High insulation building system

Abstract

A wall block ( 10 ) comprises a substantially rectangular core ( 11 ) of substantially rigid insulating material which forms structural load bearing elements in a constructed wall. The block ( 10 ) has cladding ( 12 ) bonded to its lateral surfaces. The cladding ( 12 ) is offset from the lateral surfaces with tie cladding ( 12 ) overhanging from the lower lateral edges, the overhanging portion abutting against the core ( 11 ) of the blocks ( 10 ) on the lower course. The core ( 11 ) has a longitudinal void ( 14 ) provided in the lower surface along its whole length and al least one vertically extending void ( 15 ), extending from the longitudinal void ( 14 ) to the upper surface of the core. Furthermore, recesses ( 21 ) are formed in the vertical edges of the core ( 11 ) and being adapted to receive elongated joint seals ( 22 ) to affect scaling of the joints between adjacent blocks ( 10 ).

1 . A wall block comprising a substantially rectangular core of a substantially rigid insulating material which alone forms the sole structural load bearing elements in a constructed wall, and the wall block having cladding bonded to its lateral surfaces. 
   
   
       2 . The block as claimed in  claim 1  wherein the cladding is offset from the lateral surfaces with the cladding overhanging from lower lateral edges, an overhang portion abutting against the substantially rectangular core of the blocks on a lower course. 
   
   
       3 . The block as claimed in  claim 2  comprising a longitudinal void in the lower surface of the substantially rectangular core along its length. 
   
   
       4 . The block as claimed in  claim 3  wherein the void comprises a centrally located slotted groove. 
   
   
       5 . The block as claimed in  claim 4  comprising at least one vertically extending void, the void extending from the longitudinal void to an upper surface of the core. 
   
   
       6 . The block as claimed in  claim 5  wherein the vertically extending void has a frusto-conical shape. 
   
   
       7 . The block as claimed in  claim 6  wherein the vertically extending void having a frusto-conical shape is formed by a pair of semi frusto-conical grooves formed in the end surfaces of adjacent blocks. 
   
   
       8 . The block as claimed in  claim 1  comprising recesses in vertical edges of the core, the recesses being formed behind the cladding and being adapted to receive elongated joint seals for sealing of joint between adjacent blocks. 
   
   
       9 . The block as claimed in  claim 1  comprising mating location devices on an upper and a lower surface of the substantially rectangular core. 
   
   
       10 . The block as claimed in  claim 9  wherein the mating location devices comprise a plurality of mating lugs and recesses. 
   
   
       11 . The block as claimed in claim IO wherein the lugs and recesses have a frusto-conical in shape. 
   
   
       12 . The block as claimed in  claim 1  wherein the substantially rectangular core has a protective strip bonded to an exposed surface not covered by the cladding. 
   
   
       13 . The block as claimed in  claim 1  wherein an outer lateral surface comprises a drainage channel provided adjacent a top surface of the substantially rectangular core. 
   
   
       14 . The block as claimed in  claim 1  wherein the rigid insulating material is a polyurethane foam material, the cladding is a sheet of cement material, and the protective strip is formed from galvanized steel sheet material. 
   
   
       15 . The block as claimed in  claim 1  wherein the block has part of the cladding removed from the substantially rectangular core and applied offset at an end of the core enabling the block to form a corner in a wall. 
   
   
       16 . A method of forming a wall, comprising the steps of laying courses of blocks on a floor structure, the blocks comprising a substantially rectangular core of substantially rigid insulating material which alone forms the sole structural load bearing elements in the constructed wall, with the wall block having cladding bonded to its lateral surfaces. 
   
   
       17 . The method as claimed in  claim 16  wherein the cladding is offset from the lateral surfaces with the cladding overhanging from lower lateral edges, the overhang portion abutting against the substantially rectangular core of the block(s) on a lower course, the method comprising the step of locating the overhanging cladding on the lowest course of blocks against or in the floor structure. 
   
   
       18 . The method as claimed in  claim 16  wherein a longitudinal void is provided in the lower surface of the core along its length. 
   
   
       19 . The method as claimed in  claim 18  wherein the void comprises a centrally located slotted groove. 
   
   
       20 . The method as claimed in  claim 19  wherein the block comprises at least one vertically extending void, the void extending from the longitudinal void to an upper surface of the core. 
   
   
       21 . The method as claimed in  claim 20  wherein the vertically extending void has a frusto-conical shape. 
   
   
       22 . The method as claimed in  claim 21  wherein the vertically extending void having a frusto-conical shape is formed by a pair of semi frusto-conical grooves formed in He end surfaces of adjacent blocks, the frusto-conical voids being adapted to be aligned in vertical voids for a height of the wall, the vertical voids are adapted to receive elongated compression means used to compress the course of blocks together. 
   
   
       23 . The method as claimed in  claim 22  wherein the elongated compression means comprises elongate threaded rods and corresponding nuts and plate devices located at a top and lowest courses of the blocks. 
   
   
       24 . The method as claimed in  claim 16  wherein the blocks comprise recesses which are formed in vertical edges of the substantially rectangular core, the method comprising the steps of providing elongated joint seals to affect sealing of joint between adjacent blocks, the seals being inserted behind the cladding and in the recesses. 
   
   
       25 . The method as claimed in  claim 16  wherein the block has mating location devices on upper and lower surfaces of the substantially rectangular core. 
   
   
       26 . The method as claimed in  claim 25  wherein the mating location devices comprise a plurality of mating lugs and recesses. 
   
   
       27 . The method as claimed in and recesses have a frusto-conical shape. 
   
   
       28 . The method as claimed in  claim 16  wherein the substantially rectangular core has a protective strip bonded to an exposed surface not covered by the cladding. 
   
   
       29 . The method as claimed in  claim 16  wherein the outer lateral surface has a drainage channel provided adjacent a top surface of the substantially rectangular core. 
   
   
       30 . A wall formed by a plurality of blocks, the blocks each comprising a substantially rectangular core of a substantially rigid insulating material which alone forms the sole structural load bearing elements in a constructed wall, and the blocks having cladding bonded to its lateral surfaces.