Insulated Wall Block with Reinforced Load-Bearing Walls
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Solution Overview
Problem
Existing building blocks for wall construction are not suitable for forming load-bearing structures, as they lack strength against torsional forces, require large thickness for sufficient strength, and often result in thermal bridges due to insulation placement and material weaknesses, and are difficult to assemble and disassemble efficiently.
Innovation Solution
A building block design featuring vertical load-bearing walls, high-compressive-strength insulating material, and reinforcing elements that integrate to form a load-bearing structure capable of supporting floors and ceilings, while minimizing weight and preventing thermal bridges through strategic placement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If building blocks are designed to be self-supporting, then they can stand on their own, but they lack the strength to form load-bearing structures for floors and ceilings
Solution Approach 1:
The building block combines multiple materials with different properties: a core material providing basic structure, insulating material with projections for connection, and cover materials forming the outer surface. This composite structure allows the block to achieve both self-supporting capability and load-bearing strength through the synergistic contribution of each material layer.
Solution Approach 2:
The building block is divided into distinct functional segments: a core segment providing structural support, an insulating material segment with connection projections, and cover material segments forming the outer surface. This segmentation allows each part to perform its specific function while collectively achieving the required load-bearing capacity.
2Strength
If cover materials are arranged to form the load-bearing construction, then the structure gains strength, but the insulation can only accommodate pressure forces in vertical direction
Solution Approach 1:
The insulating material is designed as a composite component with both structural and insulating functions. It contains projections that form connections between blocks while maintaining insulation properties, allowing it to resist pressure forces in multiple directions rather than only vertically.
Solution Approach 2:
The insulating material serves multiple functions simultaneously: it provides thermal insulation, forms connection projections for block assembly, and contributes to pressure resistance in both vertical and horizontal directions. This multi-functionality eliminates the need for separate structural and insulating components.
3Strength
If building blocks are designed with sufficient strength, then they can support loads, but they require relatively large thickness
Solution Approach 1:
The building block uses composite materials where each layer contributes differently to the overall strength. The core material provides basic structural support, while the cover materials and insulating projections add structural reinforcement without requiring increased thickness, achieving high strength-to-thickness ratio.
Solution Approach 2:
The block is segmented into functional layers that optimize strength distribution. The cover materials and insulating projections are strategically positioned to provide structural reinforcement at critical locations, achieving sufficient load-bearing capacity with minimized overall thickness.
4Temperature
If insulating material is placed in the center, then thermal insulation is improved, but thermal bridges are created at the boundaries
Solution Approach 1:
The building block uses composite materials where the insulating material is integrated throughout the entire structure, including the cover materials and connection projections. This continuous insulation distribution eliminates thermal bridges at boundaries while maintaining optimal thermal insulation performance.
Solution Approach 2:
The insulating material is strategically positioned not only in the center but also at the boundaries and in connection projections. This local quality enhancement ensures continuous insulation throughout the entire block, preventing thermal bridges at critical boundary locations while maintaining overall thermal insulation efficiency.
5Ease of operation
If building blocks are designed for easy assembly and disassembly, then installation efficiency is improved, but the connection strength may be reduced
Solution Approach 1:
The building block features segmented connection projections on the insulating material that can be easily inserted into corresponding recesses for assembly, while the modular design allows for straightforward disassembly. This segmentation enables easy operation without compromising connection strength through properly designed interlocking geometry.
Solution Approach 2:
The connection projections and recesses act as intermediary elements that facilitate both easy assembly and strong connections. These intermediary features provide a simple insertion mechanism for quick assembly while creating robust mechanical interlocks that ensure strong connections between blocks.
Data Source
AI summary
Building block (11) for forming a wall construction (100), which building block (11) includes insulating material (30) and vertical load-bearing walls (21) extending from one longitudinal side (12, 13) towards another longitudinal side (12, 13) of the building block (11), where the insulating material (30) is provided with recesses (31) for accommodating the load-bearing walls (21) for holding them in position, where inner part of the insulating material (30) and the load-bearing walls (21) are provided with recesses (32) for accommodating at least one longitudinal reinforcing element (40) binding the load-bearing walls (21) together in longitudinal direction of the building block (11) for forming an inner core (20) where the vertical load-bearing walls (21), insulating material (30) and the at least one reinforcing element (40) together form the basic load-bearing in the building block (11), and that the building block (11) includes at least one outer core (50) formed by parts of insulating material (30) and load-bearing walls (21) outside the at least one reinforcing element (40), where the at least one outer core (50) has supplementing and reinforcing properties for the inner core (20).