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Патент USA US2045546

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June 23, 1936.
2,045,546
c. J. CHAPLIN
INSULATING BUILDING BLOCK
Filed Aug. 26, 1935
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2 Sheets-Sheet >1
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MAE/v70»?
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June 23, 1936.
2,045,546
c. J. CHAPLIN
INSULATING BUILDING BLOCK
‘
Filed Aug. 26, 1955
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2 Sheets-Sheet 2
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lNVENTORI
2,045.546
Patented June 23; 1936
UNITED STATES PATENT OFFICE
aussis
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y.
msum'rmc BUILDING 51.0016‘
Charles J. Chaplin, Waterville, Maine, assignor
to Chaplin Corporation. Portland, Maine, :.
corporation oi.’ Maine
Application August 26, 1935, Serial No. 37,894
‘
10 Claims.
(01. 92-55)
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I
.
‘Fig. 3 is an enlarged cross sectional view of a
This invention has to do with an article and
the method of making the same, in the form of
a building block or slab made from insulating
and heat resisting material by surrounding a
insulating material and the‘ protective grid 01‘
ribbed covering deposited thereon.
mass of. insulating material with an interlocking
lattice or grid enclosing structure formed of
Fig. 4 is an exterior view of a portion otthe "
i'ormed block showing the grid or ribbed enclose
strong ?brous or similar materials.
'ing
.
The most ef?cient'heat insulating materials
have little mechanical strength in themselves and
10 are composed of materials having relative low heat
conductivity plus an ability to form large num
bers of small; individual air cells. This air cell
space in total is great in proportion to the space
occupied by the materials themselves.
I _
portion of the structure of Fig. 2. showing the .
structure.
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I
~
‘
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Fig. 5 shows the perforated suction tube which
is placed inside of the structure shown in Figs.
1 and 2.
v
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a
The structure ‘shown in Figs. 1 and 2 consists
of a grid ,frame or box of the desired shape-and inside size oi’ the block, slab or other insulating "
block or article which it is desired to make. This
To retain the e?iciency of such- material in use structure consists of a ‘bottom section 5, artop
it is necessary that it be relatively loosely packed section 6, two end sections 1 and‘8 and two side '
. in the space which is to be insulated and that sections 9 and ill. These six sections when as
the natural air‘ cell structure of this material sembled together form.‘ an enclosing structure or
be retained. It isalso undesirable to mix other box in which ,is placed the insulating material to
20 materials with the insulating material, which be used.
20
The several sides of this box-like structure are
materials may increase the heat conductivity and
made up of bars 2 between which are narrow
reduce the relative air cell spaced. 7
'
15
spaces i. These spaces -I_ are suillciently small
'so that the insulating material will not escape
from the box through these openings. They are,
however, su?lciently large. so that the pulp or
mats or sheets enclosed in wire or other forms ,-'other ?brous materials will pass between them
when carried by a suitable conveying liquid in
to retain them in approximate shape and to per
which these fibres are held in suspension.
mit handling while being installed. These ma
Extending into the interior of the box struc 80
terials, however, used in this way cause consid
ture‘ are one or more perforated tubes or pipes 4
erable di?lculties in handling, require careful in
shown in detail in Fig. 5. These pipes or tubes
stallation and must be protected after installa
tion by an additional surfacing or coat of material have small, perforations ll throughout the entire
to protect them‘ against damage and to serve tov area which is inside of the bars 20! the box.
This tube or pipe 4 is .connected tosuction or as
render the surfaces air impervious.
Another method .01. using these materials is to ’ vacuum producing equipment not shown.
In producing an article in-accordance with my
compress them into a block or‘slab adding such
binder or'other materials as may be necessary to invention the bottom 5 and the four sides ‘I, 8, 9,
retain the block or slab in shape after being and. Iii and the vacuum pipe-‘4 are placed in posi 40
pressed. Not only do the binder materials re-, tion and assembled together. The box is then
duce the insulating value but the compression ?lled with the insulating material 3 and the top
of the material into the block or slab greatly re ' 6 of the box is placed in position. The entire box
duces the air cell space resulting in a very great structure with the material therein is then im- _
named in a liquid suspension of pulp or other
reduction of the normal insulatingv value of th
fibrous material and suction is applied to the per
material from its loosely packed state. '
v
Various methods and devices have heretofore
been employed in the use of heat insulating ma
25 terials; particularly those of mineral characteris
tics or composition. They have been formed in
30
35
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45
- It is the purpose of my invention to utilize the
natural’ characteristics of the various insulating
materials in the most e?iclent manner to-produce
50 an article which can be readily handled and
easily used while retaining the natural eiilciency
of heat and other insulating values‘ 01' these'ma
terials.
'
.
Fig. 1 is an exterior view‘ofthestructure used
to produce the insulating block.
. _ I
Fig. 2 is a cross section through'the structure
online 2-2 of Fig. 1 and shows-the insulating
' material retained within the structure and ready
co"
pension to ?ow into the mass. . Due to the rela
50
tively small spaces between the individual par- >
ticles of the insulating mass the ?brous materials
. penetrate‘ only a short distance and become de
_
Reference is made to the following ilgures:
55
i'orated pipe or tube ,4. _ This results in an evacu
ation of a portion of the air within the insulating
mass causing the liquid of the ?brous‘ pulp sus
for its ?brous protective covering. ' ‘
posited largely on the surface of the mass in the
form of a. grid or ribbed structure l5 by virtue’ 55
of the spaces i between the bars 2.
To further insure the thorough and e?icient ty
ing together of the entire enclosing ?brous struc
ture smallnotches or slots l 4 are cut transversely '
of the bars 2 which provide for connecting ribs m
2.
