Insulated concrete form block, structural wall and building

Abstract

The present utility model relates to an Insulated Concrete Form Block (ICFB), a structural wall, and a building, which belong to the technical fields of construction products and concrete forms. The ICFB includes surface layer structures on an inner side and an outer side and an insulated core between the surface layer structures. At a top and / or a bottom and a left end and / or a right end of the insulated core, groove structures are formed between inner side surfaces of the two surface layer structures and a surface of the insulated core. The groove structures form horizontally and vertically communicated channels with adjacent groove structures when ICFBs are in an assembled state; the channels form a concrete grid structure with specific structural strength after reinforcing steel bars are enveloped and concrete is poured.

Description

INSULATED CONCRETE FORM BLOCK, STRUCTURAL WALL AND BUILDINGTECHNICAL FIELD

[0001] The present utility model relates to lightweight, fireproof, naturally insulating, structurally engineered and interlocking Insulated Concrete Form Block (ICFB), structural wall and building, which belong to the technical fields of construction products, construction methods, building regulations, structural engineering, concrete forms, fire protection, and insulating materials.BACKGROUND ART

[0002] 1 . Masonry Blocks

[0003] 1.1. For Centuries, the use of construction blocks has been common in construction industry globally. Whether they are hollow and solid, concrete and clay, these masonry blocks are heavy, cumbersome, and can be complex to layer evenly, straight, square and level, and bound together with mortar, usually requiring expensive, experienced, qualified block layers to layer blocks efficiently and accurately.

[0004] 1 .2. Larger block may be faster per area to lay, but the larger the block, the heavier the block, with block layers demanding higher laying costs, and many of them are not willing to undertake such heavy work.

[0005] 1.3. Although structurally sound, masonry blocks offer very little insulation benefits. Masonry Structures must have expensive, additional thermal layers or cladding of insulation materials to meet construction insulation regulation.

[0006] Masonry blocks, although fire resistant, do not sustain the heat experience with natural disaster and bush fires, and are likely to lose structural integrity and fail / crumble.

[0007] 2. Insulated Concrete Forms (ICF’s)

[0008] 2.1. The use of insulated concrete forms (ICF’s) is a relatively new, consisting of an inner-side and outer-side panels made of insulating materials (commonly polystyrene), held separated and connected, by center webs or spacers / chairs to achieve a center cavity that is filled with reinforced concrete.

[0009] 2.2. These edges of the forms are interlocking edges and a range of these light weightICF’s are assembled / stacked / interlocked / layered and braced with temporary steel frames before ready to be filled.

[0010] 2.3. ICF construction systems may be fast, efficient and include thermal insulation built in, but unlike masonry blocks, the ICF polystyrene panels are not durable, and are not aesthetically appealing. Both interior and exterior of ICF wall require render finishes or decorative cladding.

[0011] 2.4. Compared with masonry block, ICF’s are larger, lighter, faster and easier to assemble, with excellent thermal insulation performance. However, polystyrene is not fireproof, or environment friendly, the ICF system utilizes excessive volumes of concrete, and still requires cladding layers or finishes, resulting in expenses that offset any construction efficiency and cost savings.SUMMARY OF INVENTION

[0012] The objective of present utility model is to provide an Insulated Concrete Form Block (ICFB), a structural wall and a building, so as to achieve a comprehensive construction system. Utilizing the assembly of ICFB, the problems of using too much reinforced concrete and the high cost are solved; besides, the ICFB further addresses and resolves many insufficiencies and inefficiencies within the construction industry, including:1) Reduction of reinforced concrete volumes and expenses in excess of structural requirements;2) Mortarless interlocking joints, efficiency and accuracy of assembly;3) Multiple rotation options, easy assembly and various stacking finished faces;4) Light weight handling and construction cost reduction;5) Insulation regulation compliance without expense of addition cladding;6) Bush, brush, and forest fire protection;7) Carbon reducing, climate responsible, sustainable, recyclable non-petrochemical product;8) One step construction method, with prefinished exposed faces.

[0013] The above has been addressed and benefits identified and included in design, of ICFB construction system, and the following related art.

[0014] To achieve these objectives, the present utility model integrates the following solution.1 ) The horizontal and vertical channels of ICFB are of designed fixed area, which restricts the volume of reinforce concrete to what is required to achieve structural compliance, without costly excess materials and weight.2) The ICFB has been engineered and designed to control reinforced concrete volumes, structurally required to be applied to wall construction through vertical and horizontal structural lattice channels, reducing construction weight, time and cost.3) The ICFB has structural lattice channels filled with reinforced concrete, the channels are formed between two panels, one internal panel and one external panel, separated by a single central core, where the channels are located one end only, and top only, of ICFB edges of the two panels.4) The ICFB has vertical channels on one end, either left end or a right end relative to rotation. The opposite end has center core extended, that positions as Tongue and Groove Joint with adjacent ICFB during assembly. The vertical channel is enclosed by the two panels, center core and adjacent ICFB core tongue.5) The ICFB has vertical channel on top edge between two panels and center core, but can be top or bottom relative to rotation. The ICFB is designed to be rotated, then aligned and stacked onto the horizontal channel of adjacent ICFB. The horizontal channel is enclosed by four panels and two center cores.6) Further, the ICFB does not have horizontal channel at bottom edge, as the bottom edge is designed to be rotated, then aligned and stacked onto adjacent ICFB bottom edges and center cores, resulting in vertical channel being similar length to horizontal channel.7) Further, the ICFB has the horizontal channel intersecting with the vertical channel enclosing around the center core of two mirror rotated ICFBs.8) Further, the ICFB has appropriate reinforced concrete specified by the engineer, by adjusting Mpa and reinforcement applied to suit actual design loads.

[0015] Specifically, as illustrated in Fig. 2, the ICFB has the inner and outer side panels connected by a central core 2 to form a block. The central core 2 is smaller than outer panels (the inner and outer side panels) and recessed from the top and one end of the block to create groove structure in the horizontal direction and groove structure in the vertical direction between the inner and outer side panels. After the ICFBs of the present utility model are assembled into a wall, the groove structures of adjacent blocks are interconnected in the up-down direction and left-right direction to form structural lattice channels for laying reinforcements and concrete. By the dimension design of the inner side panel, the outer side panel and the center core, the volumes ofthe reinforced concrete in excess of structural requirements are reduced, and the corresponding expenses are also lowered.

