Dry Stack Block with Foam Injection and Grouted Rebars
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Solution Overview
Problem
Existing dry stack construction blocks face issues with structural strength due to notched webs that easily break and costly, poorly fitting foam inserts, leading to increased labor and manufacturing challenges.
Innovation Solution
The use of U-shaped connecting webs and liquid closed cell foam injection to create a honeycomb structure with grouted rebars, providing additional structural strength and accommodating manufacturing variations, while eliminating the need for foam inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If notched webs are used in dry stack blocks, then manufacturing is simplified, but structural strength deteriorates as the notched webs easily break
Solution Approach 1:
The web is divided into multiple segments with intermediate transverse webs positioned between the end transverse webs and the central wall. This segmentation distributes structural loads across multiple smaller elements rather than relying on a single continuous notched web, preventing breakage while maintaining manufacturing simplicity.
Solution Approach 2:
Liquid closed cell foam is injected into the blocks before final assembly to create cushioning support within the cellular structure. This foam provides structural reinforcement that prevents the webs from breaking under load, while the injection process itself is simple and integrates seamlessly with existing manufacturing workflows.
2Strength
If foam inserts are used to fill block cavities, then structural strength is improved, but cost and manufacturing complexity increase due to poor fitting
Solution Approach 1:
Liquid closed cell foam is injected into the block cavities through fluid injection rather than using pre-formed solid foam inserts. This hydraulic/pneumatic approach allows the foam to expand and fill the cavities perfectly, accommodating manufacturing variations in block dimensions without requiring precise fitting of pre-made inserts.
Solution Approach 2:
The foam is introduced in liquid form and then undergoes phase change to expand and solidify within the block cavities. This parameter change from liquid to expanded solid state allows the material to adapt to any cavity shape or size, eliminating fitting problems associated with pre-formed inserts while maintaining structural strength.
3Strength
If traditional mortared block construction is used, then structural strength and leveling are improved, but construction speed and labor cost deteriorate
Solution Approach 1:
The mortar joint is completely removed from the construction system. Instead of using mortar between blocks for bonding and leveling, the invention uses dry stack blocks with integrated cellular structures filled with foam and grouted rebars, eliminating the time-consuming mortar application and cleanup processes while maintaining structural strength.
Solution Approach 2:
The blocks are designed with self-leveling features through their geometric configuration and the foam injection system. The blocks automatically achieve proper alignment and structural integrity without requiring skilled masons to apply and level mortar, enabling unskilled labor to construct walls quickly while maintaining strength.
4Weight of moving object
If air spaces are created in block design, then weight is reduced and thermal conductivity decreases, but structural strength deteriorates
Solution Approach 1:
The block combines multiple materials with complementary properties: the outer shell provides structural framework, the air spaces provide weight reduction and thermal insulation, the liquid-to-foam injected material provides internal reinforcement, and the grouted rebars provide tensile strength. This composite structure achieves all four objectives simultaneously - lightweight, insulated, and strong.
Solution Approach 2:
The design nests multiple functional elements within the block structure: air spaces are nested within the block walls for insulation, foam is nested within the air spaces for structural reinforcement, and grouted rebars are nested within the foam-filled cavities for additional strength. This nested arrangement allows weight reduction and insulation while maintaining or enhancing structural strength.
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
Enhances structural integrity, reduces construction time, and improves insulation and soundproofing, allowing for faster and more efficient wall construction with unskilled labor.
Implementation Method 1
injection of liquid closed cell foam into the cellular voids of the block structure
Implementation Method 2
grouted rebars, providing additional structural strength
Data Source
AI summary
A dry stack block structure, comprising: at least one course comprising blocks, each comprising: a first and second side walls and a central wall positioned between and parallel to the side walls, wherein the walls are rectangular and having a bottom and top edges located in a first plane and a parallel second plane, a first end and a second end located in a third plane and a parallel fourth plane, perpendicular to the first plane; a first and second end transverse webs connecting the ends respectively of the walls in the third and fourth planes respectively, wherein the end transverse webs having a bottom edge located in the first plane; and two intermediate transverse webs positioned between the third and fourth planes and connecting the second and central walls, the intermediate transverse webs having a bottom edge and a top edge located in the first and second planes.