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Details
Inventors: Calvin, Edward L;
Assignee:
Primary Examiner: Abbott; Frank L.
Assistant Examiner: Raduazo; Henry
Attorney, Agent or Firm: Fishburne, Jr.; B. P.

A concrete block simulating a Norman brick is formed with two large cores separated by a central web. The cores are adapted to receive insulating foam during manufacturing of the block. Each block is grooved in its opposite ends and recessed in its central web for the reception of wedge elements or keys formed of plastic or the like. Adjacent blocks in each course are interlocked and the courses of walls constructed from the blocks in either a stacked bond or running bond are mechanically interlocked and properly aligned. Epoxy cement is utilized for bonding of courses in a customized wall or in prefabricated panel sections utilizing the interlocking block.

DETAILED DESCRIPTION Referring to the drawings in detail wherein like numerals designate like parts, attention is directed initially to FIGS.
1 and 2 showing a basic building module embodying the invention and designated by the reference numeral 15.
This module 15 may be formed in a standard concrete block machine using a mixture of Portland cement, sand, gravel and mineral pigment to impart a desirable brick-like color.
Internal waterproofing may be employed to control moisture absorption.
Preferably, the module 15 is shaped to provide the appearance of a standard Norman brick when included in a wall structure.
The module or brick 15 has two large core openings 16 formed therethrough to qualify it for hollow masonry construction, and preferably the core openings are filled with porous insulation 17 during the manufacturing process.
More particularly, plastic foam such as polyurethane self-foaming compound is injected in the proper amount into each core opening while the bricks are still on the pallets in the forming machine.
The amount of injected polyurethane will be controlled to completely fill the core opening upon completion of the curing process.
The foam can be placed in the green block directly from the block machine, if the block is air-cured, or can be injected after removal of the block from the curing oven.
As will be further discussed, when the insulation-filled bricks or blocks are laid up in either a running bond or a stacked bond, the aligned cores in the wall will provide an essentially continuous insulation in the wall cavity.
The cured foam insulation 17 cannot settle in the wall like loose insulation material and will not soak up water to cause loss of insulation value.
No increased labor is required to completely insulate a wall during its construction with the brick embodying the invention.
The brick 15 further comprises front and rear walls 18 and 19, or webs, a center front-to-back web 20 separating the core openings 16, and end webs 21, all integrally joined as shown



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