[0016] Further, as illustrated in Fig. 4, the opposite end and the bottom of the center core 2 extend and pass the inner panels and outer panels, to form the core tongue of Tongue and Groove Joint (horizontal insertion portion 32). When blocks are stacked / assembled together, the adjacent blocks are connected by inserting the core tongue to groove structures between panels to form horizontal and vertical internal channels that intersect each other to form a continuous horizontal and vertical internal lattice of channels, and horizontal and vertical internal channels are open for pouring concrete. Blocks in the up-down direction may also be connected through mutually matched tab-slot alignment structural 3 formed at the top of the panel and at the bottom of panel, which improves assembly efficiency and accuracy by eliminating the need for mortar when relying on structural interlocks during block assembly.

[0017] Further, the ICFB of the present utility model has an all-forward assembly manner shown in FIG. 6(b) and a staggered assembly manner with one row being forward and one row being rotated 180 degrees to be upside down shown in FIG. 9(b). With multiple rotation options and easy assembly, various finished faces after assembly and stacking can be implemented.

[0018] Further, through appropriate materials and forming processes, the ICFB of the present utility model can implement light weights to facilitate handling, assembly, and construction. In addition, blocks directly comply with insulation regulations, require no additional cladding, and can bear forest fire. The ICFB of the present utility model reduces the use of structural concrete in a construction process, and uses cement materials with low carbon emission, so that carbon emission can be reduced, thereby achieving environmental friendliness.

[0019] Further, decorative patterns may be directly formed on surfaces of two panels 1 of the ICFB of the present utility model in a forming process, so that a surface of a formed wall directly has a prefinished exposed surface, and no additional apparatus is required.

[0020] The solution of the present utility model includes:

[0021] A technical solution of an ICFB of the present utility model includes surface layer structures on an inner side and an outer side and an insulated core between the surface layer structures. At a top and / or a bottom and a left end and / or a right end of the insulated core, groove structures are formed between inner side surfaces of the two surface layer structures and asurface of the insulated core.

[0022] The beneficial effects of the present utility model are:

[0023] In the present utility model, panels on two sides are connected by a central core to form a block. The central core at least provides groove structures in a horizontal direction (horizontal groove) and a vertical direction (vertical groove) between the panels on the two sides, and the horizontal groove and vertical groove are in communication with each other. When blocks are stacked and assembled together, panels are connected by edges to form a whole, horizontal grooves of blocks in a left-right direction are in communication with each other to form a continuous horizontal channel that can be used for pouring, vertical grooves of blocks in an up-down direction are in communication with each other to form a continuous vertical channel that can be used for pouring, and the horizontal channel and the vertical channel are in communication with each other to form internal lattice of channels. After the ICFBs of the present utility model are assembled into a wall and channel pouring is completed, a concrete grid with square holes can be formed in the wall. Horizontal concrete beams and vertical concrete columns of the concrete grid all extend inside the entire wall, thereby effectively improving the structural strength of the wall. In addition, only horizontal and vertical channels between the blocks require concrete pouring, and a required amount of concrete can be effectively reduced compared with the related art.

[0024] Further, a pouring hole communicating an upper surface and a lower surface of the insulated core is further provided in the middle of the insulated core.

[0025] Further, a roof ridge structure is formed on the upper surface of the insulated core, and a top of the roof ridge structure is located at a middle position of the insulated core in a horizontal direction, so that concrete flowing down from a pouring hole of an upper block flows toward two sides, making it easier to fill a horizontal space.

[0026] Further, the groove structures form horizontally and vertically communicated channels with adjacent groove structures when ICFBs are in an assembled state; and the channels form a concrete grid structure with specific structural strength after reinforcing steel bars are enveloped and concrete is poured.

[0027] Further, to facilitate assembly and increase the connection strength between blocks in a vertical direction, limiting structures configured to insert and complementarily matchcorresponding positions of ICFBs that are disposed adjacently in the vertical direction are disposed at an inner side of thickness or an outer side of thickness at a top and a bottom of the surface layer structure on at least one side; and sealing structures configured to join corresponding positions of the ICFBs that are disposed adjacently in the vertical direction are formed at other parts of thickness other than the limiting structures of the surface layer structure.

[0028] Further, the limiting structures are tab-slot alignment structures.

[0029] Further, step structures that match corresponding positions of ICFBs that are disposed adjacent in the vertical direction and perform limiting in an inside-outside direction are disposed at a top and a bottom of the surface layer structure on at least one side.

[0030] Further, the groove structure is provided at one end of a left end and a right end of the insulated core, and the insulated core protrudes outside the two surface layer structures from between the two surface layer structures and toward the other end of the left end and the right end of the insulated core, to form insertion portions that are configured to be inserted into groove structures of adjacent blocks and perform limiting in the inside-outside direction.

[0031] Further, the groove structure is provided at an upper end of the insulated core, and the insulated core protrudes outside the two surface layer structures from between the two surface layer structures and toward a lower end of the insulated core, to form insertion portions configured to be inserted into groove structures of adjacent blocks below and perform limiting in the inside-outside direction.

[0032] Further, a thickness of the ICFB formed by the surface layer structures on the inner side and the outer side and the insulated core in the middle makes thermal insulation parameters of the ICFB meet requirements of construction standards.

[0033] A structural wall of the present utility model, including an Insulated Concrete Form Block (ICFB), and the ICFB includes surface layer structures on an inner side and an outer side and an insulated core between the surface layer structures, at a top and / or a bottom and a left end and / or a right end of the insulated core, groove structures are formed between inner side surfaces of the two surface layer structures and a surface of the insulated core.

[0034] The beneficial effects of the present utility model are:

[0035] In the present utility model, inside a wall, horizontal grooves in blocks in the same horizontal direction are horizontally connected to form a horizontal channel, and vertical groovesin blocks in the same vertical direction are vertically connected to form a vertical channel. The horizontal channel and the vertical channel may form a concrete grid with square holes in the wall after pouring. Such concrete grid with square holes can improve the structural strength of the wall. In addition, compared with pouring a large amount of concrete between prefabricated modules to form a wall in the related art, concrete is poured in the grid channel so that concrete usage can further be greatly reduced.

[0036] Further, a pouring hole communicating an upper surface and a lower surface of the insulated core is further provided in the middle of the insulated core.

