Dry-Stacked Facade Blocks With Coupling Plates for Reuse
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Solution Overview
Problem
Existing facade systems are difficult to reuse or recycle due to their bonded construction, and dry-stacked systems lack architectural flexibility and stability.
Innovation Solution
A facade system using identical building blocks with rotational symmetrical recesses and pins, coupled by coupling plates and wall ties, allowing for easy stacking and attachment to a retaining wall without mortar or glue, enabling reuse and various architectural patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If facade systems are constructed from materials bonded together with mortar or adhesive, then strength and stability are improved, but ease of reuse and recycling deteriorates
Solution Approach 1:
The facade system is divided into separate modular components: building blocks, coupling plates, and wall ties. These segments connect through mechanical interfaces (holes, pins, recesses) rather than chemical bonding, allowing individual components to be disassembled and reused. The coupling plate acts as an intermediary that mechanically links blocks to the retaining wall without permanent bonding.
Solution Approach 2:
The system enables recovery and reuse of facade components. Building blocks can be removed from the retaining wall and reused at different locations. The modular design with standardized coupling plates and wall ties facilitates the recovery of individual elements for reuse in new facade configurations, reducing waste and material consumption.
2Ease of operation
If dry-stacked building blocks are used without mortar or adhesive, then ease of assembly and reuse are improved, but stability and reliability deteriorate
Solution Approach 1:
Coupling plates serve as intermediary elements between building blocks and the retaining wall. These plates provide a stable mechanical connection point that distributes loads and secures multiple blocks simultaneously. The wall ties act as intermediaries anchoring the coupling plates to the retaining wall, creating a reliable load path without requiring mortar or adhesive between blocks.
Solution Approach 2:
The connection system transitions from two-dimensional surface bonding (mortar between block faces) to three-dimensional mechanical interlocking through holes, pins, and recesses. The coupling plates engage with blocks at multiple points in space, creating a volumetric connection that enhances stability while maintaining ease of assembly through standardized interfaces.
3Reliability
If complex mounting systems are used to achieve stable dry-stacked facades, then stability is improved, but device complexity increases
Solution Approach 1:
The coupling plate is designed as a universal component that performs multiple functions: connecting building blocks to the retaining wall, providing attachment points for wall ties, and enabling various block configurations. The standardized holes, pins, and recesses create a multi-functional interface that works with different block types and arrangements, reducing the need for specialized connection elements for each scenario.
Solution Approach 2:
The system merges the functions of connection, anchoring, and structural support into integrated components. The coupling plate combines block attachment features with wall tie mounting capabilities. The wall ties integrate the anchoring function with the connection to coupling plates, creating a consolidated system that achieves stability without requiring multiple separate complex elements.
4Adaptability or versatility
If identical building blocks with rotational symmetry are used, then ease of stacking in various patterns is improved, but manufacturing precision requirements increase
Solution Approach 1:
While the overall block design incorporates rotational symmetry for versatility, the coupling features (holes, pins, recesses) utilize asymmetric positioning relative to the block geometry. This asymmetric placement of connection elements within the symmetric framework allows for varied stacking patterns while maintaining standardized manufacturing tolerances for each individual feature, balancing architectural flexibility with manufacturing feasibility.
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5H
AI summary
Building block (1) and mounting system for manufacturing a preferably dry-stacked facade, wherein the rear side (3) of the building block (1) forms a polygon provided with at least a mounting pin (5) which extends through the rear side (3) and which is provided at least at a vertex (9) of an angle (6, 7) of the polygon, and wherein the mounting system comprises a coupling plate (20) that is provided with recesses (25) for receiving and fixing the pins (5) of adjacent vertices (9) of different adjacent building blocks (1).