections and recesses which have a substantially conical configuration.

Preferably, in the case of an insulating construction block, the side members and interconnecting means are of a one-piece integral configuration, although it will be understood that the interconnecting means and the side members can be formed separately and joined

together .

In the case of an insulating panel, it is preferred that the panel and the interconnecting means are of a one piece integral configuration; although, as in the case of the insulating block, the panel and the interconnecting means can be formed separately and joined together.

Preferably, the interconnecting web of the present invention is of a rigid material or at least non- extensible material. Although the web can be formed from any suitable material including various types of metals, preferably the web is formed of a suitable synthetic polymeric material.

Typical polymeric materials are those known in the art including polymers and copolymers of various types e.g. polyethylene or copolymers thereof, polypropylene or copolymers thereof, polystyrene or copolymers thereof, etc.

The polymer may be a foamed polymer, or more generally, such webs are formed of non-foamed material.

The structural configuration of the web can also vary considerably; generally, the web includes anchoring means for anchoring the respective ends of the web into the foam blocks. In addition, the web may be formed of two or more sections so that an adjustable web can be utilized.

In a preferred form, the web includes a pair of of vertical end members joined by an intermediate horizontal section. Each of the end members includes a cooperating engaging means extending outwardly therefrom. The cooperating engaging means are adapted to matingly

engage with cooperating receiving means of a connection insert which is provided in each panel of an insulating construction block.

Preferably the cooperating engaging means of the web are in the form of a T-shaped projection and cooperating receiving means of the connection insert have a similar T-shaped groove although any other suitable arrangement can be employed such as an arrow-head configuration, round bulb configuration, etc.

The cooperating engaging means, in a preferred form, are adapted to sliding insertion into the cooperating receiving means of the connection insert although a snap- fit or other type arrangement may be utilized.

Preferably, the web is of a height which would extend between at least two vertically stacked construction blocks and thus the web would add to the securement of the vertically stacked blocks in locking the horizontal seams of two vertically stacked blocks. Thus, where the web has a height corresponding to the height of the block, a single web could be positioned between two vertically stacked blocks so that half of the web (or any desired amount) would be located in one block and the other portion of the web in the adjacent block. In this manner, the web would seal or lock the horizontal seams otherwise occurring between blocks.

The web can be of any suitable size, i.e. the web can be of a height of two vertically stacked blocks or larger.

The web preferably includes at least one line of weakness which provides a break point to permit the web to be transversely separated into two or more sections. This permits adjustability in the height of the web and permits its use in blocks of varying heights.

As noted above, the connection insert for the insulating construction block has a channel or groove portion, to receive the cooperating engaging means of the web therein.

Preferably, the major portion of the connection insert is embedded in the construction block with a front face including the channel portion being accessible from the top and/or bottom inside surfaces of the panels of the block.

The connection insert includes at least one pair of anchoring arms to aid in securely anchoring the insert in a construction panel. In a particularly preferred form, two paris of spaced apart anchoring arms are provided.

Preferably the connection insert also provides at least one utility line chase therein.

The connection insert may be formed of a material similar to the material of the web or any other suitable material.

The number of webs and connection inserts utilized in a typical block will vary depending on the size and dimensions of the block; typically, small blocks may have one or two webs and connection inserts with up to 10 or more webs and connection inserts on standard (one metre) size blocks.

The web may be manufactured in varying widths to permit the use of the web in construction blocks having different widths.

The insulating construction members of the present invention are preferably formed of a foamed material, such as any of the foamed polyolefins, e.g. polyethylene, polypropylene, etc. or other foamed polymers which find use in the construction industry such as foamed styrene polymers and copolymers, foamed urethanes, etc.