[0037] Further, a roof ridge structure is formed on the upper surface of the insulated core, and a top of the roof ridge structure is located at a middle position of the insulated core in a horizontal direction, so that concrete flowing down from a pouring hole of an upper block flows toward two sides, making it easier to fill a horizontal space.

[0038] Further, the groove structures form horizontally and vertically communicated channels with adjacent groove structures when ICFBs are in an assembled state; and the channels form a concrete grid structure with specific structural strength after reinforcing steel bars are enveloped and concrete is poured.

[0039] Further, to facilitate assembly and increase the connection strength between blocks in a vertical direction, limiting structures configured to insert and complementarily match corresponding positions of ICFBs that are disposed adjacently in the vertical direction are disposed at an inner side of thickness or an outer side of thickness at a top and a bottom of the surface layer structure on at least one side; and sealing structures configured to join corresponding positions of the ICFBs that are disposed adjacently in the vertical direction are formed at other parts of thickness other than the limiting structures of the surface layer structure.

[0040] Further, the limiting structures are tab-slot alignment structures.

[0041] Further, step structures that match corresponding positions of ICFBs that are disposed adjacent in the vertical direction and perform limiting in an inside-outside direction are disposed at a top and a bottom of the surface layer structure on at least one side.

[0042] Further, the groove structure is provided at one end of a left end and a right end of the insulated core, and the insulated core protrudes outside the two surface layer structures from between the two surface layer structures and toward the other end of the left end and the rightend of the insulated core, to form insertion portions that are configured to be inserted into groove structures of adjacent blocks and perform limiting in the inside-outside direction.

[0043] Further, the groove structure is provided at an upper end of the insulated core, and the insulated core protrudes outside the two surface layer structures from between the two surface layer structures and toward a lower end of the insulated core, to form insertion portions configured to be inserted into groove structures of adjacent blocks below and perform limiting in the inside-outside direction.

[0044] Further, a thickness of the ICFB formed by the surface layer structures on the inner side and the outer side and the insulated core in the middle makes thermal insulation parameters of the ICFB meet requirements of construction standards.

[0045] A building in the present utility model includes the foregoing structural wall.

[0046] The beneficial effects of the present utility model are:

[0047] In the present utility model, inside a wall of a building, horizontal grooves in blocks in the same horizontal direction are horizontally connected to form a horizontal channel, and vertical grooves in blocks in the same vertical direction are vertically connected to form a vertical channel. The horizontal channel and the vertical channel may form a concrete grid with square holes in the wall after pouring. Such concrete grid with square holes can improve the structural strength of the wall. In addition, compared with pouring a large amount of concrete between prefabricated modules to form a wall in the related art, concrete is poured in the grid channel so that concrete usage can further be greatly reduced.BRIEF DESCRIPTION OF THE DRAWINGS

[0048] FIG. 1 (a) is a front view of an ICFB according to the present utility model;

[0049] FIG. 1 (b) is a rear view of an ICFB according to the present utility model;

[0050] FIG. 1 (c) is a left view of an ICFB according to the present utility model;

[0051] FIG. 1 (d) is a right view of an ICFB according to the present utility model;

[0052] FIG. 1 (e) is a top view of an ICFB according to the present utility model;

[0053] FIG. 1 (f) is a bottom view of an ICFB according to the present utility model;

[0054] FIG. 2 is a three-dimensional view of an ICFB from a top angle according to the present utility model;

[0055] FIG. 3 is a three-dimensional view of an ICFB from a bottom angle according to the present utility model;

[0056] FIG. 4 is a three-dimensional view of an ICFB from another top angle according to the present utility model;

[0057] FIG. 5 is a three-dimensional view of an ICFB from another bottom angle according to the present utility model;

[0058] FIG. 6(a) is a schematic diagram of a wall structure of a wall formed through linear assembly of ICFBs according to the present utility model;

[0059] FIG. 6(b) is a schematic diagram of linear assembly of ICFBs according to the present utility model;

[0060] FIG. 7 is a schematic diagram of a reinforced concrete grid structure formed after ICFBs are assembled and concrete is poured and force bearing according to the present utility model;

[0061] FIG. 8 is a schematic diagram of a reinforced concrete grid structure formed after a building is constructed with ICFBs according to the present utility model;

[0062] FIG. 9(a) is a schematic diagram of a wall structure of a wall formed by staggered assembly of ICFBs according to the present utility model;

[0063] FIG. 9(b) is a schematic diagram of staggered assembly of ICFBs according to the present utility model;

[0064] FIG. 10(a) is a schematic diagram of forming a pouring channel between the upper and lower blocks during staggered assembly of ICFBs according to the present utility model;

[0065] FIG. 10(b) is a schematic diagram of forming a pouring channel between the upper and lower blocks during linear assembly of ICFBs according to the present utility model;

[0066] FIG. 11 (a) is a schematic top view of a structural relationship between an ICFB and a reinforcing steel bar according to the present utility model; and

[0067] FIG. 11 (b) is a schematic front view of a structural relationship between an ICFB and a reinforcing steel bar according to the present utility model.

[0068] In the drawings: 1. panel; 11. joint surface; 12. panel end; 13. tab-slot alignment structure; 131. protrusion tongue; 132. recess; 2. central core; 21. pouring hole; 22. slope; 23. horizontal insertion portion; 24. electrical and plumbing pipe installation slot; 25. side; 3. vertical groove; 4. horizontal groove; 5. reinforcing steel bar; 51. vertical-direction reinforcing steel bar; 52.horizontal-direction reinforcing steel bar; 61 . horizontal concrete beam; and 62. vertical concrete column.DESCRIPTION OF EMBODIMENTS

[0069] The idea of the present utility model is to provide an Insulated Concrete Form Block (ICFB). The block is formed by parallel panels on two sides and a solid central core made of insulation material, the central core (insulated core) is located between the panels on two sides and connects the panels on two sides. A vertical groove vertically penetrating the entire block is reserved between the panels on two sides of at least one end of the block by the central core, a horizontal groove horizontally penetrating the entire block is further reserved between the panels on two sides of a top and / or a bottom of the block, and the vertical groove and the horizontal groove are both located at edges of the panels and are in communication with each other.

