Concrete Unit with Interlocking 3D Patterns for Seamless Joints
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Solution Overview
Problem
Concrete units with texturized patterns often have joints between adjacent units that are wider than desired, posing a tripping hazard and potential non-compliance with accessibility standards, as existing solutions fail to create a seamless appearance.
Innovation Solution
Designing concrete units with a 6-sided body featuring three pairs of opposed rectangular faces, where at least one pair has irregular three-dimensional patterns that are mirror images, allowing these patterns to nest when units are aligned, minimizing the space between adjacent edges and creating a seamless joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If texturized patterns are added to the exposed face of concrete units, then aesthetic appearance is improved, but the joint width between adjacent units increases
Solution Approach 1:
The patent applies asymmetry by creating non-symmetric pattern profiles on adjacent concrete units that are complementary to each other. When viewed from the front, the patterns appear symmetric and aesthetically pleasing, but in cross-section, the patterns have asymmetric profiles that interlock to minimize joint width. This resolves the contradiction by allowing aesthetic symmetry to be maintained while achieving minimal joint width through asymmetric cross-sectional geometry.
Solution Approach 2:
The patent implements nesting by designing the patterned faces of adjacent concrete units to interlock like nested shapes. The protrusions and recessions of the texturized patterns on one unit fit into the complementary patterns of the adjacent unit, creating a nested configuration that minimizes the space between units while maintaining aesthetic appearance.
2Shape
If texturized patterns are used on concrete unit faces, then aesthetic appeal is enhanced, but tripping hazards are created due to wider joints
Solution Approach 1:
The asymmetric cross-sectional design of the texturized patterns creates interlocking profiles that minimize joint width to less than 1/8 inch. This reduced joint width eliminates the tripping hazard while preserving the aesthetic appeal of the texturized patterns on the exposed faces of the concrete units.
Solution Approach 2:
The nested configuration of complementary patterns on adjacent units creates a seamless appearance that eliminates gaps and protrusions which could cause tripping. The interlocking patterns ensure that the joint between units is minimal and flush with the surrounding surface, removing the tripping hazard while maintaining aesthetic appeal.
3Ease of operation
If conventional concrete units are placed together, then assembly is simple, but the joints are visible and non-seamless
Solution Approach 1:
The patent applies local quality by differentiating between the exposed faces and the joint faces of the concrete units. The texturized patterns are designed with specific local characteristics on the joint faces that enable seamless interlocking, while the exposed faces maintain their aesthetic texturized appearance. This localized design allows the joint area to have different properties (complementary patterns for interlocking) than the exposed areas.
Data Source
AI summary
A concrete unit includes a six sided body having three pairs of opposed rectangular faces. Two opposed faces each has an irregular three dimensional pattern extending across the entire face to provide two aesthetic faces on the unit. The two opposed faces have patterns that are mirror images of each other such that when two of the units are placed with their patterned faces aligned and in contact, the three dimensional patterns on the opposed faces nest to minimize the space between the adjacent edges of the units. The concrete units may be used as steps or in other applications.