Structural thermal break

Abstract

A load-bearing thermal break construction element for use in buildings, particularly with overhangs or extensions projecting from the exterior building envelope, comprises a concrete and insulation-filled shell with rebar extending therethrough. The shell has an interior space and a plurality of shafts extending through the interior space. The shafts are shaped to receive rebar in an interference fit, and may be shaped to permit the rebar to pivot while retained in place in the shell. The interior of the shell is filled with insulation and concrete prior to installation in a building.

1 . A thermal break, comprising:
 a shell, comprising:
 an interior space defined by exterior walls; and 
 a plurality of shafts extending through the interior space between a first wall and an opposing second wall of the exterior walls, the plurality of shafts shaped to receive and retain corresponding pieces of rebar; 
   the corresponding pieces of rebar, retained in the plurality of shafts;   the interior space being filled with concrete and insulation.   
     
     
         2 . The thermal break of  claim 1 , wherein the shell further comprises at least one projection extending longitudinally along each of the first wall and the second wall to provide a shear lock. 
     
     
         3 . The thermal break of  claim 2 , wherein the first wall comprises a projection at the bottom of the thermal break and the second wall comprises a projection at the top of the thermal break. 
     
     
         4 . The thermal break of  claim 3 , wherein each of the first wall and the second wall each comprises a further projection located at midportion of the first wall and the second wall, respectively. 
     
     
         5 . The thermal break of  claim 1 , wherein the plurality of shafts comprises a series of shafts arranged longitudinally. 
     
     
         6 . The thermal break of  claim 5 , wherein the plurality of shafts comprises at least two series of shafts arranged longitudinally at different heights of the thermal break. 
     
     
         7 . The thermal break of  claim 1 , wherein each shaft is defined by shaft walls tapering from initial diameters at the first wall and the second wall towards a smaller diameter waist sized to retain the rebar. 
     
     
         8 . The thermal break of  claim 1 , wherein the shell further comprises a shield member projecting upward from an upper surface of the shell. 
     
     
         9 . A shell for a thermal break, comprising:
 an interior space defined by exterior walls; and   a plurality of shafts extending through the interior space between a first wall and an opposing second wall of the exterior walls, the plurality of shafts shaped to receive and retain corresponding pieces of rebar.   
     
     
         10 . The shell of  claim 9 , wherein the shell further comprises at least one projection extending longitudinally along each of the first wall and the second wall to provide a shear lock. 
     
     
         11 . The shell of  claim 10 , wherein the first wall comprises a projection at the bottom of the shell and the second wall comprises a projection at the top of the shell. 
     
     
         12 . The shell of  claim 11 , wherein each of the first wall and the second wall each comprises a further projection located at midportion of the first wall and the second wall, respectively. 
     
     
         13 . The shell of  claim 9 , wherein the plurality of shafts comprises a series of shafts arranged longitudinally. 
     
     
         14 . The shell of  claim 13 , wherein the plurality of shafts comprises at least two series of shafts arranged longitudinally at different heights of the shell. 
     
     
         15 . The shell of  claim 9 , wherein each shaft is defined by shaft walls tapering from initial diameters at the first wall and the second wall towards a smaller diameter waist sized to retain the rebar. 
     
     
         16 . The shell of  claim 9 , further comprising a shield member projecting upward from an upper surface of the shell. 
     
     
         17 . A method of manufacturing a thermal break, the method comprising:
 inserting rebar through shafts provided in a shell, the shafts extending between opposing walls of the shell through an interior space of the shell, such that the rebar extends through the shell and protrudes from either opposing wall;   inserting insulation in the interior space of the shell; and   filling the interior space with concrete.   
     
     
         18 . The method of  claim 17 , wherein the concrete completely submerges the insulation. 
     
     
         19 . The method of  claim 17 , wherein the insulation is extruded foam. 
     
     
         20 . The method of  claim 17 , wherein the concrete is basalt or carbon fiber reinforced concrete.