[0070] After the ICFBs of the present utility model are stacked and assembled into a wall, panels on the same side of different blocks are connected, and panels on two sides after connections respectively form wall surfaces on two sides of the wall. In addition, horizontal grooves and vertical grooves on upper, lower, left, and right sides of central cores are connected to and combined with each other to form lattice of channels, i.e. continuous horizontal-direction pouring channels and vertical-direction pouring channels between the central cores between the wall surfaces on two sides.

[0071] In a process of forming the wall with blocks course by course, reinforcing steel bars are arranged in the pouring channels in the two directions, concrete is poured into the pouring channels in the two directions, and finally a reinforced concrete grid with square holes can be formed inside the wall. The reinforced concrete grid fixes all the blocks forming the wall in the square holes of the grid, and concrete poured into a horizontal direction and a vertical direction in the concrete grid are all located at same straight lines, which can bear stronger structural static load and dynamic load.

[0072] In addition, the central cores in the panels on two sides of the blocks form the main part, and the pouring channels are only reserved on sides of the central cores. When the blocks form the wall, the central cores of all the blocks account for the main volume of the entire wall. Therefore, a pouring amount of concrete in a wall construction process is greatly reduced.

[0073] As a further optimized technical solution, as a horizontal limiting structure between the upper and lower blocks, protrusion tongues and recesses matching each other are respectively iodisposed at upper ends and lower ends of the panels on two sides of the blocks, so that during block assembly, two upper and lower blocks can be embedded in alignment through tab-slot alignment structures to form secure connections without mortar, thereby further improving the structural strength of the wall.

[0074] As a further optimized technical solution, the central core in the block of the present utility model protrudes from one end (a first end) of each of the panels on two sides in the horizontal direction. A vertical groove is reserved at the other end (a second end) of each of the panels on two sides, a size of the vertical groove in the horizontal direction parallel to the panels is greater than a size of a part of the central core protruding from the first end, and an extra size is used to form a pouring channel of the block in the vertical direction. In this way, during block assembly, between horizontally adjacent blocks, the insertion fit between the adjacent blocks in the horizontal direction through the tab-slot alignment structures can be implemented by inserting the protruding part of the central core into the vertical groove reserved between adjacent blocks, thereby further improving the structural strength of the wall.

[0075] To fully inject concrete into the horizontal-direction pouring channels, further, a lower portion of the central core in the block in the present utility model is flush with bottom ends of the panels on two sides, and the horizontal groove is reserved at tops of the panels on two sides. After one course of blocks is laid, a complete horizontal-direction pouring channel is defined between the panels on two sides of the tops of the blocks and above the central cores. After reinforcing steel bars are laid for the horizontal-direction pouring channel at the top of the course of blocks, a next course of blocks can be laid. After each course or a plurality of courses of blocks is laid, concrete is fully poured into the pouring channel.

[0076] Furthermore, as another implementation, only one vertical pouring hole may be opened at a middle position of the solid central core. Because a distance between a position below the middle position of the central core and the vertical-direction pouring channel is the largest, it is difficult to ensure even and full pouring of concrete at the position only by supplementing concrete in the vertical-direction pouring channel. Therefore, for the pouring hole, after one course or a plurality of courses of blocks are laid, concrete may be supplemented into the horizontal-direction pouring channel communicated below the pouring hole through the pouring hole, to implement more solid concrete filling at positions of the horizontal-direction pouring channel below the middle of thecentral cores.

[0077] To make the objectives, technical solutions, and advantages of the present utility model clearer, the following further describes in detail a preferred typical implementation of the present utility model with reference to the accompanying drawings and embodiments.

[0078] Embodiment 1 of an ICFB:

[0079] FIG. 1 (a), FIG. 1 (b), FIG. 1 (c), FIG. 1 (d), FIG. 1 (e), and FIG. 1 (f) are views of orthogonal projections of six faces of an ICFB according to this embodiment. The views are sequentially a front view, a rear view, a left view, a right view, a top view, and a bottom view of the ICFB.

[0080] For ease of description, the following definitions are now made. In the front view of the views of the orthogonal projections of the six faces shown in FIG. 1 (a), a face (that is, the front panel surface) shown and a face (that is, a rear panel surface, a face shown in the rear view shown in FIG. 1 (b)) behind the front panel surface of the block in the figure are two side surfaces of the ICFB. Faces shown in the left view and the right view shown in FIG. 1 (c) and FIG. 1 (d) are two ends of the ICFB. Faces shown in the top view and the bottom view shown in FIG. 1 (e) and FIG. 1 (f) are a top and a bottom of the ICFB.

[0081] An ICFB in this embodiment shown in FIG. 2 includes two parallel panels 1 that are right opposite and used to form a front surface layer structure and a back surface layer structure respectively. After the blocks are assembled to form a wall, the front panel surface and the rear panel surface on the two panels 1 form an inner wall surface and an outer wall surface of the wall. The panels 1 on two sides are connected by a central core 2, and projections of the central core 2 on the panels 1 on two sides have surface areas smaller than a surface area of the panel 1 , so that a horizontal groove 4 is reserved at the top and / or the bottom of the block, and a vertical groove 3 is reserved at least at one of two ends of the block .

[0082] Specifically, as shown in FIG. 3, a bottom of the central core 2 is flush with bottom ends of the panels 1 on two sides to form the bottom of the block, and as shown in FIG. 2, a horizontal groove 4 is avoided between the panels 1 on two sides at a top of the block, and the horizontal groove 4 penetrates a left end and a right end of the block. At one end of the block, the central core 2 avoids a vertical groove 3 between the panels 1 on two sides, and the vertical groove 3 penetrates the top and the bottom of the block.

[0083] During block assembly, in the vertical direction, tops of panels 1 on two sides of a lowerblock may be joined and assembled to bottoms of panels 1 on two sides of an upper block, and in a horizontal direction, panel ends 12 of panels on two sides of a block may be joined and assembled to corresponding panel ends 12 of panels on two sides of a corresponding adjacent block in the horizontal direction.

[0084] Surface treatment with colours and textures is performed on the front panel surface and the rear panel surface on the panels 1 , the front panel surface and the rear panel surface are configured to form the inner wall surface and the outer wall surface of the wall, so as to avoid plastering, cladding, or other surface treatment for aesthetics, thereby saving time and money.