The design of the insulating construction member in preferred forms permits the member to be interconnected with a like member in any of a plurality of positions. More specifically, the members are bi-directional and reversible which means that there is not only one right way to interconnect the members, i.e. they do not have to be interconnected in one particular way such as bottom to top. Such an arrangement allows installers to proceed at a much faster pace than previously possible as they do not have to orient the members in one certain way for interconnection. Also, such an arrangement creates less waste, i.e. a portion cut for forming a window or door opening, for example, can be utilized anywhere in the construction due to the symmetry of the interconnecting means.

In some embodiments of the present invention, the blocks may also be mounted, one to another, at right angles to each other. Thus, not only do such blocks of such embodiments have the capability of reverse and bi¬ directional mounting, but further, mounting perpendicularly to each other.

The insulating panels or blocks may be of the standard straight configuration, above noted arcuate configuration, or they may be angled corner units. A corner unit would have the same interconnecting means above specified, i.e. a pattern of alternating projections and recesses substantially the same shape and dimensions, the pattern on the top being symmetrical with the pattern on the bottom. With such a corner unit a single corner unit can be utilized for either the left or the right hand corner by simply reversing the unit. Thus the corner units would also be bi-directional and reversible. Similar arrangements apply to "T" shaped inεulating members as well as "x" shaped insulating members

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus generally described the invention, reference will now be made to the drawings which illustrate preferred embodiments of the invention, wherein:

Figure 1 is a perspective view of an insulating block according to one embodiment of the present invention;

Figure 2 is a perspective view of an insulating panel according to an embodiment of the present invention;

Figure 3 is a cross sectional view of a pair of insulating panels interconnected together;

Figure 4 is a cross sectional view of a pair of insulating panels interconnected together;

Figure 5 is a cross sectional view of a pair of insulating panels interconnected together;

Figure 6 is a perspective view of another embodiment of an insulating block of the present invention;

Figure 7 is a top plan view of a portion of a side panel and end piece of an insulating block showing their interconnection;

Figure 8 is a front elevational view of one embodiment of the connecting spacer web of the present invention;

Figure 9 is a front elevational view of a second embodiment of the connecting spacer web of the present invention;

Figure 10 is a front elevational view of a third embodiment of the connecting spacer web of the present invention;

Figure 11 is a top plan view of an embodiment of a connecting spacer web according to the present invention;

Figure 12 is a side elevational view of an embodiment of a connecting spacer web according to the present invention;

Figure 13 is a top plan view of a connection

insert for an insulating construction member according to one embodiment of the present invention;

Figure 14 is a top plan view of a connection insert for an insulating construction member according to another embodiment of the present invention;

Figure 15 is a top plan view of an insulating construction member having a connection insert therein, the connection insert being shown in dotted lines;

Figure 16 is a front elevational view of a construction member having an embodiment of the connection insert therein;

Figure 17 is a front elevational view of an arcuate insulating construction member according to an embodiment of the present invention; and

Figure 18 is a top plan view of the arcuate insulating construction member.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference will initially be made to Figure 1 of the drawings which illustrates a preferred embodiment of an insulating construction block of the present invention. The insulating construction block includes a pair of generally parallel panels or side walls 10, 12. Side walls 10, 12 are joined together by webs 14. Interconnection means 16 are provided on the top and bottom edges of the side walls 10, 12.

The interconnection means 16 permit the stacking and interconnection of a plurality of like blocks as would be required in the construction of a wall or similar arrangement. the interconnection means 16 include a plurality of projections 18 and recesses 20 arranged in an alternating pattern; the projections 18 and recesses 20 being of substantially the same shape and having substantially the same dimensions. The interconnection means 16 on the top and bottom edges of the side walls 10,

12 are substantially symmetrical, thereby permitting the interconnection of like blocks in a bi-directional and/or reversible manner. In the preferred embodiment illustrated in Figure 1, the interconnection means 16 include two rows of alternating projections 18 and recesses 20; although other arrangements can be utilized as will be described later with reference to Figures 3 through 6. When two or more rows of projections 18 and recesses 20 are utilized the projections 18 and recesses 20 must alternate in both the x and y axis, i.e. a projection 18 of one row must be adjacent to a recess 20 of the other row as well as being adjacent to a recess 20 in the same row. As noted above the interconnection means 16 of the top edge of the sides 10, 12 must be symmetrical with the interconnection means 16 of the bottom edge of the sides 10, 12. Such an arrangement permits the interconnection of like blocks in almost any orientation such as bottom to top, top to top as well as in either direction. In other words, the blocks are bi-directional as well as being reversible.

