Dry-Cast Concrete Block System With Coupled Face And Support Blocks
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Solution Overview
Problem
Conventional concrete blocks with a natural stone appearance face limitations in design versatility and production efficiency, as dry-cast blocks require mechanical aging processes to achieve the desired appearance, while wet-cast blocks have long production times and are impractical for mass-production.
Innovation Solution
A dry-cast concrete block system comprising a support block and a face block with coupling parts, where the face block features a cast texture with a natural stone appearance, allowing for efficient assembly and mass-production without the need for mechanical aging, and can be used in various structures like walls, columns, and steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dry-cast concrete blocks are used for mass-production, then production time is reduced and mass-production is facilitated, but the surface irregularity required for natural stone appearance cannot be achieved during casting
Solution Approach 1:
The patent applies preliminary action by incorporating the desired surface irregularity into the mold cavity before casting. The mold is pre-formed with a textured surface that matches the natural stone appearance, so when concrete is cast against this mold, the surface irregularity is automatically imprinted during the casting process itself, eliminating the need for subsequent mechanical aging or weathering processes.
Solution Approach 2:
The patent uses copying by creating a mold that replicates the natural stone surface characteristics. The mold cavity is designed to copy the texture, patterns, and irregularities of natural stone, and this copied surface is then transferred to the concrete block during casting, achieving the natural stone appearance without requiring actual natural stone or lengthy aging processes.
2Manufacturing precision
If wet-cast concrete blocks are used to achieve natural stone appearance during casting, then surface quality is improved, but production time increases and mass-production becomes impractical
Solution Approach 1:
The patent applies parameter changes by modifying the concrete mixture to a dry-cast formulation with specific rheological properties. This dry-cast concrete has controlled water content and additives that allow it to flow into the textured mold cavity and then rapidly set, maintaining the surface quality achieved during casting while dramatically reducing the production cycle time compared to traditional wet-cast methods.
3Strength
If monolithic concrete blocks are used, then structural integrity is maintained, but design versatility and ability to accommodate design constraints are reduced
Solution Approach 1:
The patent applies segmentation by dividing the concrete block into two separate components: a support block and a face block. The support block provides structural integrity and can be optimized for strength and stability, while the face block contains the textured surface for natural stone appearance. These two blocks are connected through coupling parts, allowing each component to be independently optimized for its specific function while maintaining overall structural integrity.
Solution Approach 2:
The patent applies universality by designing the support block and face block as separate, standardized components that can be combined in various configurations. The coupling parts enable multiple assembly options, allowing the same basic blocks to accommodate different design constraints, wall heights, and structural requirements, thereby significantly increasing design versatility while maintaining structural integrity through the standardized connection system.
Data Source
AI summary
A dry-cast concrete block system for use in a structure. The dry-cast concrete block system comprises a support block comprising a first coupling part and a face block comprising a second coupling part. The first coupling part and the second coupling part enable the face block to be coupled to the support block. The face block comprises a surface adapted to be exposed when the face block is coupled to the support block and the dry-cast concrete block system is positioned in the structure. In one embodiment, at least a portion of the surface has a cast texture with a natural stone appearance. In one embodiment, the structure is a wall and the concrete block system is a wall block system. For example, the wall may be a retaining wall and the wall block system may be a retaining wall block system. In another embodiment, the structure is a column and the concrete block system is a column block system. In yet another embodiment, the structure is steps and the concrete block system is a steps block system.