[0085] The central core 2 is formed by using an appropriate concrete material, to make a thermal insulation value and a thermal resistance thereof meet requirements of building codes, reduce bulk concrete to be poured, therefore a formed structure is lighter, reduce structural strength for support, the use of construction materials, and costs are reduced.

[0086] After the blocks are assembled, the horizontal grooves 4 and the vertical grooves 3 form a pouring channel (lattice of channels) that is continuous in the horizontal direction and the vertical direction. After concrete is fully poured into the pouring channel, a square-hole grid surrounding the blocks is formed in a constructed wall, to reinforce the blocks in the wall in a surrounding manner.

[0087] The vertical-direction pouring channel enables reinforcing steel bars to be fixed in position, and allows blocks to be stacked around the mounted reinforcing steel bars, thereby reducing a construction time, the usage and costs of concrete materials.

[0088] Further, to strengthen the bonding between the concrete grid and the blocks, structural grooves are opened in end surfaces on left and right sides of the central cores 2 of the blocks, and the end surfaces are configured to form the vertical-direction pouring channel. Cylindrical concrete formed after pouring in the pouring channel forms protruding keys at positions corresponding to the structural grooves. Through the cooperation of the keys and key grooves (the structural grooves), a more secure and reliable embedding bonding relationship is formed between the concrete grid and the central cores 2 of the blocks.

[0089] Further, as shown in FIG. 2, FIG. 3, FIG. 4, and FIG. 5, electrical and plumbing pipe installation slots 24 are opened in end surfaces that are configured to form the vertical-direction pouring channel on left and right sides of the central cores 2 of the blocks, and are configured toarrange pipes for electrical and plumbing systems.

[0090] Further, as shown in FIG. 2 and FIG. 3, matching tab-slot alignment structures 13 are disposed at the tops and the bottoms of the panels 1 on two sides of the block. Two vertical blocks may be embedded with each other through the tab-slot alignment structures 13 at the bottom of the upper block and the tab-slot alignment structures 13 at the top of the lower block without mortar.

[0091] Specifically, the tab-slot alignment structure 13 at the top of the block is shown in FIG. 4, and protrusion tongues 131 and recesses 132 are disposed at intervals at the top of the panel 1 . The tab-slot alignment structure 13 at the bottom of the block is shown in FIG. 3, and protrusion tongues 131 and recesses 132 are disposed at intervals at the bottom of the panel 1. The protrusion tongues 131 and the recesses 132 of the tab-slot alignment structure 13 at the top and the tab-slot alignment structure 13 at the bottom match correspondingly. To be specific, the recesses 132 of the tab-slot alignment structure 13 at the bottom are located right below the protrusion tongues 131 of the tab-slot alignment structure 13 at the top, and the protrusion tongues 131 of the tab-slot alignment structure 13 at the bottom are located right below the recesses 132 of the tab-slot alignment structure 13 at the top. In this way, when two blocks are assembled linearly (assembled right opposite) in the vertical direction, the tab-slot alignment structures 13 at the top and the bottom inserted in a matching manner with each other exactly.

[0092] The recesses 132 in the tab-slot alignment structure 13 may be formed by spaces between adjacent protrusion tongues 131 , and shapes of the protrusion tongues 131 and the recesses 132 should match each other. To provide guidance in an insertion process and implement easier assembly, the protrusion tongue 131 is a trapezoid with a smaller top and slopes on two sides. In this way, a recess 132 with an inverted trapezoidal shape is formed between protrusion tongues 131. In an insertion and assembly process, through the guidance and cooperation between the slopes on two sides of the trapezoid of the protrusion tongue 131 and the slopes on two sides of the corresponding recess 132, the protrusion tongue 131 can enter the recess 132 more easily. This facilitates assembly, reduces difficulty in operation, and also reduces dimensional tolerance requirements.

[0093] Embodiment 2 of an ICFB:

[0094] Based on the block described in Embodiment 1 , as another implementation, as shown inFIG. 2 and FIG. 4, the top of the panel 1 is divided into two layers in a thickness direction of the panel 1 . A joint surface 11 for assembly and joint of panels during block assembly is formed at an outer layer, and a tab-slot alignment structure 13 is formed at an inner layer. It is the same with the bottom of the panel 1 , as shown in FIG. 3. After the tab-slot alignment structures 13 are inserted in a matching manner, the joint surface 11 of the top of the lower block and the joint surface 11 of the bottom of the upper block are closely and seamlessly joined to each other. In this way, when the blocks are assembled to form a wall, the tab-slot alignment structures 13 are blocked inside, so that surface joints of the wall are straight, which is more aesthetically pleasing. In addition, after being inserted in a matching manner, the tab-slot alignment structures 13 provide limitation in a direction perpendicular to the surface of the panel 1 through the joint surface 11 , to ensure that an even wall surface after assembly. More importantly, the sealing effect of the joint after the tab-slot alignment structures 13 are inserted in a matching manner can also be improved. In view of that concrete grout is subjected to greater grout pressure in the pouring channel under the wall before setting, this can prevent the overflow of grout poured into the horizontal-direction pouring channel behind the joint.

[0095] Further, the top of the protrusion tongue 131 in the tab-slot alignment structure 13 is higher than the joint surface 11 , the bottom of the recess 132 is lower than the joint surface 11 , and the joint surface 11 is located at a middle position between the top of the protrusion tongue 131 and the bottom of the recess 132. Through the joint surface 11 , the structural strength of the tab-slot alignment structures 13 at the top and the bottom of the block is increased.

[0096] As another implementation, the top and the bottom of the panel 1 are divided into two layers with different heights in a thickness direction (an inside-outside direction) of the panel 1 to form step structures in thickness, and the step structures are configured to perform limiting in the inside-outside direction through corresponding matching step structures when two vertical blocks are assembled. For the step structures matching each other, one should be high inside and low outside in thickness, and the other should be low inside and high outside in thickness.

[0097] Embodiment 3 of an ICFB:

[0098] Based on the foregoing embodiments, as shown in FIG. 4, a side 25 with a specific thickness is also formed at the top of the central core 2 on two sides of the horizontal groove 4. A top surface of the side 25 is configured to be connected to a bottom surface of a central core 2 of ablock above the block during assembly. The side 25 is located on an inner side of the tab-slot alignment structure 13 at the top, and can also provide limitation in a direction perpendicular to the surface of the panel 1. In addition, the sealing effect of the horizontal-direction pouring channel at the joint formed by the tab-slot alignment structures 13 is enhanced, thereby reducing the possibility of seepage of the poured concrete or grout. In addition, considering that during assembly and construction to form a wall, a horizontal concrete beam 61 of the concrete grid shown in FIG. 7 that is formed inside the wall after concrete is poured is subjected to smaller force than a vertical concrete column 62, the size of the horizontal groove 4 is reduced through the side 25 to reduce the size of the horizontal concrete beam 61 in the grid, thereby further reducing concrete usage of the wall while ensuring structural strength.

