Foam Concrete Construction Block with Density-Graded Shells
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Solution Overview
Problem
Existing blocks fail to achieve a balance between high thermal insulation and effective load transfer, as they either prioritize one property over the other or lack efficient manufacturing methods for construction sites.
Innovation Solution
A block with a sandwich-like construction comprising two outer shells and a middle shell, all made of foam concrete, where the outer shells have higher bulk density for load transfer and the middle shell has lower bulk density for insulation, connected using various methods such as cement milk, adhesive mortar, or dowels, allowing for efficient assembly and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the block uses foam concrete with low bulk density for thermal insulation, then thermal insulation performance is improved, but load-bearing capacity deteriorates
Solution Approach 1:
The block is divided into three separate foam concrete shells (two outer shells and one middle shell) that are manufactured independently and then assembled together. This segmentation allows each shell to be optimized for its specific function while maintaining overall structural integrity.
Solution Approach 2:
Different regions of the block are assigned different bulk densities to optimize local performance. The outer shells use foam concrete with higher bulk density (350-700 kg/m³) for load-bearing, while the middle shell uses foam concrete with lower bulk density (80-100 kg/m³) for enhanced thermal insulation.
2Ease of manufacture
If the block uses a single uniform foam concrete structure, then manufacturing simplicity is improved, but functional performance (both insulation and load bearing) deteriorates
Solution Approach 1:
The block is divided into three separate foam concrete shells (two outer shells and one middle shell) that are manufactured independently and then assembled together. This segmentation allows each shell to be optimized for its specific function while maintaining overall structural integrity.
Solution Approach 2:
Different regions of the block are assigned different bulk densities to optimize local performance. The outer shells use foam concrete with higher bulk density (350-700 kg/m³) for load-bearing, while the middle shell uses foam concrete with lower bulk density (80-100 kg/m³) for enhanced thermal insulation.
3Ease of manufacture
If the block uses a single uniform foam concrete structure, then manufacturing simplicity is improved, but load-bearing capacity deteriorates
Solution Approach 1:
The block is divided into three separate foam concrete shells (two outer shells and one middle shell) that are manufactured independently and then assembled together. This segmentation allows each shell to be optimized for its specific function while maintaining overall structural integrity.
Solution Approach 2:
Different regions of the block are assigned different bulk densities to optimize local performance. The outer shells use foam concrete with higher bulk density (350-700 kg/m³) for load-bearing, while the middle shell uses foam concrete with lower bulk density (80-100 kg/m³) for enhanced thermal insulation.
4Adaptability or versatility
If the block components are assembled on-site, then construction flexibility is improved, but installation time and labor complexity deteriorate
Solution Approach 1:
The three foam concrete shells are pre-manufactured and pre-assembled into complete block units at the factory before delivery to the construction site. This preliminary assembly eliminates on-site construction complexity and significantly reduces installation time, while the modular nature of the blocks retains construction flexibility.
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
The block achieves both good thermal insulation and load transfer capabilities, with the foam concrete structure providing minimal water absorption and improved manufacturing efficiency by pre-assembling the components in a factory for on-site installation.
Implementation Method 1
The block according to the invention enables high thermal insulation with good or improved load bearing
Implementation Method 2
The foam concrete shells absorb little or no water
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The invention relates, inter alia, to a construction block (10) comprising two outer shells (14, 15) and a central shell (16) provided therebetween. The outer shells and the central shell consist of foamed concrete, the outer shells each have a higher bulk density and the central shell has a lower bulk density relative thereto, and the central shell is permanently connected to the two outer shells.