Cellular Building Blocks with Interlocking Barbs
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Solution Overview
Problem
There is a need for a building material that mimics wood's characteristics such as high strength, low density, and earthquake resistance, but can be manufactured using local materials without trees and with minimal expense, especially in areas with limited wood supply.
Innovation Solution
The development of cellular building blocks that connect in two-dimensional or three-dimensional patterns, made from various materials and geometries like rectangular and hexagonal designs, providing cohesion and strength through mechanical connections such as barbs, recesses, and other mechanisms, allowing for the creation of structures with low density, strength, and fire resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wood is used as building material, then high strength and low density are achieved, but limited supply and deforestation occur
Solution Approach 1:
The invention divides the building material into modular cellular units that can be manufactured separately and assembled into larger structures. Each cell is a self-contained module with standardized geometry, allowing mass production and reducing dependence on natural wood resources while maintaining structural integrity through repetitive geometric patterns
Solution Approach 2:
The cellular building blocks are constructed from composite materials including concrete, metal, or plastic combinations that replicate wood's strength-to-weight ratio. The multi-material construction allows optimization of both mechanical properties and resource availability, substituting depleted natural resources with engineered alternatives
2Strength
If cellular building blocks are used, then low density and strength are achieved, but manufacturing complexity increases
Solution Approach 1:
A single standardized cell geometry serves multiple functions: structural support, connection interface, and assembly guide. The universal design allows the same basic unit to be used in various configurations and locations, reducing the number of different parts that need to be manufactured while maintaining structural performance
Solution Approach 2:
The cellular structure incorporates self-aligning and self-locking geometric features that automatically position and secure cells during assembly without requiring complex external tools or machinery. The interlocking geometry provides inherent guidance and stabilization, reducing manufacturing and assembly complexity
3Strength
If cellular building blocks connect mechanically, then cohesion and strength are achieved, but device complexity increases
Solution Approach 1:
The connection mechanism merges multiple functions into a single integrated geometric feature: mechanical interlocking, alignment guidance, and load transfer all occur through one unified interface design. This eliminates the need for separate connection components while achieving strong cohesive bonds between cells
Solution Approach 2:
Instead of using active fastening mechanisms (screws, welds, adhesives), the design uses passive geometric interlocking where the cell shapes themselves create the connection. The inverted approach transforms the connection from an added component into an inherent feature of the cell geometry, reducing overall system complexity
Data Source
AI summary
An improved cellular building block including a middle beam and two legs. The cellular building block having the first leg coupled to the middle beam such that the leg is perpendicular to the middle beam and a second leg coupled to the middle beam such that the leg is perpendicular to the middle beam and spaced apart from the first leg, the first leg and the second leg having an inside edge and an outside edge. Having at least one barb located on the inside edge of the first leg and on the inside edge of the second leg and further configured to lock into a recess. The cellular building blocks connect in a two dimensional or three dimensional pattern and a produce a structured material that holds itself together and exhibits beneficial characteristics.