Foam block wall and fabrication method

Claim 1

A method for fabricating a foam block wall comprising the steps of: a. providing a plurality of first foam blocks aligned end to end horizontally, each first foam block having an upper surface, a lower surface, opposing, parallel oriented exterior side surfaces and a plurality of first passageways extending vertically between the upper and lower block surfaces and defining a reduced thickness sidewall between the exterior side surface and each first passageway; b. providing a plurality of second foam blocks aligned end to end horizontally, each second foam block having an upper surface, a lower surface, opposing, parallel oriented exterior side surfaces and a plurality of second passageways extending vertically between the upper and lower block surfaces and defining a reduced thickness sidewall between the exterior surface and each second passageway; c. positioning the lower surfaces of the plurality of second foam blocks on the upper surfaces of the plurality of first foam blocks with each second passageway aligned with a corresponding first passageway; d. providing a plurality of block alignment elements, each block alignment element having a first end, a second end, and first and second edge alignment surfaces disposed between the first and second ends and dimensioned to simultaneously engage the first and second passageways of the first and second blocks at angularly spaced apart intervals; e. positioning each block alignment element through one of the second passageways of one of the second foam blocks and through the second passageway of the second block and through one of the corresponding first passageways of one of the first foam blocks, and further engaging the first and second passageways of the first and second foam blocks with the edge alignment surfaces to align the first and second foam blocks relative to each; and f. grouting a plurality of aligned first and second passageways with a material.

Claim 2

A method for fabricating a foam block wall comprising the steps of: a. providing a plurality of first foam blocks aligned end to end horizontally, each first foam block having an upper surface, a lower surface, opposing, parallel oriented exterior side surfaces and a plurality of first passageways extending vertically between the upper and lower block surfaces and defining a reduced thickness sidewall between the exterior side surface and each first passageway; b. providing a plurality of second foam blocks aligned end to end horizontally, each second foam block having an upper surface, a lower surface, opposing, parallel oriented exterior side surfaces and a plurality of second passageways extending vertically between the upper and lower block surfaces and defining a reduced thickness sidewall between the exterior surface and each second passageway; c. positioning the lower surfaces of the plurality of second foam blocks on the upper surfaces of the plurality of first foam blocks with each second passageway aligned with a corresponding first passageway; d. providing a plurality of block alignment elements, each block alignment element having a first end, a second end, and first and second edge alignment surfaces disposed between the first and second ends and dimensioned to simultaneously engage the first and second passageways of the first and second blocks at angularly spaced apart intervals; e. positioning each block alignment element through one of the second passageways of one of the second foam blocks and through the second passageway of the second block and through one of the corresponding first passageways of one of the first foam blocks, and further engaging the first and second passageways of the first and second foam blocks with the edge alignment surfaces to align the first and second foam blocks relative to each; and f. grouting a plurality of aligned first and second passageways with a material.