Steel-Reinforced Concrete Formwork with Integral Tie-Rod

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Solution Overview

Problem

Conventional concrete masonry units (CMU) face limitations in size, thermal resistance, and structural integrity due to inadequate bonding between reinforced grout or concrete and rebar, leading to potential fractures and poor structural performance.

Innovation Solution

A construction block system featuring 3000 psi steel-reinforced concrete side-panels connected by a tie-rod, incorporating integral thermal insulation and allowing for high-vibration concrete casting, which provides enhanced strength, thermal insulation, and reduced labor and material costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional CMU is used for construction, then the construction process is simplified, but the thermal resistance is insufficient and structural integrity is compromised

Engineering Contradiction:

Improveconstruction process simplicityVSAvoidstructural integrity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent uses composite materials by combining concrete masonry units with steel reinforcement bars (rebar) and grout to create a reinforced concrete masonry structure. The concrete blocks provide compressive strength while the steel rebar provides tensile strength, creating a composite material system that achieves both ease of construction and high structural integrity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements nesting by placing steel reinforcement bars inside the concrete masonry units and filling the cavities with grout. The rebar is nested within the block cavities, and the grout is nested around the rebar, creating a multi-layered composite structure that enhances strength while maintaining the modular construction advantage.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Productivity

If conventional CMU is used for construction, then construction speed is maintained, but thermal insulation is insufficient requiring additional walls

Engineering Contradiction:

Improveconstruction speedVSAvoidthermal resistance

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent makes the concrete masonry unit multi-functional by designing it to serve both as a structural element and as a thermal insulation component. The blocks incorporate insulated cavities that can be filled with insulation materials, allowing the same construction element to provide both structural support and thermal resistance, eliminating the need for additional insulation walls.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent creates a composite wall system by combining concrete masonry units with thermal insulation materials filled in the block cavities. This composite construction provides both the structural strength of concrete and the thermal insulation properties of the insulation material, achieving dual functionality in a single construction system.

Inventive Principle:

Principle #40Composite materials

3Strength

If rigorous internal vibration compaction is used to bond rebar to concrete, then bonding strength is improved, but CMU fractures and structural reliability decreases

Engineering Contradiction:

Improvebonding strengthVSAvoidstructural reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies partial vibration compaction rather than rigorous vibration throughout. The grout is vibrated just enough to ensure proper bonding between the rebar and concrete, but not so much that it causes the CMU to fracture. This controlled, partial action achieves the necessary bonding strength while avoiding the harmful effects of excessive vibration.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The patent provides beforehand cushioning by carefully controlling the vibration compaction process to prevent CMU fracture. The vibration is applied in a controlled manner that cushions against the risk of breaking the concrete blocks, ensuring that the bonding strength is achieved without compromising the structural reliability of the CMU.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Adaptability or versatility

If larger monolithic concrete structures are required, then design flexibility is improved, but CMU size limitations prevent application

Engineering Contradiction:

Improvedesign flexibilityVSAvoidstructure size

Core Design Contradiction:

Adaptability or versatilityVSLength of stationary object

Solution Approach 1:

The patent applies segmentation by using modular concrete masonry units that can be assembled to create structures of various sizes. Instead of requiring a single large monolithic concrete pour, the structure is divided into smaller CMU blocks that can be stacked and configured to achieve the desired large-scale structure, providing design flexibility while overcoming size limitations.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20230220666A1Permanent Concrete Form

Publication Date: 2023.07.13 HORTON MARVIN RICHARDS

AI summary

A Permanent concrete form (construction-block) for Structural Code monolithic reinforced-concrete. Construction blocks are sand-cement steel-reinforced side-panels, with one central embedded steel nut (3/4-10) [M20>2.5] that connects a threaded steel-tie-rod (or bolt) to a second side-panel. Tie-rod can also be #5 (16 mm) welded rebar. Typical side-panel size 500×250×40 mm (20″×10″×1.5″). The central single spacer tie-rod length is sized (width of wall) to provide space for concrete, rebar, thermal-insulation, conduits, ducts, and other embedment. Construction block tested for dry-stacking, and 3 m (10 ft) high anti-blow-out vibrated concrete placement.