[0099] Embodiment 4 of an ICFB:

[0100] Based on the foregoing embodiments, as shown in FIG. 1 (e), FIG. 1 (f) and FIG. 5, at the other end of the block without the vertical groove 3, the central core 2 protrudes from the panel 1 at the end by a specific distance to form a horizontal insertion portion 23. During block assembly, in two horizontally adjacent blocks, a horizontal insertion portion 23 of one block is inserted into a vertical groove 3 of the other block, to jointly define, with panels 1 on two sides and a central core 2 of the other block, a closed vertical-direction pouring channel. The central core 2 protrudes to form the horizontal insertion portion 23, which can implement insertion and fitting between two horizontal blocks in the horizontal direction and form mutual embedding to further increase the structural strength of the wall after the wall is formed.

[0101] As another implementation, the central core 2 may further protrude downward from the panel 1 by a specific distance to form a vertical insertion portion that is vertical downward. A vertical size of the vertical insertion portion protruding from the panel is less than a height of the horizontal groove 4, and a difference between the two is a height of the horizontal-direction pouring channel. During block assembly, in two vertically adjacent blocks, a vertical insertion portion of an upper block is inserted into a horizontal groove 4 of a lower block, to jointly define, with panels 1 on two sides and a central core 2 of the lower block, a closed horizontal-direction pouring channel. The central core 2 protrudes downward to form the vertical insertion portion, which can implement insertion and fitting between two vertical blocks in the horizontal direction and form mutual embedding to further increase the structural strength of the wall after the wall isformed.

[0102] The following describes a manner of forming a wall by assembling and stacking the blocks described in this embodiment, to make the structure, the use method, and advantages of the ICFB of the present utility model clearer.

[0103] As shown in FIG. 6(a), the blocks may be assembled in a linear manner (without a overlap-joint) to form a wall. In the figure, the wall has an opening for a window or a door with a width of 900 units. Each square in the figure is a side panel 1 of a block, i.e., a block. As shown in the figure, the blocks may be made in different sizes to adapt to different construction requirements, as long as the structure is consistent with the description of the foregoing embodiments.

[0104] In this case, the assembly of blocks is shown in FIG. 6(b). Two vertically adjacent blocks are connected through insertion and embedding between tab-slot alignment structures 13 at a bottom of the upper block and tab-slot alignment structures 13 at a top of the lower block. Two horizontally adjacent blocks are connected by inserting a horizontal insertion portion 23 at a right end of the left block in the figure into a vertical groove 3 at a left end of the right block in the figure. The assembly and connection between the blocks can be implemented without mortar.

[0105] For ease of description, in FIG. 6(b), the vertical groove 3 and the horizontal groove 4 are displayed in the blocks in a perspective manner. After the blocks are assembled and connected, the vertical grooves 3 of the blocks in the same vertical direction are in communication with each other to form a vertical-direction pouring channel, and the horizontal grooves 4 of the blocks in the same horizontal direction are in communication with each other to form a horizontal-direction pouring channel. In a construction process, reinforcing steel bars 5 are arranged in the vertical-direction pouring channel and the horizontal-direction pouring channel, and concrete is pumped. Finally, a reinforced concrete grid shown in FIG. 7 is formed in a completed wall.

[0106] As shown in FIG. 8, in a reinforced concrete grid in a structural wall finally formed by the blocks of the present utility model, each horizontal concrete beam 61 in the horizontal direction is a continuous whole that is located on the same horizontal straight line and covers the entire wall, and each vertical concrete column 62 in the vertical direction is also a continuous whole that is located on the same vertical straight line and covers the entire wall. This reinforced concrete grid can withstand higher static load (structural resistance) and dynamic load (horizontal force).

[0107] The blocks in the foregoing embodiments may be further assembled in a staggered (overlap-joint) manner shown in FIG. 9(a), and the reinforced concrete grid shown in FIG. 7 can also be finally formed. In this case, the assembly of the blocks is shown in FIG. 9(b). In the figure, blocks in the first course are assembled with each other through the horizontal insertion portions 23, and a vertical-direction pouring channel corresponding to the first course is formed. In the figure, blocks in the second course are all rotated 180 degrees about an axis perpendicular to the panel 1 and connected through insertion and embedding between the tab-slot alignment structures 13 at the tops and the tab-slot alignment structures 13 at the tops of the blocks below. Adjacent blocks in the horizontal direction in the second course are still connected by embedding the horizontal insertion portions 23 into the vertical grooves 3 of the adjacent blocks. For a rotated block and a block below the block, central cores 2 of the two blocks are right opposite (aligned in the vertical direction), so that the vertical grooves 3 of the two blocks are respectively located on left and right sides of two central cores 2 which aligned in the vertical direction. In this way, a vertical groove 3 of a block in the second course and a vertical groove 3 of a block located on the right side of a block right below the block in the first course in the figure are aligned in the vertical direction, to be specific, can form the same vertical-direction pouring channel. In this way, the blocks are assembled together through laying with one course non-inverted and one course inverted, so that a pouring channel that is complete and continuous in the vertical direction can be formed in a staggered overlap-joint manner.

[0108] In this case, for the horizontal-direction pouring channel, it can be learned from FIG. 9(a) that, the block in the second course in the figure is rotated by 180 degrees, and the horizontal groove 4 at the top of the block faces downward. Therefore, the horizontal grooves 4 of the blocks in the first course and the second course in the figure are combined to form the horizontal-direction pouring channel. The block in the third course in the figure is a non-inverted block. Therefore, the blocks in the second course and the third course in the figure are connected to each other through insertion and embedding of the tab-slot alignment structures 13 at the bottoms of the blocks. In this way, no horizontal groove 4 forms the horizontal-direction pouring channel.