As best shown in Figure 1, the interconnection means 16 may also include a sealing member 22. In the arrangement illustrated having two rows of projections 18 and recesses 20, the sealing member 22 is positioned therebetween and is in the form of a raised member which projects upwardly to a height less than the height of the projections 18. The sealing member 22 may also be positioned alongside of the projections 18 and recesses 20 of the interconnecting means 16.

Figure 2 illustrates an insulating panel. The insulating panel 34 includes interconnecting means 16. In the arrangement illustrated in Figure 2, the interconnecting means 16 includes a plurality of projections 18 and recesses 20 in an arrangement similar to

the arrangement of interconnecting means 16 described with reference to the block of Figure 1.

Figures 3, 4 and 5 illustrate cross-sectional views of panels of two like members A and B interconnected together, the figures show various embodiments of the interconnection means 16.

Figure 3 illustrates the arrangement of interconnecting means 16 as illustrated in Figure 1, i.e. two rows of alternating projections 18 and recesses 20 with a sealing means 22 positioned therebetween.

Figure 4 illustrates an arrangement of interconnecting means 16 which includes two rows of side- by-side alternating projections 18 and recesses 20. The arrangement of Figure 4 does not include an extra sealing means.

Figure 5 illustrates an arrangement where the interconnecting means 16 includes four rows of alternating projections 18 and recesses 20. The specific arrangement of interconnection means 16 in the embodiment illustrated in Figure 5, permits the mounting of blocks in a perpendicular fashion in addition to bi-directional and reversible mounting.

Figure 6 illustrates an insulating block according to another embodiment. In this arrangement the insulating block has a pair of generally parallel panels or side walls 10, 12 joined together by webs 14.

The interconnection means 16 of this embodiment includes four rows of alternating projections 18 and recesses 20. As discussed with respect to Figure 5, the

specific arrangement of interconnection means 16 in the embodiment illustrated in this figure, permits the mounting of blocks in a perpendicular fashion in addition to bi¬ directional and reversible mounting.

The block also includes end pieces 24 which are adapted for releasable engagement with the side members 10, 12. Such end pieces 24 are slidably and releasably inserted in the block by way of a tongue and groove arrangement. In this respect the side walls 10, 12 may include tongues or grooves (or both) on the inside surfaces which are adapted for mating engagement with tongues or grooves present on ends of the end piece 24; this feature is best illustrated in Figure 7.

Figure 7 is a top plan view of a portion of an insulating block (such as that illustrated in Figure 6) illustrating the interconnection between a side wall 10 with the end piece 24. As illustrated, the end piece 24 includes projections 30 which are slidably received in grooves 32 on an inside surface of the side wall 10.

Figure 8 is a front elevational view of an embodiment of a connecting spacer web 40 of the present invention. The web includes a pair of spaced apart cross members 41, 43 located between opposed outside frame members 42, 44. The cross members 41, 43 include a plurality of apertures 46 adapted to receive and retain reinforcing bars (not shown) . The apertures 46 include a plurality of teeth or flanges 48 which aid in the retaining of the reinforcing bars.

The outside frame members 42, 44 include lines of weakness 50 about the mid portion, which lines of weakness 50 permit the web structure to be broken apart into two

separate sorter webs when desired.

The complete connecting spacer web 40 is of a height which would permit it to extend through two vertically stacked construction panels or blocks. Thus, if the connecting spacer web 40 is broken in half at the lines of weakness 50, each half will be of a dimension suitable for use with a single construction block. Preferably, the web can be further broken into quarters; one quarter being inserted into a block or panel at the base of a wall and thereafter full webs could be utilized to extend through and secure at least two vertically stacked panels or blocks.

