US 6,148,576 AGranted

Energy conserving wall unit and method of forming same

OwnerPeter Janopaul, Jr.inventor

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Abstract

A wall which is energy conserving, particularly useful for a prison or other types of buildings, has a security inner structural element structure which may be formed of concrete blocks, the outer facings of which are formed with vertical sockets shaped as mortise grooves. Spaced outwardly from the inner structural element is a decorative weatherskin element, the inner faces of which are also formed with vertical sockets. Horizontal spacers interconnect the inner and the outer elements so that there is a space therebetween. The spacers have enlarged heads at either end which are received in the sockets, then twisted and hold the two elements a given distance apart. The space between the two walls is filled by pouring insulating material such as polyurethane foam. Alternatively the outer structural element may be formed of clay bricks or other facing materials, one end of the spacers being paddle shaped to fit into the mortar joint between courses of bricks.

Claims25

Dependent claims

A wall construction comprising an inner structural element having an outer face, said outer face being formed with a first spacer receptor,

an outer weatherskin element having an inner face formed with a second spacer receptor aligned with said first spacer receptor, said inner structural element being spaced from said outer weatherskin element,
a spacer having a center portion and first and second ends shaped to engage within said first and second spacer receptors, respectively,
said spacer receptors each having an inner portion and a throat slightly wider than said center portion of said spacer and narrower than a respective one of said spacer ends, and
wherein the thickness of each said respective spacer end is narrower than a respective throat allowing said respective spacer end to pass through said respective throat and the width of each said respective spacer end is wider than said respective throat so as to prevent removal of each said respective spacer end from a respective spacer receptor and locate said outer weatherskin element a desired distance from said structural element upon 90.degree. rotation of said spacer about its longitudinal axis, and
wherein said spacer receptors have lengths substantially greater than the widths of said spacer ends,
said spacers being located below an upper surface of said inner structural element a distance substantially greater than the widths of said spacer ends.

3 more elements

A method of forming a wall construction comprising the steps of:

positioning an inner structural element having an outer face,
positioning an outer weatherskin element having an inner face spaced from said inner structural element,
each said outer and inner faces including a groove having a throat and an inner portion, each said throat having a width,
providing a spacer having a center with a longitudinal axis and first and second ends, each said end having a thickness less than the width of a respective said throat whereby each said end of said spacer is insertable into a respective said inner portion through said respective throat, each said end having a width greater than said width of said respective throat and less than the width of said respective inner portion,
orienting said spacer such that said thickness of each said end is aligned with a respective said throat,
inserting one of said first and second ends through a respective said throat into a respective said inner portion, and
inserting the other of said first and second ends through a respective said throat into a respective said inner portion.

4 more elements

Dependencies are inferred from the claim text.