[0109] Therefore, during assembly in a staggered manner, a horizontal-direction pouring channel that is horizontally complete and continuous is formed in every two rows of blocks. Compared with a horizontal-direction pouring channel that is horizontally complete andcontinuous in two adjacent rows of blocks assembled in a linear manner, an interval between horizontal concrete beams 61 of a concrete grid formed by staggered assembly in a wall is larger, and is about twice as large as that in linear assembly. However, as shown in FIG. 10(a), the corresponding horizontal-direction pouring channel is formed by combining horizontal grooves 4 of two blocks. Therefore, the horizontal concrete beam 61 formed in the wall in a staggered manner is thicker, and is approximately twice as thick as a horizontal concrete beam 61 when a horizontal-direction pouring channel is formed by horizontal grooves 4 of linearly assembled individual blocks shown in FIG. 10(b).

[0110] To cooperate with the staggered assembly manner, each of the protrusion tongues 131 or the recesses 132 at the two ends of the tab-slot alignment structures 13 at the top and the bottom of the blocks is a half of a complete protrusion tongue 131 or recess 132. In this way, during staggered overlap-joint assembly, as shown in the dashed circle in FIG. 9(b), at a overlap-joint position of an upper block on blocks in a lower course, a complete protrusion tongue formed by two half-protrusion tongues 131 at ends where two lower horizontally adjacent blocks are connected can be tightly held by a complete recess 132, thereby further increasing the structural strength during staggered assembly.

[0111] A typical construction procedure for constructing a structural wall using the blocks described in this embodiment is to fix vertical reinforcing steel bars to a foundation before laying the first course of blocks and then start to assemble the blocks. The vertical groove 3 for forming a pouring channel of each block is a semi-open structure. For a block in the related art as described in the BACKGROUND, a hole for grouting reinforcement is a hole that has a closed circumference and is formed in a block body, making it difficult to arrange reinforcing steel bars and assemble blocks, or causing reduced structural strength without reinforcing steel bars. Therefore, the solution in this embodiment makes block assembly very easy and efficient, which is faster than block assembly in the related art. In an assembly process, before the horizontal-direction pouring channel is closed, a horizontal-direction reinforcing steel bar is arranged in the horizontal-direction pouring channel, and the horizontal-direction reinforcing steel bar may be bound and fixed at an intersection with a vertical-direction reinforcing steel bar. A positional relationship between the vertical-direction reinforcing steel bar 51 and a horizontal-direction reinforcing steel bar 52 and a block is shown in FIG. 11 (a) and FIG. 11 (b).

[0112] Each time after a plurality of courses of blocks are laid, the vertical-direction and horizontal-direction pouring channels are fully pumped, and the pouring channels are vibrated to remove cavities from concrete to make the concrete tight and solid. In an assembly process, concrete sets in a wall at a relatively low height and reinforces the wall, In addition, it is only necessary to continue to assemble and lay blocks in an upper course, and no expensive external support is required to keep a wall vertical and square, thereby saving time and reducing construction costs.

[0113] The required concrete or grout can be reduced under the premise of structural compliance, thereby reducing internal mass, pressure leakage, and bursting.

[0114] The overall strength of the concrete grid structure may be adjusted as required through engineering calculation. Objects of the adjustment include increasing grouting strength (Mpa) and cross section (mm2) of a reinforcing steel bar or the like.

[0115] A person skilled in the art should understand that the expressions of "horizontal direction" and "vertical direction" used in the embodiments are to consider that generally, structural wall of a building are constructed above a horizontal foundation or a horizontal ground. In this case, the blocks are laid horizontally. A case that a wall is constructed along an inclined ground is not excluded. In this case, the "horizontal direction" and the "vertical direction" are to be understood as a horizontal direction and a vertical direction based on a block. That is, the horizontal direction is a direction parallel to a top and a bottom of the block, and the vertical direction is a direction perpendicular to the top and the bottom of the block.

[0116] Embodiment 5 of an ICFB:

[0117] Based on Embodiment 4, to allow concrete to enter a position below the central core 2 of the block in the horizontal-direction pouring channel more easily and to prevent air bubbles being formed in concrete beams, in this embodiment, as shown in FIG. 2 and FIG. 4, at a right middle position of the central core 2 of the block, a pouring hole 21 penetrating the entire central core 2 is opened in the vertical direction from the top to the bottom of the block. In a process of pouring concrete, after pouring is directly performed at the pouring hole 21 of the block in the uppermost course or at another location, concrete may flow toward the pouring hole 21 along a horizontal-direction pouring channel and flow into the pouring hole 21. Regardless of linear assembly or staggered assembly, the pouring holes 21 of the vertical blocks are located in thesame vertical direction, i.e., the pouring holes 21 are opposite vertically, and the concrete can directly flow through the pouring holes 21 to the lower horizontal-direction pouring channels, to compensate for the deficiency that when pouring is performed through only the vertical-direction pouring channel to the lower horizontal direction pouring channel, it is difficult for concrete with poor flowability to fill the pouring channels below the central core 2.

[0118] As a further improvement, as shown in FIG. 2 and FIG. 4, a laterally facing slope 22 that is high in the middle and low on two sides is formed at a top of the central core 2 of the block, i.e., a side of the central core 2 adjacent to the horizontal groove 4 of the block, and a pouring hole 21 is located at the highest position in the middle, so that in the horizontal-direction pouring channel of this course, concrete falling from the pouring hole 21 of the upper block can quickly flow toward two sides of the pouring hole 21 as soon as possible through the laterally facing slope 22 of the bottom surface of the pouring channel, i.e., laterally facing slope 22 at the top of the central core 2 of this block, to avoid a case that when concrete accumulates right below the pouring hole 21 of the upper block, concrete fails to be filled at other positions below the central core 2 of the upper block.

[0119] Embodiment 6 of an ICFB:

[0120] Based on the block structure provided in the foregoing embodiments, this embodiment provides a typical material formula for making blocks. Components that are specifically used may be adjusted according to existing materials in a manufacturing country and requirements of building codes in a country to which blocks are to be sold. Possible compositions include, but are not limited to:

[0121] light materials and sand: volcanic rock and volcanic glass (also known as scoria), pumice, perlite, clay, slate, and shale;

[0122] light fine powder and powder: carbonates, sulfates, oxides, and hydroxides of calcium, silicon, magnesium, and aluminum;

[0123] light pozzolans: volcanic ash, fly ash, and slag;

[0124] thermal resistance substitutes: expanded polystyrene (EPS), polyurethane (PUR), polyisocyanurats (PIR), and the like;

[0125] cement and binders: portland cement, high-alumina cement such as calcium aluminate cement (CAC) or calcium sulfoaluminate cement (CSA), and sodium silicate; and

[0126] aerating agents: chemical additives, plasticizer, foam generation, and aerogel.