As will be clearer from Figure 11, the outside frame members 42, 44 include a projecting portion of a "T" shaped configuration. This configuration enables the sliding engagement of the connecting spacer web 40 with a groove of a connecting insert which is located within the construction panel.

Figures 9 and 10 illustrate other embodiments of the connecting spacer web 40 of the present invention. Figure 9 represents a connecting spacer web of a greater width than that illustrated in Figure 8; and Figure 10 illustrates a connecting spacer web with a smaller width than that illustrated in Figure 8. Like reference numerals, to those noted above with respect to Figure 8, illustrate like parts in Figures 9 and 10.

Figure 11 is a top plan view of the connecting spacer web 40 illustrating the "T" shaped projecting configuration of the outer frame members 42, 44.

Figure 12 is a side elevational view of the connecting spacer web 40.

Figure 13 is a top plan view of a connection insert 60 for use with construction panel (not shown) . The connection insert 60 is positioned within a construction

panel (not shown) so that the front surface 62 in the example shown is flush with the inside surface of the panel (although this is not essential) . The front surface 6 ₂ includes a grooved portion 64 which is of a configuration adapted to slidingly receive the projecting portions of the outside frame members 42, 44 of connecting spacer web 40.

The connection insert 60 includes anchoring arms 66, 68, 70 and 72 which aid in the secure anchoring of the connection insert 60 within a construction panel. The spaces 74 and 76 formed by the anchoring arms 66, 68, 70 ad 72, if closed by a wall can be utilized for running utility lines therethrough.

Figure 14 illustrates another embodiment of a connection insert of the present invention, generally designated by reference numeral 80. In this arrangement, there are provided anchoring arms 82, 84, 86 and 88 which aid in the secure anchoring of the connection insert 80 within a construction panel. This embodiment also includes a front surface 90 having a grooved portion 92 for slidably receiving an outside frame member of a connecting spacer web. In this arrangement, two enclosed utility line chases 100 and 102 are provided.

Figure 15 is a top view of a construction panel 104 showing a connection insert similar to that illustrated in Figure 13 located therein; the connection insert being shown in dotted lines. Like reference numerals to those used in Figure 13 are used herein. Connection insert 60 is located within the construction panel 104 with the front surface being flush with the inside surface 106 of the construction panel 104.

Figure 16 is an elevational view o the inside surface 106 of the construction panel 104. From this view

the front surface 62 and groove 64 of the connection insert 60 are visible.

Figures 17 and 18 are views of an arcuate construction panel 200, for making angled or round walls. Figure 17 is a front elevational view of the arcuate panel 200 whereas Figure 18 is a top plan view of the arcuate construction panel 200.

As illustrated in Figures 17 and 18, the arcuate construction panel 200 has as an example four connection inserts 201 therein. The number of connection inserts may vary.

Construction panel 200 includes a relatively straight central portion 204 and a pair of arcuate end portions 206, 208. The arcuate end portions 206, 208 are of a height dimension smaller than the height o the central portion 204. The arcuate end portions 206, 208 are on opposite ends of the central portion 204; one of the arcuate end portions 206 being adjacent an upper portion of the central portion 204 and the other arcuate end portion 208 being adjacent a lower portion of the central portion 204.

The central portion 204 of the arcuate construction panel 200 includes, on the top and bottom surfaces thereof, interconnection means 16. As previously, described in detail with respect to Figs. 1, 2, 6 and 7, the interconnection means 16 includes a pattern of alternating projections 18 and recesses 20.

The specific configuration of the construction panel 200 and the interconnection means 16 enables this angled panel to be used in a reversible and bi-directional manner.

Having described preferred embodiments of the

present invention, it will be understood that various modifications can be made to the above embodiments without departing from the spirit or scope of the invention.