L
'' 2,045,540
between the main ribs, which are formed between ' on the mass of the material a ?brous binder, for
the bars 2. In Fig. 4 the main ribs are shown at adherence to and con?nement substantially to
l2 and the connecting ribs at I3.
,
-
When'a su?icient quantity of the ?brous mate
rials have been deposited on the surface of the
. insulating mass and in the spaces I and I4 be
tween and under the bars 2, the box isremoved
‘from the liquid suspension with vacuum still be
ing applied to the pipe 4. I The continued appli
10 cation of vacuum causes air to pass through the
‘fibrous enclosing material and to‘ replace the
water of the liquid pulp suspension which has
been drawn into the insulating mass. The water
which is thus replaced by the air is drawn o?'
15 through the pipe 4 and the entire mass of insu
the exterior of the mass.
>
2. The method of retaining a mass of loosely I
packed insulating material in a predetermined 5
‘shape which consists in placing the material in
an enclosing structure having a plurality of open
ings and of encasing the materialby depositing
‘through said openings and the surface of the mass
of the material a'?brous binder.
10
3. The method of retaininga mass of loosely
packed insulating ‘material in a predetermined
shape which consists .in placing the material in
an enclosing structure having a plurality of open- .
ings and of depositing by vacuum through said -
lating material and surrounding ‘?brous grid
openings and the surface of the mass of the
structure is solidified so that it can be removed‘ material a ?brous binder.
,
n
from the box by removing the top and sides of . _ 4.‘ The method of forming a block of insulating
; this structure.v The perforated ,.\pipe 4 is then material which consists in placing the material in
withdrawn and the article after :being removed a container having a plurality of openings, of im
from the box can be further dried to'insure that ‘
all remaining water or liquid is removed from the
‘ insulating material and the ?brous structure
which now encloses it. If desired the hole left in
25 the articleby the perforated tube can be filled.
with insulating material.
mersing the container in a liquid containing
?brous material in suspension, creating a vacu-v
um inside the mass of material and of deposit-'
ing a ?brous coating on the insulating material.v
.
5. The method of forming an insulating block
which consists in'placing an insulating material
'
__ During such drying the ?brous enclosing grid
structure has a tendency to shrink slightly in
in a box having narrow openings therein, of in
serting a perforated suction tube in the approxi
. suring that this structure holds the mass of in- _ mate center of the mass of material and placing
sulating material ?rmly in place but does not
'compress it sufficiently to materially reduce the
natural air cell space which this material inher
ently provides. Nor does my invention make it
necessary to use any foreign or binding material
in the insulating mass in order to retain itin the
35
‘shape desired. .
the container in a liquid containing pulp ?bres in 30
suspension and of creating suction in the per
forated tube.
_
a
6. The method of forming‘a block ofinsulating
material which consists in providing a closed con
'tainer composed of bars, with openings therebe?
tween, of‘ providing a plurality of notches on the
A further advantage of my article is to pro-’ inner surface of said bars, of providingv a per
forated suction pipe in ‘the approximate center
vide one which has‘ a minimum of enclosing pro
i
tective material and one which is so constructed
of said container, of ?lling said container with v
40
40 as. to be mechanically strong and to provide an._ insulating material and of depositing on the sur
attractive and useful insulating unit which can
"be readily installed in place. The rib or grid sur
‘ v'face structure also provides additional air space
between the surface of the article and the wall or
other surface against which this article may be
face of the material through the openings in‘ the
bars a layer of ?brous material by creating a ,
suction within the mass of insulating material.
7. An article of theclass described comprising
a mass of insulating material and a ?brous coat
ing surrounding said mass deposited thereon by
It. also. provides for a certain‘ ?exibility of ‘ar-‘ ' suction, said coating being united to the mass and
ticle surface enabling it to readily adapt itself to con?ned substantially to. the exterior thereof.
used.
small unevenness of the vsurfaces against which ‘
150
, r
45
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8. An article of the class described comprising
it is placed and-to insure ‘an air tight and e?lcient
a mass of insulating material and a'?brous c'ov
joint or contact between the article and the build -
ering over such material, said ?brous covering be
Wing structure with which it may be associated.
If necessary or desirable the ?brous enclosing
material can be treated to make it ?re resistant.
ing deposited on'the surface of said material by
suction created within the mass of said material,
said coating being united to the mass and con-4
It alsomay be treated to‘ make it waterproof. ~?ned substantially to the exterior thereof.
55
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This waterproof treatment may‘beaccomplished
9. An article of the class described comprising
_ by treatingathe ?brous materials before they are
‘ formed about the insulating mass‘ or by coating or
impregnating this material after it has been
formed and dried in place. This treatment will
f not only render the protective coating waterproof
,
but also will make it air impervious so that the
. insulating-characteristics of the material within
the ?brous structure will be maintained inde?
>_ nitely.
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What I_ therefore claim and desire to secure
' by Letters Patent is:-
_
_
I
a mass of material, a ?brous coating of ribbed
cross'section surrounding said material and de
posited thereon by suction, said coating being
united to the mass as con?ned substantially to 6°
the exterior thereof/
_ .
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.
- 10. The method/of retaining amass of loosely
._ packed material in a predetermined shape which
consists-in placing the material in an enclosing 65
structure and of encasing ‘the collective material
as a single unit by depositing on the exterior of
1. The method of retaining .a_ mass of loosely ‘ the collective ‘mass of the -material a ?brous
70
packed insulating ,material .in" a predetermined
binder forming a substantially seamless enclo
shape which consists in placing the'material in an _ ‘sure con?ned substantially to the exterior of the 70
enclosing structure having a plurality of open
I ings and of encasing the material by depositing
mass.
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