Composite Frame Brick with Hollow Box Structure
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Solution Overview
Problem
Conventional construction materials for intermediate walls, such as brick and steel-based materials, are heavy, costly, and inadequate for thermal and noise insulation, requiring a more efficient and lightweight solution.
Innovation Solution
A frame brick made of composite material with a hollow box form, comprising fibers and resin, featuring cutouts and connection extensions for reduced weight and improved insulation, and a formulation with mineral powder and chemical additives for enhanced mechanical properties and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional materials like brick and steel-based materials are used for intermediate walls, then structural resistance is maintained, but weight increases excessively
Solution Approach 1:
The patent employs composite materials consisting of at least one type of fiber and at least one type of resin to manufacture the frame brick body. This composite structure provides high strength-to-weight ratio, maintaining structural resistance while significantly reducing weight compared to conventional brick and steel-based materials.
Solution Approach 2:
The frame brick features a hollow box form with voids or cavities within its structure. This porous design reduces the overall weight of the wall while maintaining sufficient structural resistance through the optimized hollow configuration, directly addressing the contradiction between weight reduction and strength maintenance.
2Strength
If heavy materials are used for intermediate walls, then structural strength is ensured, but transportation costs increase
Solution Approach 1:
The use of composite materials (fiber and resin combination) creates a lightweight yet strong frame brick that requires less material quantity for the same structural strength, thereby reducing transportation costs associated with moving heavy conventional materials.
Solution Approach 2:
The hollow box form with internal voids reduces the material quantity needed while maintaining structural integrity, leading to lower weight and consequently reduced transportation costs compared to solid conventional materials.
3Ease of manufacture
If conventional intermediate wall materials are used, then construction is feasible, but thermal and noise insulation performance is insufficient
Solution Approach 1:
The hollow box form creates air pockets or voids within the frame brick structure that provide thermal insulation by trapping air and reducing heat transfer. The porous configuration also contributes to noise insulation by dampening sound waves, thereby improving insulation performance while maintaining construction feasibility.
Solution Approach 2:
The composite material composition (fiber and resin) provides inherent insulation properties that complement the hollow structure, enhancing both thermal and noise insulation performance while keeping the manufacturing process feasible and straightforward.
4Ease of manufacture
If conventional materials are used for intermediate walls, then construction can proceed, but additional materials and labor are required
Solution Approach 1:
The frame brick integrates multiple functions into a single component: the hollow box form provides both structural support and insulation, while the composite material offers strength and durability. This merging eliminates the need for separate insulation materials, adhesives, and plastering layers required by conventional systems, reducing both material quantity and labor requirements.
Solution Approach 2:
The frame brick serves multiple purposes simultaneously: it acts as a structural element, an insulation barrier, and a finished surface component. This multi-functionality reduces the complexity of the construction process by eliminating sequential steps like insulation installation and plastering that are necessary when using conventional materials.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The frame bricks are significantly lighter, reducing transportation and assembly costs while maintaining structural resistance, and providing superior thermal and noise insulation, with the ability to incorporate insulation materials and facilitate easier installation.
Implementation Method 1
a brick body made of composite material and which is in a form similar to a hollow box and which comprises at least one type of fiber and at least one type of resin
Data Source
AI summary
The present invention is a frame brick (10) having a brick body (12) made of composite material and which is in hollow box form and which comprises at least one type of fiber and at least one type of resin, and at least one connection extension (15) which is one-piece with said brick body (12) and which provides connection to another structure element with the same characteristics. As an improvement, at least one cutout (201) is provided at least partially in the direction of the height of the brick body (12) on at least one of two wall surfaces (20) extending mutually on a brick length section (19) of the brick body (12).