[0127] The ICFB in this embodiment is made from light weight aggregates and aerated cementitious technology, and therefore is lighter and easier to handle. Light weight aggregates and aerated cements have naturally insulating properties, and the ICFB in this embodiment is conform to and surpass current Building Codes and Regulations for Thermal Insulation and Fire Resistance.

[0128] Although the polystyrene concrete form (insulated concrete form, ICF) is lighter, easier for a technician to assemble, and has a certain thermal insulation effect, the surface of the form is not made of a concrete material, still requires an expensive coating or two-sided decorative surfaces, and is filled with 70% more concrete than required by a structure.

[0129] The structural engineering reinforced concrete members of many current buildings are evaluated, and a significant phenomenon is that 40% of the structural concrete needs to support more than 70% of excess non-structural concrete (self-weight). This hardly generates any thermal insulation value, and leads to unnecessary engineering structure and construction expenses. These expenses can be used for current structural construction.

[0130] In contrast, 80% of the volume of the ICFB in this embodiment (the panels on two sides and the central core, i.e., the structural grid) has non-flammable thermal resistance, thermal insulation, and fire resistance.

[0131] By removing unnecessary non-structural concrete from the building, the total weight of the building can be reduced, which means that the volume of the structural concrete is reduced (which can be reduced by 70% of the current concrete usage). Since the carbon dioxide emission generated in the concrete production process is expected to account for 4% to 8% of the total global carbon dioxide emission, the building of the block provided in this embodiment has much less impact on climate changes. Refractory cement with low carbon dioxide emission is used in actual products, so that impact on weather can be further reduced.

[0132] The ICFB in this embodiment has an appearance of industrial concrete, does not require additional thermal insulation, coating, or plastering, and can reduce costs compared with a polystyrene concrete form that still needs to be coated. Certainly, according to aesthetic needs, decoration, painting, or finish addition can still be performed.

[0133] Based on the foregoing embodiments, wall construction costs of current buildings are also evaluated. The ICFB of the present utility model has advantages of high constructionefficiency, high structural strength, low costs, and energy saving and environmental protection.

[0134] Embodiment of a structural wall:

[0135] A structural wall in this embodiment is formed by assembling and stacking ICFBs in the present utility model. A specific structure and a specific assembly method of the ICFBs and a structure of a formed structural wall have been described in the embodiments of the ICFB sufficiently clear. Details are not described herein again.

[0136] Embodiment of a building:

[0137] A building in this embodiment, comprising a structural wall described in the embodiment of a structural wall. The structural wall is formed by assembling and stacking ICFBs in the present utility model. A specific structure and a specific assembly method of the ICFBs and a structure of a formed structural wall have been described in the embodiments of the ICFB sufficiently clear. Details are not described herein again.

Claims

CLAIMS1 . An Insulated Concrete Form Block, comprising surface layer structures on an inner side and an outer side and an insulated core between the surface layer structures, at a top and / or a bottom and a left end and / or a right end of the insulated core, groove structures are formed between inner side surfaces of the two surface layer structures and a surface of the insulated core.

2. The Insulated Concrete Form Block according to claim 1 , characterized in that a pouring hole communicating an upper surface and a lower surface of the insulated core is further provided in the middle of the insulated core.

3. The Insulated Concrete Form Block according to claim 2, characterized in that a roof ridge structure is formed on the upper surface of the insulated core, and a top of the roof ridge structure is located at a middle position of the insulated core in a horizontal direction.

4. The Insulated Concrete Form Block according to any one of claims 1 to 3, characterized in that the groove structures form horizontally and vertically communicated channels with adjacent groove structures when ICFBs are in an assembled state, and the channels form a concrete grid structure with specific structural strength after reinforcing steel bars are enveloped and concrete is poured.

5. The Insulated Concrete Form Block according to any one of claims 1 to 3, characterized in that limiting structures are disposed at an inner side of thickness or an outer side of thickness at a top and a bottom of the surface layer structure on at least one side, the limiting structures are configured to insert and complementarily match corresponding positions of ICFBs that are disposed adjacently in the vertical direction, and sealing structures are formed at other sections of thickness other than the limiting structures of the surface layer structure, the sealing structures are configured to join corresponding positions of the ICFBs that are disposed adjacently in the vertical direction.

6. The Insulated Concrete Form Block according to claim 5, characterized in that the limiting structures are tab-slot alignment structures.

7. The Insulated Concrete Form Block according to any one of claims 1 to 3, characterized in that step structures matching corresponding positions of ICFBs that are disposed adjacently in the vertical direction are disposed at a top and a bottom of the surface layer structure on at least one side, and the step structures are configured to perform limiting in an inside-outside direction.

8. The Insulated Concrete Form Block according to any one of claims 1 to 3, characterized in that the groove structure is provided at one end of a left end and a right end of the insulated core, and the insulated core protrudes outside the two surface layer structures from between the two surface layer structures and toward the other end of the left end and the right end of the insulated core, to form insertion portions that are configured to be inserted into groove structures of adjacent blocks and perform limiting in the inside-outside direction.

9. The Insulated Concrete Form Block according to any one of claims 1 to 3, characterized in that the groove structure is provided at an upper end of the insulated core, and the insulated core protrudes outside the two surface layer structures from between the two surface layer structures and toward a lower end of the insulated core, to form insertion portions configured to be inserted into groove structures of adjacent blocks below and perform limiting in the inside-outside direction.

10. The Insulated Concrete Form Block according to any one of claims 1 to 3, characterized in that a thickness of the ICFB formed by the surface layer structures on the inner side and the outer side and the insulated core in the middle makes thermal insulation parameters of the ICFB meet requirements of construction standards.1 1 . A structural wall, characterized in that the structural wall includes the Insulated Concrete Form Block according to any one of claims 4 to 9 in a linear manner or in a staggered manner, and the concrete grid structure formed in the channels.

12. A building, characterized in that the building comprises the structural wall according to claim

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